Bell-John Deere 315 SK Workshop Service Repair PDF

315SK Backhoe Loader
Repair
REPAIR TECHNICAL MANUAL
Backhoe Loaders (T3/S3A) models 315SK (PIN: 1T0315SK**D229820-;

1T0315SK**C219607-)
TM12472 27 DEC 15 (ENGLISH)
For complete service information also see:

315SK Backhoe Loader Diagnostic TM12471
JDLink (MTG) Technical Manual TM114519
PowerTech E 4.5 and 6.8L Diesel Engines Level 16 Electronic Fuel
CTM502
System With Denso HPCR
PowerTech 4.5L & 6.8L Diesel Engines Level 12 Electronic Fuel
CTM331
System With Stanadyne DE10 Pump
Super Caddy Oil Cleanup Procedure CTM310
120 Series Hydraulic Cylinders CTM120519
PowerTech 4.5L & 6.8L Diesel Engines Tier 1/Stage I, Tier 2/Stage II,
CTM104
Tier 3/Stage IIIA, Tier 3/Stage IIA Tier 3/Stage III, (Base Engine)
COOLANT HEATER SERVICE MANUAL CTM10090X19
John Deere Construction and Forestry

Pinted by Belgreen
315SK Backhoe Loader Repair (g) by Belgreen v2.1
Table of contents
FOREWORD
MANUAL IDENTIFICATION—READ THIS FIRST!
Section 00 - GENERAL INFORMATION
Group 0001 - Safety
Group 0003 - Torque Values
Section 01 - WHEELS
Group 0110 - Powered or Non-Powered Wheels and Fastenings
Section 02 - AXLES AND SUSPENSION SYSTEMS
Group 0225 - Input Drive Shafts and U-Joints
Group 0230 - Non-Powered Wheel Axles
Group 0240 - Powered Wheel Axle (MFWD)
Group 0250 - Axle Shaft, Bearings, and Reduction Gears
Section 03 - TRANSMISSION
Group 0300 - Removal and Installation
Group 0315 - Controls Linkage
Group 0350 - Gear, Shafts, and Power Shift Clutches
Group 0360 - Hydraulic System
Section 04 - ENGINE
Section 05 - ENGINE AUXILIARY SYSTEM
Group 0505 - Cold Weather Starting Aids
Group 0510 - Cooling Systems
Group 0515 - Speed Controls
Group 0520 - Intake System
Group 0530 - Exhaust Systems
Group 0560 - External Fuel Supply Systems
Section 06 - TORQUE CONVERTER
Group 0651 - Turbine, Gears, and Shaft
Section 09 - STEERING SYSTEM
Section 10 - SERVICE BRAKES
Group 1011 - Active Elements
Section 11 - PARK BRAKE
Section 17 - FRAME OR SUPPORTING STRUCTURE
Group 1740 - Frame Installation
Group 1749 - Chassis Weights
Section 18 - OPERATOR′S STATION
Group 1810 - Operator Enclosure
Group 1821 - Seat and Seat Belt
Group 1830 - Heating and Air Conditioning
Section 19 - SHEET METAL AND STYLING
Group 1910 - Hood or Engine Enclosure
Group 1913 - Miscellaneous Shields
Group 1921 - Grille and Grille Housing
Section 20 - SAFETY AND CONVENIENCE
Group 2001 - Radio
Group 2004 - Horn and Warning Devices
Section 21 - MAIN HYDRAULIC SYSTEM
<- Go to Global Table of contents 315SK Backhoe Loader Repair
Section 31 - LOADER
Group 3100 - Loader
Group 3102 - Bucket
Group 3115 - Control Linkage
Section 33 - BACKHOE
Group 3302 - Bucket
Group 3340 - Frames
Section 99 - DEALER FABRICATED TOOLS
Group 9900 - Dealer Fabricated Tools

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

Manual Identification—READ THIS FIRST!

IMPORTANT:
Use only supporting manuals designated for your specific machine. If incorrect manual is chosen,
improper service may occur. Verify product identification number (PIN) when choosing the correct
manual.
Choosing the Correct Supporting Manuals

John Deere backhoe loaders are available in different machine configurations based on the various markets into which they are
sold. Different supporting manuals exist for different machine configurations.
When necessary, product identification numbers are listed on the front covers of backhoe loader manuals. These numbers are
used to identify the correct supporting manual for your machine.
Product Identification Number
PIN Plate Location
Example of PIN Plate

LEGEND:
1 PIN Plate
2 17 Digit PIN
The product identification number (PIN) plate (1) is located on the left-side of machine on the loader frame. Each machine has
a 17 digit PIN (2) shown on PIN plate.

GENERAL INFORMATION (g) by Belgreen v2.0
The PIN identifies the producing factory, machine model number, machine option, year of manufacture, engine emission level,
and machine serial number.
PIN Identification Table
17 Digit PIN Example
(3) (4) (5) (4) (6) (7) (8) (9)
1 T 0 3 1 5 S K C 2 1 9 6 0 7
(3)—World Code —Identifies location where machine is manufactured.

(4)—Machine Model Identifier —Identifies model number.
(5)—Machine Option Code —Identifies which major machine option is equipped. This digit will change from one
machine to another.
(6)—Check Letter —This is a random character assigned by the factory. This is not used in machine identification.
(7)—Manufacturing Year Code —Identifies year of machine manufacture.
(8)—Engine Emission Code —Represents engine emission certification.
(9)—Machine Serial Number —Identifies machine serial number. This digit will change from one machine to another.
The following is an example for a 315SK machine that meets Tier 2 and Stage II emission levels:
PIN Identification
1T0315SK_ _C219607
1T0 .......... World Code (manufacturing location)
1DW .......... Davenport Works
1T8 .......... Thibodaux Works
1T0 .......... Dubuque Works
315_K .......... Machine Model Identifier
S .......... Machine Option Code
X .......... Base Machine
S .......... Super Duty
E .......... Easy Power (EP)
T .......... Total Machine Control (TMC) Configuration
_ .......... Check Letter (variable)
_ .......... Manufacturing Year Code (variable)
C .......... 2012
D .......... 2013
E .......... 2014
F .......... 2015
G .......... 2016
C .......... Engine Emission Code
C .......... Tier 2 and Stage II
D .......... Tier 3 and Stage III A
E .......... Interim Tier 4 and Stage III B
F .......... Tier 4
G .......... Interim Tier 4 and Stage III A (19-56 kW)
219607 .......... Machine Serial Number
<- Go to Section TOC Section 00 page 2 315SK Backhoe Loader Repair

Section 00 - GENERAL INFORMATION

Table of contents
Group 0001 - Safety ................................................................................................................................. 1
Recognize Safety Information ............................................................................................................... 1
Follow Safety Instructions ..................................................................................................................... 1
Operate Only If Qualified ...................................................................................................................... 2
Wear Protective Equipment .................................................................................................................. 3
Avoid Unauthorized Machine Modifications .......................................................................................... 3
Inspect Machine ................................................................................................................................... 3
Stay Clear of Moving Parts ................................................................................................................... 4
Avoid High-Pressure Fluids ................................................................................................................... 4
Avoid High-Pressure Oils ...................................................................................................................... 5
Work In Ventilated Area ........................................................................................................................ 5
Prevent Fires ........................................................................................................................................ 6
Prevent Battery Explosions ................................................................................................................... 7
Handle Chemical Products Safely ......................................................................................................... 7
Decommissioning: Proper Recycling and Disposal of Fluids and Components ..................................... 7
Prepare for Emergencies ...................................................................................................................... 8
Clean Debris from Machine .................................................................................................................. 9
Add Cab Guarding for Special Uses ...................................................................................................... 9
Use Steps and Handholds Correctly ..................................................................................................... 9
Start Only From Operator′s Seat ........................................................................................................... 9
Use and Maintain Seat Belt ................................................................................................................ 10
Prevent Unintended Machine Movement ............................................................................................ 10
Prevent Unintended Machine Movement—If Equipped With Pilot Controls ......................................... 11
Avoid Work Site Hazards .................................................................................................................... 11
Keep Riders Off Machine .................................................................................................................... 12
Avoid Backover Accidents .................................................................................................................. 12
Avoid Machine Tipover ....................................................................................................................... 14
Inspect and Maintain ROPS ................................................................................................................. 14
Add and Operate Attachments Safely ................................................................................................ 14
Operating or Traveling On Public Roads ............................................................................................. 15
Park and Prepare for Service Safely ................................................................................................... 15
Service Cooling System Safely ........................................................................................................... 16
Remove Paint Before Welding or Heating ........................................................................................... 16
Make Welding Repairs Safely ............................................................................................................. 17
Drive Metal Pins Safely ....................................................................................................................... 17
Service Tires Safely ............................................................................................................................ 18
Group 0003 - Torque Values ................................................................................................................. 19
Metric Bolt and Cap Screw Torque Values .......................................................................................... 19
Additional Metric Cap Screw Torque Values ....................................................................................... 20
Unified Inch Bolt and Cap Screw Torque Values ................................................................................. 22
Service Recommendations for 37° Flare and 30° Cone Seat Connectors ........................................... 23
Service Recommendations for O-Ring Boss Fittings ........................................................................... 24
O-Ring Boss Fittings In Aluminum Housing Service Recommendations—Excavators ......................... 26
Service Recommendations For Flared Connections—Straight or Tapered Threads ............................ 28
Service Recommendations For Flat Face O-Ring Seal Fittings ............................................................ 30
O-Ring Face Seal Fittings With SAE Inch Hex Nut And Stud End For High Pressure Service
Recommendations ....................................................................................................................... 31
O-Ring Face Seal Fittings With Metric Hex Nut And Stud End For Standard Pressure Service
O-Ring Face Seal Fittings With Metric Hex Nut And Stud End For High Pressure Service

Service Recommendations for Metric Series Four Bolt Flange Fitting ................................................. 37
Service Recommendations For Inch Series Four Bolt Flange Fittings ................................................. 38
Inch Series Four Bolt Flange Fitting For High Pressure Service Recommendations ............................ 39
Service Recommendations For Non-Restricted Banjo (Adjustable) Fittings ........................................ 40
Service Recommendations For O-Ring Boss Fittings With Shoulder ................................................... 42
Metric 24° O-Ring Seal DIN 20078 Service Recommendations ........................................................... 45

Section 00 - GENERAL INFORMATION Group 0001: Safety
Group 0001 - Safety

Recognize Safety Information
Safety alert Symbols
Safety Alert Symbols
This is the safety alert symbol. When you see this symbol on your machine or in this manual, be alert for the
potential of personal injury.
Follow the precautions and safe operating practices highlighted by this symbol.
A signal word — DANGER, WARNING, or CAUTION — is used with the safety alert symbol. DANGER identifies the most serious
hazards.
On your machine, DANGER signs are red in color, WARNING signs are orange, and CAUTION signs are yellow. DANGER and
WARNING signs are located near specific hazards. General precautions are on CAUTION labels.
Follow Safety Instructions
Safety Messages
Carefully read all safety messages in this manual and on your machine safety signs. Keep safety signs in good condition.
Replace missing or damaged safety signs. Use this operator’s manual for correct safety sign placement. Be sure that new
equipment components and repair parts include the current safety signs. Replacement safety signs are available from your
John Deere dealer.

There can be additional safety information contained on parts and components sourced from suppliers that is not reproduced in
this operator′s manual.
Learn how to operate the machine and how to use controls properly. Do not let anyone operate without instruction.
Keep your machine in proper working condition. Unauthorized modifications to the machine could impair the function or safety
and affect machine life.
If you do not understand any part of this manual and need assistance, contact your John Deere dealer.
Operate Only If Qualified

Do not operate this machine unless the operator′s manual has been read carefully, and you have been qualified by supervised
training and instruction.
Operator should be familiar with the job site and surroundings before operating. Try all controls and machine functions with the
machine in an open area before starting to work.
Know and observe all safety rules that may apply to every work situation and work site.

Wear Protective Equipment
Protective Clothing
Guard against injury from flying pieces or metal or debris; wear goggles or safety glasses.
Wear close fitting clothing and safety equipment appropriate to the job.
Operating equipment safely requires the full attention of the operator. Do not wear radio or music headphones while operating
machine.
Prolonged exposure to loud noise can cause impairment or loss of hearing. Wear suitable hearing protection such as earmuffs
or earplugs to protect against objectionable or uncomfortable loud noises. Radio or music headphones are not suitable to use
for hearing protection.
Avoid Unauthorized Machine Modifications

John Deere recommends using only genuine John Deere replacement parts to ensure machine performance. Never substitute
genuine John Deere parts with alternate parts not intended for the application as these can create hazardous situations or
hazardous performance. Non-John Deere parts, or any damage or failures resulting from their use are not covered by any John
Deere warranty.
Modifications of this machine, or addition of unapproved products or attachments, may affect machine stability or reliability,
and may create a hazard for the operator or others near the machine. The installer of any modification which may affect the
electronic controls of this machine is responsible for establishing that the modification does not adversely affect the machine or
its performance.
Always contact an authorized dealer before making machine modifications that change the intended use, weight or balance of
the machine, or that alter machine controls, performance or reliability.
Inspect Machine

Inspect Machine
Inspect machine carefully each day by walking around it before starting.

Keep all guards and shields in good condition and properly installed. Fix damage and replace worn or broken parts
immediately. Pay special attention to hydraulic hoses and electrical wiring.
Stay Clear of Moving Parts
Stay Clear of Moving Parts
Entanglements in moving parts can cause serious injury.

Stop engine before examining, adjusting, or maintaining any part of machine with moving parts.
Keep guards and shields in place. Replace any guard or shield that has been removed for access as soon as service or repair is
complete.
Avoid High-Pressure Fluids
High Pressure
Inspect hydraulic hoses periodically – at least once per year – for leakage, kinking, cuts, cracks, abrasion, blisters, corrosion,
exposed wire braid or any other signs of wear or damage.
Replace worn or damaged hose assemblies immediately with John Deere approved replacement parts.

Escaping fluid under pressure can penetrate the skin causing serious injury.
Avoid the hazard by relieving pressure before disconnecting hydraulic or other lines. Tighten all connections before applying
pressure.
Search for leaks with a piece of cardboard. Protect hands and body from high-pressure fluids.
If an accident occurs, see a doctor immediately. Any fluid injected into the skin must be surgically removed within a few hours
or gangrene may result. Doctors unfamiliar with this type of injury should reference a knowledgeable medical source. Such
information is available in English from Deere & Company Medical Department in Moline, Illinois, U.S.A., by calling
1-800-822-8262 or +1 309-748-5636.
Avoid High-Pressure Oils
Avoid High Pressure Oils
Avoid High-Pressure Oils
This machine uses a high-pressure hydraulic system. Escaping oil under pressure can penetrate the skin causing serious injury.
Never search for leaks with your hands. Protect hands. Use a piece of cardboard to find location of escaping oil. Stop
engine and relieve pressure before disconnecting lines or working on hydraulic system.
If hydraulic oil penetrates your skin, see a doctor immediately. Injected oil must be removed surgically within
hours or gangrene could result. Contact a knowledgeable medical source or the Deere & Company Medical Department in
Moline, Illinois, U.S.A.
Work In Ventilated Area

Engine exhaust fumes
Engine exhaust fumes can cause sickness or death. If it is necessary to run an engine in an enclosed area, remove the exhaust
fumes from the area with an exhaust pipe extension.
If you do not have an exhaust pipe extension, open the doors and get outside air into the area.
Prevent Fires
Handle Fuel Safely
Clean Machine Regularly
Carry A Fire Extinguisher
Handle Fuel Safely: Store flammable fluids away from fire hazards. Never refuel machine while smoking or when near sparks
or flame.
Clean Machine Regularly: Keep trash, debris, grease and oil from accumulating in engine compartment, around fuel lines,
hydraulic lines, exhaust components, and electrical wiring. Never store oily rags or flammable materials inside a machine
compartment.
Maintain Hoses and Wiring: Replace hydraulic hoses immediately if they begin to leak, and clean up any oil spills. Examine
electrical wiring and connectors frequently for damage.
Keep A Fire Extinguisher Available: Always keep a multipurpose fire extinguisher on or near the machine. Know how to use
extinguisher properly.
Prevent Battery Explosions
Battery Explosions
Keep sparks, lighted matches, and open flame away from the top of battery. Battery gas can explode.
Never check battery charge by placing a metal object across the posts. Use a volt-meter or hydrometer.
Do not charge a frozen battery; it may explode. Warm battery to 16°C (60°F).
Handle Chemical Products Safely
Material Safety Data Sheet
Direct exposure to hazardous chemicals can cause serious injury. Potentially hazardous chemicals used with John Deere
equipment include such items as lubricants, coolants, paints, and adhesives.
A Material Safety Data Sheet (MSDS) provides specific details on chemical products: physical and health hazards, safety
procedures, and emergency response techniques.
Check the MSDS before you start any job using a hazardous chemical. That way you will know exactly what the risks are and
how to do the job safely. Then follow procedures and recommended equipment.
(See your John Deere dealer for MSDS’s on chemical products used with John Deere equipment.)
Decommissioning: Proper Recycling and Disposal of Fluids and

Components

Recycle Waste
Safety and environmental stewardship measures must be taken into account when decommissioning a machine and/or
component. These measures include the following:
Use appropriate tools and personal protective equipment such as clothing, gloves, face shields or glasses, during the
removal or handling of objects and materials.
Follow instructions for specialized components.
Release stored energy by lowering suspended machine elements, relaxing springs, disconnecting the battery or other
electrical power, and releasing pressure in hydraulic components, accumulators, and other similar systems.
Minimize exposure to components which may have residue from agricultural chemicals, such as fertilizers and pesticides.
Handle and dispose of these components appropriately.
Carefully drain engines, fuel tanks, radiators, hydraulic cylinders, reservoirs, and lines before recycling components. Use
leak-proof containers when draining fluids. Do not use food or beverage containers.
Do not pour waste fluids onto the ground, down a drain, or into any water source.
Observe all national, state, and local laws, regulations, or ordinances governing the handling or disposal of waste fluids
(example: oil, fuel, coolant, brake fluid); filters; batteries; and, other substances or parts. Burning of flammable fluids or
components in other than specially designed incinerators may be prohibited by law and could result in exposure to
harmful fumes or ashes.
Service and dispose of air conditioning systems appropriately. Government regulations may require a certified service
center to recover and recycle air conditioning refrigerants which could damage the atmosphere if allowed to escape.
Evaluate recycling options for tires, metal, plastic, glass, rubber, and electronic components which may be recyclable, in
part or completely.
Contact your local environmental or recycling center, or your John Deere dealer for information on the proper way to
recycle or dispose of waste.
Prepare for Emergencies
First Aid Kit
Be prepared if a fire starts.

Keep a first aid kit and fire extinguisher handy.

Keep emergency numbers for doctors, ambulance service, hospital, and fire department near your telephone.
Clean Debris from Machine
Clean Debris From Machine
Keep engine compartment, radiator, batteries, hydraulic lines, exhaust components, fuel tank, and operator′s station clean and
free of debris.
Clean any oil spills or fuel spills on machine surfaces.
Temperature in engine compartment could go up immediately after engine is stopped. BE ON GUARD FOR FIRES DURING THIS
PERIOD.
Open access door(s) to cool the engine faster, and clean engine compartment.
Add Cab Guarding for Special Uses

Special work situations or machine attachments could create an environment with falling or flying objects. Working near an
overhead bank, demolition work, using a hydraulic hammer or winch, working in a forestry application or wooded area, or
working in a waste management application, for example, could require added guarding to protect the operator.
Additional level II FOPS (falling object protective structure), forestry protection packages, and special screens or guarding
should be installed when falling or flying objects could enter or damage the machine. A rear screen should always be used with
a winch to protect against a snapping cable. Before operating in any special work environments, follow the operator protection
recommendations of the manufacturer of any specialized attachment or equipment. Contact your authorized John Deere dealer
for information on protective guarding.
Use Steps and Handholds Correctly
Use Handholds And Steps
Prevent falls by facing the machine when you get on and off. Maintain 3-point contact with steps and handrails. Never use
machine controls as handholds.
Use extra care when mud, snow, or moisture present slippery conditions. Keep steps clean and free of grease or oil. Never
jump when exiting machine. Never mount or dismount a moving machine.
Start Only From Operator′s Seat

Operate Only From Operators Seat
Avoid unexpected machine movement. Start engine only while sitting in operator′s seat. Ensure that all controls and working
tools are in proper position for a parked machine.
Never attempt to start engine from the ground. Do not attempt to start engine by shorting across the starter solenoid
terminals.
Use and Maintain Seat Belt
Use and Maintain Seat Belt
Use seat belt when operating machine . Remember to fasten seat belt when loading and unloading from trucks and during
other uses.
Examine seat belt frequently. Be sure that webbing is not cut or torn. Replace seat belt immediately if any part is damaged or
does not function properly.
The complete seat belt assembly should be replaced every three years, regardless of appearance.
Prevent Unintended Machine Movement
LOCKED Position
Always move the park lock levers to the up (locked) position before leaving the operator′s seat for any reason .

Be careful not to accidentally actuate controls when coworkers are present. Engage park lock and lower work equipment to the
ground during work interruptions. Stop the engine before allowing anyone to approach the machine. Follow these same
precautions before standing up, leaving the operator′s seat, or exiting the machine.
Prevent Unintended Machine Movement—If Equipped With Pilot

Controls
Pilot Control Enable/Disable Switch
Be careful not to accidentally actuate control levers when coworkers are present. Always lock hydraulics on backhoe during
work interruptions. Lock hydraulics before allowing anyone to approach machine.
Avoid Work Site Hazards
Avoid contact with gas lines

Avoid collapsing banks
Avoid contact with gas lines, buried cables and water lines. Call utility line location services to identify all
underground utilities before you dig.
Prepare work site properly . Avoid operating near structures or objects that could fall onto the machine. Clear away debris
that could move unexpectedly if run over.
Avoid boom or attachment contact with overhead obstacles or overhead electrical lines. Never move any part of
machine or load closer than 3 m (10 ft) plus twice the line insulator length to overhead wires.
Keep bystanders clear at all times. Keep bystanders away from raised booms, attachments, and unsupported loads. Avoid
swinging or raising booms, attachments, or loads over or near personnel. Use barricades or a signal person to keep vehicles
and pedestrians away. Use a signal person if moving machine in congested areas or where visibility is restricted. Always keep
signal person in view. Coordinate hand signals before starting machine.
Operate only on solid footing with strength sufficient to support machine. Be especially alert working near embankments or
excavations.
Avoid working under over-hanging embankments or stockpiles that could collapse on machine.
Reduce machine speed when operating with tool on or near ground when obstacles may be hidden (e.g., during snow
removal or clearing mud, dirt, etc.). At high speeds hitting obstacles (rocks, uneven concrete or manholes) can cause a sudden
stop. Always wear your seat belt.
Keep Riders Off Machine
Keep Riders Off
Only allow the operator on the machine. Keep riders off.

Riders on machine are subject to injury such as being struck by foreign objects and being thrown off of the machine. Riders
also obstruct the operator’s view resulting in the machine being operated in an unsafe manner.
Avoid Backover Accidents

Avoid Backover Accidents
Before moving machine, be sure all persons are clear of the machine travel path. Turn around and look directly for
best visibility. Use mirror to assist in checking behind the machine. Keep windows and mirror clean and in good repair.
Be certain backup warning alarm is working properly.
Use a signal person when backing if view is obstructed or when in close quarters. Keep signal person in view at all
times. Use prearranged hand signals to communicate.

Avoid Machine Tipover
Avoid Machine Tipover
Use seat belt at all times.

Do not jump if the machine tips. You will be unlikely to jump clear and the machine may crush you.
Load and unload from trucks or trailers carefully. Be sure truck is wide enough and secured on a firm level surface. Use
loading ramps and attach them properly to truck bed.
Be careful on slopes. Use extra care on soft, rocky or frozen ground because machine may slip sideways in these conditions.
Ensure solid footing. Use extra care when operating on stockpile materials, or near banks or excavations that may cave-in
and cause machine to tip or fall.
Inspect and Maintain ROPS

A damaged rollover protective structure (ROPS) should be replaced, not reused.
The protection offered by ROPS could be impaired if ROPS is subjected to structural damage, is involved in an overturn
incident, or is in any way altered by welding, bending, drilling, or cutting.
If ROPS was loosened or removed for any reason, inspect it carefully before operating the machine again.
To maintain the ROPS:
Replace missing hardware using correct grade hardware.

Check hardware torque.
Check isolation mounts for damage, looseness, or wear; replace them if necessary.
Check ROPS for cracks or physical damage.
Add and Operate Attachments Safely

Always verify compatibility of attachments by contacting your authorized dealer. Adding unapproved attachments could affect

machine stability or reliability and could create a hazard for others near the machine.
Ensure that a qualified person is involved in attachment installation. Add guards to machine if operator protection is required or
recommended. Verify that all connections are secure and attachment responds properly to controls.
Carefully read attachment manual and follow all instructions and warnings. In an area free of bystanders and obstructions,
carefully operate attachment to learn its characteristics and range of motion.
Operating or Traveling On Public Roads
Operating or Traveling On Public Roads
Machines that work near vehicle traffic or travel slower than normal highway speeds must have proper lighting and markings to
assure they are visible to other drivers.
Install additional lights, beacons, slow moving vehicle (SMV) emblems, or other devices and use as required to make the
machine visible and identify it as a work machine. Check state and local regulations to assure compliance. Keep these devices
clean and in working condition.
Park and Prepare for Service Safely
Do Not Operate Tag

Support Machine Properly
Warn others of service work. Always park and prepare your machine for service or repair properly.
Park machine on a level surface and lower equipment to the ground.

Engage park brake.
Stop engine and remove key.
Attach a “Do Not Operate” tag in an obvious place in the operator′s station.
Securely support machine or attachment before working under it.
Do not support machine with any hydraulically actuated tools or attachments.

Do not support machine with cinder blocks or wooden pieces that may crumble or crush.
Do not support machine with a single jack or other devices that may slip out of place.
Always install boom lock before working on or around this machine with the loader boom raised.
Understand service procedures before beginning repairs. Keep service area clean and dry. Use two people whenever the
engine must be running for service work.
Service Cooling System Safely
Cooling System
Explosive release of fluids from pressurized cooling system can cause serious burns.
Do not service radiator through the radiator cap. Only fill through the surge tank filler cap. Shut off engine. Only remove surge
tank filler cap when cool enough to touch with bare hands. Slowly loosen cap to relieve pressure before removing completely.
Remove Paint Before Welding or Heating
Toxic Fumes
Avoid potentially toxic fumes and dust.

Hazardous fumes can be generated when paint is heated by welding, soldering, or using a torch.
Remove paint before heating:
Remove paint a minimum of 100 mm (4 in.) from area to be affected by heating. If paint cannot be removed, wear an
approved respirator before heating or welding.
If you sand or grind paint, avoid breathing the dust. Wear an approved respirator.
If you use solvent or paint stripper, remove stripper with soap and water before welding. Remove solvent or paint stripper
containers and other flammable material from area. Allow fumes to disperse at least 15 minutes before welding or
heating.
Do not use a chlorinated solvent in areas where welding will take place.
Do all work in an area that is well ventilated to carry toxic fumes and dust away.
Dispose of paint and solvent properly.
Make Welding Repairs Safely
Heating Near Pressurized Fluid Lines
IMPORTANT:
Disable electrical power before welding. Turn off main battery switch and disconnect positive (+) and
negative (-) battery cables.
Do not weld or apply heat on any part of a reservoir or tank that has contained oil or fuel. Heat from welding and cutting can
cause oil, fuel, or cleaning solution to create gases which are explosive, flammable, or toxic.
Avoid welding or heating near pressurized fluid lines. Flammable spray may result and cause severe burns if pressurized lines
malfunction as a result of heating. Do not let heat go beyond work area to nearby pressurized lines.
Remove paint properly. Do not inhale paint dust or fumes. Use a qualified welding technician for structural repairs. Make sure
there is good ventilation. Wear eye protection and protective equipment when welding.
Drive Metal Pins Safely
Hardened Metal Parts
Always wear protective goggles or safety glasses and other protective equipment before striking hardened parts. Hammering
hardened metal parts such as pins and bucket teeth could dislodge chips at high velocity.
Use a soft hammer or a brass bar between hammer and object to prevent chipping.

Section 00 - GENERAL INFORMATION Group 0003: Torque Values
Service Tires Safely
Explosive Tire and Rim Parts
Explosive separation of a tire and rim parts can cause serious injury or death.
Do not attempt to mount a tire unless you have the proper equipment and experience to perform the job.
Always maintain the correct tire pressure. Do not inflate the tires above the recommended pressure. Never weld or heat a
wheel and tire assembly. The heat can cause an increase in air pressure resulting in a tire explosion. Welding can structurally
weaken or deform the wheel.
When inflating tires, use a clip-on chuck and extension hose long enough to allow you to stand to one side and NOT in front of
or over the tire assembly. Use a safety cage if available.
Check wheels for low pressure, cuts, bubbles, damaged rims or missing lug bolts and nuts.

Group 0003 - Torque Values

Metric Bolt and Cap Screw Torque Values
Metric Bolt and Cap Screw Torque Values
METRIC BOLT AND CAP SCREW TORQUE VALUES—Tolerance is ±10% unless otherwise specified
Top—Property Class and Head Markings; Bottom—Property Class and Nut Markings
Class 4.8 Class 8.8 or 9.8 Class 10.9 Class 12.9

a b a b a b
Lubricated Nm Dry Lubricated Nm Dry Lubricated Nm Dry Lubricated a Nm Dry b
Thread Size
(lb-ft) Nm (lb-ft) (lb-ft) Nm (lb-ft) (lb-ft) Nm (lb-ft) (lb-ft) Nm (lb-ft)
M6 4.7 (3.5) 6 (4.4) 9 (6.6) 11.5 (8.5) 13 (9.5) 16.5 (12.2) 15.5 (11.5) 19.5 (14.5)
M8 11.5 (8.5) 14.5 (10.7) 22 (16) 28 (20.5) 32 (23.5) 40 (29.5) 37 (27.5) 47 (35)
M10 23 (17) 29 (21) 43 (32) 55 (40) 63 (46) 80 (59) 75 (55) 95 (70)
M12 40 (29.5) 50 (37) 75 (55) 95 (70) 110 (80) 140 (105) 130 (95) 165 (120)
M14 63 (46) 80 (59) 120 (88) 150 (110) 175 (130) 220 (165) 205 (150) 260 (190)
M16 100 (74) 125 (92) 190 (140) 240 (175) 275 (200) 350 (255) 320 (235) 400 (300)
M18 135 (100) 170 (125) 265 (195) 330 (245) 375 (275) 475 (350) 440 (325) 560 (410)
M20 190 (140) 245 (180) 375 (275) 475 (350) 530 (390) 675 (500) 625 (460) 790 (580)
M22 265 (195) 330 (245) 510 (375) 650 (480) 725 (535) 920 (680) 850 (625) 1080 (800)
M24 330 (245) 425 (315) 650 (480) 820 (600) 920 (680) 1150 (850) 1080 (800) 1350 (1000)
M27 490 (360) 625 (460) 950 (700) 1200 (885) 1350 (1000) 1700 (1250) 1580 (1160) 2000 (1475)
M30 660 (490) 850 (625) 1290 (950) 1630 (1200) 1850 (1350) 2300 (1700) 2140 (1580) 2700 (2000)
M33 900 (665) 1150 (850) 1750 (1300) 2200 (1625) 2500 (1850) 3150 (2325) 2900 (2150) 3700 (2730)
M36 1150 (850) 1450 (1075) 2250 (1650) 2850 (2100) 3200 (2350) 4050 (3000) 3750 (2770) 4750 (3500)
a
"Lubricated" means coated with a lubricant such as engine oil, or fasteners with phosphate and oil coatings.
b
"Dry" means plain or zinc plated without any lubrication.
Metric Bolt and Cap Screw Torque Value Instructions
Fasteners should be replaced with the same or higher property class. If higher
CAUTION: property class fasteners are used, these should only be tightened to the strength
Use only metric tools on metric hardware. Other tools may not fit of the original.
properly. Tool may slip and cause injury. Make sure fastener threads are clean and that you properly start thread
DO NOT use these values if a different torque value or tightening engagement. This will prevent them from failing when tightening.
procedure is given for a specific application. Torque values listed are for Tighten plastic insert or crimped steel-type lock nuts to approximately 50 percent
general use only. Check tightness of fasteners periodically. of the dry torque shown in the chart, applied to the nut, not to the bolt head.
Shear bolts are designed to fail under predetermined loads. Always Tighten toothed or serrated-type lock nuts to the full torque value.
replace shear bolts with identical property class.

Additional Metric Cap Screw Torque Values
T-Bolt
H-Bolt
M-Bolt
CAUTION:
Use only metric tools on metric hardware. Other tools may not fit properly. They may slip and cause
injury.
Check tightness of cap screws periodically. Torque values listed are for general use only. Do not use these values if a different
torque value or tightening procedure is listed for a specific application.
Shear bolts are designed to fail under predetermined loads. Always replace shear bolts with identical grade.
Fasteners should be replaced with the same or higher grade. If higher grade fasteners are used, these should only be tightened
to the strength of the original.
Make sure fastener threads are clean and you properly start thread engagement. This will prevent them from failing when
tightening.
Tighten cap screws having lock nuts to approximately 50 percent of amount shown in chart.

Metric Cap Screw Torque Values
METRIC CAP SCREW TORQUE VALUES

[ Torque tolerance is ±10%. ]
T-Bolt H-Bolt M-Bolt
Nominal Dia N˙m lb-ft N˙m lb-ft N˙m lb-ft
8 29 21 20 15 10 7
10 63 46 45 33 20 15
12 108 80 88 65 34 25
14 176 130 137 101 54 40
16 265 195 206 152 78 58
18 392 289 294 217 118 87
20 539 398 392 289 167 125
22 735 542 539 398 216 159
24 931 687 686 506 274 202
27 1372 1012 1029 759 392 289
30 1911 1410 1421 1049 539 398
33 2548 1890 1911 1410 735 542
36 3136 2314 2401 1772 931 687

Unified Inch Bolt and Cap Screw Torque Values

Unified Inch Bolt and Cap Screw Torque Values
UNIFIED INCH BOLT AND CAP SCREW TORQUE VALUES—Tolerance is ±10% unless otherwise specified
Top—SAE Grade and Head Markings; Bottom—SAE Grade and Nut Markings
Grade 1 (No Mark) Grade 2 a (No Mark) Grade 5, 5.1 or 5.2 Grade 8 or 8.2
b c b c b c b c
Lubricated N˙m Dry Lubricated N˙m Dry Lubricated N˙m Dry Lubricated N˙m Dry
Thread Size
(lb-ft) N˙m (lb-ft) (lb-ft) N˙m (lb-ft) (lb-ft) N˙m (lb-ft) (lb-ft) N˙m (lb-ft)
1/4 3.8 (2.8) 4.7 (3.5) 6 (4.4) 7.5 (5.5) 9.5 (7) 12 (9) 13.5 (10) 17 (12.5)
5/16 7.7 (5.7) 9.8 (7.2) 12 (9) 15.5 (11.5) 19.5 (14.5) 25 (18.5) 28 (20.5) 35 (26)
3/8 13.5 (10) 17.5 (13) 22 (16) 27.5 (20) 35 (26) 44 (32.5) 49 (36) 63 (46)
7/16 22 (16) 28 (20.5) 35 (26) 44 (32.5) 56 (41) 70 (52) 80 (59) 100 (74)
1/2 34 (25) 42 (31) 53 (39) 67 (49) 85 (63) 110 (80) 120 (88) 155 (115)
9/16 48 (35.5) 60 (45) 76 (56) 95 (70) 125 (92) 155 (115) 175 (130) 220 (165)
5/8 67 (49) 85 (63) 105 (77) 135 (100) 170 (125) 215 (160) 240 (175) 305 (225)
3/4 120 (88) 150 (110) 190 (140) 240 (175) 300 (220) 380 (280) 425 (315) 540 (400)
7/8 190 (140) 240 (175) 190 (140) 240 (175) 490 (360) 615 (455) 690 (510) 870 (640)
1 285 (210) 360 (265) 285 (210) 360 (265) 730 (540) 920 (680) 1030 (760) 1300 (960)
1-1/8 400 (300) 510 (375) 400 (300) 510 (375) 910 (670) 1150 (850) 1450 (1075) 1850 (1350)
1-1/4 570 (420) 725 (535) 570 (420) 725 (535) 1280 (945) 1630 (1200) 2050 (1500) 2600 (1920)
1-3/8 750 (550) 950 (700) 750 (550) 950 (700) 1700 (1250) 2140 (1580) 2700 (2000) 3400 (2500)
1-1/2 990 (730) 1250 (930) 990 (730) 1250 (930) 2250 (1650) 2850 (2100) 3600 (2650) 4550 (3350)
a
Grade 2 applies for hex cap screws (not hex bolts) up to 6 in. (152 mm) long. Grade 1 applies for hex cap screws over 6 in. (152 mm) long, and for all other types of
bolts and screws of any length.
b
"Lubricated" means coated with a lubricant such as engine oil, or fasteners with phosphate and oil coatings.
c
"Dry" means plain or zinc plated without any lubrication.
Unified Inch Bolt and Cap Screw Torque Value Instructions
DO NOT use these values if a different torque value or tightening procedure is

given for a specific application. Torque values listed are for general use only.
Make sure fastener threads are clean and that you properly start thread engagement.
Check tightness of fasteners periodically.
This will prevent them from failing when tightening.
Shear bolts are designed to fail under predetermined loads. Always replace
Tighten plastic insert or crimped steel-type lock nuts to approximately 50 percent of
shear bolts with identical grade.
the dry torque shown in the chart, applied to the nut, not to the bolt head. Tighten
Fasteners should be replaced with the same or higher grade. If higher grade
toothed or serrated-type lock nuts to the full torque value.
fasteners are used, these should only be tightened to the strength of the
original.

Service Recommendations for 37° Flare and 30° Cone Seat Connectors
Cone Seat Connector
[1] - Inspect flare and flare seat. They must be free of dirt or obvious defects.
[2] - Defects in tube flare cannot be repaired. Overtightening a defective flared fitting will not stop leaks.
[3] - Align tube with fitting before attempting to start nut.
[4] - Lubricate male threads with hydraulic fluid or petroleum jelly.
[5] - Index angle fittings and tighten by hand.
[6] - Tighten fitting or nut to torque value shown on torque chart. Do not allow hoses to twist when tightening fittings.
Straight Fitting or Special Nut Torque Chart
STRAIGHT FITTING OR SPECIAL NUT TORQUE CHART
Thread Size N˙m lb-ft
3/8 - 24 UNF 8 6
7/16 - 20 UNF 12 9
1/2 - 20 UNF 16 12
9/16 - 18 UNF 24 18
3/4 - 16 UNF 46 34
7/8 - 14 UNF 62 46
1-1/16 - 12 UN 102 75
1-3/16 - 12 UN 122 90
1-5/16 - 12 UN 142 105
1-5/8 - 12 190 140
1-7/8 - 12 UN 217 160
→NOTE:
Torque tolerance is ± 10%.

Service Recommendations for O-Ring Boss Fittings

Straight Fitting
Straight Fitting
[1] - Inspect O-ring boss seat for dirt or defects.
[2] - Lubricate O-ring with petroleum jelly. Place electrical tape over threads to protect O-ring. Slide O-ring over tape and into
O-ring groove of fitting. Remove tape.
[3] - Tighten fitting to torque value shown on chart.
Angle Fitting
Angle Fitting
[1] - Back-off lock nut (A) and back-up washer (B) completely to head-end (C) of fitting.
[2] - Turn fitting into threaded boss until back-up washer contacts face of boss.
[3] - Turn fitting head-end counterclockwise to proper index (maximum of one turn).
[4] -
→NOTE:
Do not allow hoses to twist when tightening fittings.
Hold fitting head-end with a wrench and tighten locknut and back-up washer to proper torque value.

Straight Fitting or Special Nut Torque Chart
STRAIGHT FITTING OR SPECIAL NUT TORQUE CHART
3/8-24 UNF 8 6
7/16-20 UNF 12 9
1/2-20 UNF 16 12
9/16-18 UNF 24 18
3/4-16 UNF 46 34
7/8-14 UNF 62 46
1-1/16-12 UN 102 75
1-3/16-12 UN 122 90
1-5/16-12 UN 142 105
1-5/8-12 UN 190 140
1-7/8-12 UN 217 160
→NOTE:
Torque tolerance is ± 10%.

O-Ring Boss Fittings In Aluminum Housing Service

Recommendations—Excavators
O-Ring Boss Straight and Adjustable Fittings

LEGEND:
1 Straight Fitting
2 O-Ring
3 Stud End
4 Adjustable Fitting
5 Hex Nut
6 Backup Washer
Straight or Adjustable Fitting Stud End Nut with Metric Thread in Aluminum Housing Torque Values
O-RING BOSS STRAIGHT OR ADJUSTABLE FITTING STUD END NUT WITH METRIC THREAD IN ALUMINUM HOUSING TORQUE VALUES—Tolerance is ±
10% unless otherwise specified
Thread Size Hex Nut Size

Nm (lb-ft)
mm mm
M12 x 1.5 17 39 (29)
M14 x 1.5 19 39 (29)
M16 x 1.5 22 55 (41)
M22 x 1.5 27 75 (55)
M27 x 2 32 110 (81)
M30 x 2 36 141 (104)
M33 x 2 41 165 (122)
M38 x 2 46 165 (122)
M42 x 2 50 275 (203)
Straight or Adjustable Fitting Stud End Nut with Inch Thread in Aluminum Housing Torque Values
O-RING BOSS STRAIGHT OR ADJUSTABLE FITTING STUD END NUT WITH INCH THREAD IN ALUMINUM HOUSING TORQUE VALUES—Tolerance is ± 10%
unless otherwise specified
Thread Size
Nm (lb-ft)
in.
1/8 —
1/4 28 (20)
3/8 39 (29)
1/2 75 (55)
3/4 126 (93)
1 165 (122)
1-1/8 —
1-1/4 259 (191)
1-3/8 —
1-1/2 330 (243)
1-3/4 —

O-RING BOSS STRAIGHT OR ADJUSTABLE FITTING STUD END NUT WITH INCH THREAD IN ALUMINUM HOUSING TORQUE VALUES—Tolerance is ± 10%
unless otherwise specified
Thread Size
Nm (lb-ft)
in.
2 —
O-Ring Boss Plug Stud End with Inch Thread in Aluminum Housing Torque Values
O-RING BOSS PLUG STUD END WITH INCH THREAD IN ALUMINUM HOUSING TORQUE VALUES—Tolerance is ± 10% unless otherwise specified
Thread Size
Nm (lb-ft)
in.
1/8 7.8 (5.80)
1/4 11.8 (8.70)
3/8 23 (17)
1/2 39 (29)
3/4 55 (41)
1 86 (64)
1-1/4 126 (93)
1-1/2 157 (116)
2 204 (150)
[1] - Inspect fitting and O-ring boss sealing surfaces and the O-ring. They must be free of dirt, scratches, nicks, or burrs. O-ring
must be free of dirt, cuts, cracks, swelling or flatten condition.
[2] - Back the stud end hex nut (5) off as far as possible. Push backup washer (6) towards the nut to fully expose the turn down
section of stud end. Washer must fit turned down section and not be too loose
[3] - Wrap electrical tape over threads to protect O-ring. Slide O-ring over the tape into turned down section. Remove tape.
Apply hydraulic oil to the threads of stud end, turned down section, and O-ring.
[4] - Turn fitting into the boss by hand until face of nut or backup washer squeezes O-ring into the seat and contacts face of
boss. Loosen an adjustable fitting no more than one turn for alignment.
[5] - Tighten straight fitting or hex nut to the torque value given. Hold body of adjustable fitting using a second wrench when
tightening hex nut.

Service Recommendations For Flared Connections—Straight or Tapered

Threads
Straight Thread
Tapered Thread
[1] - Inspect flare and flare seat. They must be free of dirt or obvious defects.
[2] - Defects in the tube flare cannot be repaired. Overtightening a defective flared fitting will not stop leaks.
[3] - Align the tube with the fitting before attempting to start the nut.
[4] - Lubricate the male threads with hydraulic fluid or petroleum jelly.
[5] - Index angle fittings and tighten by hand.
[6] - Tighten fitting or nut to torque value shown on the chart. Do not allow hoses to twist when tightening fittings.
Torque Chart
TORQUE CHART
Straight Thread
Tapered Thread
[ With seat face. ]
Thread Size N˙m lb-ft N˙m lb-ft
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

TORQUE CHART
Straight Thread Tapered Thread

[ With seat face. ]
Thread Size N˙m lb-ft N˙m lb-ft
1-1/2 196 145 539 398
2 255 188 588 434
→NOTE:
If female thread is cast iron (control valves, brake valves motors, etc.), torque must be reduced
approximately 10%.

Service Recommendations For Flat Face O-Ring Seal Fittings

[1] - Inspect the fitting sealing surfaces and O-ring. They must be free of dirt or defects.
[2] - Lubricate O-rings and install into grove using petroleum jelly to hold in place.
[3] - Index angle fittings and tighten by hand pressing joint together to insure O-ring remains in place.
[4] - Tighten fitting or nut to torque value shown on the chart. Do not allow hoses to twist when tightening fittings, use backup
wrench on straight hose couplings.
IMPORTANT:
Tighten fittings to 150% of listed torque value if indexing is necessary or if fitting is attached to an
actuating devise.
Tighten fittings to 50% of listed torque value if used in aluminum housing.
O-ring Seal Fitting Torque
FLAT FACE O-RING SEAL FITTING TORQUE*
Nomial Tube O.D. Thread Size Swivel Nut Bulkhead Nut
mm in. in. N˙m lb-ft N˙m lb-ft
6.35 0.250 9/16-18 16 12 12 9
9.52 0.375 11/16-16 24 18 24 18
12.70 0.500 13/16-16 50 37 46 34
15.88 0.625 1-14 69 51 62 46
19.05 0.750 1 3/16-12 102 75 102 75
22.22 0.875 1 3/16-12 102 75 102 75
25.40 1.000 1 7/16-12 142 105 142 105
31.75 1.250 1 11/16-12 190 140 190 140
38.10 1.500 2-12 217 160 217 160
*Torque tolerance is +15 -20% unless otherwise specified.
Stud End O-ring Seal Torque for Straight and Adjustable Fittings*
Thread Size Straight Hex Size Locknut Hex Size Straight Fitting or Locknut Toque
Inch Inch Inch N˙m lb-ft
3/8-24 5/8 9/16 12 9
7/16-20 5/8 5/8 21 15
1/2-20 3/4 11/16 26 19
9/16-18 3/4 3/4 34 25
3/4-16 7/8 15/16 73 55
7/8-14 1 1/16 1 1/16 104 76
1 1/16-12 1 1/4 1 3/8 176 130
1 3/16-12 1 3/8 1 1/2 230 170
1 5/16-12 1 1/2 1 5/8 285 210
*Torque tolerance is +15 -20% unless otherwise specified.

O-Ring Face Seal Fittings With SAE Inch Hex Nut And Stud End For High
Pressure Service Recommendations
O-Ring Face Seal Fittings with SAE Inch Hex Nut and Stud End for High Pressure Torque Values
O-RING FACE SEAL FITTINGS WITH SAE INCH HEX NUT AND STUD END FOR HIGH PRESSURE, ABOVE 27 600 kPa (276 bar) (4000 psi), TORQUE
VALUES—Tolerance is +15 -20% unless otherwise specified
O-Ring Face Seal Fitting

LEGEND:
A 90° Swivel Elbow and Tube Nut
B 90° Adjustable Stud Elbow
C Stud Straight and Tube Nut
D Bulkhead Union and Nut
E Stud End
F Tube Nut
G Swivel Nut
H Hex Nut
Nominal Tube OD or Hose ID O-Ring Face Seal Hose or Tube Swivel Nut Bulkhead Nut
Metric Tube OD Inch Tube OD or Hose ID Thread Size Hex Size Torque Hex Size Torque
mm Dash Size mm (in.) in. in. Nm (lb-ft) in. Nm (lb-ft)
5 -3 4.78 (0.188) — — — — —
6 -4 6.35 (0.250) 9/16-18 11/16 24 (18) 13/16 32 (24)
8 -5 7.92 (0.312) — — — — —
10 -6 9.53 (0.375) 11/16-16 13/16 37 (27) 1 42 (31)
12 -8 12.70 (0.500) 13/16-16 15/16 75 (55) 1-1/8 93 (69)
16 -10 15.88 (0.625) 1-14 1-1/8 103 (76) 1-5/16 118 (87)
20 -12 19.05 (0.750) 1-3/16-12 1-3/8 152 (112) 1-1/2 175 (129)
22 -14 22.23 (0.875) 1-3/16-12 — 152 (112) — 175 (129)
25 -16 25.40 (1.000) 1-7/16-12 1-5/8 214 (158) 1-3/4 247 (182)
32 -20 31.75 (1.250) 1-11/16-12 1-7/8 286 (211) 2 328 (242)
38 -24 38.10 (1.500) 2-12 2-1/4 326 (240) 2-3/8 374 (276)
O-RING STRAIGHT, ADJUSTABLE, AND EXTERNAL HEX PLUG WITH SAE INCH STUD END FOR HIGH PRESSURE, ABOVE 27 600 kPa (276 bar) (4000 psi),
TORQUE VALUES—Tolerance is +15 -20% unless otherwise specified
a
Thread Size Straight Hex Size Adjustable Nut Hex Size Steel or Gray Iron Torque
in. in. in. Nm (lb-ft)
3/8-24 5/8 9/16 18 (13)
7/16-20 5/8 5/8 24 (18)
1/2-20 3/4 11/16 30 (22)
9/16-18 3/4 3/4 37 (27)
3/4-16 7/8 15/16 75 (55)
7/8-14 1-1/16 1-1/16 103 (76)
1-1/16-12 1-1/4 1-3/8 177 (131)
1-3/16-12 1-3/8 1-1/2 231 (170)
1-5/16-12 1-1/2 1-5/8 270 (199)
1-5/8-12 1-3/4 1-7/8 286 (211)

O-RING STRAIGHT, ADJUSTABLE, AND EXTERNAL HEX PLUG WITH SAE INCH STUD END FOR HIGH PRESSURE, ABOVE 27 600 kPa (276 bar) (4000 psi),
a
in. in. in. Nm (lb-ft)
1-7/8-12 2-1/8 2-1/8 326 (240)

a
Straight hex size applies to fittings only and may not be the same as the corresponding plug of the same thread size.
[1] - Inspect fitting and connector sealing surfaces and the O-rings. They must be free of dirt, scratches, nicks, and burrs. O-
ring must be free of dirt, cuts, cracks, swelling or flatten condition.
[2] - Back the stud end hex nut off as far as possible. Push backup washer towards the nut to fully expose the turn down
section. Washer must fit turned down section and not be too loose
[3] - Lubricate O-rings using a thin film of clean hydraulic oil or as needed, petroleum jelly to hold O-ring in place.
Install O-ring into groove making sure it is seated at the bottom. Excess petroleum jelly will prevent seating of O-ring and cause
it to pop out.
To protect an O-ring from threads, wrap electrical tape over the threads. Slide O-ring over the tape into the turned down
section. Remove the tape.
[4] - Turn fitting into the boss by hand until face of nut or washer squeezes the O-ring into the seat and contacts face of boss.
Loosen adjustable fittings no more than one turn for alignment.
Hold connections together while tightening nut to ensure O-ring remains in place.
[5] - Tighten fitting or nut to torque value shown. Use a second wrench to hold the fitting in position or to keep hose from
twisting while tightening nut.

O-Ring Face Seal Fittings With Metric Hex Nut And Stud End For
Standard Pressure Service Recommendations
O-Ring Face Seal Fittings with Metric Hex and Stud End for Standard Pressure Torque Values
O-RING FACE SEAL AND FITTINGS WITH METRIC HEX NUT AND STUD END FOR STANDARD PRESSURE, BELOW 27 600 kPa (275.8 bar) (4,000 psi),
O-Ring Face Seal Fittings

LEGEND:
1 90° Swivel Elbow
2 90° Adjustable Stud Elbow
3 Stud Straight
4 Bulkhead Union and Nut
5 External Hex Stud End Plug
6 Tube Nut
7 Swivel Nut
8 Stud End
9 Hex Nut
10 O-Ring
11 Identification Groove
mm Dash Size mm (in.) in. mm Nm (lb-ft) mm Nm (lb-ft)
4 -2 3.18 (0.125) — — — — —
5 -3 4.78 (0.188) — — — — —
6 -4 6.35 (0.250) 9/16-18 17 16 (12) 22 32 (24)
8 -5 7.92 (0.312) — — — — —
10 -6 9.53 (0.375) 11/16-16 22 24 (18) 27 42 (31)
12 -8 12.70 (0.500) 13/16-16 24 50 (37) 30 93 (69)
16 -10 15.88 (0.625 1-14 30 69 (51) 36 118 (87)
20 -12 19.05 (0.750) 1-3/16-12 36 102 (75) 41 175 (129)
22 -14 22.23 (0.875) 1-3/16-12 36 102 (75) 41 175 (129)
25 -16 25.40 (1.000) 1-7/16-12 41 142 (105) 46 247 (182)
28 — — — — — — —
32 -20 31.75 (1.250) 1-11/16-12 50 190 (140) 50 328 (242)
38 -24 38.10 (1.500) 2-12 60 217 (160) 60 374 (276)
50 -32 50.80 (2.000) — — — — —
O-RING STRAIGHT, ADJUSTABLE, AND EXTERNAL HEX PLUG WITH METRIC STUD END FOR STANDARD PRESSURE, BELOW 27 600 kPa (275.8 bar)
(4,000 psi), TORQUE VALUES—Tolerance is +15 -20% unless otherwise specified
a b
Thread Size Straight Hex Size Adjustable Nut Hex Size Steel or Gray Iron Torque Aluminum or Brass Torque
mm. mm mm Nm (lb-ft) Nm (lb-ft)
M8 x 1 12 12 8 (6) 5 (4)
M10 x 1 14 14 15 (11) 10 (7)
M12 x 1.5 17 17 25 (18) 17 (12)
M14 x 1.5 19 19 40 (30) 27 (20)

O-RING STRAIGHT, ADJUSTABLE, AND EXTERNAL HEX PLUG WITH METRIC STUD END FOR STANDARD PRESSURE, BELOW 27 600 kPa (275.8 bar)
(4,000 psi), TORQUE VALUES—Tolerance is +15 -20% unless otherwise specified
a b
Thread Size Straight Hex Size Adjustable Nut Hex Size Steel or Gray Iron Torque Aluminum or Brass Torque
mm. mm mm Nm (lb-ft) Nm (lb-ft)
M16 x 1.5 22 22 45 (33) 30 (22)
M18 x 1.5 24 24 50 (37) 33 (25)
M22 x 1.5 27 27 69 (51) 46 (34)
M27 x 2 32 32 100 (74) 67 (49)
M30 x 2 36 36 130 (96) 87 (64)
M33 x 2 41 41 160 (118) 107 (79)
M38 x 2 46 46 176 (130) 117 (87)
M42 x 2 50 50 210 (155) 140 (103)
M48 x 2 55 55 260 (192) 173 (128)
M60 x 2 65 65 315 (232) 210 (155)

a
Stud end threads are identified as metric by an identification groove in the hex nut next to the O-ring.
b
it to pop out.

O-Ring Face Seal Fittings With Metric Hex Nut And Stud End For High
Pressure Service Recommendations
O-Ring Face Seal Fittings with Metric Hex Nut and Stud End For Standard Pressure Torque Values
O-RING FACE SEAL FITTINGS WITH METRIC HEX NUT AND STUD END FOR HIGH PRESSURE, ABOVE 27 600 kPa (275.8 bar) (4,000 psi), TORQUE
VALUES—Tolerance is +15 -20% unless otherwise specified
O-Ring Face Seal Fittings

LEGEND:
1 90° Swivel Elbow
2 90° Adjustable Stud Elbow
3 Stud Straight
4 Bulkhead Union and Nut
5 External Hex Stud End Plug
6 Tube Nut
7 Swivel Nut
8 Stud End
9 Hex Nut
10 O-Ring
11 Identification Groove
mm Dash Size mm (in.) in. mm Nm (lb-ft) mm Nm (lb-ft)
4 -2 3.18 (0.125) — — — — —
5 -3 4.78 (0.188) — — — — —
6 -4 6.35 (0.250) 9/16-18 17 24 (18) 22 32 (24)
8 -5 7.92 (0.312) — — — — —
10 -6 9.53 (0.375) 11/16-16 22 37 (27) 27 42 (31)
12 -8 12.70 (0.500) 13/16-16 24 75 (55) 30 93 (69)
16 -10 15.88 (0.625) 1-14 30 103 (76) 36 118 (87)
20 -12 19.05 (0.750) 1-3/16-12 36 152 (112) 41 175 (129)
22 -14 22.23 (0.875) 1-3/16-12 36 152 (112) 41 175 (129)
25 -16 25.40 (1.000) 1-7/16-12 41 214 (158) 46 247 (182)
28 — — — — — — —
32 -20 31.75 (1.250) 1-11/16-12 — 286 (211) 50 328 (242)
38 -24 38.10 (1.500) 2-12 — 326 (240) 60 374 (276)
O-RING STRAIGHT, ADJUSTABLE, AND EXTERNAL HEX PLUG WITH METRIC STUD END FOR HIGH PRESSURE, ABOVE 27 600 KPA (275.8 BAR) (4,000
PSI), TORQUE VALUES—Tolerance is +15 -20% unless otherwise specified
a b
mm. mm mm Nm (lb-ft)
M8 x 1 12 12 8 (6)
M10 x 1 14 14 15 (11)
M12 x 1.5 17 17 35 (26)
M14 x 1.5 19 19 45 (33)
M16 x 1.5 22 22 55 (41)

O-RING STRAIGHT, ADJUSTABLE, AND EXTERNAL HEX PLUG WITH METRIC STUD END FOR HIGH PRESSURE, ABOVE 27 600 KPA (275.8 BAR) (4,000
PSI), TORQUE VALUES—Tolerance is +15 -20% unless otherwise specified
a b
mm. mm mm Nm (lb-ft)
M18 x 1.5 24 24 70 (52)
M22 x 1.5 27 27 100 (74)
M27 x 2 32 32 170 (125)
M30 x 2 36 36 215 159)
M33 x 2 41 41 260 (192)
M38 x 2 46 46 320 (236)
M42 x 2 50 50 360 (266)
M48 x 2 55 55 420 (310)

a
Stud end threads are identified as metric by an identification groove in the hex nut next to the O-ring.
b
it to pop out.

Service Recommendations for Metric Series Four Bolt Flange Fitting
Metric Series Four Bolt Flange Fitting

LEGEND:
A Sealing Surface
B Split Flange
C Pinched O-Ring
D Single Piece Flange
[1] - Clean sealing surfaces (A). Inspect. Scratches cause leaks. Roughness causes seal wear. Out-of-flat causes seal extrusion.
If defects cannot be polished out, replace component.
[2] - Install the correct O-ring (and backup washer if required) into groove using petroleum jelly to hold it in place.
[3] - Split flange: Loosely assemble split flange (B) halves. Make sure split is centrally located and perpendicular to the port.
Hand tighten cap screws to hold parts in place. Do not pinch O-ring (C).
[4] - Single piece flange (D): Place hydraulic line in center of flange and install four cap screws. Flange must be centrally
located on port. Hand tighten cap screws to hold flange in place. Do not pinch O-ring.
[5] - After components are properly positioned and cap screws are hand tightened, tighten one cap screw, then tighten the
diagonally opposite cap screw. Tighten two remaining cap screws. Tighten all cap screws as specified in the chart below.
DO NOT use air wrenches. DO NOT tighten one cap screw fully before tightening the others. DO NOT over tighten.
Torque Chart
TORQUE CHART
[ Tolerance ± 10%. The torques given are enough for the given size connection with the recommended working pressure. Increasing cap screw torque beyond these amounts will
result in flange and cap screw bending and connection failures. ]
Thread
N˙m lb-ft
[ Metric standard thread. ]
M6 12 9
M8 30 22
M10 57 42
M12 95 70
M14 157 116
M16 217 160
M18 334 246
M20 421 318

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

Inch Series Four Bolt Flange Fitting For High Pressure Service
Recommendations
Four Bolt Flange Fittings

LEGEND:
A Sealing Surface
B Split Flange
C Pinched O-Ring
Inch Series Four Bolt Flange Fitting High Pressure Torque Values
INCH SERIES FOUR BOLT FLANGE FITTING FOR 41 400 kPa (414 bar) (6000 psi) PRESSURE SERIES TORQUE VALUES—Tolerance is ± 10% unless
otherwise specified
a
Nominal Flange Size Cap Screw Size Min—Max Torque
b
in. in. Nm (lb-ft)
1/2 5/16-18 UNC 20—31 (15—23)
3/4 3/8-16 UNC 34—54 (25—40)
1 7/16-14 UNC 57—85 (42—63)
1-1/4 1/2-13 UNC 85—131 (63—97)
1-1/2 5/8-11 UNC 159—264 (117—195)
2 3/4-10 UNC 271—468 (200—345)

a
JDM A17D, SAE Grade 5 or better cap screws with plated hardware.
Lock washers are permissible but not recommended.
b
Minimum torques given are enough for the given size connection with the recommended working pressure. Torques can be increased to the maximum shown for
each cap screw size if desired. Increasing cap screw torque beyond the maximum will result in flange and cap screw bending and connection failures.
[1] - Clean sealing surfaces (A). Inspect. Scratches, nicks, and burrs cause leaks. Roughness causes O-ring wear. Out-of-flat
causes O-ring extrusion. If imperfection cannot be polished out, replace component.
[2] - Install the O-ring (and backup ring, if used) into groove. Use petroleum jelly to hold it in place.
[3] -
IMPORTANT:
DO NOT use air wrenches. DO NOT tighten one cap screw fully before tightening the others. DO NOT over
tighten.
Split flange: Loosely assemble split flange (B) halves. Make sure split is centrally located and perpendicular to port. Hand
tighten cap screws to hold flange halves and line in place. Do not pinch O-ring (C).
Single piece flange (D): Make sure flange is centrally located on port and line is centered in flange. Install the cap screws. Hand
tighten cap screws to hold flange and line in place. Do not pinch O-ring.
[4] - Tighten one cap screw and then the diagonally opposite cap screw. Tighten the two remaining cap screws. Tighten cap
screws within the specified torque values.

Service Recommendations For Non-Restricted Banjo (Adjustable)

Fittings
Non-Restricted Banjo Fitting
[1] - Inspect all fitting sealing surfaces. They must be free of dirt and defects.
[2] - Inspect O-ring (A). It must be free of damage or defects.
[3] - Inspect sealing ring (B) for damage or defects.
[4] - Hold body in desired position while tightening stud by hand.
[5] - Tighten stud (C) to torque value shown on the chart. Do not allow body to twist when tightening stud.
→NOTE:
The L in the Tube Fitting OD Size column indicates “light” designed fitting and the S indicates “heavy”
designed fitting.
Torque Value—Metric
Torque Value
Tube Fitting O.D. Size Metric Thread N˙m lb-ft
6L M 10 x 1 30 22
8L M 12 x 1.5 40 30
10 L M 14 x 1.5 60 44
12 L M 16 x 1.5 100 74
15 L M 18 x 1.5 130 96
18 L M 22 x 1.5 160 118
22 L M 26 x 1.5 250 184
28 L M 33 x 2 400 295
35 L M 42 x 2 600 443
42 L M48 x 2 800 590
6S M 12 x 1.5 40 30

Torque Value
8S M 14 x 1.5 60 44
10 S M 16 x 1.5 100 74
12 S M 18 x 1.5 130 96
14 S M 20 x 1.5 160 118
16 S M 22 x 1.5 160 118
20 S M 27 x 2 250 184
25 S M 33 x 2 400 295
30 S M 42 x 2 600 443
38 S M 48 x 2 800 590
Torque Value—Inch
Torque Value
Tube Fitting O.D. Size Inch Size N˙m lb-ft
6L 1/8 25 18
8L 1/4 50 37
10 L 1/4 50 37
12 L 3/8 90 66
15 L 1/2 130 96
18 L 1/2 150 111
22 L 3/4 250 184
28 L 1 400 295
35 L 1-1/4 600 443
42 L 1-1/2 800 590
6S 1/4 50 37
8S 1/4 50 37
10 S 3/8 90 66
12 S 3/8 100 74
14 S 1/2 130 96
16 S 1/2 150 111
20 S 3/4 250 184
25 S 1 400 295
30 S 1-1/4 600 443
38 S 1-1/2 800 590

Service Recommendations For O-Ring Boss Fittings With Shoulder
O-Ring Boss Fitting With Shoulder
[1] - Inspect component seal boss seat for dirt or defects.
[2] - Inspect EOlastic seal (A) for damage. Replace seal or fitting as necessary.
To replace seal, put electrical tape over threads to protect seal. Slide seal over tape and into seal groove of fitting. Remove
tape.
[3] - Tighten fitting to torque value shown on chart.
IMPORTANT:
Do not allow hoses to twist when tightening fittings.
→NOTE:
The L in the Tube Fitting OD Size column indicates “light” designed fitting and the S indicates “heavy”
designed fitting.
Torque Value—Metric
Torque Value
6L M 10 x 1 20 15
8L M 12 x 1.5 30 22
10 L M 14 x 1.5 45 33
12 L M 16 x 1.5 60 44
15 L M 18 x 1.5 80 59
18 L M 22 x 1.5 130 96
22 L M 26 x 1.5 190 140
28 L M 33 x 2 300 221
35 L M 42 x 2 600 443
42 L M48 x 2 800 590
6S M 12 x 1.5 40 30
8S M 14 x 1.5 60 44
10 S M 16 x 1.5 80 59
12 S M 18 x 1.5 110 81
14 S M 20 x 1.5 140 103
16 S M 22 x 1.5 170 125
20 S M 27 x 2 250 184
25 S M 33 x 2 450 332

Torque Value
30 S M 42 x 2 600 443
38 S M 48 x 2 800 590
Torque Value—Inch
Torque Value
Tube Fitting O.D. Size Inch Size N˙m lb-ft
6L 1/8 20 15
8L 1/4 40 30
10 L 1/4 40 30
12 L 3/8 80 59
15 L 1/2 140 103
18 L 1/2 100 74
22 L 3/4 180 133
28 L 1 300 221
35 L 1-1/4 600 443
42 L 1-1/2 800 590
6S 1/4 50 37
8S 1/4 50 37
10 S 3/8 90 66
12 S 3/8 90 66
14 S 1/2 160 118
16 S 1/2 140 103
20 S 3/4 250 184
25 S 1 400 295
30 S 1-1/4 650 479
38 S 1-1/2 800 590
Torque Value—Hex Socket Head Plugs Only
Hex Socket Head Plugs Only
Torque Value
M 10 x 1 13 10
M 12 x 1.5 30 22
M 14 x 1.5 40 30
M 16 x 1.5 60 44
M 18 x 1.5 70 52
M 20 x 1.5 90 66
M 22 x 1.5 100 74
M 26 x 1.5 120 89
M 27 x 2 150 111
M 33 x 2 250 184
M 42 x 2 400 295
M 48 x 2 500 369
1/8 15 11
1/4 33 24
3/8 70 52
1/2 90 66

Hex Socket Head Plugs Only
Torque Value
3/4 150 111
1 220 162
1-1/4 600 443
1-1/2 800 590

Metric 24° O-Ring Seal DIN 20078 Service Recommendations

Metric 24° O-Ring Seal Din 20078 Torque Values
METRIC 24° O-RING SEAL DIN 20078 TORQUE VALUES
Connection
Fitting Tube OD Size Heavy Fitting Size Light Fitting Size Torque
mm mm mm Turns
6 — M12 x 1.5
Hand tighten so O-ring contacts seat plus an additional 1/4—1/3 turn using a wrench

METRIC 24° O-RING SEAL DIN 20078 TORQUE VALUES
Connection
Fitting Tube OD Size Heavy Fitting Size Light Fitting Size Torque
mm mm mm Turns
8 M16 x 1.5 M14 x 1.5
10 M18 x 1.5 M16 x 1.5
12 M20 x 1.5 M18 x 1.5
14 M22 x 1.5 —
15 — M22 x 1.5
16 M24 x 1.5 —
18 — M26 x 1.5
20 M30 x 2 —
22 — M30 x 2
25 M36 x 2 —
28 — M36 x 2
30 M42 x 2 —
35 — M45 x 2
38 M52 x 2 —
[1] -

WHEELS (g) by Belgreen v2.0
→NOTE:
These fittings are also referred to as EO and EO-2 Bite Type or Ermeto style fittings.
IMPORTANT:
In this style of fittings, there are “heavy” and “light” designs. Usually “heavy” is used for pressure lines
and “light” for return lines.
Some “heavy” and “light” sizes can be threaded together but do not seal properly. Be sure not to mix
“heavy” and “light” fittings.
Inspect the fitting sealing surfaces. They must be free of dirt scratches, nicks, and burrs.
[2] - Inspect the O-ring. It must be free dirt, cuts, cracks, swelling or flatten condition.
[3] - Lubricate O-rings using a thin film of clean hydraulic oil.
[4] - Align an adjustable fitting with the tube.

Hold connections together while tightening nut to ensure proper seal.
[5] - Tighten nut (A) hand tight so O-ring contacts seat and then an additional 1/4—1/3 turn using a wrench.

Section 01 - WHEELS
Table of contents
Group 0110 - Powered or Non-Powered Wheels and Fastenings ..................................................... 1
Rear Wheel Assembly Remove and Install ........................................................................................... 1
Front Wheel Assembly Remove and Install ........................................................................................... 3
Tire Remove and Install ........................................................................................................................ 5

Section 01 - WHEELS Group 0110: Powered or Non-Powered Wheels and Fastenings
Group 0110 - Powered or Non-Powered Wheels and Fastenings

Rear Wheel Assembly Remove and Install
LEGEND:
1 Wheel Fastener (10 used per tire)
2 Wheel Lift
Rear Wheel Assembly on Wheel Lift
Specifications
SPECIFICATIONS
115—166 kg
Rear Wheel (without fluid) Weight (approximate)
254—365 lb.
368—448 kg
Rear Wheel (with fluid) Weight (approximate)
811—988 lb.
725 N·m
Rear Wheel Nut Torque
535 lb.-ft.
Service Equipment and Tools
SERVICE EQUIPMENT AND TOOLS
Shop Floor Stand
Heavy Duty Wheel Lift
[1] - Park and prepare machine for service. See Park and Prepare for Service Safely . (Group 0001.)
[2] - Loosen wheel fasteners (1) before lifting wheel off ground.
[3] - Lift wheel off ground and put shop floor stand under axle housing.
Shop Floor Stand
Used to support unit while removing and installing wheels.
[4] -
CAUTION:
Prevent possible crushing injury from heavy component. Use appropriate lifting device.
Position wheel lift (2) under wheel. Fasten safety chain around upper portion of tire.
Item Measurement Specification
Rear Wheel (without fluid) Weight (approximate) 115—166 kg
254—365 lb.
Rear Wheel (with fluid) Weight (approximate) 368—448 kg
811—988 lb.
Heavy Duty Wheel Lift

Used to remove and install wheels.
[5] - Remove wheel fasteners. Pull wheel assembly away from axle.

[6] - Inspect all parts for damage. Replace parts as necessary.
[7] - Thoroughly clean wheel fasteners, mounting surfaces, and wheel studs in flanged axle. Use compressed air to dry all
parts and tapped holes.
[8] - Install wheel using wheel lift.
[9] -
IMPORTANT:
Install wheel fasteners several turns by hand to prevent thread damage. If a power wrench is used, be
sure wheel fasteners are fully engaged to prevent stripping.
Install wheel fasteners several turns by hand. Tighten to specification.

Rear Wheel Nut Torque 725 N·m
535 lb.-ft.
[10] -
IMPORTANT:
Prevent possible damage to machine. Verify wheel fasteners are tightened to specification.
Tighten wheel fasteners to specification after first 50—100 hours of loaded operation after installing wheel. After first 50—100
hours, tighten wheel fasteners as required.

Front Wheel Assembly Remove and Install

LEGEND:
1 Wheel Fastener (8 used per tire)
2 Wheel Assembly
Front Wheel Assembly
Specifications
SPECIFICATIONS
41—65 kg
Front Wheel (without fluid) Weight (approximate)
90—143 lb.
90—121 kg
Front Wheel (with fluid) Weight (approximate)
198—267 lb.
230 N·m
Wheel Fastener (non-powered front axle) Torque
170 lb.-ft.
725 N·m
Wheel Fastener (MFWD) Torque
535 lb.-ft.
[2] - Loosen wheel fasteners (1).
[3] -
CAUTION:
Lift wheel off ground and put shop floor stand under axle housing.
Front Wheel (without fluid) Weight (approximate) 41—65 kg
90—143 lb.
Front Wheel (with fluid) Weight (approximate) 90—121 kg
198—267 lb.
[4] - Put wheel lift under wheel assembly (2). Fasten safety chain around upper portion of tire.
[5] - Remove wheel fasteners. Pull wheel assembly away from axle.
[6] - Inspect all parts for damage. Replace parts as necessary.
[7] - Clean wheel fasteners and tapped studs. Use compressed air to dry all parts.
[8] - Install wheel assembly.
[9] -
IMPORTANT:
Prevent thread damage to hub studs and wheel fasteners. Install wheel fasteners several turns by hand.
If a power wrench is used be sure wheel fasteners are fully engaged to prevent stripping.
Install wheel fasteners several turns by hand, then tighten to specification.

Wheel Fastener (non-powered front axle) Torque 230 N·m
170 lb.-ft.
Wheel Fastener (MFWD) Torque 725 N·m
535 lb.-ft.
[10] - Lower machine to ground.
[11] -
IMPORTANT:
Prevent possible damage to machine. Verify wheel fasteners are tightened to specification.
Tighten wheel fasteners to specification after first 50—100 hours of loaded operation after installing wheel. After first 50—100
hours, tighten wheel fasteners as required.

Tire Remove and Install

[1] -
CAUTION:
Explosive separation of a tire and rim parts can cause serious injury or death.
Do not attempt to mount a tire unless you have proper equipment and experience to perform job.
Always maintain correct tire pressure. Do not inflate tires above recommended pressure. Never weld or
heat a wheel and tire assembly. Heat can cause an increase in air pressure resulting in a tire explosion.
Welding can structurally weaken or deform wheel.
When inflating tires, use a clip-on chuck and extension hose long enough to allow you to stand to one
side and NOT in front of or over tire assembly. Use a safety cage if available.
Check wheels for low pressure, cuts, bubbles, damaged rims or missing lug bolts and nuts.
→NOTE:
Tire can be removed without removing wheel from machine.
Service Tires Safely

LEGEND:
1 Valve Core
2 Valve Nut
Wheel Valve Stem

Always completely deflate tire by removing valve core (1) from valve before attempting any demounting operation. Check
valve stem by running a probe through it to make sure valve stem is not plugged. Remove valve nut (2).
[2] - Remove tire.
[3] -
LEGEND:
3 Rim
4 Valve Core
5 Side Flange
Tire Valve Stem

Inspect all parts for damage and replace parts as necessary.
[4] - Make sure all parts are clean and free from rust or grease before assembly.
[5] - To prevent slipping of wheel under load, inside and outside of wheel must be free of paint, rust, oil, grease, dirt or other
foreign material before installation.
[6] - Install valve stem in rim base and tighten valve core (4) housing finger tight.
[7] - Before mounting tire on rim, add soap lubricant to bead of tire.
[8] - Install tire.
[9] - Clear area of all persons.
[10] -

AXLES AND SUSPENSION SYSTEMS (g) by Belgreen v2.0
CAUTION:
Tire repair should only be performed by a qualified service technician. Do not attempt to mount or
demount a tire unless you have proper equipment and experience to perform job safely. Failure to follow
proper procedures when mounting or demounting a tire from a wheel or rim can result in explosive
separation of a tire and rim parts, causing serious injury or death
LEGEND:
6 Pressure Regulating Valve With Clip-On Chuck
Turn Tire
Turn tire so valve stem is positioned at 12 o′clock. Use a pressure regulating valve with clip-on chuck (6) and extension hose
long enough to allow you to stand to one side and NOT in front of tire while inflating.
[11] - Use only recommended air pressure. Pressure over this limit can cause an explosion.
[12] - Add air until side flange of tire slides out against rim.
[13] - Adjust air pressure to proper specification.

Section 02 - AXLES AND SUSPENSION SYSTEMS

Table of contents
Group 0225 - Input Drive Shafts and U-Joints ..................................................................................... 1
Universal Joint and Drive Shaft Remove and Install .............................................................................. 1
Group 0230 - Non-Powered Wheel Axles ............................................................................................. 5
Hub Assembly Remove and Install ....................................................................................................... 5
Spindle Assembly Remove and Install .................................................................................................. 7
Tie Rod Remove and Install ................................................................................................................ 10
Non-Powered Front Axle Remove and Install—If Equipped ................................................................. 12
Group 0240 - Powered Wheel Axle (MFWD) ...................................................................................... 15
Mechanical Front Wheel Drive (MFWD) Axle Remove and Install ....................................................... 15
Mechanical Front Wheel Drive (MFWD) Axle Disassemble .................................................................. 18
Mechanical Front Wheel Drive (MFWD) Axle Assemble ...................................................................... 33
Open Differential Disassemble and Assemble—If Equipped ............................................................... 58
Limited Slip Differential Disassemble and Assemble—If Equipped ..................................................... 64
Group 0250 - Axle Shaft, Bearings, and Reduction Gears ............................................................... 72
Service Brakes Inspection .................................................................................................................. 72
Rear Axle Remove and Install ............................................................................................................. 74
Rear Axle Disassemble ....................................................................................................................... 77
Rear Axle Assemble ............................................................................................................................ 90
Park Brake Disassemble and Assemble ............................................................................................ 111
Contact Pattern Check ...................................................................................................................... 126

Section 02 - AXLES AND SUSPENSION SYSTEMS Group 0225: Input Drive Shafts and U-Joints
Group 0225 - Input Drive Shafts and U-Joints

Universal Joint and Drive Shaft Remove and Install
Specifications
SPECIFICATIONS
32 N·m
Rear Drive Shaft Cap Screw Torque
24 lb·ft
92 N·m
Universal Joint Yoke Cap Screw Torque
67 lb·ft
32 N·m
Mechanical Front Wheel Drive (MFWD) Drive Shaft Cap Screw Torque
24 lb·ft
Other Material
OTHER MATERIAL
Loctite ™ 242® Threadlocker (medium strength)

Mechanical Front Wheel Drive (MFWD) and Rear Drive Shafts

LEGEND:
1 U-Joint (2 used)
2 Snap Ring (6 used)
3 Joint Yoke
4 Cap Screw (4 used)
6 Half Clamp (2 used)
7 Yoke
8 Seal
9 U-Joint (2 used)
12 Half Clamp (2 used)
71 Drive Shaft (rear)
79 Mechanical Front Wheel Drive (MFWD) Drive Shaft (if equipped)
Rear Drive Shaft Remove and Install
[1] - Remove cap screws (4 and 5), half clamps (6), and rear drive shaft (71).
[2] - Discard cap screws.
[3] - Repair or replace parts as needed.
[4] - Apply Loctite® 242® Threadlocker (medium strength) to cap screws.
Number Name Use

• PM37418 (us)
Thread Lock and Sealer (medium strength) Applied to drive shaft cap screws.
• 242 Loctite ™ (loctite)
[5] - Install drive shaft, half clamps, and cap screws. Tighten to specification.
Rear Drive Shaft Cap Screw Torque 32 N·m
24 lb·ft
Universal Joint Yoke Cap Screw Torque 92 N·m
67 lb·ft
MFWD Drive Shaft Remove and Install—If Equipped
[1] - Remove cap screws (11), half clamps (12), and mechanical front wheel drive (MFWD) drive shaft (79).
[2] - Discard cap screws.
[3] - Slide drive shaft off transmission output shaft.
[4] - Repair or replace parts as needed.
[5] - Apply Loctite® 242® Threadlocker (medium strength) to cap screws.
Number Name Use

• PM37418 (us)
Thread Lock and Sealer (medium strength) Applied to drive shaft cap screws.
[6] - Install drive shaft, half clamps, and cap screws. Tighten to specification.
MFWD Drive Shaft Cap Screw Torque 32 N·m
24 lb·ft
U-Joint Remove and Install
[1] - Remove drive shaft.
[2] - Remove grease fittings and snap rings (2 or 10).
[3] -

Section 02 - AXLES AND SUSPENSION SYSTEMS Group 0230: Non-Powered Wheel Axles
LEGEND:
13 Bearing Cap
14 Cross
Cross and Bearing Assembly

Put drive shaft on a vise so both ears of one of the drive shaft yokes rests on the open jaws of the vise. Force the opposite yoke
down using a hammer and brass rod until bearing cap (13) is approximately halfway out.
[4] - Remove bearing cap and cross (14). Remove opposite bearing cap. Replace parts if necessary.
[5] -
LEGEND:
14 Cross
15 Needle Bearing
16 Seal
U-Joint Needle Bearing and Seal

Install needle bearing (15). Use grease to hold needle bearing elements in position.
[6] - Install seal (16) on bearing cap.
[7] - Install cross between yoke ears.
[8] - Push bearing caps into yoke until bearing caps clear snap ring grooves. Install snap rings.
[9] - Install grease fitting and inject grease into U-joint. Do not force grease out seal.
[10] - Install drive shaft.

Group 0230 - Non-Powered Wheel Axles

Hub Assembly Remove and Install
Specifications
SPECIFICATIONS
120 N·m
Thrust Plate Cap Screws Torque
89 lb.-ft.
15 N·m
Wheel Hub Cover Plug Torque
133 lb.-in.
Other Material
OTHER MATERIAL
271 LOCTITE ™ Thread Lock and Sealer (high strength)
[1] -
Wheel Hub Assembly

LEGEND:
1 Seal Ring
2 Bearing Cone
3 Wheel Hub
4 O-Ring
5 Stud
6 Bearing Cone
7 Thrust Plate
9 Wheel Hub Cover
10 Wheel Hub Cover Plug
Park and prepare machine for service. See Park and Prepare for Service Safely . (Group 0001.)
[2] - Raise machine and install jack stands so front wheels are off ground.

CAUTION:
Prevent possible crushing injury from heavy component. Secure wheel hub (3) with a lifting strap before
removing any components.
[3] - Remove front wheel. See Front Wheel Assembly Remove and Install . (Group 0110.)
[4] - Remove wheel hub cover plug (10) and remove wheel hub cover (9). Remove and inspect O-ring (4), replace if necessary.
[5] - Remove cap screws (8) and thrust plate (7).
[6] - Remove bearing cone (6).
[7] - Remove and inspect wheel hub (3) with bearing cups. To replace bearing cups, place wheel hub on flat surface and drive
bearing cups out.
[8] -
IMPORTANT:
Removing seal ring (1) will destroy the seal. Do not remove seal ring unless damage is noted.
Remove bearing cone (2).
[9] - Clean all dirt and grease from bearings, spindle, and hub assembly.
[10] - Inspect grease seals for damage or hardened lips. Replace as necessary.
[11] - Pack bearings and coat seal lips with grease.
[12] - Install bearing cone on spindle.
[13] - Install wheel hub on spindle.
[14] - Install bearing cone to hub and spindle.
[15] - Apply PM37421 Thread Lock and Sealer (high strength) to cap screws. Position thrust plate on spindle in hub and install
cap screws. Tighten cap screws to specification.
Number Name Use

• PM37421 (us)
Thread Lock and Sealer (high strength) Secure thrust plate cap screws to spindle.
• 271 LOCTITE ™ (loctite)
Thrust Plate Cap Screws Torque 120 N·m
89 lb.-ft.
[16] - Grease and install O-ring on wheel hub cover. Install wheel hub cover into wheel hub.
[17] - Install hub cover plug and tighten to specification.

Wheel Hub Cover Plug Torque 15 N·m
133 lb.-in.
[18] - Install wheel. See Front Wheel Assembly Remove and Install . (Group 0110.)

Spindle Assembly Remove and Install

Specifications
SPECIFICATIONS
120 N·m
Lower King Pin Cap Screws Torque
86 lb.-ft.
120 N·m
Upper King Pin Cap Screws Torque
86 lb.-ft.
[2] - Remove wheel hub. See Hub Assembly Remove and Install . (Group 0110.)
[3] -
LEGEND:
1 Locking Nut
2 Ball Joint Separator
Tie Rod and Ball Joint

Loosen tie rod locking nut (1).
[4] - Break loose ball joint using ball joint separator (2).
[5] - Remove and discard locking nut and remove tie rod threaded pin from swivel housing.
[6] -
CAUTION:
Prevent possible crushing injury from heavy component. Secure swivel housing with lifting strap.
LEGEND:
4 King Pin (upper)
5 King Pin (lower)
King Pin Removal (upper king pin shown)

Remove cap screws (3) from swivel housing king pins (4 and 5).
[7] -
→NOTE:
Be aware of Belleville washer placement between king pins and swivel housing.
Remove king pins using pry bars.

[8] -
→NOTE:
King pin is serviced as an assembly.
LEGEND:
4 King Pin (upper)
5 King Pin (lower)
King Pins
Inspect king pins for wear or damage. Replace if necessary.
[9] -
Swivel Housing
Axle Bushings and Washers

LEGEND:
6 Swivel Housing
7 Axle Beam
8 Washer (2 used)
9 Bushing (2 used)
10 Bushing (2 used)
11 Washer (2 used)
Remove swivel housing (6) and washers (8 and 11).
[10] - Inspect bushings (9 and 10) for damage or wear.
[11] - Replace if necessary.
[12] -
IMPORTANT:
Bushings must be fully seated or king pins will be damaged.
Fill king pin seat with grease.
[13] - Position swivel housing on axle beam (7).
[14] - Grease king pin surfaces.
[15] - Install lower king pin with washer (11) positioned as shown. Tighten cap screws to specification.
Lower King Pin Cap Screws Torque 120 N·m
86 lb.-ft.
[16] -
→NOTE:
Upper king pin must be installed with grease fitting pointed towards center of axle.
Install upper king pin with washer (8) positioned as shown.
[17] - Tighten cap screws to specification.

Upper King Pin Cap Screws Torque 120 N·m
86 lb.-ft.
[18] - Install tie rod threaded pin into swivel housing with new locking nut.
[19] - Install wheel hub. See Hub Assembly Remove and Install . (Group 0110.)
[20] -
→NOTE:
If tie rod, spindle assembly, or steering cylinder are adjusted or serviced, perform the following
procedures.
Adjust tracking angle. See Tracking Angle Check and Adjust . (Group 9020-20.)
[21] - Adjust toe-in. See Toe-In Check and Adjust . (Group 9020-20.)
[22] - Adjust steering angle. See Steering Angle Check and Adjust . (Group 9020-20.)

Tie Rod Remove and Install

[2] - Remove front wheels. See Front Wheel Assembly Remove and Install . (Group 0110.)
[3] -
→NOTE:
Start engine and turn wheel to extend cylinder rod beyond machine main frame for left or right side tie
rod.
LEGEND:
1 Lock Nut
2 Ball Joint Separator
Tie Rod and Ball Joint

Loosen tie rod lock nut (1).
[4] - Break loose ball joint using ball joint separator (2).
[5] - Remove and discard lock nut and remove tie rod threaded pin from swivel housing.
[6] -
LEGEND:
3 Tie Rod
4 Jam Nut
5 Ball Joint
6 Cylinder Rod
Tie Rod Removal

Separate tie rod (3) from steering cylinder by loosening jam nut (4).
[7] - Replace parts as necessary.
[8] - Install tie rod (3) to ball joint (5).
[9] - Install front wheels. See Front Wheel Assembly Remove and Install . (Group 0110.)
[10] -
→NOTE:
If tie rod, spindle assembly, or steering cylinder are adjusted or serviced, perform the following
procedures.
Adjust tracking angle. Perform Tracking Angle Check and Adjust . (Group 9020-20.)
[11] - Adjust toe-in. See Toe-In Check and Adjust . (Group 9020-20.)

[12] - Adjust steering angle. See Steering Angle Check and Adjust . (Group 9020-20.)

Non-Powered Front Axle Remove and Install—If Equipped

Specifications
SPECIFICATIONS
8391 kg
Machine Weight (approximate)
18 500 lb.
215 N·m
Axle Pivot Pin Cap Screw Torque
158 lb.-ft.
Essential Tools
ESSENTIAL TOOLS
JT01642A Low-Lift Transmission Jack
[2] - Raise loader and install boom lock bar. See Loader Boom Service Lock . (Operator’s Manual.)
[3] - Remove counterweights, if equipped. See Counterweight Remove and Install—If Equipped . (Group 1749.)
[4] - Release hydraulic system pressure. See Hydraulic Circuit Pressure Release . (Group 9025-25.)
[5] -
CAUTION:
Machine Weight (approximate) 8391 kg
18 500 lb.
Raise and support front of machine. Position floor stands under main frame.
[7] -

Non-Powered Front Axle

LEGEND:
1 Steering Hose (2 used)
2 Lubrication Line
3 Cap Screw
4 Washer
5 Bushing
6 Pin
7 Thrust Washer (as needed)
8 Pivot Bushing (2 used)
74 Front Axle (non-powered)
125 Steering Cylinder
Tag and disconnect steering hoses (1). Close all openings using caps and plugs.
[8] - Disconnect lubrication line (2) from front axle (74).
[9] - Position JT01642A Low Lift Jack under center of front axle. Attach adjustable-grip arms and safety chains from lift jack to
axle housing.
Low-Lift Transmission Jack
JT01642A
Used to remove axle
[10] - Remove cap screw (3), washer (4), and bushing (5).
[11] - Remove pin (6), thrust washers (7), and axle.
[12] - Inspect pivot bushings (8). Replace if worn or damaged.

Section 02 - AXLES AND SUSPENSION SYSTEMS Group 0240: Powered Wheel Axle (MFWD)
[13] -
→NOTE:
Surfaces must be free of grease, oil, dirt, or paint.
Install pivot bushings, if removed.
[14] - Position axle under front frame assembly.
[15] -
→NOTE:
Use as many thrust washers as will fit between axle and frame.
Apply multipurpose grease on pin. Install pin into bore with thrust washers.
[16] - Install axle pivot pin bushing, washer, and cap screw. Tighten to specification.
Axle Pivot Pin Cap Screw Torque 215 N·m
158 lb.-ft.
[17] - Connect lubrication line and steering cylinder hoses.
[19] - Install counterweights. See Counterweight Remove and Install—If Equipped . (Group 1749.)
[20] - Remove boom lock bar and lower loader. See Loader Boom Service Lock . (Operator’s Manual.)

Group 0240 - Powered Wheel Axle (MFWD)

Mechanical Front Wheel Drive (MFWD) Axle Remove and Install
Specifications
SPECIFICATIONS
6237—8391 kg
13 750—18 500 lb.
335 kg
Mechanical Front Wheel Drive (MFWD) Axle Weight (approximate)
739 lb.
215 N·m
Axle Pivot Pin Cap Screw Torque
158 lb.-ft.
Essential Tools
ESSENTIAL TOOLS
[4] -
CAUTION:
Machine Weight (approximate) 6237—8391 kg
13 750—18 500 lb.
[6] - Remove MWFD drive shaft. See Universal Joint and Drive Shaft Remove and Install . (Group 0225.)
[7] -

MFWD Axle
LEGEND:
2 Lubrication Line
3 Cap Screw
4 Washer
5 Bushing
6 Pin
7 Thrust Washer (as needed)
8 Pivot Bushing (2 used)
80 Mechanical Front Wheel Drive (MFWD) Axle
Tag and disconnect steering hoses (1). Close all openings using caps and plugs.
[8] - Disconnect lubrication line (2) from mechanical front wheel drive (MFWD) axle (80).
[9] - Position JT01642A Low Lift Jack under center of front axle. Attach adjustable-grip arms and safety chains from lift jack to
axle housing.
JT01642A
Used to remove axle
[10] - Remove cap screw (3), washer (4), and bushing (5).
[11] -

CAUTION:
Remove pin (6), thrust washers (7), and axle.

Mechanical Front Wheel Drive (MFWD) Axle Weight (approximate) 335 kg
739 lb.
[12] - Inspect pivot bushings (8). Replace if worn or damaged.
[13] -
→NOTE:
Surfaces must be free of grease, oil, dirt, or paint.
Install pivot bushings, if removed.
[14] - Position axle under front frame assembly.
[15] - Apply multipurpose grease on pin. Install pin into bore with thrust washers.
[16] - Install axle pivot pin bushing, washer, and cap screw. Tighten to specification.
Axle Pivot Pin Cap Screw Torque 215 N·m
158 lb.-ft.
[17] - Connect lubrication line and steering cylinder hoses.
[18] - Install drive shaft. See Universal Joint and Drive Shaft Remove and Install . (Group 0225.)

Mechanical Front Wheel Drive (MFWD) Axle Disassemble

Essential Tools
ESSENTIAL TOOLS
JDG10939 Snap Ring Pliers
D01003AA Repair Stand
D01048AA 17 1/2 - Ton Capacity Puller Set
JDG10799 Tie Rod End Separating Tool
JDG10693 Clamping Fork
JDG10830 Internal Extractor
For more information on specific mechanical front wheel drive axle components:
See Planetary Drive Remove.
See Ring Gear Remove.
See Planetary Gears Remove.
See Wheel Hub Remove and Disassemble.
See Tie Rods Remove.
See Steering Cylinder Remove.
See Knuckle Housing Remove.
See Drive Shaft Remove.
See Knuckle Housing Disassemble.
See Drive Shaft Disassemble.
See Axle Housing Disassemble.
Planetary Drive Remove
[1] -
LEGEND:
1 Axle
2 D01003AA Repair Stand
Axle Support Stand

Place axle (1) in D01003AA Repair Stand (2).
Repair Stand
D01003AA
For supporting front axle.
[2] -
→NOTE:
Pressure can build up in planetary carrier housing. To relieve pressure, turn hub until plug is in top
position and carefully remove plug. Then turn hub until oil drain bore is in bottom position and drain oil.
Slowly remove drain plug. Drain planetary housing oil, see Change MFWD Planetary Housing Oil—If Equipped . (Operator′s
Manual.)

[3] -
LEGEND:
4 Planetary Carrier
Planetary Carrier Cap Screws

Remove cap screws (3) and remove planetary carrier (4).
Ring Gear Remove
[1] -
LEGEND:
2 Ring Gear
Ring Gear Cap Screws

Remove cap screws (1) from ring gear (2).
[2] -
LEGEND:
2 Ring Gear
3 Wheel Hub
4 17 1/2-Ton Capacity Puller
Ring Gear
Remove ring gear (2) from wheel hub (3) using 17 1/2-ton capacity puller (4).
17 1/2 - Ton Capacity Puller Set
D01048AA
For removing and installing gears and bearings.
Planetary Gears Remove
[1] -

LEGEND:
2 Planetary Gear (3 used)
Planetary Gear Snap Ring

Remove snap rings (1) from planetary gears (2).
[2] -
LEGEND:
3 Two-Armed Puller
Planetary Gear
Using a two-armed puller (3), remove planetary gears (2) with roller bearings.
Wheel Hub Remove and Disassemble
[1] -
→NOTE:
Support tapered roller bearing when removing wheel hub.
LEGEND:
1 Knuckle Housing
2 Wheel Hub
3 Tapered Roller Bearing
Wheel Hub
Pull wheel hub (2) with tapered roller bearing (3) from knuckle housing (1).
[2] -

LEGEND:
1 Knuckle Housing
Tapered Roller Bearing

Pull tapered roller bearing (3) from knuckle housing (1).
[3] -
LEGEND:
2 Wheel Hub
4 Seal Ring
Seal Ring
Remove seal ring (4) from wheel hub (2).
[4] -
LEGEND:
2 Wheel Hub
5 O-Ring
6 Tapered Roller Bearing Cup (2 used)
Tapered Roller Bearing Cups

Remove tapered roller bearing cups (6) from wheel hub (2). Remove and replace O-ring (5).
[5] -
LEGEND:
2 Wheel Hub
7 Wheel Hub Stud (8 used)

Wheel Hub Studs

Remove and inspect wheel hub studs (7). Replace as necessary.
Tie Rods Remove
[1] -
LEGEND:
1 Tie Rod
2 Lock Nut
Self-Locking Nut
Remove lock nut (2) from tie rod (1).
[2] -
LEGEND:
1 Tie Rod
3 Knuckle Housing
4 Tie Rod End Separating Tool
Tie Rod Out of Knuckle Housing

Remove tie rod (1) from knuckle housing (3) with tie rod end separating tool (4).
Tie Rod End Separating Tool
JDG10799
For separating tie rod end.
[3] -
LEGEND:
1 Tie Rod
5 Steering Cylinder Piston Rod
Tie Rod From Piston Rod Removal

Remove tie rod (1) from steering cylinder piston rod (5).

Steering Cylinder Remove
[1] -
LEGEND:
1 Axle Housing
2 Steering Cylinder Cap Screw (3 used)
Steering Cylinder Cap Screws

Remove steering cylinder cap screws (2) from axle housing (1).
[2] -
LEGEND:
1 Axle Housing
3 Steering Cylinder
Steering Cylinder
Remove steering cylinder (3) from axle housing.
[3] - For disassembly of steering cylinder, see Mechanical Front Wheel Drive (MFWD) Axle Steering Cylinder Disassemble and
Assemble . (Group 0960.)
Knuckle Housing Remove
[1] -
LEGEND:
2 Upper King Pin
3 Lower King Pin
King Pin Cap Screws

Drain oil from axle housing, see Change MFWD Front Axle Housing Oil—If Equipped . (Operator′s Manual.)
[2] - Remove cap screws (1) from upper king pin (2) and lower king pin (3).
[3] - Remove upper and lower king pins.
[4] -

→NOTE:
Use caution when removing knuckle housing to avoid damaging shaft seal ring in axle housing.
LEGEND:
4 Axle Housing
5 Knuckle Housing With Drive Shaft
Knuckle Housing With Drive Shaft

Remove knuckle housing with drive shaft (5) from axle housing (4).
Drive Shaft Remove
[1] -
LEGEND:
1 External Snap Ring
2 Sun Gear Shaft
Sun Gear
Open external snap ring (1) and remove sun gear shaft (2).
[2] -
→NOTE:
For aid in removal of drive shaft internal snap ring (3), tap on drive shaft (5) universal joint towards
knuckle housing (6).
LEGEND:
3 Drive Shaft Internal Snap Ring
4 Snap Ring Pliers
5 Drive Shaft
6 Knuckle Housing
Drive Shaft Internal Snap Ring

Drive Shaft
Using snap ring pliers (4), remove drive shaft internal snap ring (3).
Snap Ring Pliers
JDG10939
Use to remove drive shaft internal snap ring.
[3] - Remove drive shaft (5) from knuckle housing (6).
Knuckle Housing Disassemble
[1] -
LEGEND:
2 Shaft Seal
3 King Pin
King Pin Tapered Roller Bearing

Remove tapered roller bearing (1) and shaft seal (2) from king pin (3).
[2] -
LEGEND:
4 Shaft Seal
Knuckle Housing Shaft Seal

Remove shaft seal (4) from knuckle housing.
[3] -

LEGEND:
5 Snap Ring
6 Ball Bearing
Knuckle Bearing
Remove snap ring (5) and remove ball bearing (6) from knuckle housing.
[4] -
LEGEND:
7 Bushing (8 used)
Knuckle Housing Bushings

Remove bushings (7) from knuckle housing as required.
Drive Shaft Disassemble
[1] -
LEGEND:
Cross and Bearing Assembly Snap Ring

Remove snap rings (1).
[2] -

LEGEND:
2 Cross and Bearing Assembly (2 used)

Remove cross and bearing assemblies (2).
Axle Housing Disassemble
[1] -
LEGEND:
2 Axle Housing
King Pin Tapered Roller Bearing Cup

Remove tapered roller bearing cups (1) from axle housing (2).
[2] -
LEGEND:
3 Shaft Seal
4 Bushing
Drive Shaft Seal and Bushing

Remove shaft seal (3) and bushing (4).
[3] -

LEGEND:
5 Axle Housing Cap Screw (15 used)
Axle Housing Cap Screws

Remove axle housing cap screws (5) and remove axle housing.
[4] -
LEGEND:
6 Differential Tapered Roller Bearing Cup
7 Shim
8 O-Ring
Differential Tapered Roller Bearing Cup and O-Ring

Remove differential tapered roller bearing cup (6), shim (7), and O-ring (8).
[5] -
LEGEND:
8 Differential
Differential
Remove differential (8) from axle housing.
[6] - For disassembly of differential see one of the following:
Open Differential Disassemble and Assemble—If Equipped (Group 0240.)

Limited Slip Differential Disassemble and Assemble—If Equipped (Group 0240.)
[7] -

LEGEND:
9 Differential Tapered Roller Bearing Cup
10 Shim
Differential Tapered Roller Bearing Ring and Shim

Remove differential tapered roller bearing cup (9) and shim (10).
[8] -
LEGEND:
11 Lock Nut
12 Washer
13 Clamping Fork
Yoke Lock Nut and Washer

Remove lock nut (11) and washer (12) using clamping fork (13).
Clamping Fork
JDG10693
For removal and installation of universal joint yoke nut.
[9] -
LEGEND:
14 Universal Joint Yoke
15 Bevel Gear Drive
Yoke
Remove universal joint yoke (14) from bevel gear drive (15).
[10] -

LEGEND:
16 Guard
Guard
Remove guard (16) from universal joint yoke (14).
[11] -
LEGEND:
15 Bevel Gear Drive
Bevel Gear Drive

Remove bevel gear drive (15) from axle housing.
[12] -
LEGEND:
18 Spacer
19 Bushing
Bevel Gear Drive Spacer and Bushing

Remove spacer (18) and bushing (19) from bevel gear drive.
[13] -
LEGEND:

Bevel Gear Drive Tapered Roller Bearing

Remove tapered roller bearing (20) from bevel gear drive.
[14] -
LEGEND:
21 Shaft Seal
Axle Housing Shaft Seal and Tapered Roller Bearing

Remove shaft seal (21) and tapered roller bearing (22) from axle housing.
[15] -
LEGEND:
23 Outer Tapered Roller Bearing Cup
Axle Housing Tapered Roller Bearing Cup

Remove outer tapered roller bearing cup (23) from axle housing.
[16] -
LEGEND:
24 Inner Tapered Roller Bearing Cup
Axle Housing Inner Tapered Roller Bearing Cup

Remove inner tapered roller bearing cup (24) from axle housing.
[17] -

LEGEND:
25 Bushing (2 used)
Axle Housing Bushings

Remove bushings (25) from axle housing as required, using internal extractor.
Internal Extractor
JDG10830
Used to remove bushings from axle housing.

Mechanical Front Wheel Drive (MFWD) Axle Assemble

Specifications
SPECIFICATIONS
95°C
Tapered Roller Bearing Temperature (approximate)
205°F
450 N·m
Universal Joint Yoke Torque
330 lb.-ft.
1.0—3.0 N·m
Bevel Gear Drive Tapered Roller Bearings Rolling Drag Torque (without shaft seal)
10—30 lb.-in.
0.90 mm
Tapered Roller Bearing Cup Shim Size (recommended)
0.035 in.
0.10 mm
Dimension III Tapered Roller Bearing Preload
0.004 in.
0.10 mm
Axle Housings Gap (approximate)
0.004 in.
280 N·m
Axle Housing Cap Screws Torque
210 lb.-ft.
0.12—0.24 mm
Differential Bevel Gear Drive Backlash
0.005—0.009 in.
450 N·m
Yoke Lock Nut Torque
330 lb.-ft.
117 N·m
King Pin Cap Screws Torque
85 lb.-ft.
90 N·m
Ring Gear Cap Screws Torque
65 lb.-ft.
95°C
Planetary Gear Assembly Temperature (approximate)
205°F
32 N·m
Planetary Carrier Cap Screws Torque
25 lb.-ft.
240 N·m
Steering Cylinder Cap Screws Torque
175 lb.-ft.
300 N·m
Tie Rod Assembly to Steering Cylinder Piston Rod Torque
220 lb.-ft.
100 N·m
Tie Rod Lock Nut Torque
70 lb.-ft.
Essential Tools
ESSENTIAL TOOLS
JDG10599 Assembly Fixture
JDG10600 Assembly Ring
JDG10816 Torsion Bar
JDG10817 Cone Connection
JDG10590 Axle Housing Seal Ring Driver
JDG10818 Seal Driver
JDG10593 Seal Ring Driver
D01045AA Bushing, Bearing, and Seal Driver Sets
27489 Large Handle

Other Material
OTHER MATERIAL
242 Loctite ™ Thread Lock and Sealer (medium strength)
Loctite ™ NEVER-SEEZ ™ Anti-Seize Lubricant
Axle Housing Assemble
[1] -
LEGEND:
1 Inner Tapered Roller Bearing Cup
2 JDG10599 Assembly Fixture
3 JDG10600 Assembly Ring
Bevel Gear Drive Inner Tapered Roller Bearing Cup

Install inner tapered roller bearing cup (1) using JDG10599 Assembly Fixture (2) and JDG10600 Assembly Ring (3).
Assembly Fixture
JDG10599
For use installing inner roller bearing cup on axle housing.
Assembly Ring
JDG10600
For use installing inner roller bearing cup on axle housing.
[2] -
LEGEND:
4 Outer Tapered Roller Bearing Cup
5 D01045AA Bushing, Bearing, and Seal Driver Set
Bevel Gear Drive Outer Tapered Roller Bearing Cup

Install outer tapered roller bearing cup (4) using D01045AA Bushing, Bearing, and Seal Driver Set (5).
Bushing, Bearing, and Seal Driver Sets
D01045AA
For removal and installation of bushings, bearings and seals.
[3] -
→NOTE:
Step 3—6 are used to determine thickness of shim used with bevel gear drive.

LEGEND:
6 Axle Housing Stamping
7 Bevel Gear Drive Stamping
8 Tapered Roll Bearing Width
Axle Housing Stamping
Bevel Gear Drive Stamping
Tapered Roller Bearing Width

Record axle housing stamping (6) as dimension I.
[4] - Record bevel gear drive stamping (7) as dimension II.
[5] - Measure and record tapered roller bearing width (8) as dimension III.
[6] - Calculate shim thickness by subtracting the sum of dimensions II and III from dimension I. See example:
Shim Width Calculation
Example of Shim Thickness Calculation

Dimension I - (Dimension II + Dimension III) = Shim Thickness
119.80 mm
Dimension I (axle housing stamping)
(4.72 in.)
88.00 mm
Dimension II (bevel gear drive stamping)
(3.46 in.)
28.30 mm
Dimension III (tapered roll bearing width)
(1.11 in.)
119.80 mm - (88.00 mm + 28.30 mm) = 3.5 mm

Shim Thickness
[4.72 in. - (3.46 in. + 1.11 in.) = 0.15 in.]
[7] -

LEGEND:
9 Shim
Bevel Gear Drive Shim

Install predetermined shim (9) on bevel gear drive.
[8] -
CAUTION:
Prevent possible burn injury. Use appropriate hand protection when handling hot components.
LEGEND:
Tapered Roller Bearing

Heat tapered roller bearing (10) to specification and install on bevel gear drive.
Tapered Roller Bearing Temperature 95°C
205°F
[9] -
LEGEND:
11 Bushing
12 Spacer Ring
Bevel Gear Drive Bushing and Ring

Install bushing (11) and spacer ring (12) on bevel gear drive.
[10] -

CAUTION:
LEGEND:
14 Bevel Gear Drive
Bevel Gear Drive and Tapered Roller Bearing

Install bevel gear drive (14) into axle housing. Heat tapered roller bearing (13) to specification and install on bevel gear drive.
Tapered Roller Bearing Temperature (approximate) 95°C
205°F
[11] -
LEGEND:
15 Guard
Universal Joint Yoke Guard

Install guard (15) on universal joint yoke (16).
[12] -
→NOTE:
Shaft seal ring is mounted after bevel gear drive contact pattern is checked.
LEGEND:
18 Lock Nut
Universal Joint Yoke

Install universal joint yoke (17) without shaft seal. Install lock nut (18) and tighten to specification. While torquing lock nut,
rotate bevel gear drive several times in both directions.
Universal Joint Yoke Torque 450 N·m
330 lb.-ft.
[13] -
LEGEND:
19 Tapered Roller Bearing (2 used)
Bevel Gear Drive Tapered Roller Bearing

Check rolling drag torque of tapered roller bearings (19). If rolling drag torque is below specification, install thinner spacer ring
on bevel gear drive. If rolling drag torque is above specification, install thicker spacer ring on bevel gear drive.
Bevel Gear Drive Tapered Roller Bearings Rolling Drag Torque (without shaft seal) 1.0—3.0 N·m
10—30 lb.-in.
[14] -
LEGEND:
20 Shim
21 Tapered Roller Bearing Cup
Shim and Bearing Cup

Install shim (20) and tapered roller bearing cup (21) into axle housing.
Tapered Roller Bearing Cup Shim Size (recommended) 0.90 mm
0.035 in.
[15] -
LEGEND:
22 Gear
23 Differential
Differential Gear Marking Ink

Apply marking ink to gear (22) on differential (23) for checking gear tooth contact pattern later in procedure.

[16] -
LEGEND:
23 Differential
Differential
Install differential (23) in axle housing.
[17] -
LEGEND:
24 Bearing Cup
Differential Tapered Roller Bearing Cup

Install bearing cup (24) on tapered roller bearing (25).
[18] - Rotate differential and tapered roller bearing cup in both directions to ensure rollers are positioned correctly.
[19] -
LEGEND:
27 Depth Gauge
28 Straight Edge
Dimension I

Dimension II
Using a depth gauge (27) and straight edge (28), measure distance between axle housing contact face and front face of
tapered roller bearing cup. Take several measurements at different locations to find the average value and record as
dimension I.
[20] - Using a depth gauge and straight edge, measure distance between axle housing contact face and contact face of
tapered roller bearing cup. Take several measurements at different locations to find the average value and record as
dimension II.
[21] - Calculate shim thickness by adding dimension III to difference of dimensions I and II. See example:
Dimension III Tapered Roller Bearing Preload 0.10 mm
0.004 in.

Dimension I – Dimension II + Dimension III = Shim Thickness
9.50 mm
Dimension I (example)
0.374 in.
8.80 mm
Dimension II (example)
0.346 in.
0.10 mm
Dimension III
0.004 in.
(9.50 mm – 8.80 mm) + 0.10 mm = 0.80 mm

Shim Thickness
(0.374 in. – 0.346 in.) + 0.004 in. = 0.032 in.
[22] -
LEGEND:
30 Tapered Roller Bearing Cup
31 Shim
Axle Housing Shim and Bearing Cup

Install predetermined shim (31) and tapered roller bearing cup (30).
[23] -
→NOTE:
Install axle housings together without O-ring to get accurate shim calculations.
LEGEND:
32 O-Ring
33 Axle Housing (2 used)
Axle Housings

Remove O-ring (32). Install axle housings (33) together.
[24] -
→NOTE:
If shim calculation was done correctly, the gap width should be at approximate specification.
LEGEND:
34 Gap
Axle Housings Gap Check

Check specified gap (34) between axle housings. Take several measurements at different locations to determine average
value.
Axle Housings Gap (approximate) 0.10 mm
0.004 in.
[25] -
LEGEND:
Axle Housings Cap Screws

Install axle housing cap screws (35) and tighten to specification.
Axle Housing Cap Screws Torque 280 N·m
210 lb.-ft.
[26] -
LEGEND:
36 JDG10817 Cone Connection
37 JDG10816 Torsion Bar
Backlash Checking Tool

Insert JDG10816 Torsion Bar (37) with JDG10817 Cone Connection (36) into differential.
Torsion Bar
JDG10816
For checking backlash on differential bevel gear drive.
Cone Connection
JDG10817
For checking backlash on differential bevel gear drive.
[27] -
LEGEND:
39 Axle Oil Drain Hole
40 Dial Indicator
Axle Oil Drain Hole

Insert dial indicator (40) through axle oil drain hole (39) at a tooth flank of differential bevel gear drive. Check backlash to
specification.
Differential Bevel Gear Drive Backlash 0.12—0.24 mm
0.005—0.009 in.
[28] -
LEGEND:
20 Shim
31 Shim
Inner Axle Housing Shim
Outer Axle Housing Shim

If backlash does not meet specification, correct with corresponding shims:

a. Below Backlash Specification:

Install thicker shim (20) and thinner shim (31).
b. Above Backlash Specification:
Install thinner shim (20) and thicker shim (31).
[29] - Check gear tooth contact pattern. See Gear Tooth Contact Pattern Check . (Group 0250.)
[30] -
LEGEND:
23 Differential
Differential Installation
Install differential (23) in axle housing.
[31] -
LEGEND:
32 O-Ring
33 Axle Housing (2 used)
Axle Housings
Axle Housings Cap Screws

Install O-ring (32).
[32] - Assemble axle housings (33) and install axle housing cap screws (35). Tighten to specification.
Axle Housing Cap Screws Torque 280 N·m
210 lb.-ft.
[33] -

LEGEND:
15 Lock Nut
16 Yoke
Yoke Lock Nut

Remove lock nut (15) and yoke (16).
[34] -
→NOTE:
Shaft seal ring must be installed with seal lip facing inward on axle housing. Lubricate seal before
installation. Confirm seal is recessed in axle housing.
LEGEND:
44 Shaft Seal Ring
45 JDG10590 Axle Housing Seal Ring Driver
Shaft Seal Ring

Install shaft seal ring (44) with JDG10590 Axle Housing Seal Ring Driver (45) in axle housing.
Axle Housing Seal Ring Driver
JDG10590
For installing axle housing seal ring.
[35] -
LEGEND:
15 Lock Nut
16 Yoke
Yoke
Install yoke (16) with lock nut (15). Tighten to specification.
Yoke Lock Nut Torque 450 N·m
330 lb.-ft.

[36] -
→NOTE:
Bushing must be installed in axle housing with joint of bushing facing upward or 12 o′clock position.
LEGEND:
46 Axle Housing Bushing
Axle Housing Bushing

Install axle housing bushing (46) flush with axle housing.
[37] -
LEGEND:
47 Shaft Seal
48 JDG10818 Seal Driver
Axle Housing Shaft Seal

Lubricate outer diameter of shaft seal (47) ring. Fill area between seal lips with grease.
[38] - With seal lip facing inwards, install shaft seal using JDG10818 Seal Driver (48) and JDG10819 Seal Driver (49).
Seal Driver
JDG10818
For installing shaft seal in axle housing.
Seal Driver
JDG10819
For installing shaft seal in axle housing.
[39] -
LEGEND:
51 King Pin Bearing Cup (2 each)
Axle Housing King Pin Bearing Cups

Install king pin bearing cups (51) in axle housing.
Knuckle Housing Assemble
[1] -
→NOTE:
Upper and lower king pin seals are different sizes.
LEGEND:
1 Seal (2 used)
2 King Pin (2 used)
King Pin Seal

Install seals (1) with JDG10821 Seal Driver (lower) and JDG10822 Seal Driver (upper) on king pins (2).
Seal Driver
JDG10821
For installing seal on king pin.
Seal Driver
JDG10822
For installing seal on king pin.
[2] -
→NOTE:
Upper and lower king pin bearings are different sizes.
LEGEND:
3 Bearing (2 used)
2 King Pin (2 used)
King Pin Bearing

Install bearings (3) on king pins (2).
[3] -

LEGEND:
6 Bushing (8 used)
Knuckle Housing Bushings

If removed, install bushings (6) in knuckle housing.
[4] -
LEGEND:
8 Ball Bearing
9 Snap Ring
Knuckle Housing Ball Bearing
Ball Bearing Snap Ring

Install ball bearing (8) in knuckle housing.
[5] - Install snap ring (9).
[6] -
LEGEND:
11 Seal
Knuckle Housing Seal

Lubricate outside edge of seal (11) and install flush with knuckle housing using JDG10820 Seal Driver (12).
Seal Driver
JDG10820
For installing seal in knuckle housing.
Drive Shaft Assemble
[1] -
LEGEND:
1 Cross and Bearing Assembly (2 used)

Install cross and bearing assemblies (1).
[2] -
LEGEND:
Cross and Bearing Assembly Snap Ring

Install snap rings (3).
Drive Shaft Install
[1] -
LEGEND:
1 Drive Shaft
Drive Shaft
Install drive shaft (1) in knuckle housing.
[2] -

LEGEND:
3 Drive Shaft Snap Ring
Drive Shaft Snap Ring

Install drive shaft snap ring (3).
[3] -
LEGEND:
1 Drive Shaft
4 Sun Gear Shaft Retaining Ring
Sun Gear Shaft Retaining Ring

Install sun gear shaft retaining ring (4) in groove on drive shaft (1).
[4] -
LEGEND:
4 Sun Gear Shaft Retaining Ring
5 Sun Gear Shaft
Sun Gear Shaft

Install sun gear shaft (5) in drive shaft with sun gear shaft retaining ring (4).
Knuckle Housing Install
[1] -
→NOTE:
For ease of assembly, turn drive shaft during installation until splines engage in differential.

LEGEND:
1 Knuckle Housing and Drive Shaft
2 Axle Housing
Knuckle Housing and Drive Shaft

Install knuckle housing and drive shaft (1) in axle housing (2).
[2] -
LEGEND:
1 Knuckle Housing and Drive Shaft
3 Lower King Pin
4 Upper King Pin
Lower King Pin
Upper King Pin

Coat lower and upper king pins (3 and 4) with multipurpose grease. Install lower and upper king pins into knuckle housing.
[3] -
LEGEND:
3 Lower King Pin
4 Upper King Pin
5 King Pin Cap Screw (8 used)
King Pin Cap Screws

Install king pin cap screws (5) on upper king pin (4) and lower king pin (3). Tighten to specification.

King Pin Cap Screws Torque 117 N·m
85 lb.-ft.
[4] - Fill axle housing with oil. See Change MFWD Front Axle Housing Oil—If Equipped . (Operator′s Manual.)
Wheel Hub Assemble
[1] -
LEGEND:
1 Wheel Hub
Tapered Roller Bearing Cups

Install tapered roller bearing cups (2) in wheel hub (1).
[2] -
IMPORTANT:
To prevent seal damage, seal ring label outside needs to be facing toward seal ring driver tool.
LEGEND:
1 Wheel Hub
3 Seal Ring
4 JDG10593 Seal Ring Driver
5 27489 Large Handle
Seal Ring
Using JDG10593 Seal Ring Driver (4) and 27489 Large Handle (5), install seal ring (3) flush with wheel hub (1).
Seal Ring Driver
JDG10593
Installing seal ring in wheel hub.
Large Handle
27489
Use with seal ring driver tool.
Wheel Hub Install
[1] -
CAUTION:

LEGEND:
1 Knuckle Bearing
Tapered Roller Bearing Installation

Heat tapered roller bearing (2) to specification and install on knuckle housing (1).
205°F
[2] -
→NOTE:
For ease of installation, lightly coat wheel hub and knuckle housing surface with oil.
LEGEND:
3 Wheel Hub
Wheel Hub
Install wheel hub (3).
[3] -
CAUTION:
LEGEND:
3 Wheel Hub
4 Taper Roller Bearing
Taper Roller Bearing On Wheel Hub

Heat tapered roller bearing (4) to specification and install.

205°F
Ring Gear Install
[1] -
LEGEND:
2 Ring Gear
Ring Gear Cap Screws

Install ring gear (2).
[2] - Apply PM37418 Thread Lock and Sealer (medium strength) to threads of cap screws (1).
Number Name Use

• PM37418 (us)
• PM38621 (canadian) Thread Lock and Sealer (medium strength) Cap screws used to retain ring gear.
[3] - Install cap screws and tighten to specification.

Ring Gear Cap Screws Torque 90 N·m
65 lb.-ft.
Planetary Gears Install
[1] -
→NOTE:
The packaging sleeve is used as an assembly aid.
LEGEND:
1 Roller Bearing (3 used)
2 Packaging Sleeve (3 used)
Planetary Gear and Roller Bearing

Press roller bearing (1) through packaging sleeve (2) until snap ring (3) engages groove on planetary gear (4).
[2] -

CAUTION:
LEGEND:
5 Planetary Carrier
Planetary Gear
Heat planetary gears (4) to specification and install in planetary carrier (5) with beveled edge of roller bearing inner ring facing
downward.
Planetary Gear Assembly Temperature 90—100°C
195—215°F
[3] -
LEGEND:
Planetary Gear Snap Ring

Planetary Carrier Install
[1] -
LEGEND:
1 O-Ring
2 Wheel Hub
Planetary Carrier O-Ring

Install O-ring (1) on groove of wheel hub (2) and grease.

[2] -
LEGEND:
3 Planetary Carrier
Planetary Carrier Cap Screws

Install planetary carrier (3) and tighten cap screws (4) to specification.
Planetary Carrier Cap Screws Torque 32 N·m
25 lb.-ft.
[3] - Fill planetary drive with oil. See Change MFWD Planetary Housing Oil—If Equipped . (Operator′s Manual.)
Steering Cylinder Install
[1] -
LEGEND:
1 Steering Cylinder Contact Surface
Steering Cylinder Contact Points

Apply TY24811 Anti-Seize Lubricant to steering cylinder contact surface (1).
Number Name Use

• NA Loctite ™ (loctite) NEVER-SEEZ ™ Anti-Seize Lubricant Steering cylinder contact surface.
[2] -
LEGEND:
2 Steering Cylinder
3 Steering Cylinder Cap Screw (3 used)
Steering Cylinder
Install steering cylinder (2) and steering cylinder cap screws (3). Tighten to specification.

Steering Cylinder Cap Screws Torque 240 N·m
175 lb.-ft.
Tie Rods Install
[1] -
LEGEND:
1 Tie Rod
2 Nut
3 Tie Rod End
Tie Rod
Install nut (2) and tie rod (1) on tie rod end (3).
[2] - Apply PM37418 Thread Lock and Sealer (medium strength) to tie rod end.
[3] -
LEGEND:
4 Tie Rod Assembly
5 Steering Cylinder Piston Rod
Tie Rod To Piston Rod
Number Name Use

• 242 Loctite ™ (loctite) Thread Lock and Sealer (medium strength) Cap screws used to retain ring gear.
Install tie rod assembly (4) to steering cylinder piston rod (5). Tighten to specification.
Tie Rod Assembly to Steering Cylinder Piston Rod Torque 300 N·m
220 lb.-ft.
[4] -
LEGEND:
1 Tie Rod
6 Lock Nut
Tie Rod Lock Nut

Install lock nut (6) to tie rod (1) and tighten to specification plus an additional 180°—225° of rotation.
Tie Rod Lock Nut Torque 100 N·m
70 lb.-ft.

Open Differential Disassemble and Assemble—If Equipped

Specifications
SPECIFICATIONS
120°C
Bevel Gear Temperature
248°F
68 N·m
Bevel Gear Cap Screw Torque
50 lb.-ft.
120°C
Tapered Roller Bearing Temperature
248°F
Other Material
OTHER MATERIAL
242 Loctite ™ U.S. Thread Lock and Sealer (medium strength)
[1] -
LEGEND:
1 Bearing Puller
3 Differential
Differential Tapered Roller Bearings

Using a bearing puller (1), remove tapered roller bearings (2) from differential (3).
[2] -
LEGEND:
3 Differential
4 Bevel Gear Cap Screw (16 used)
Differential Bevel Gear Cap Screws

Remove bevel gear cap screws (4) from differential (3).
[3] -

LEGEND:
5 Cover
6 Bevel Gear
Bevel Gear
Remove cover (5) and bevel gear (6) from differential.
[4] -
LEGEND:
8 Bevel Gear
9 Thrust Washer
10 Spacer
Bevel Gear, Thrust Washer, and Spacer

Remove bevel gear (8), thrust washer (9), and spacer (10) from top of differential.
[5] -
LEGEND:
12 Pinion Shaft Pin
13 Pinion Shaft
14 Bevel Gear (2 used)
15 Thrust Washer (2 used)
Pinion Shaft Pin
Pinion Shaft and Bevel Gears

Drive pinion shaft pin (12) from pinion shaft (13).
[6] - Remove pinion shaft, bevel gears (14), and thrust washers (15).
[7] -
LEGEND:
8 Bevel Gear
9 Thrust Washer
10 Spacer

Remove bevel gear (8), thrust washer (9), and spacer (10) from bottom of differential.
[8] - Inspect and replace parts as necessary.
[9] - Assemble bevel gear (8), thrust washer (9), and spacer (10) and install in bottom of differential.
[10] -
LEGEND:
12 Pinion Shaft Pin
13 Pinion Shaft
Pinion Shaft and Bevel Gears
Pinion Shaft Pin

Install bevel gears (14), thrust washers (15), and pinion shaft (13).
[11] - Install pinion shaft pin (12) to retain pinion shaft.
[12] -

Bevel Gear
LEGEND:
8 Bevel Gear
9 Thrust Washer
10 Spacer
Assemble bevel gear (8), thrust washer (9), and spacer (10). Install in top of differential.
[13] -

LEGEND:
5 Cover
17 Alignment Pin (2 used)
Alignment Pins and Cover

Install alignment pins (17) and install cover (5).
[14] -
CAUTION:
Prevent possible burns from heated components. Use appropriate hand protection when handling heated
components.
LEGEND:
6 Bevel Gear
Bevel Gear
Heat bevel gear (6) to specification and install on differential.
Bevel Gear Temperature 120°C
248°F
[15] -
LEGEND:
3 Differential
Bevel Gear Cap Screws

Apply PM37418 Loctite ™ Thread Lock and Sealer (medium strength) to bevel gear cap screws (4). Install bevel gear cap
screws and tighten to specification.
Bevel Gear Cap Screw Torque 68 N·m

50 lb.-ft.
Number Name Use

Apply to threads of cap screws to prevent them from
• 242 Loctite ™ (us) Thread Lock and Sealer (medium strength)
backing out.
[16] -
CAUTION:
Prevent possible burns from heated components. Use appropriate hand protection when handling heated
components.
LEGEND:
Tapered Roller Bearings

Heat tapered roller bearings (1) to specification and install on differential.
248°F

Limited Slip Differential Disassemble and Assemble—If Equipped

Specifications
SPECIFICATIONS
0.152—0.508 mm
Bevel Gear Drive Axial Play
0.006—0.020 in.
95°C
Bevel Gear Drive Temperature
205°F
68 N·m
Bevel Gear Cap Screw Torque
50 lb.-ft.
95°C
Tapered Roller Bearing Temperature
205°F
Other Material
OTHER MATERIAL
242 Loctite ™ Thread Lock and Sealer (medium strength)
[1] -
LEGEND:
1 Bearing Puller
3 Differential
Differential Tapered Roller Bearings

Using a bearing puller (1), remove tapered roller bearings (2) from differential (3).
[2] -
LEGEND:
3 Differential

Remove bevel gear cap screws (4) from differential (3).
[3] -

LEGEND:
5 Cover
6 Bevel Gear
Differential Bevel Gear

Remove cover (5) and bevel gear (6) from differential.
[4] -
Differential Clutch Disks and Plates (exploded view)
Differential Clutch Disks and Plates

LEGEND:
8 Bevel Gear Drive
9 Thrust Washer
10 Clutch Plate (5 used)
11 Clutch Disk (4 used)
Remove bevel gear drive (8), thrust washer (9), clutch plates (10), and clutch disks (11) from top of differential.
[5] -

LEGEND:
12 Pinion Shaft
13 Spring Pin
Differential Pinion Shaft Removal

Tap pinion shaft (12) to shear off spring pin (13), remove pinion shaft. Remove sheared spring pin from differential and pinion
shaft.
[6] -
LEGEND:
Pinion Bevel Gears and Thrust Washers

Remove bevel gears (15) and thrust washers (16).
[7] -
Differential Clutch Disks (exploded view)

Differential Bevel Gear Drive and Clutch Disks

LEGEND:
8 Bevel Gear Drive
9 Thrust Washer
Remove bevel gear drive (8), thrust washer (9), clutch plates (10), and clutch disks (11) from bottom of differential.
[9] -
→NOTE:
In order to achieve an accurate measurement for axial play on bevel gear drives (8), install parts first
without lubrication.
Differential Clutch Disks (exploded view)

Differential Bevel Gear Drive and Clutch Disks

LEGEND:
8 Bevel Gear Drive
9 Thrust Washer
Assemble bevel gear drive (8), thrust washer (9) with coated surface facing clutch disk, clutch plates (10), and clutch disks
(11). Install parts in differential housing.
[10] -
LEGEND:
12 Pinion Shaft
Differential Pinion Shaft and Gears

Install pinion shaft (12) with bevel gears (15) and thrust washers (16).
[11] -
LEGEND:
8 Bevel Gear Drive
14 Differential Opening
18 Dial Indicator
Differential Axial Play

Using a dial indicator (18) through differential opening (14), check axial play (up and down) of bevel gear drive (8) to
specification.
Bevel Gear Drive Axial Play 0.152—0.508 mm
0.006—0.020 in.
[12] - If axial play is out of specification, install clutch plates of different thicknesses to meet specification.
[13] - Disassemble differential and lightly oil all parts.
[14] - Install oiled bevel gear drive, thrust washer (9), clutch disks, and clutch plates.
[15] - Install bevel gears, thrust washers (16), and pinion shaft.
[16] -
→NOTE:
Be aware of depth on spring pin when installing through differential housing and pinion shaft.

LEGEND:
2 Differential
12 Pinion Shaft
13 Spring Pin
Spring Pin
Install spring pin through differential and pinion shaft.
[17] -
→NOTE:
Thickness and coating of clutch disks must be identical on both sides of differential housing.
Differential Clutch Disks and plates (exploded view)
Differential Clutch Disks and plates

LEGEND:
8 Bevel Gear Drive
9 Thrust Washer
Install bevel gear drive, thrust washer (9) with coated surface facing away from gear drive, clutch plates, and clutch disks in
bottom of differential.
[18] -
LEGEND:
5 Cover
Differential Cover
Install alignment pins (20) and cover (5).
[19] -
CAUTION:
Prevent possible burn injury. Use hand protection when handling heated components.
LEGEND:
6 Bevel Gear Drive
Bevel Gear Drive

Heat bevel gear drive (6) to specification and install on differential.
Bevel Gear Drive Temperature 95°C
205°F
[20] -
LEGEND:
3 Differential

Apply PM37418 Thread Lock and Sealer (medium strength) to bevel gear cap screws (4). Install bevel gear cap screws and
tighten to specification.

Section 02 - AXLES AND SUSPENSION SYSTEMS Group 0250: Axle Shaft, Bearings, and Reduction Gears
Number Name Use

• PM37418 (us)
Thread Lock and Sealer (medium strength) Seal threads of bevel gear drive cap screws.
Bevel Gear Cap Screw Torque 68 N·m
50 lb.-ft.
[21] -
CAUTION:
Prevent possible burn injury. Use hand protection when handling heated components.
LEGEND:
Heated Tapered Roller Bearings

Heat tapered roller bearings (1) to specification and install on differential.
205°F

Group 0250 - Axle Shaft, Bearings, and Reduction Gears

Service Brakes Inspection
[1] -
LEGEND:
1 Right Side Brake Inspection Port
2 Left Side Brake Inspection Port
Right External Inspection Port
Left Side External Inspection Port

Remove plugs from right and left side brake inspection ports (1 and 2).
[2] -
→NOTE:
If axle is removed from machine, skip steps 2 and 3 and apply hydraulic pressure directly to axle service
brake ports using a manually operated hydraulic pump.
Start engine. Do not release park brake.
[3] - Apply service brakes.
[4] -
→NOTE:
When service brakes are applied, gap measurement (4) will equal overall thickness of brake disks (6).
A piece of metal bar stock with a thickness of 4.5 mm (0.177 in.) can be used as a gauge to check gap. If
the 4.5 mm (0.177 in.) gauge cannot fit between two separator plates, replace brake disks.

Service Brake Inspection Port (left side shown)
Disk Clearance
LEGEND:
3 Brake Inspection Port
4 Gap Measurement
5 Separator Plate (4 used)
6 Brake Disk (3 used)
Check gap measurement between two separator plates using a feeler gauge.
[5] - Replace brake disks if gap is less than 4.5 mm (0.177 in.). See Rear Axle Disassemble . (Group 0250.)
Rear Axle
Service Brake Disk Thickness (minimum) 4.5 mm
0.177 in.

Rear Axle Remove and Install

Specifications
SPECIFICATIONS
5103—8163 kg
Rear of Machine Weight (approximate)
11 250—18 000 lb.
490 kg
Rear Axle Weight
1080 lb.
620 N·m
Mounting Cap Screw Torque
457 lb.-ft.
JT01642A Low Lift Jack
[2] -
CAUTION:
High Pressure Fluids

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 connections before applying
pressure.
Release hydraulic system pressure. See Hydraulic Circuit Pressure Release . (Group 9025-25.)
[3] -
CAUTION:
Raise and support rear of machine. Position floor stands under main frame.
Rear of Machine Weight (approximate) 5103—8163 kg
11 250—18 000 lb.
[4] - Remove both rear wheels. See Rear Wheel Assembly Remove and Install . (Group 0110.)
[5] - Drain rear axle. See Change Rear Axle and Planetary Housing Oil . (Operator’s Manual.)
[6] - Remove rear drive shaft. See Universal Joint and Drive Shaft Remove and Install . (Group 0225.)
[7] -
Rear Axle
LEGEND:
73 Rear Axle
75 Park Brake Valve-to-Park Brake Line
77 Service Brake Valve-to-Service Brake Line (2 used)
78 Differential Lock Valve-to-Differential Lock Line
B13 Park Brake Pressure Switch
Tag and disconnect park brake valve-to-park brake line (75), service brake valve-to-service brake lines (77), and differential
lock valve-to-differential lock line (78) from rear axle (73). Close all openings using caps and plugs.
[8] - Disconnect park brake pressure switch (B13) electrical connector.
[9] - Position a JT01642 Low Lift Jack under center of rear axle. Attach the adjustable-grip arms and safety chains of the low lift
jack to the axle housing.
Low Lift Jack
JT01642A
Used to remove and install rear axle.
[10] -
CAUTION:

LEGEND:
Rear Axle Mounting Hardware

Remove cap screws (1) on each side of axle and lower axle from machine.
Rear Axle Weight 490 kg
1080 lb.
[11] - Repair axle as necessary. See Rear Axle Disassemble . (Group 0250.)
[12] - Install rear axle.
[13] - Install and tighten axle mounting cap screws to specification.

Mounting Cap Screw Torque 620 N·m
457 lb.-ft.
[14] - Connect lines to service brakes, differential lock, and park brake.
[15] - Connect park brake pressure switch (B13) electrical connector.
[16] - Install rear wheels and lower machine to ground. See Rear Wheel Assembly Remove and Install . (Group 0110.)
[17] - Fill rear axle with proper oil. See Change Rear Axle and Planetary Housing Oil and see Transmission, Axles, and
Mechanical Front Wheel Drive (MFWD) Oil . (Operator’s Manual.)

Rear Axle Disassemble

Specifications
SPECIFICATIONS
490 kg
Rear Axle Weight (approximate)
1080 lb.
36 kg
Planetary Weight (approximate)
79 lb.
23 kg
Rear Axle Hub Weight (approximate)
50 lb.
82 kg
Axle Housing Weight (approximate)
181 lb.
23 kg
Differential Weight (approximate)
50 lb.
[1] -
CAUTION:
Using appropriate lifting device, place rear axle on stand or steel table.
Rear Axle Weight (approximate) 490 kg
1080 lb.
[2] -
→NOTE:
Procedures for left and right sides of rear axle disassembly are the same. Differential lock components
are located behind left side axle housing.
LEGEND:
Planetary Cap Screws

Remove cap screws (1).
[3] -
CAUTION:

LEGEND:
2 Planetary
Planetary
Using appropriate lifting device, remove planetary (2).
Planetary Weight (approximate) 36 kg
79 lb.
[4] -
LEGEND:
Planetary Snap Rings

Remove snap rings (3).
[5] -
LEGEND:
Planetary Gear
Remove planetary gears (4).
[6] -
LEGEND:
5 Sun Gear Shaft
6 O-Ring
Sun Gear Shaft

Remove sun gear shaft (5) and O-ring (6).
[7] -
LEGEND:
Internal Gear Cap Screws

[8] -
LEGEND:
8 M14 Guide Screw (2 used)
9 Jack Screw (2 used)
10 Hub
Internal Gear and Jack Screws

Install M14 guide screws (8).
[9] - Install jack screws (9) into threaded holes of internal gear.
[10] - Pull internal gear away from hub (10) by evenly tightening jack screws until internal gear is loose.
[11] -
→NOTE:
Remove bushings (12) only if necessary.

LEGEND:
12 Bushing (8 used)
Bushings
If necessary, remove bushings (12).
[12] -
CAUTION:
LEGEND:
10 Hub
Rear Axle Hub

Using appropriate lifting device, remove hub (10).
Rear Axle Hub Weight (approximate) 23 kg
50 lb.
[13] -
LEGEND:
14 Hub Seal
15 Outer Bearing Cup (2 used)
Hub Seal and Bearing Cups

Remove hub seal (14) and outer bearing cups (15).
[14] -
LEGEND:
18 Bearing Inner Ring
Bearing Inner Ring

Remove bearing inner ring (18).
[15] -
CAUTION:
LEGEND:
21 Axle Housing

Support axle housing (21) and remove cap screws (20).
Axle Housing Weight (approximate) 82 kg
181 lb.
[16] -
LEGEND:
Axle Housing
Install M16 guide screws (23) and remove axle housing.
[17] -

LEGEND:
24 Axle Shaft
Axle Shaft
Remove axle shaft (24) from axle housing.
[18] -
LEGEND:
25 Snap Ring
Shaft Snap Ring

Remove snap ring (25).
[19] -
LEGEND:
26 Brake Disk Package
27 O-Ring
28 O-Ring
29 O-Ring
Disk Package
Remove brake disk package (26).
[20] - Remove O-rings (27—29).
[21] -

LEGEND:
31 Coupling Ring
Coupling Ring
Remove cap screws (30) and remove coupling ring (31).
[22] -
LEGEND:
33 Disk Spring
34 Snap Ring
35 Washer
Snap Ring Bevel Springs

Preload disk spring (33).
[23] - Remove snap ring (34) and washer (35).
[24] -
CAUTION:
Prevent possible personal injury. Wear proper face and body protection when using compressed air.
Using compressed air, remove piston (36).

LEGEND:
36 Brake Piston
Brake Piston
[25] -
LEGEND:
36 Brake Piston
38 Brake Piston Lip Seal
39 Backup Ring
42 Backup Ring
Piston Seals
Axle Housing Seals

Remove brake piston lip seal (38) and backup ring (39) from axle housing.
[26] - Remove brake piston lip seal (41) and backup ring (42) from piston.
[27] -
LEGEND:
44 Differential Cover
Differential Cover
Remove differential cover (44).
[28] -
LEGEND:
46 O-Ring
47 Piston
Piston
Remove O-ring (46).
[29] -
CAUTION:
Using compressed air, remove piston (47).
[30] -
LEGEND:
49 Bearing Cup
50 Shim
Bearing Cup and Shim

Remove bearing cup (49) and shim (50).
[31] -
LEGEND:
52 O-Ring (2 used)
O-Rings
Remove O-rings (52).
[32] -
LEGEND:
54 O-Ring (2 used)
55 Differential Lock
O-Ring and Differential Lock Coil Spring (left side of axle

shown)
[33] -
→NOTE:
Differential lock is on left side only.
Left Side of Axle Only:
a. Remove differential lock (55).

LEGEND:
57 Needle Bearing
58 Locking Slide
59 Compression Spring
b.
Differential Lock
Remove needle bearing (57), locking slide (58), and compression spring (59) from differential lock.
[34] -
CAUTION:
LEGEND:
61 Differential
Differential
Using appropriate lifting device, remove differential (61).
Differential Weight (approximate) 23 kg
50 lb.
[35] -

LEGEND:
62 Bearing
63 Bearing
Differential Bearings
Remove bearings (62 and 63).
[36] -
LEGEND:
Differential Case Cap Screws

[37] -

LEGEND:
66 Differential Case Half
67 Differential Case Half
69 Bevel Gear
71 Side Gear (4 used)
72 Pinion Shaft
73 Bevel Gear
74 Spacer
Differential
Separate differential case halves (66 and 67).
[38] - Remove thrust washer (68) and bevel gear (69).
[39] - Remove thrust washers (70), side gears (71), and pinion shaft (72).
[40] - Remove bevel gear (73), lower thrust washer (68), and spacer (74).
[41] -
LEGEND:
76 Ring Gear
Ring Gear
Remove ring gear (76).
[42] -
→NOTE:
To aid in assembly, mark shim location.

LEGEND:
78 Differential Bearing Cup
79 Shim
Differential Bearing Outer Cup and Shim

Remove differential bearing cup (78) and shim (79) from axle housing.

Rear Axle Assemble

Specifications
SPECIFICATIONS
135 N·m
Differential Case Cap Screw Torque
100 lb.-ft.
1.7 mm
Outer Bearing Cup Shim Thickness
0.067 in.
23 kg
Differential Weight (approximate)
50 lb.
195 N·m
Differential Housing Cover Cap Screw Torque
144 lb.-ft.
0.15—0.25 mm
Rear Axle Ring Gear Backlash
0.006—0.010 in.
23 N·m
Coupling Ring Cap Screw Torque
17 lb.-ft.
82 kg
Axle Housing Weight
181 lb.
195 N·m
Axle Housing Cap Screw Torque
144 lb.-ft.
120°C
Inner Bearing Temperature
248°F
23 kg
Rear Axle Hub Weight (approximate)
50 lb.
120°C
Outer Bearing Temperature
248°F
250 N·m
Internal Gear Cap Screw Torque
184 lb.-ft.
120°C
Planetary Gear Temperature
248°F
36 kg
Planetary Weight (approximate)
79 lb.
55 N·m
Planetary Carrier Cap Screw Torque
41 lb.-ft.
Essential Tools
ESSENTIAL TOOLS
D01047AA 17-1/2 & 30-Ton Puller Set
JDG10524 Driver
JDG10525 Handle
JDG10526 Driver
DFT1286 Backlash Measurement Tool
Other Material
OTHER MATERIAL
Loctite ™ Klean ‘N Prime
Loctite ™ High Flex Form-In-Place Gasket
[1] -

LEGEND:
2 Differential Half
Differential Half Cap Screws

Install cap screws (1) into threaded holes of differential half (2).
[2] -
IMPORTANT:
Differential damage may occur if thrust washer is installed improperly. Install with dimpled side facing
bevel gear.
LEGEND:
4 Thrust Washer
5 Bevel Gear
Bevel Gears and Thrust Washer

Install thrust washer (4) with dimpled side facing bevel gear (5).
[3] -
LEGEND:
7 Differential Shaft
8 Side Gear (4 used)
Differential Assembly (exploded view)

Differential Assembly
Assemble side gears (8) and thrust washers (9) on differential shaft (7). Install in differential half (2) with thrust washer locking
tabs facing upwards.
[4] -
LEGEND:
11 Bevel Gear
12 Thrust Washer
13 Spacer Ring
Differential Bevel Gear and Thrust Washer

Install bevel gear (11), thrust washer (12), and spacer ring (13).
[5] -
LEGEND:
16 Stamped Number
Differential Housing Alignment

Align differential halves (2 and 15) using stamped number (16) on housing.
[6] -

LEGEND:
17 Ring Gear
Ring Gear
Install ring gear (17) and press until bottomed.
[7] -
LEGEND:
Differential Case Cap Screws

Install cap screws (18) and tighten to specification.
Differential Case Cap Screw Torque 135 N·m
100 lb.-ft.
[8] -
IMPORTANT:
Bearing damage may occur if force is applied to bearing cage. Make sure force is applied to inner race of
bearing only.
LEGEND:
19 Bearing
20 Bearing

Bearing Installation
Press bearings (19 and 20) until bottomed.
[9] -
→NOTE:
It is recommended to use shim found in disassembly.
LEGEND:
22 Shim
23 Outer Bearing Cup

Install original shim (22) and outer bearing cup (23) if in serviceable condition.
[10] - If new shim (22) is required, install specified shim.

Outer Bearing Cup Shim Thickness 1.7 mm
0.067 in.
[11] -
LEGEND:
16 Ring Gear
24 Differential
Differential Installation
Apply marking ink to teeth of ring gear (16) for checking contact pattern later.
[12] -
CAUTION:
Install differential (24).

Differential Weight (approximate) 23 kg
50 lb.
[13] -
LEGEND:
25 Straight Edge
26 Depth Gauge
Dimension I
Measure and record dimension I using straight edge (25) and a depth gauge (26).
Example
Example of Dimension (I)
6.64 mm
Flange mounting surface-to-outer bearing cup
0.261 in.
[14] -
LEGEND:
25 Straight Edge
26 Depth Gauge
Dimension II
Measure and record dimension II using straight edge (25) and a depth gauge (26).
Example
Example of Dimension (II)
5.35 mm
Brake housing flange-to-shoulder of outer bearing cup
0.217 in.
[15] -

LEGEND:
28 Shim (as required)
29 Bearing Cup
30 Differential Housing Cover

Difference of dimension I and dimension II equals total shims (28) required. When installing new bearings, add 0.10 mm to
calculated shim thickness for required new bearing preload. Round dimension to nearest shim size.
Shim Pack Equation
Example of Differential Bearing Shim Calculation

(Dimension I – Dimension II) + New Bearing Preload = Differential Bearing Shim
6.64 mm
Dimension I
0.261 in.
—5.35 mm
Subtract Dimension II
—0.217 in.
+0.10 mm
Add New Bearing Preload (only if installing new bearings)
+0.003 in.
1.39 mm
Equals
0.055 in.
=1.40 mm
Equals Total Differential Bearing Shim (rounded value)
=0.051 in.
[16] - Install predetermined shims (28) and bearing cup (29) into differential housing cover (30).
[17] -
LEGEND:
Differential Housing
Install differential housing cover (30) and cap screws (31). Tighten to specification.
Differential Housing Cover Cap Screw Torque 195 N·m
144 lb.-ft.
[18] -

LEGEND:
33 DFT1286 Backlash Measurement Tool
34 Dial Indicator
35 Input Flange
Backlash Tool
Install DFT1286 Backlash Measurement Tool (33) onto input flange (35). For information on DFT1286 Backlash Measurement
Tool, see DFT1286 Backlash Measurement Tool . (Group 9900.)
Backlash Measurement Tool
DFT1286
Used to measure backlash between ring gear and pinion.
[19] -
→NOTE:
Straightedge of DFT1286 Backlash Measurement Tool indicates position to record backlash.
Install dial indicator (34) so it is positioned 126 mm from center of input flange to correspond to outer tooth diameter of ring
gear. Hold ring gear stationary and check backlash.
Rear Axle Ring Gear Backlash 0.15—0.25 mm
0.006—0.010 in.
[20] -
LEGEND:
22 Shim
29 Bearing Cup

Too Little Backlash:

Install thicker shim (22) behind outer bearing cup (23). Shim (28) thickness must be reduced accordingly.
[21] - Too Much Backlash:

Install thinner shim (22) behind outer bearing cup (23). Shim (28) thickness must be increased accordingly.
[22] - Remove differential housing cover (30) and differential.
[23] - Check gear tooth contact pattern. See Gear Tooth Contact Pattern Check . (Group 0250.)
[24] - Install differential into housing.
[25] -
LEGEND:
36 Needle Bearing
37 Locking Slide
39 O-Ring (2 used)
40 Differential Lock
Differential Lock (exploded view)
Differential Lock Installation

Apply grease to needle bearing (36) and install onto locking slide (37).
[26] - Install compression spring (38) onto locking slide and install differential lock (40) assembly.
[27] - Apply grease to O-rings (39) and install onto axle housing.
[28] -
LEGEND:
42 O-Ring
43 O-Ring
44 O-Ring
O-Rings
Apply oil to O-rings (42—44) and install onto differential housing cover (30).
[29] -

LEGEND:
45 Piston
Differential Housing Piston

Press piston (45) into place.
[30] -
LEGEND:
Differential Housing Cover

Install M16 guide screws (46) and differential housing cover (30).
[31] -
Axle Housing Seals
Brake Piston Seals

Axle Housing and Brake Piston Seals (cross-section)

LEGEND:
47 Backup Ring
49 Axle Housing
50 Backup Ring
52 Spring Pin (4 used)
53 Brake Piston
Install brake piston lip seal (48) and backup ring (47) with open face of brake piston lip seal facing out of axle housing (49).
[32] -
→NOTE:
Spring pins may have moved in brake piston to compensate for friction material wear and require
resetting in brake piston.
If required, drive spring pins (52) flush with the face of the brake piston (53).
[33] - Install brake piston lip seal (51) and backup ring (50) so open face of brake piston lip seal faces into axle housing.
[34] -
LEGEND:
55 Disk Spring
56 Washer
Disk Spring
Install disk spring (55) and washer (56).
[35] -
LEGEND:
49 Axle Housing
53 Brake Piston
57 Two-Armed Puller
Brake Piston Installation

Apply clean transmission oil to brake piston (53) and press into axle housing (49) using a two-armed puller (57) from D01047AA
17-1/2 & 30-Ton Puller Set.
17-1/2 & 30-Ton Puller Set
D01047AA
Contains hydraulic units, adapters and attachments necessary to accomplish different pulling or pushing jobs
[36] -
LEGEND:
59 Washer
60 Disk Spring
61 Coupling Ring
Washer and Disk Spring

Install disk spring (60) and washer (59) onto coupling ring (61).
[37] -
LEGEND:
59 Disk Spring
62 Snap Ring
Snap Ring
Compress disk spring (59) and install snap ring (62).
[38] -
LEGEND:
61 Coupling Ring
Coupling Ring
Install coupling ring (61) and cap screws (64). Tighten to specification.
Coupling Ring Cap Screw Torque 23 N·m
17 lb.-ft.
[39] -
LEGEND:
66 Separator Plate (4 used)
67 Brake Disk (3 used)
68 O-Ring
69 O-Ring
70 O-Ring
Brake Disk
Alternately install separator plates (66) and brake disks (67) starting with a separator plate.
[40] - Apply oil to O-rings (68—70).
[41] -
LEGEND:
72 Disk Carrier
73 Snap Ring
74 Axle Shaft
Axle Shaft
Install disk carrier (72) and snap ring (73) on axle shaft (74).
[42] -
LEGEND:
49 Axle Housing
74 Axle Shaft
Axle Shaft Installation

Install axle shaft (74) into axle housing (49).
[43] -
CAUTION:
LEGEND:
49 Axle Housing
Axle Housing Installation

Insert axle housing (49) onto M16 guide screws (46).
Axle Housing Weight 82 kg
181 lb.
[44] -
LEGEND:

Axle Housing Cap Screw Torque 195 N·m
144 lb.-ft.
[45] -
LEGEND:
79 Wheel Stud (10 used)
80 Wheel Hub
Wheel Studs
Press wheel studs (79) into wheel hub (80) until bottomed.
[46] -
IMPORTANT:
Prevent wheel studs from pushing out of wheel hub and damaging threads. Wheel hub must not be
supported by wheel studs.
LEGEND:
81 Outer Bearing Cup (2 used)
82 JDG10524 Driver
83 JDG10525 Handle
Outer Bearing Cup

Install outer bearing cups (81) using JDG10524 Driver (82) and JDG10525 Handle (83).
Driver
JDG10524
Install hub bearing races.
Handle
JDG10525
Handle for JDG10524 driver tool.
[47] -
LEGEND:
84 Hub Seal
85 JDG10526 Driver
Hub Seal
Hub Seal
Apply PM37509 Klean ‘N Prime and PM38657 High Flex Form-In-Place Gasket to outer face of hub seal (84).
Number Name Use

• Loctite ™ (loctite) Klean ‘N Prime Used to clean the outer face of hub seal.
• 17430 Loctite ™ (loctite) High Flex Form-In-Place Gasket Used on outer face of hub seal.
[48] -
IMPORTANT:
Axle damage and leaking may occur if old seal is used. Replace with new seal.
Install hub seal using JDG10526 Driver.

Driver
JDG10526
Used to install hub seal.
[49] -
CAUTION:
Prevent possible burn injury when handling heated components. Use appropriate hand protection.
LEGEND:
86 Inner Bearing
87 Sun Gear Shaft
Inner Bearing
Heat inner bearing (86) to specification and install.
Inner Bearing Temperature 120°C
248°F
[50] - Install sun gear shaft (87).
[51] -
CAUTION:
LEGEND:
80 Wheel Hub
84 Hub Seal
88 Outer Bearing
Hub and Bearing Inner Ring

Clean off axle contacting parts of hub seal (84) with mineral spirit. Install wheel hub (80) until bottomed.
Rear Axle Hub Weight (approximate) 23 kg
50 lb.-ft.
[52] -
CAUTION:
Heat outer bearing (88) to specification and install.

Outer Bearing Temperature 120°C
248°F
[53] -
LEGEND:
89 Bushing (8 used)
90 Internal Gear Housing
Bushing
If removed, install bushings (89) into internal gear housing (90) using a press.
[54] -
LEGEND:
90 Internal Gear Housing
Internal Gear Housing

Using cap screws (92) removed during disassembly, draw internal gear housing (90) onto bosses.
[55] - Remove and discard old cap screws (92).
[56] -
IMPORTANT:
Rear axle damage may occur if old cap screws are used. Cap screws are designed for one time use only,
replace with new cap screws.
Install new cap screws (92) and tighten to specification.

Internal Gear Cap Screw Torque 250 N·m
184 lb.-ft.
[57] -
LEGEND:
93 Assembly Sleeve (4 used)
95 Planetary Bearing (4 used)
96 Stop Pin
Planetary Gear
Planetary Gears and Stop Pin

If installing new planetary bearings (95), press into planetary gear (94) and discard assembly sleeve (93).
[58] -
CAUTION:
Heat planetary gear to specification and install with larger opening facing downward.
Planetary Gear Temperature 120°C
248°F
[59] - If removed, install stop pin (96).
[60] -
LEGEND:
Snap Ring
[61] -
LEGEND:
87 Sun Gear Shaft
99 O-Ring
O-Ring
Sun Gear Shaft

Apply clean transmission oil to O-ring (99) and install O-ring onto wheel hub.
[62] - Remove sun gear shaft (87) from axle housing and install into planetary.
[63] -
CAUTION:
LEGEND:
100 Planetary Carrier
Planetary Carrier
Install planetary carrier (100).
Planetary Weight (approximate) 36 kg
79 lb.
[64] -
LEGEND:
Planetary Cap Screws

Planetary Carrier Cap Screw Torque 55 N·m
41 lb.-ft.
Park Brake Disassemble and Assemble

Specifications
SPECIFICATIONS
195 N·m
Park Brake Housing Cap Screw Torque
144 lb.-ft.
120°C
Inner Pinion Bearing Temperature
248°F
120°C
Outer Pinion Bearing Temperature
248°F
600 N·m
Input Flange Nut Torque
443 lb.-ft.
2 N·m
New Bearing Rolling Drag Torque
20 lb.-in.
1 N·m
Old Bearing Rolling Drag Torque
7 lb.-in.
46 N·m
Park Brake Cover Cap Screw and Nut Torque
34 lb.-ft.
29 mm
Park Brake Release Cap Screw Height
1.1 in.
46 N·m
Park Brake Release Cap Screw Torque
34 lb.-ft.
Essential Tools
ESSENTIAL TOOLS
JDG10527 Park Brake Seal Driver
Other Material
OTHER MATERIAL
[1] -
LEGEND:
1 Nut
2 Input Flange
Input Flange and Nut

Remove nut (1) and input flange (2).
[2] -
LEGEND:
4 Shaft Seal
6 Nut (2 used)
Park Brake Cover Cap Screws

Remove shaft seal (4)
[3] - Remove cap screws (5) and nuts (6).
[4] -
LEGEND:
8 Park Brake Release Screw (2 used)
9 Cover
Park Brake Cover

Remove park brake release screws (8).
[5] - Remove cover (9).
[6] -
LEGEND:
11 Disk Carrier
12 Outer Spring (14 used)
13 Inner Spring (14 used)
Disk Carrier and Springs

Remove disk carrier (11).
[7] - Remove outer springs (12) and inner springs (13).
[8] -
CAUTION:
→NOTE:
For ease of assembly, mark piston alignment in brake housing.
LEGEND:
14 Piston
15 O-Ring
Park Brake Piston

Use compressed air to remove piston (14).
[9] - Remove O-ring (15).
[10] -
LEGEND:
17 Inner O-Ring
18 Outer O-ring
Piston O-Rings
Remove inner O-ring (17) and outer O-ring (18) from park brake piston.
[11] -
LEGEND:
20 Disk and Plate Assembly
Disk and Plate Assembly

Remove disk and plate assembly (20).
[12] -
LEGEND:
22 Pin (2 used)
Pin Removal
Remove pins (22).
[13] -
LEGEND:
24 Pinion
25 Outer Pinion Bearing
26 Two-Armed Puller
Pinion Removal
Remove pinon (24) and outer pinion bearing (25) using a two-armed puller (26) from D01047AA 17-1/2—30 Ton Puller Set.
[14] -
LEGEND:
28 Spacer Ring
29 Inner Pinion Bearing
Spacer and Inner Pinion Bearing Removal

Remove spacer ring (28) and inner pinion bearing (29).
[15] -
→NOTE:
For aid in assembly, mark shim location.
LEGEND:
31 Inner Bearing Cup
32 Shim
Inner Bearing Cup Removal

Remove inner bearing cup (31) and shim (32).
[16] -
LEGEND:
34 Two-Armed Puller
Outer Bearing Cup Remove

Remove outer bearing cup (33) using a two-armed puller (34) from D01047AA 17-1/2—30 Ton Puller Set.
[17] -
LEGEND:
37 M16 Jack Screw (2 used)
38 Dead Blow Hammer
39 Park Brake Housing
Park Brake Housing Removal

Remove cap screws (36) and install M16 jack screws (37).
[18] - Tighten M16 jack screws while lightly tapping on back of park brake housing (39) with dead blow hammer (38) until
loose.
[20] -
→NOTE:
It is recommended to reuse shim found in disassembly of park brake.
LEGEND:
32 Shim
Shim Installation
Install shim (32).
[21] -
LEGEND:
Outer Bearing Cup

Install outer bearing cup (33).
[22] -
LEGEND:
Inner Bearing Cup

Install inner bearing cup (31).
[23] -
IMPORTANT:
To prevent oil leakage, make sure area around return port (34) is completely covered with PM38657 High
Flex Form-in-Place Gasket.
LEGEND:
34 Return Port
Park Brake Housing Gasket Application

Apply PM37509 Klean ‘N Prime to sealing surface.
Number Name Use

• PM37509 (us)
Klean ‘N Prime Used on park brake housing.
• Loctite ™ (loctite)
[24] - Apply PM38657 High Flex Form-In-Place Gasket to park brake housing all the way around return port (34).
Number Name Use

• PM38657 (us)
High Flex Form-In-Place Gasket Used to clean park brake housing.
• Loctite ™ (loctite)
[25] -
LEGEND:
39 Park Brake Housing
Park Brake Housing Installation

Install park brake housing (39) and cap screws (36). Moving in a star pattern, tighten cap screws to specification.
Park Brake Housing Cap Screw Torque 195 N·m
144 lb.-ft.
[26] - Determine Pinion Position and Shim Requirement:
a. Dimension I is the measurement from axle center line to inner bearing contact position.
Dimension I
Example of Dimension I
165 mm
Axle Center Line-to-Inner Bearing Contact
6.5 in.
LEGEND:
41 Dimension II
b.
Dimension II
Record etched number at end of pinion shaft as dimension II (41).
Dimension II
Example of Dimension II
127 mm
Dimension II Etched on Top of Pinion Gear
5 in.
LEGEND:
c.
Dimension III
Rotate inner pinion bearing (29) in both directions several times while recessed in inner bearing cup (31) to determine
roller setting.
d. Measure and record bearing width from flat side of inner bearing cup to flat surface of inner pinion bearing as dimension
III.
Dimension III
Example of Dimension III
36.60 – 0.05 = 35.5 mm

Width of Bearing—Experience Value of 0.05 mm (0.002 in.)
1.44 – .002 = 1.42 in.
e. Subtract dimension I from sum of dimensions II and III to determine number of shims required behind pinion shaft inner
bearing cup.
Shim Calculation
Example of Shim Calculation

Dimension (I) - Dimension (II + III)
165.04 mm - (126.9 mm +36.55 mm)

Dimension (I)
6.5 in.
Minus Dimension (II+III)

—163.45 mm
126.9 mm + 36.55 mm
—6.40 in.
(4.98 in.+ 1.42 in.)
=1.59 mm
Result
=0.10 in.
=1.60 mm
Required Shim
=0.10 in.
[27] -
CAUTION:
LEGEND:
24 Pinion
Pinion Bearing Installation

Heat inner pinion bearing (29) to specification and install on pinion (24) until bottomed.
Inner Pinion Bearing Temperature 120°C
248°F
[28] -
→NOTE:
If shim (32) was replaced, install a spacer ring (28) adjusted by same correction value.
LEGEND:
28 Spacer Ring
Spacer Ring Installation

Install spacer ring (28).
[29] -
LEGEND:
24 Pinion
25 Outer Pinion Bearing
Pinion and Outer Bearing Installation

Install pinion (24).
[30] -
CAUTION:
Heat outer pinion bearing (25) to specification and install on pinion.

Outer Pinion Bearing Temperature 120°C
248°F
[31] -
LEGEND:
1 Nut
2 Input Flange
11 Disk Carrier
Disk Carrier Installation
Input Flange Nut

Install disk carrier (11).
[32] - Install input flange (2).
[33] - Install input flange nut (1) and tighten to specification.

Input Flange Nut Torque 600 N·m
443 lb.-ft.
[34] - Check rolling torque.

New Bearing Rolling Drag Torque 2 N·m
20 lb.-in.
Old Bearing Rolling Drag Torque 1 N·m
7 lb.-in.
[35] -
LEGEND:
28 Spacer Ring
Spacer Ring Installation

If rolling torque is not within specification, remove pinion and replace spacer ring (28).
[36] -
LEGEND:
1 Nut
2 Input Flange
11 Disk Carrier
Input Flange Nut
Disk Carrier Installation

Remove nut (1), input flange (2), and disk carrier (11).
[37] -
LEGEND:
22 Pin (2 used)
Pin Installation
Install pins (22).
[38] -
LEGEND:
Disk and Plate Installation
Disk and Plate Assembly

Starting with a plate, alternately install disk and brake assembly (20) as shown.
[39] -
LEGEND:
14 Piston
15 O-Ring
17 Inner O-Ring
18 Outer O-Ring
Piston O-Rings
Park Brake Piston Installation

Install inner O-ring (17), outer O-ring (18), and apply petroleum jelly.
[40] - Press park brake piston (14) into housing.
[41] - Install O-ring (15).
[42] -
LEGEND:
12 Outer Spring (14 used)
13 Inner Spring (14 used)
Spring Installation
Install outer springs (12) and inner springs (13).
[43] -
LEGEND:
6 Nut (2 used)
9 Cover
11 Disk Carrier
Park Brake Cover Installation

Install park brake cover (9), cap screws (5), and nuts (6). Tighten cap screws and nut to specification.
Park Brake Cover Cap Screw and Nut Torque 46 N·m
34 lb.-ft.
[44] - Install disk carrier (11).
[45] -
LEGEND:
4 Shaft Seal
42 JDG10527 Park Brake Seal Drive
Park Brake Seal Installation

Apply PM37509 Klean ‘N Prime and PM38657 High Flex Form-In-Place Gasket to contacting parts of park brake seal (4).
Number Name Use

• Loctite ™ (loctite) Klean ‘N Prime Used clean contacting parts of park brake seal.
• Loctite ™ (loctite) High Flex Form-In-Place Gasket Apply to contacting parts of park brake seal.
[46] - Install park brake seal using JDG10527 Park Brake Seal Driver (42).
Park Brake Seal Driver
JDG10527
Used to install park brake seal.
[47] -
LEGEND:
2 Input Flange
43 Dust Cover
Dust Cover Installation

Inspect dust cover (43). Remove and replace if necessary.
[48] - Install dust cover into input flange (2) until bottomed.
[49] -
LEGEND:
1 Nut
2 Input Flange
Input Flange
Install input flange (2).
[50] - Rotate pinion in both directions several times while tightening input flange nut (1).
Input Flange Nut Torque 600 N·m
443 lb.-ft.
[51] -
LEGEND:
8 Park Brake Release Screw (2 used)
44 Locking Nut (2 used)
Park Brake Release Cap Screws

Install park brake release screws (8) to height specification. Torque locking nuts (44) on park brake release screws to
specification.
Park Brake Release Cap Screw Height 29 mm
1.1 in.
Park Brake Release Cap Screw Torque 46 N·m
34 lb.-ft.
Gear Tooth Contact Pattern Check

[1] -
IMPORTANT:
Gear tooth contact pattern must be checked on the coast side and drive side with a load applied. The
pattern may be correct on the drive side and incorrect on the coast side causing the differential to
“whine” when it is not engaged.
Apply grease to several teeth of ring gear with a load applied.
[2] - Apply pressure to park brake using a hydraulic hand pump or park brake release screws. If park brake release screws are
used, return them to original position after test is complete.
[3] - Turn pinion in both directions to determine gear-tooth contact pattern. If pattern is not correct, cone point distance must
be increased or decreased.
Contact Pattern Check

( 1 ) Ideal Tooth Contact Pattern
Action:
LEGEND:
1 Coast Side (concave)
2 Drive Side (convex)
Ideal Tooth Contact Pattern
Does contact pattern match?
Result:
YES:Checks complete.
NO:Contact pattern at top of gear tooth indicates pinion shim is too thick. Go to Cone Point Decrease . Contact pattern at
bottom of gear tooth indicated pinion shim is too thin. Go to Cone Point Increase.
( 2 ) Cone Point Increase
Action:
LEGEND:
Thicker Pinion Shim Needed
Result:
YES:Replace pinion shim with thicker shim.

NO: Go to Ideal Tooth Contact Pattern .
( 3 ) Cone Point Decrease
Action:
LEGEND:
Thinner Pinion Shim Needed
TRANSMISSION (g) by Belgreen v2.0
Result:
YES:Replace pinion shim with thinner shim.

NO: Go to Ideal Tooth Contact Pattern .
Section 03 - TRANSMISSION
Table of contents
Group 0300 - Removal and Installation ................................................................................................ 1
Transmission Remove and Install ......................................................................................................... 1
Group 0315 - Controls Linkage ............................................................................................................ 11
Transmission Control Lever (TCL) Remove and Install ........................................................................ 11
Group 0350 - Gear, Shafts, and Power Shift Clutches ..................................................................... 13
Transmission Outer Components Removal ......................................................................................... 13
Transmission Case Disassemble—Torque Converter Side .................................................................. 17
Clutch Packs Remove ......................................................................................................................... 20
High Range Forward, Low Range Forward, and Reverse Clutch Packs Disassemble and Assemble
..................................................................................................................................................... 25
First Speed and Third Speed Clutch Disassemble and Assemble ....................................................... 41
Second Speed Clutch Disassemble and Assemble .............................................................................. 57
Mechanical Front Wheel Drive (MFWD) Clutch Disassemble and Assemble ....................................... 66
Pump Drive Shaft Install ..................................................................................................................... 75
Clutch Packs Install ............................................................................................................................. 77
Transmission Case Assemble—Torque Converter Side ....................................................................... 82
Transmission Outer Components Install ............................................................................................. 86
Group 0360 - Hydraulic System ........................................................................................................... 90
Transmission Charge Pump Remove and Install ................................................................................. 90
Transmission Charge Pump Disassemble and Assemble .................................................................... 95

Section 03 - TRANSMISSION Group 0300: Removal and Installation

Transmission Remove and Install
Specifications
SPECIFICATIONS
247 kg
Transmission Weight (approximate)
545 lb.
73 N·m
Transmission-to-Flywheel Housing Cap Screw Torque
54 lb.-ft.
320 N·m
Mounting Bracket-to-Transmission Cap Screw Torque
236 lb.-ft.
275 N·m
Isolator-to-Frame Cap Screw Torque
203 lb.-ft.
73 N·m
Flex Plate Cap Screw Torque
54 lb.-ft.
D24206WK 10-Ton Shop Stand
JDG820 Flywheel Turning Tool
D01004AA Universal Mounting Arm (2 used)
DFT1285 or DFT1285A Engine Support Bracket
[1] -
Machine Supported on Floor Stands

Raise machine approximately 940 mm (37 in.) from the floor to the bottom of battery box. The floor jack must raise high
enough to support the transmission.
[2] - Install four 10-ton shop stands under machine as shown.

10-Ton Shop Stand
D24206WK
Used to support whole machine off ground.
[3] - If equipped with mechanical front wheel drive (MFWD):

Remove MFWD drive shaft. See Universal Joint and Drive Shaft Remove and Install . (Group 0225.)
[4] - Remove rear axle drive shaft. See Universal Joint and Drive Shaft Remove and Install . (Group 0225.)
[5] -

LEGEND:
2 Washer (4 used)
3 Floor Plate
5 Washer (4 used)
6 Floor Plate
Cab Floor Plates

Remove floor mat, cap screws (1), washers (2), and front floor plate (3).
[6] - Remove cap screws (4), washers (5), and floor plate (6).
[7] -
LEGEND:
Y1 Transmission Forward Direction Solenoid
Y2 Transmission Reverse Direction Solenoid
Y3 Transmission Speed Solenoid 1
Y7 Park Brake Release Solenoid
Y10 Differential Lock Solenoid
Transmission Solenoid Connectors (top view)

Tag and disconnect solenoids (Y1—Y3, Y7, and Y10).
[8] - Drain transmission and hydraulic reservoir. See Change Transmission Oil and Replace Filter and see Change Hydraulic
Reservoir Oil . (Operator’s Manual.)
[9] -
LEGEND:
8 Transmission Oil Cooler Hose (2 used)
B6 Torque Converter Oil Temperature Sensor
B14 Transmission Output Speed Sensor (if equipped)
Transmission (front view)

Tag and disconnect transmission cooler hoses (8). Close all openings using caps and plugs.

[10] - Tag and disconnect torque converter oil temperature sensor (B6) and transmission output speed sensor (B14) (if
equipped).
[11] -
LEGEND:
10 Transmission Solenoid Guard
Transmission Solenoid Guard

Remove cap screws (9) and transmission solenoid guard (10).
[12] -
LEGEND:
Y6 Transmission Speed Solenoid 4 (if equipped)
Y11 Mechanical Front Wheel Drive (MFWD) Solenoid
Transmission Solenoid Connectors (lower view 310K

only)
Transmission Solenoid Connectors (lower view)

Tag and disconnect solenoids (Y4—Y6 and Y11).
[13] - Remove hydraulic pump. See Hydraulic Pump Remove and Install . (Group 2160.)
[14] -

Transmission (hydraulic pump side)

LEGEND:
11 Brake Boost Return Hose
12 Brake Boost Pressure Hose
13 Differential Lock Hose
14 Park Brake Hose
Tag and disconnect brake boost return hose and brake boost pressure hose (11 and 12). Close all openings with caps and
plugs.
[15] - Tag and disconnect differential lock hose and park brake hose (13 and 14). Close all openings with caps and plugs.
[16] -
LEGEND:
17 Transmission Fill Tube
Transmission Fill Tube

Remove cap screws (16) and transmission fill tube (17). Close all openings with caps and plugs.
[17] -

LEGEND:
20 Access Plate
21 Flywheel Housing
22 Plug
23 JDG820 Flywheel Turning Tool
24 Flex Plate Cap Screw (4 used)
25 Transmission-To-Flywheel Housing Cap Screw (12 used)
Flywheel Access Plate
Torque Converter Flex Plate

Remove cap screws (19) and access plate (20) at bottom of flywheel housing (21).
[18] - Remove plug (22) located at right front side of flywheel housing, and insert JDG820 Flywheel Turning Tool (23). Turn
flywheel to remove flex plate cap screws (24).
Flywheel Turning Tool
JDG820
Used to turn flywheel when installing flex plate-to-flywheel cap screws.
[19] -
→NOTE:
Upper six transmission-to-flywheel housing cap screws (25) must be left in place until engine and
transmission are supported.
Remove lower six transmission-to-flywheel housing cap screws (25).
[20] -

Kremnut Fasteners
LEGEND:
27 RIVNUT® (kremnut) (2 used)
Install RIVNUT ™ ® fasteners (27) in outside holes in frame near flywheel housing. See RIVNUT® (KREMNUT) Fasteners
Remove and Install . (Group 1740.)
[21] -
→NOTE:
When installing the DFT1285 or DFT1285A Engine Support Bracket (30), use M10 cap screws that are at
least 80 mm (3 in.) in length and with 40 mm (1.5 in.) of thread.
DFT1285 Engine Support Bracket

LEGEND:
30 Small Spacer (2 used)
31 Large Spacer (2 used)
32 DFT1285 or DFT1285A Engine Support Bracket
33 Washer (4 used)
34 Nut (2 used)
Install cap screws (29), small and large spacers (30 and 31), DFT1285 or DFT1285A Engine Support Bracket (32), washers (33),

and nuts (34). See DFT1285 Engine Support Bracket . (Group 9900.)
[22] -
CAUTION:
Transmission Weight (approximate) 247 kg
545 lb.
LEGEND:
36 JT01642A Low-Lift Transmission Jack
37 Shim (2 used)
38 D01004AA Universal Mounting Arm (2 used)
39 Angle Bracket
Low Lift Transmission Jack and Mounting Brackets (right

side)
Low Lift Transmission Jack and Mounting Brackets (left

side)
Support transmission using JT01642A Low-Lift Transmission Jack (36). Fasten jack to transmission as follows:
JT01642A
Used to remove and install transmission.
Universal Mounting Arm (2 used)
D01004AA
Used to fasten transmission to low lift jack.

a. Install appropriately sized shim (37) between jack and bottom of transmission as shown.
b. Raise and adjust low-lift jack until jack mounting plate and block are tight against bottom of transmission.
c. Fasten jack to transmission using D01004AA Universal Mounting Arms (38).
d. To provide as much offset and stability as possible, fasten angle brackets (39) to transmission so each points in opposite
direction, then fasten mounting arms to opposite (diagonal) corners of mounting plate.
e. Make sure all mounting arm hardware is tight before removing transmission.
[23] -
Transmission Mounting Brackets

LEGEND:
41 Isolator-to-Frame Cap Screw (2 used)
42 Mounting bracket (2 used)
43 Mounting Bracket-to-Transmission Cap Screw (4 used)
44 Washer (4 used)
Remove isolator-to-frame cap screws (41) from mounting brackets (42).
[24] - Remove mounting bracket-to-transmission cap screws (43), washers (44), and mounting brackets (42) from
transmission.
[25] - Remove remaining six transmission-to-flywheel housing cap screws (25).
[26] -
IMPORTANT:
Torque converter can fall out of housing. Care must be taken when removing transmission with torque
converter.
LEGEND:
45 Torque Converter
Torque Converter

Move transmission away from engine until torque converter (45) clears flywheel housing.
[27] - Lower transmission until top of transmission clears bottom of battery box or fuel tank.
[28] - Carefully move jack and transmission out from under machine.
[29] - Repair or replace transmission as necessary. See Transmission Outer Components Removal . (Group 0350.)
[30] - Position transmission (with torque converter) under machine using low lift jack. Carefully raise transmission and slide
into engine.
[31] - Install transmission-to-flywheel housing cap screws (25) and torque to specification.
Transmission-to-Flywheel Housing Cap Screw Torque 73 N·m
54 lb.-ft.
[32] -
IMPORTANT:
Prevent possible damage to transmission case and mounting bracket-to-transmission cap screws (43).
Ensure washers (44) are installed. If washers are not installed damage to cap screws (43) may occur.
Install mounting brackets (42), mounting bracket-to-transmission cap screws (43), washers (44), and isolator-to-frame cap
screws (41). Tighten to specification.
Mounting Bracket-to-Transmission Cap Screw Torque 320 N·m
236 lb.-ft.
Isolator-to-Frame Cap Screw Torque 275 N·m
203 lb.-ft.
[33] - Remove angle brackets, D01004AA Universal Mounting Arms, and JT01642A Low-Lift Transmission Jack.
[34] - Remove nuts, cap screws, washers, spacers, and DFT1285 Engine Support Bracket.
[35] - Use JDG820 Flywheel Turning Tool to turn flywheel and install four flex plate cap screws. Tighten cap screws to
specification.
Flex Plate Cap Screw Torque 73 N·m
54 lb.-ft.
[36] - Install access plate to bottom of torque converter housing.
[37] - Install transmission fill tube and cap screws (16).
[38] - Install differential lock hose and park brake hose.
[39] - Connect brake boost return hose and brake boost pressure hose.
[40] - Install hydraulic pump. See Hydraulic Pump Remove and Install . (Group 2160.)
[41] - Connect solenoids (Y4—Y6 and Y11).
[42] - Install transmission solenoid guard and cap screws (9).
[43] - Connect torque converter oil temperature sensor and transmission cooler hoses.
[44] - Fill transmission and hydraulic reservoir. See Change Transmission Oil and Replace Filter and see Change Hydraulic
Reservoir Oil . (Operator’s Manual.)
[45] - Connect solenoids (Y1—Y3, Y7, and Y10).
[46] - Install floor plate (6), washers (5), and cap screws (4).
[47] - Install floor plate (3), washers (2), cap screws (1), and floor mat.

Section 03 - TRANSMISSION Group 0315: Controls Linkage
[48] - Install rear axle drive shaft. See Universal Joint and Drive Shaft Remove and Install . (Group 0225.)
[49] - If equipped with mechanical front wheel drive (MFWD):

Install MFWD drive shaft. See Universal Joint and Drive Shaft Remove and Install . (Group 0225.)
[50] - Remove shop stands from under machine and lower machine to ground.

Section 03 - TRANSMISSION Group 0315: Controls Linkage
Group 0315 - Controls Linkage

Transmission Control Lever (TCL) Remove and Install
[1] -
LEGEND:
2 Upper Steering Console Cover
E75 Bucket Position Indicator (if equipped)
Upper Steering Console Cover

Remove cap screws (1) and remove upper steering console cover (2).
[2] - Disconnect bucket position indicator (if equipped) (E75).
[3] -
LEGEND:
5 Transmission Control Lever (TCL)
X48 Transmission Control Lever (TCL) Connector
Transmission Control Lever (TCL)

Disconnect transmission control lever (TCL) connector (X48).
[4] - Remove cap screws (4) and TCL (5).
[6] - Connect TCL connector.
[7] - Install TCL and cap screws (4).
[8] - Connect bucket position indicator (if equipped).

Section 03 - TRANSMISSION Group 0350: Gear, Shafts, and Power Shift Clutches
[9] - Install upper steering console cover and cap screws (1).

Group 0350 - Gear, Shafts, and Power Shift Clutches

Transmission Outer Components Removal
Essential Tools
ESSENTIAL TOOLS
JDG10476 Bracket
D05223ST Engine Roll Over Stand
[1] -
→NOTE:
Following procedure is to remove all transmission outer components in order to disassemble inner
transmission.
Transmission Roll Over Stand Bracket

Attach transmission to D05223ST Engine Roll Over Stand using JDG10476 Bracket.
Bracket
JDG10476
Used to aid in disassembly of transmission.
Engine Roll Over Stand
D05223ST
Used to aid in disassembly of transmission.
[2] - Remove transmission oil filter.
[3] -
LEGEND:
1 Filter Head
Filter Head

Remove cap screws (2) and remove filter head (1).
[4] -
LEGEND:
3 O-Ring (2 used)
Filter Head O-Rings

Remove O-rings (3) from filter head.
[5] -
LEGEND:
5 Dipstick Tube
Dipstick Tube Remove

Remove dipstick tube (5).
[6] -
LEGEND:
7 Output Flange
Output Flange
Remove output flange (7).

[7] -
LEGEND:
Transmission Speed Solenoid 4 (not used on 210K and
Y6
310K machines)
Transmission Solenoids
Tag and remove solenoids (Y1—Y7, Y10, and Y11).
[8] -
LEGEND:
14 Directional Clutch Orifice
15 1st Speed Clutch Orifice
16 2nd Speed Clutch Orifice
17 3rd Speed Clutch Orifice
Directional Clutch Orifice
Gear Clutch Orifices

Remove orifices (14—17).
[9] -

LEGEND:
18 Plug
19 Plug
20 Plug
Plugs
Remove plugs (18—20).
[10] - Repair or replace parts as necessary.

Transmission Case Disassemble—Torque Converter Side

[1] - Remove torque converter. See Torque Converter Remove and Install . (Group 0651.)
[2] -
→NOTE:
Transmission pump cannot be removed until transmission case is separated and transmission pump inner
cap screws have been removed.
Remove transmission charge pump. See Transmission Charge Pump Remove and Install . (Group 0360.)
[3] -
Bell Housing Cap Screws
Bell Housing Cap Screw

LEGEND:
2 Cap Screw
Remove cap screws (1 and 2).
[4] -

LEGEND:
4 Plug
5 O-Ring
6 Torque Converter Bell Housing
Torque Converter Bell Housing

Remove plug (4) and O-ring (5).
[5] - Remove torque converter bell housing (6).
[6] -
LEGEND:
11 Plug
12 O-Ring
13 Piston
14 O-Ring (2 used)
16 System Relief Port
System Relief Valve

Remove plug (11), O-ring (12), piston (13), O-rings (14), and compression spring (15).
[7] -
LEGEND:
18 Torque Converter Safety Valve
Torque Converter Safety Valve

Remove torque converter safety valve (18).
[8] -
→NOTE:
Remove pins (20) only if necessary.

LEGEND:
20 Pin (2 used)
21 Screen
22 Set Screw
Guide Pins and Screen

Remove pins (20) and screen (21).
[9] - 210K and 310K Only:

Remove set screw (22).

Clutch Packs Remove

Specifications
SPECIFICATIONS
42 kg
Transmission Case Half Weight (approximate)
93 lb.
27 kg
Second, Third, and MFWD Clutch Pack Weight (approximate)
60 lb.
[2] -
LEGEND:
2 Transmission Filter Assembly
Transmission Oil Filter Assembly

Remove cap screws (1) and transmission filter assembly (2) from transmission.
[3] -
LEGEND:
3 Dowel Pin (2 used)
4 Socket Head Cap Screw (24 used)
Transmission Cap Screws and Dowel Pins

Drive dowel pins (3) out of torque converter side of transmission case.
[4] - Remove socket head cap screws (4) from transmission housing.
[5] -
CAUTION:

LEGEND:
6 Lifting Bracket (2 used)
7 MFWD Output Shaft (if equipped)
8 Seal Guard
Transmission Case Separation (shown with MFWD)

Machines with Mechanical Front Wheel Drive (MFWD):
Attach appropriate lifting device to lifting brackets and separate transmission case halves approximately 10 mm (3/8 in.). Tap
on MFWD output shaft (7) with a plastic hammer to separate seal guard (8) from transmission case.
Transmission Case Half Weight (approximate) 42 kg
93 lb.
Machines without Mechanical Front Wheel Drive (MFWD):

Attach appropriate lifting device to lifting brackets and separate transmission case halves.
93 lb.
[6] -
→NOTE:
Shown with 5X3 transmission clutch pack assembly with MFWD, 210K and 310K machines do not have
third speed clutch pack.
LEGEND:
12 High Range Forward Clutch Pack
13 Low Range Forward Clutch Pack
14 Reverse Clutch Pack
15 First Speed Clutch Pack
16 Second Speed Clutch Pack
17 Third Speed Clutch Pack
Mechanical Front Wheel Drive (MFWD) Clutch Pack (if
18
equipped)
Clutch
Before removing clutch packs from case, mark clutch packs and transmission case for aid of assembly.
[7] - Remove high range forward clutch pack (12).
[8] - Remove low range forward clutch pack (13) and reverse clutch pack (14) together.
[9] - Slightly lift second speed clutch pack (16) and remove first speed clutch pack (15).
[10] -

LEGEND:
Mechanical Front Wheel Drive (MFWD) Clutch Pack (if
18
equipped)
19 Eyebolt M8 X 1 (2 used)
20 Screen Sheet
Second, Third, and MFWD Clutch Packs

Install eyebolts (19).
[11] -
CAUTION:
Remove clutch packs (16—18) together with screen sheet (20).

Second, Third, and MFWD Clutch Pack Weight (approximate) 27 kg
60 lb.
[12] -
LEGEND:
21 Snap Ring
22 Pump Drive Shaft
Pump Drive Shaft

Remove snap ring (21) and remove pump drive shaft (22).
[13] -

LEGEND:
22 Pump Drive Shaft
23 Snap Ring
24 Ball Bearing
Pump Shaft Bearing

Remove snap ring (23) and ball bearing (24) from pump drive shaft.
[14] -
LEGEND:
25 O-Ring (2 used)
26 Bearing Cup (5 used)
O-Ring and Bearing Outer Races

[15] -
IMPORTANT:
Internal transmission damage can occur if bearing cone and cup are replaced separately. If either bearing
cone or cup requires replacement, replace both as a set.
→NOTE:
Mark bearing cup (26) and transmission case for aid of assembly.
Inspect bearings cups (26), replace if necessary.
[16] -

LEGEND:
28 Oil Suction Tube
Torque Converter Side Bearing Outer Rings and Suction

Tube
Remove cap screws (27) and oil suction tube (28).
[17] -
IMPORTANT:
Internal transmission damage can occur if bearing cone and cup are replaced separately. If either bearing
cone or cup requires replacement, replace both as a set.
→NOTE:
Mark bearing cup (29) and transmission case for aid of assembly.
Inspect bearing cups (29), replace if necessary.

High Range Forward, Low Range Forward, and Reverse Clutch Packs
Disassemble and Assemble
Specifications
SPECIFICATIONS
20 N
Clutch End Plate Force (approximate)
4.5 lbf
1.4—1.7 mm
High Range Forward Clutch (K4) Pack Plate Clearance
0.055—0.067 in
2.0—2.3 mm
Low Range Forward Clutch (KV) and Reverse Clutch (KR) Pack Plate Clearance
0.079—0.091 in
Essential Tools
ESSENTIAL TOOLS
JDG10510 Assembly Aid
[1] -
→NOTE:
Disassembly and assembly of high range forward directional clutch (K4) pack, low range forward clutch
(KV) pack, and reverse clutch (KR) packs are the same.
LEGEND:
5 Seal Ring
Seal Ring
Remove seal ring (5).
[2] -

LEGEND:
6 Bearing Puller
7 Inner Disc Carrier
8 Thrust Washer
9 Needle Bearing
10 Beveled Thrust Washer
11 Bearing
Bearing Puller
Bearing and Inner Disc Carrier

Using a bearing puller (6), remove inner disc carrier (7), thrust washers (8 and 10), needle bearing (9), and bearing (11).
[3] -

LEGEND:
12 Needle Bearing (2 used)
First Speed Clutch (K1), High Range Forward Clutch

(K4), Low Range Forward Clutch (KV), and Reverse
Clutch (KR)
Remove needle bearings (12).
[4] -
LEGEND:
8 Thrust Washer
9 Needle Bearing
Thrust Washers and Needle Bearing

Remove thrust washers (8 and 10) and needle bearing (9).
[5] -

LEGEND:
13 Snap Ring
Snap Ring
[6] -
LEGEND:
14 Retainer
15 Disc and Plate Assembly
16 End Plate
End Plate, Disc and Plate Assembly, and Retainer

Remove end plate (16), disc and plate assembly (15), and retainer (14).
[7] -

LEGEND:
17 Snap Ring
Snap Ring
[8] -
LEGEND:
18 JDG10510 Assembly Aid
19 Snap Ring
Snap Ring
Use JDG10510 Assembly Aid (18) to remove snap ring (19).
Assembly Aid
JDG10510
Used to preload compression spring to remove and install snap ring.
[9] -

LEGEND:
21 Retainer
Compression Spring and Retainer

Remove retainer (21) and compression spring (20).
[10] -
CAUTION:
LEGEND:
22 Oil Passage
23 Piston
Piston
Remove piston (23) using compressed air through oil passage (22).
[11] -
LEGEND:
23 Piston
24 O-Ring
25 O-Ring
Piston O-Rings
Remove O-rings (24 and 25) from piston (23).
[12] -
LEGEND:
26 Seal Ring
27 Bearing
28 Snap Ring
29 Gear
30 Drum
31 Shaft
Bearing and Seal Ring

Parts Not Serviced Separately

[13] -
IMPORTANT:
Prevent damage to gear (29), drum (30), and shaft (31). Do not disassemble. Gear, drum, and shaft are
serviced as an assembly.
Remove bearing (27).
[14] -
CAUTION:
Check all oil passages with compressed air.
[16] -
LEGEND:
26 Seal Ring
27 Bearing
Bearing and Seal Ring

Install bearing (27) onto clutch shaft with a press, applying pressure to bearing inner race with appropriate diameter driver.
[17] - Install seal ring (26).
[18] -
IMPORTANT:
Prevent damage to clutch pack. Inspect O-rings before installing piston.
LEGEND:
23 Piston
24 O-Ring
25 O-Ring
Piston O-Rings
Apply transmission oil to O-rings (24 and 25).
[19] - Install O-rings (24 and 25) to piston (23).
[20] -
LEGEND:
23 Piston
Piston

Press piston (23) into place using JDG10510 Assembly Aid.

Assembly Aid
JDG10510
Used to install piston.
[21] -
LEGEND:
21 Retainer
Compression Spring and Retainer

Install compression spring (20) and retainer (21).
[22] -
LEGEND:
19 Snap Ring

Snap Ring
Preload compression spring using JDG10510 Assembly Aid and install snap ring (19).
[23] -
LEGEND:
17 Snap Ring
Snap Ring
Install snap ring (17).
[24] -
LEGEND:
14 Retainer
23 Piston
32 Input Shaft
Retainer

High Range Forward Clutch (cross section)

Install retainer (14).
[25] -
→NOTE:
High range forward clutch (K4) uses seven plates and seven discs. Low range forward clutch (KV) and
reverse clutch (KR) uses 10 plates and 10 discs.
LEGEND:
33 Disc (K4, 7 used; KV and KR, 10 used)
34 Plate (K4, 7 used; KV and KR, 10 used)
Plate and Disc Orientation

Starting with a plate, alternately install plates (34) and discs (33).
[26] -

LEGEND:
13 Snap Ring
16 End Plate
End Plate
Install end plate (16) with flat side facing down.
[28] -
End Plate Clearance Measurement

Check End Plate Clearance:
a. Apply specified force to end plate (16) and set dial indicator to zero.
Clutch End Plate Force (approximate) 20 N
4.5 lbf
b. Using screwdrivers, pry up on end plate and record disc clearance.

High Range Forward Clutch Pack Plate Clearance 1.4—1.7 mm
0.055—0.067 in

Low Range Forward and Reverse Clutch Pack Plate Clearance 2.0—2.3 mm
0.079—0.091 in
c. Allowable clearance is obtained with end plate snap ring (13) thickness.
[29] -
LEGEND:
8 Thrust Washer
9 Needle Bearing
Thrust Washers and Needle Bearing

Apply clean transmission oil to thrust washers (8 and 10) and needle bearing (9).
[30] -
IMPORTANT:
Prevent internal transmission damage. Do not install beveled thrust washer with bevel side toward
needle bearing. Install flat surface of thrust washer facing needle bearings.
Install beveled thrust washer (10) with beveled side facing toward snap ring of clutch pack.
[31] - Install needle bearing (9) and thrust washer (8).
[32] -
LEGEND:
First Speed Clutch (K1), High Range Forward Clutch

(K4), Low Range Forward Clutch (KV), and Reverse

Clutch (KR)
Apply clean transmission oil to needle bearings (12) and install.
[33] -
LEGEND:
8 Thrust Washer
9 Needle Bearing
11 Bearing
Bearings and Inner Disc Carrier

Install inner disc carrier (7) until bottomed.
[34] - Install thrust washer (8) and needle bearing (9).
[35] -
IMPORTANT:
Prevent internal transmission damage. Do not install beveled thrust washer with bevel side toward
Install beveled thrust washer (10) with beveled side facing toward bearing (11).
[36] - Install bearing (11) onto clutch shaft with a press, applying pressure to bearing inner race with appropriate diameter
driver.
[37] -

LEGEND:
5 Seal Ring
22 Oil Passage
Seal Ring
Install seal ring (5).
[38] -
CAUTION:
Check closing and opening of clutch by applying compressed air through oil passage (22).

First Speed and Third Speed Clutch Disassemble and Assemble

Specifications
SPECIFICATIONS
20 N
Applied to Clutch End Plate Force (approximate)
4.5 lb.
2.0—2.3 mm
First Speed Clutch (K1) Distance
0.079—0.118 in.
1.8—2.1 mm
Third Speed Clutch (K3) Distance
0.071—0.083 in.
Essential Tools
ESSENTIAL TOOLS
[1] -
LEGEND:
1 Seal Ring
Seal Ring
[2] -

LEGEND:
2 Disk Carrier
3 Bearing
5 Needle Bearing
6 Thrust Washer
Disk Carrier
Bearing, Thrust Washers, and Needle Bearing

Remove disk carrier (2), thrust washers (4 and 6), needle bearing (5), and bearing (3).
[3] -

LEGEND:
35 Bushing
First Speed Clutch
Third Speed Clutch

Remove needle bearings (7).
[4] - Third Speed Clutch Only:

Remove bushing (35).
[5] -

LEGEND:
8 Thrust Washer
9 Needle Bearing
Needle Bearing and Thrust Washers

Remove thrust washers (8 and 10) and needle bearing (9).
[6] -
LEGEND:
11 Snap Ring
Snap Ring
[7] -

LEGEND:
12 End Plate
14 Disk Spring
Disk Spring, Disk and Plate Assembly, and End Plate

Remove end plate (12).
[8] - Remove disk and plate assembly (13).
[9] - Remove disk spring (14).
[10] -
LEGEND:
Snap Ring
Press compression spring using JDG10510 Assembly Aid (30) to remove snap rings (15).
Assembly Aid
JDG10510
Used to remove compression spring snap ring.
[11] -

LEGEND:
16 Retainer
Retainer and Compression Spring

Remove retainer (16) and compression spring (17).
[12] -
CAUTION:
LEGEND:
18 Oil Passage
19 Piston
Piston
Remove piston (19) by applying compressed air through oil passage (18).
[13] -

LEGEND:
19 Piston
20 O-Ring
21 O-Ring
Piston O-Rings
Remove O-rings (20 and 21) from piston (19).
[14] -
LEGEND:
22 Seal Ring
23 Bearing
Seal Ring and Bearing

Remove seal ring (22) and bearing (23).
[15] -
CAUTION:
IMPORTANT:
Damage will occur if gear (24), drum (25), and input shaft (26) are disassembled. Gear, drum, and shaft
are serviced as an assembly.

LEGEND:
24 Gear
25 Drum
26 Input Shaft

Check all oil passages with compressed air.
[17] -
LEGEND:
22 Seal Ring
23 Bearing
Seal Ring and Bearing

Install bearing (23) onto clutch shaft with a press, applying pressure to bearing inner race with appropriate diameter driver.
[19] -

LEGEND:
19 Piston
20 O-Ring
21 O-Ring
Piston O-Rings
Install O-rings (20 and 21) onto piston (19).
[20] -
LEGEND:
Piston
Install piston using JDG10510 Assembly Aid (30).
Assembly Aid
JDG10510
Used to install clutch piston.
[21] -

LEGEND:
16 Retainer
Retainer and Compression Spring

Install compression spring (17) and retainer (16).
[22] -
LEGEND:
Snap Ring
Press compression spring using JDG10510 Assembly Aid (30) and install snap rings (15).
[23] -

LEGEND:
14 Disk Spring
19 Piston
26 Input Shaft
Disk Spring
Disk Spring Installation (cross section)

Install disk spring (14) with convex side toward piston.
[24] -
→NOTE:
Third speed clutch uses nine plates and nine disks.

LEGEND:
27 Disk (10 used)
28 Plate (10 used)
Plates and Disks Install (first speed clutch shown)

Starting with a plate, alternately install plates (28) and disks (27).
[25] -
LEGEND:
11 Snap Ring
12 End Plate
Snap Ring and End Plate

Install end plate (12) with flat side down on disk and plate assembly.
[27] -

LEGEND:
12 End Plate

a. Apply approximately 20 N (4.5 lb.-force) of force to end plate (12) and set dial indicator to zero.
Applied to Clutch End Plate Force (approximate) 20 N
4.5 lb.
b. Using screwdrivers, pry up on end plate and record the disk clearance.
First Speed Clutch Distance 2.0—2.3 mm
0.079—0.118 in.
Third Speed Clutch Distance 1.8—2.1 mm
0.071—0.083 in.
c. Allowable clearance is obtained with end plate snap ring (11) thickness.
[28] -

IMPORTANT:
Internal transmission damage will occur if beveled thrust washer is installed with bevel side toward
LEGEND:
8 Thrust Washer
9 Needle Bearing
Needle Bearing and Thrust Washers Install

Apply clean transmission oil to thrust washers (8 and 10) and needle bearing (9).
[29] - Install beveled thrust washer (10) with beveled side facing toward snap ring of clutch pack.
[30] - Install needle bearing (9) and thrust washer (8).
[31] -
LEGEND:
35 Bushing
First Speed Clutch

Third Speed Clutch

Install needle bearings (7).
[32] - Third Speed Clutch Only:

Install bushing (35).
[33] -
LEGEND:
2 Disk Carrier
3 Bearing
5 Needle Bearing
6 Thrust Washer
Bearing, Thrust Washers, and Needle Bearing Install

Disk Carrier Install

Install disk carrier (2) until bottomed on shaft.
[34] -
IMPORTANT:
Internal transmission damage will occur if beveled thrust washer is installed with bevel side toward
Install thrust washer (6) and needle bearing (5).
[35] - Install beveled thrust washer (4) with beveled side facing toward bearing (3).
[36] - Install bearing (3) onto clutch shaft with a press, applying pressure to bearing inner race with appropriate diameter
driver.
[37] -
LEGEND:
1 Seal Ring
29 Oil Passage
Seal Ring Install

Install seal ring (1).
[38] - Check closing and opening of clutch by applying compressed air through oil passage (29).

Second Speed Clutch Disassemble and Assemble

Specifications
SPECIFICATIONS
20 N
End Plate Force (approximate)
4.5 lbf
2.20—2.50 mm
Second Speed Clutch (K2) Clearance
0.087—0.098 in
Essential Tools
ESSENTIAL TOOLS
Second Speed Clutch (K2) (exploded view)

LEGEND:
1 Seal Ring
4 Snap Ring
8 Gear Hub
11 End Plate Snap Ring
12 End Plate
15 Clutch Disc (13 used)
16 Cup Spring
18 Thrust Washer
23 Disc Spring (7 used)
25 O-Ring (2 used)
26 Piston
27 Clutch
28 Seal Ring (2 used)

DISASSEMBLE
[1] -
LEGEND:
1 Seal Ring
Second Speed Clutch (K2)

[2] -
LEGEND:
2 Bearing Puller
4 Snap Ring
Bearing Puller and Tapered Roller Bearing
Snap Ring

Attach bearing puller (2) to tapered roller bearing (3).
[3] - Remove tapered roller bearing (3).
[4] - Remove snap ring (4).
[5] -
Bearing Puller
LEGEND:
5 Bearing Puller
7 Disc Carrier
8 Gear Hub
Tapered Roller Bearing, Gear Hub, and Disc Carrier

Attach bearing puller (5) to disc carrier (7).
[6] - Remove tapered roller bearing (6) and gear hub (8).
[7] -
IMPORTANT:
Avoid transmission component damage. DO NOT reuse end plate snap ring when servicing second speed
clutch (K2) assembly. Always replace with new snap ring.

LEGEND:
12 End Plate
15 Clutch Disc (13 used)
16 Cup Spring
End Plate Snap Ring

Remove end plate snap ring (11) and discard.
[8] - Remove end plate (12).
[9] - Remove clutch plates (14), clutch discs (15), and cup spring (16).
[10] -
LEGEND:
10 Bearing Puller
Bearing Puller
Attach bearing puller (10) to tapered roller bearing (9).
[11] - Remove tapered roller bearing (9).
[12] -

LEGEND:
18 Thrust Washer
Snap Rings
Apply pressure to thrust washer (18) using JDG10510 Assembly Aid (13) and remove snap rings (24).
[13] - Remove thrust washer (18) and disc springs (23).
[14] -
CAUTION:
Using compressed air can cause the piston to come out at a high rate of speed. Personal injury can
occur. Wear proper face and body protection when using compressed air.

LEGEND:
17 Oil Passage
25 O-Ring (2 used)
26 Piston
Piston
Remove piston (26) by applying compressed air through oil passage (17).
[15] - Remove O-rings (25) from piston.
[16] -
IMPORTANT:
Damage to clutch will occur if gears (19 and 20), shaft (21), and disc carrier (7) are disassembled. Gears,
shaft, and disc carrier are serviced as an assembly.
LEGEND:
7 Disc Carrier
19 Gear
20 Helical Gear
21 Shaft

Replace parts as necessary.
ASSEMBLE

LEGEND:
18 Thrust Washer
Disc Spring and Thrust Washer
Assemble components as shown.

Additional Information
IMPORTANT:
Beginning with convex side facing thrust washer, install disc springs (23) by alternating between convex
side and concave side to avoid transmission component damage.
[1] -
Dimension I and II

Second Speed Clutch (K2) (cross section)

LEGEND:
8 Gear Hub
32 Dimension I
33 Dimension II
34 Inner Disc Carrier Dimension
35 Dimension III
36 Snap Ring Thickness
Determining snap ring (4) thickness:
a. Using a depth gauge and straight edge, measure distance between top of gear hub (8) and bottom of tapered roller
bearing (9) and record as dimension I (32).
b. Using a depth gauge and straight edge, measure distance between top of gear hub (8) and top of tapered roller bearing
(6) and record as dimension II (33).
c. Calculate inner disc carrier dimension (34) by subtracting dimension I by dimension II.
d. Using a depth gauge and straight edge, measure distance between top of snap ring groove and top of snap ring (24) and
record as dimension III (35).
e. Calculate snap ring (4) thickness (36) by subtracting dimension III (35) by inner disc carrier dimension (34). See example:
→NOTE:
Snap ring (4) is available in following thicknesses between 2.00 mm—4.00 mm (0.08 in—0.16 in), in 0.25
mm (0.01 in) increments.
Example
Example of Snap Ring Thickness Calculation

Dimension III - (Dimension I - Dimension II) = Snap Ring Thickness
89.75 mm
Dimension I (example)
3.533 in
32.85 mm
Dimension II (example)
1.293 in
59.50 mm
Dimension III (example)
2.343 in
59.50 mm - (89.75 mm - 32.85 mm) = 2.60 mm

Snap Ring Thickness
2.343 in - (3.533 in - 1.293 in) = 0.103 in
[2] -

LEGEND:
31 Dial Indicator

Check end plate clearance:
a. Apply specified force to end plate (12) and set dial indicator (31) to zero.
End Plate Force (approximate) 20 N
4.5 lbf
b. Using screwdrivers, pry up on end plate and read disc clearance.

c. Adjust second speed clutch (K2) clearance to specification using end plate snap ring (11) thickness.
Second Speed Clutch (K2) Clearance Distance 2.20—2.50 mm
0.087—0.098 in

Mechanical Front Wheel Drive (MFWD) Clutch Disassemble and

Assemble
Specifications
SPECIFICATIONS
120°C
Bearing Temperature
248°F
20 N
End Plate Force (approximate)
4.5 lb
2.3—2.8 mm
MFWD Clutch (VA) End Plate Distance
0.091—0.110 in
Essential Tools
ESSENTIAL TOOLS
JDG10510 Clutch Assembly Aid
DFT1163 MFWD Snap Ring Removal and Installation Tool
[1] -
LEGEND:
1 Seal Ring
2 Bearing
Seal Ring and Bearing Removal

[2] - Using a puller, remove bearing (2).
[3] -

LEGEND:
Inner Disc Carrier Removal

Remove beveled thrust washer (3).
[4] - Remove inner disc carrier (4).
[5] -
IMPORTANT:
Avoid transmission component damage. DO NOT reuse end plate snap ring (5) when servicing MFWD
clutch assembly. Always replace with new snap ring.
LEGEND:
End Plate Snap Ring Removal

Remove end plate snap ring (5) and discard.
[6] -

LEGEND:
6 Plate and Disc Assembly
7 End Plate
Plate and Disc Assembly Removal

Remove end plate (7) and plate and disc assembly (6).
[7] -
LEGEND:
8 Snap Ring
DFT1163 MFWD Snap Ring Removal and Installation
9
Tool
10 Washer
Snap Ring Removal

Disc Spring Removal

Using DFT1163 Mechanical Front Wheel Drive (MFWD) Snap Ring Removal and Installation Tool (9), preload disc springs (11)
and remove snap ring (8). For specifications on DFT1163, see DFT1163 MFWD Snap Ring Removal and Installation Tool . (Group
9900.)
MFWD Snap Ring Removal and Installation Tool
DFT1163
Used to remove and install MFWD clutch snap ring
[8] - Remove washer (10) and disc springs.
[9] -
CAUTION:
Using compressed air can cause the piston to come out at a high rate of speed. Personal injury can
occur. Wear proper face and body protection when using compressed air.
LEGEND:
12 Oil Passage
13 Piston
14 Bearing
Piston Removal
Apply compressed air through oil passage (12) to remove piston (13).
[10] - Remove bearing (14).
[11] -
IMPORTANT:
Damage will occur to shaft (15) and drum (16) if disassembled. Shaft and drum are serviced as an
assembly only.
LEGEND:
15 Shaft
16 Drum

Inspect and replace parts as necessary.
[12] -
CAUTION:
LEGEND:
12 Oil Passage
13 Piston
14 Bearing
25 JDG10510 Clutch Assembly Aid

Bearing Installation
JDG10510 Clutch Assembly Aid

Check oil passage (12) using compressed air.
[13] -
CAUTION:
Prevent possible burns. Use appropriate hand protection when handling hot components.
Heat bearing (14) to specification and install until bottomed on shaft.

Bearing Temperature 120°C
248°F
[14] - Install piston (13) using JDG10510 Clutch Assembly Aid (25).
Clutch Assembly Aid
JDG10510
Press piston into place.
[15] -
LEGEND:
10 Washer
Disc Spring Installation

Install washer (10) and disc springs (11).

[16] -
LEGEND:
8 Snap Ring
9 DFT1163 MFWD Snap Ring Removal and Installation Tool
Disc Spring Snap Ring Installation

Preload disc springs using DFT1163 MFWD Snap Ring Removal and Installation Tool (9) and install snap ring (8). For
specifications on DFT1163, see DFT1163 MFWD Snap Ring Removal and Installation Tool . (Group 9900.)
MFWD Snap Ring Removal and Installation Tool
DFT1163
Used to remove and install MFWD clutch snap ring
[17] -
LEGEND:
22 Disc (12 used)
23 Plate (12 used)
Plate and Disc Installation

Starting with a plate (23), alternately install plates and discs (22).
[18] -

LEGEND:
5 Snap Ring
7 End Plate
End Plate and Snap Ring Installation

Install end plate (7) with flat side facing discs and plates.
[19] -
IMPORTANT:
Avoid transmission component damage. DO NOT reuse end plate snap ring (5) when servicing MFWD
clutch assembly. Always replace with new snap ring.
Install end plate snap ring (5).
[20] -
LEGEND:
7 End Plate
17 Dial Indicator


a. Apply specified force to end plate (7) and set dial indicator (17) to zero.
End Plate Force (approximate) 20 N
4.5 lb
b. Using screwdrivers, pry up on end plate and read disc clearance.

c. Specified clearance is obtained with end plate snap ring (5) thickness.
MFWD Clutch End Plate Distance 2.3—2.8 mm
0.091—0.110 in
[21] -
LEGEND:
Inner Disc Carrier Install

Install inner disc carrier (4).
[22] - Install beveled thrust washer (3).
[23] -
CAUTION:
Prevent possible burns. Use appropriate hand protection when handling hot components.

LEGEND:
1 Seal Ring
2 Bearing
24 Oil Passage
Seal Ring and Bearing Install

Heat bearing (2) to specification and install until bottomed on shaft.
Bearing Temperature 120°C
248°F
[25] -
CAUTION:
Check closing and opening of clutch by use of compressed air through oil passage (24).
Pump Drive Shaft Install

[1] -
LEGEND:
1 Ball Bearing
2 Pump Drive Shaft
3 Snap Ring
Pump Drive Shaft Bearing

Press ball bearing (1) onto pump drive shaft (2) until bottomed.
[3] -

LEGEND:
2 Pump Drive Shaft
4 Snap Ring
Pump Drive Shaft Install

Install pump drive shaft into transmission housing.

Clutch Packs Install

Specifications
SPECIFICATIONS
27 kg
Second, Third, and MFWD Clutch Pack Weight (approximate)
60 lb.
42 kg
93 lb.
20 N·m
Transmission Case Mounting Cap Screw Initial Torque
177 lb.-in.
65 N·m
Transmission Case Mounting Cap Screw Final Torque
48 lb.-ft.
Other Material
OTHER MATERIAL
[1] -
LEGEND:
28 Oil Suction Tube
Torque Converter Side Bearing Outer Rings and Suction

Tube
Apply petroleum jelly to bearing cups (29) and install.
[2] - Install oil suction tube (28) and cap screws (27).
[3] -
LEGEND:
25 O-Ring (2 used)
O-Ring and Bearing Outer Races

Apply petroleum jelly to bearing cups (26) and install.
[4] -
→NOTE:
Use petroleum jelly to hold O-rings (25) in place during assembly.
Install O-rings (25).
[5] -
→NOTE:
210K and 310K machines do not have a third speed clutch pack.
LEGEND:
18 MFWD Clutch Pack (if equipped)
19 Eyebolt (M8 X 1.0) (2 used)
20 Screen Sheet
30 Sealing Ring (2 used)
31 Sealing Ring
32 Pilot Hole (2 used)
Second, Third, and Mechanical Front Wheel Drive

(MFWD) Clutch Packs
Apply petroleum jelly to sealing rings (30 and 31).
[6] -
CAUTION:
Align alignment pins (33) with pilot holes (32) and install clutch packs (16—18) together with screen sheet.
Second, Third, and MFWD Clutch Pack Weight (approximate) 27 kg
60 lb.
[7] -

LEGEND:
15 First Speed Clutch
First Speed Clutch

Apply petroleum jelly to sealing rings (34) and install first speed clutch (15).
[8] -
LEGEND:
13 Low Range Forward Clutch Pack
14 Reverse Clutch Pack
Reverse and Low Range Clutch Packs

Apply petroleum jelly to sealing rings (35 and 36) and install clutch packs (13 and 14) together.
[9] -
LEGEND:
12 High Range Forward Clutch
High Range Forward Clutch

Apply petroleum jelly to sealing rings (37) and install high range forward clutch (12).
[10] -
CAUTION:

→NOTE:
Alignment pins (33) must be installed properly into pilot holes (32) when transmission halves are joined.
LEGEND:
Transmission Case
Install lifting brackets (6) and attach appropriate lifting device.
[11] - Clean mating surfaces of transmission case halves with PM37509 Klean ‘N Prime.
Number Name Use

• Loctite ™ (loctite) Klean ‘N Prime Used to clean mating surfaces of transmission housing.
[12] - Apply PM38657 High Flex Form-In-Place Gasket to mating surfaces of transmission halves.
Number Name Use

• Loctite ™ (loctite) High Flex Form-In-Place Gasket Apply to mating surfaces of transmission halves.
[13] - Assemble transmission case halves.

93 lb.
[14] -
LEGEND:
5 Wiring Harness Retaining Bracket (2 used)
7 Lifting Bracket
Transmission Case Cap Screws and Pins

Align dowel pin holes in transmission case halves and install dowel pins (3) until flush with case.
[15] - Install wiring harness retaining brackets (5), lifting bracket (7), and cap screws (4). Tighten to initial torque specification.
Transmission Case Mounting Cap Screw Initial Torque 20 N·m
177 lb.-in.

[16] - Tighten cap screw (4) to final torque specification.

Transmission Case Mounting Cap Screw Final Torque 65 N·m
48 lb.-ft.

Transmission Case Assemble—Torque Converter Side

Specifications
SPECIFICATIONS
50 N·m
System Relief Plug Torque
37 lb.-ft.
46 N·m
Transmission Bell Housing Cap Screw Torque
34 lb.-ft.
25 N·m
Plug Torque
18 lb.-ft.
Essential Tools
ESSENTIAL TOOLS
JDG10480 Valve Installer
Other Material
OTHER MATERIAL
[1] -
IMPORTANT:
Damage to clutches and torque converter will result if cooling and lubrication pressure is reduced. On
210K and 310K only, install set screw into front transmission case.
LEGEND:
20 Pin (2 used)
21 Screen
22 Set Screw
Front Transmission Case

210K and 310K Machines Only:
Install set screw (22) into front of transmission case.
[2] - Install screen (21).
[3] - Install pins (20) if removed.
[4] -

LEGEND:
18 Torque Converter Safety Valve
19 JDG10480 Valve Installer
Torque Converter Safety Valve

Use JDG10480 Valve Installer (19) to install torque converter safety valve (18).
Valve Installer
JDG10480
Use to install torque converter relief valve
[5] -
→NOTE:
Transmission system pressure must be checked after system relief piston has been removed or replaced.
See Transmission System Pressure Test . (Group 9020-25).
LEGEND:
11 Plug
12 O-Ring
13 Piston
14 O-Ring (2 used)
16 System Relief Port
System Relief Valve

Install compression spring (15), O-rings (14), piston (13), and O-ring (12).
[6] - Install plug (11) and tighten to specification.

System Relief Plug Torque 50 N·m
37 lb.-ft.
[7] -

LEGEND:
M10 Guide Screws

Install M10 guide screws (10) to aid in assembly.
[8] -
IMPORTANT:
Transmission case may leak if gasket sealer is applied to transmission case. Apply gasket sealer to
mating surface of torque convertor bell housing (6) only.
Apply PM37509 Klean ‘N Prime and PM38657 High Flex Form-In-Place Gasket to mating surfaces of torque converter bell
housing (6).
Number Name Use

Used to clean mating surfaces of torque converter bell housing and
• Loctite ™ (loctite) Klean ‘N Prime
transmission case
• 17430 (us) Used on mating surfaces of torque converter bell housing and
High Flex Form-In-Place Gasket
• Loctite ™ (loctite) transmission case
[9] - Install torque converter bell housing and remove M10 guide screws.
[10] -
Transmission Bell Housing Cap Screws

Transmission Bell Housing Cap Screw

LEGEND:
2 Cap Screw
Install cap screws (1 and 2). Tighten to specification.
Transmission Bell Housing Cap Screw Torque 46 N·m
34 lb.-ft.
[11] -
LEGEND:
4 Plug
5 O-Ring
Plug and O-Ring Install

Install plug (4) and O-ring (5). Tighten to specification.
Plug Torque 25 N·m
18 lb.-ft.
[12] - Install charge pump. See Transmission Charge Pump Remove and Install . (Group 0360.)

Transmission Outer Components Install

Specifications
SPECIFICATIONS
15 N·m
Plug (18) Torque
133 lb.-in.
28 N·m
Plug (19) Torque
21 lb.-ft
6 N·m
Plug (20) Torque
53 lb.-in.
10 N·m
Orifice Torque
89 lb.-in.
23 N·m
Filter Head Cap Screw Torque
204 lb.-in.
Essential Tools
ESSENTIAL TOOLS
JDG10481 Seal Installer
JDG10483 Driver Tool
[1] -
LEGEND:
18 Plug
19 Plug
20 Plug
Plugs
Install plugs (18—20). Tighten to specification.
Plug (18) Torque 15 N·m
133 lb.-in.
21 lb.-ft
53 lb.-in.
[2] -

LEGEND:
14 Directional Clutch Orifice
15 First Speed Clutch Orifice
16 Second Speed Clutch Orifice
17 Third Speed Clutch Orifice
Directional Clutch Orifice
Gear Clutch Orifices

Install directional clutch orifices (14) and first, second, and third speed clutch orifices (15—17). Tighten to specification.
Orifice Torque 10 N·m
89 lb.-in.
[3] -
LEGEND:
Transmission Speed Solenoid 4 (not used on 210K and
Y6
310K machines)
Transmission Solenoids
Install transmission forward and reverse direction solenoids (Y1 and Y2).
[4] - Install transmission speed solenoids 1, 2, 3, and 4 (Y3, Y4, Y5, and Y6).

[5] - Install park brake release solenoid (Y7), differential lock solenoid (Y10), and mechanical front wheel drive (MFWD)
solenoid (Y11).
[6] -
LEGEND:
7 Rear Output Flange
9 Seal
10 Seal Guard
11 Dust Cover
12 Transmission Housing
Rear Output Flange Cross Section
Rear Output Flange Install

Install seal (9) and seal guard (10) into transmission housing (12) using JDG10481 Seal Installer.
Seal Installer
JDG10481
Used to install rear output flange seal.
[7] - Press dust cover (11) into rear output flange (7) until bottomed.
[8] - Install rear output flange.
[9] -

Section 03 - TRANSMISSION Group 0360: Hydraulic System
LEGEND:
5 Dipstick Tube
Dipstick Tube Install

Install dipstick tube (5) using JDG10483 Driver Tool.
Driver Tool
JDG10483
Used to install dipstick tube.
[10] -
LEGEND:
1 Filter Head
3 O-Ring (2 used)
Filter Head O-Rings
Filter Head
Install new O-rings (3) on filter head (1).
[11] - Install filter head and cap screws (2). Tighten to specification.
Filter Head Cap Screw Torque 23 N·m
204 lb.-in.


Transmission Charge Pump Remove and Install
Specifications
SPECIFICATIONS
42 kg
93 lb.
23 N·m
Transmission Charge Pump Inner Cap Screw Torque
17 lb.-ft.
20 N·m
Transmission Case Cap Screw Initial Torque
177 lb.-in.
65 N·m
Transmission Case Cap Screw Final Torque
48 lb.-ft.
23 N·m
Filter Assembly Cap Screw Torque
17 lb.-ft.
Essential Tools
ESSENTIAL TOOLS
JDG10482 Output Shaft Seal Installer
Other Material
OTHER MATERIAL
7649 Loctite ™ Klean ′N Prime
17430 Loctite ™ High Flex Form-In-Place
[1] - Park and Prepare machine for service. See Park and Prepare for Service Safely . (Group 0001.)
[2] - Remove transmission. See Transmission Remove and Install . (Group 0300.)
[4] -
→NOTE:
Transmission charge pump cannot be removed until the transmission case is separated and the
transmission charge pump inner cap screws have been removed.
LEGEND:
2 Transmission Oil Filter Assembly
Transmission Oil Filter Assembly

Remove cap screws (1) and transmission filter assembly (2) from transmission.
[5] -

LEGEND:
Transmission Cap Screws and Dowel Pins

Drive dowel pins (3) out of torque converter side of transmission case.
[6] - Remove socket head cap screws (4) from transmission housing.
[7] -
CAUTION:
LEGEND:
7 MFWD Output Shaft
8 Seal Guard
Transmission Case Separation (shown with MFWD)

Install lifting brackets (6) to torque converter side of transmission case as shown.
93 lb.
[8] - Machines with Mechanical Front Wheel Drive (MFWD)

Attach appropriate lifting device to lifting brackets and separate transmission case halves approximately 10 mm (3/8 in.). Tap
on MFWD output shaft (7) with a plastic hammer to separate seal guard (8) from transmission case.
Machines without Mechanical From Wheel Drive (MFWD)
Attach appropriate lifting device to lifting brackets and separate transmission case halves.
[9] - Remove transmission charge pump cap screws (9).
[10] -
→NOTE:
Mark transmission charge pump and transmission housing for aid in assembly.

LEGEND:
11 Guide Pin (2 used)
Guide Pins
Install guide pins (11).
[11] -
IMPORTANT:
Avoid damage to transmission charge pump. Transmission charge pump may fall out of transmission case
while removing cap screws (13 and 14) causing damage to transmission charge pump. Hold transmission
charge pump in place while removing cap screws.
LEGEND:
Transmission Charge Pump Inner Cap Screws

Remove cap screws (13 and 14).
[12] - Remove transmission charge pump.
[14] - Install transmission charge pump.
[15] - Install cap screws (13 and 14) and tighten to specification.
Transmission Charge Pump Inner Cap Screw Torque 23 N·m
17 lb.-ft.
[16] - Remove guide pins.
[17] - Install cap screws (9) and tighten to specification.

Transmission Charge Pump Cap Screw Torque 23 N·m
17 lb.-ft.
[18] - Clean mating surfaces of transmission halves and apply PM37509 Loctite ™ Klean ′N Prime.

Number Name Use

• PM37509 (us)
Klean ′N Prime Apply to mounting surfaces of transmission halves.
[19] - Apply PM38657 Loctite ™ High Flex Form-In-Place Gasket to mating surfaces of transmission halves.
Number Name Use

• PM38657 (us)
High Flex Form-In-Place Apply to mounting surfaces of transmission halves.
[20] -
CAUTION:
Attach appropriate lifting device to lifting brackets and assemble transmission case halves.
93 lb.
[21] - Align dowel pin holes in transmission case halves and install dowel pins until flush with case.
[22] - Tighten cap screws (4) evenly to initial torque specification.

Transmission Case Cap Screw Initial Torque 20 N·m
177 lb.-in.
[23] - Tighten cap screws (4) evenly to final torque specification.

Transmission Case Cap Screw Final Torque 65 N·m
48 lb.-ft.
[24] -
LEGEND:
8 Seal Guard
16 JDG10482 MFWD Output Shaft Seal Installer
17 MFWD Output Shaft
MFWD Output Shaft Seal Guard Installation

MFWD Output Shaft Cross Section

Machines with mechanical front wheel drive (MFWD) only.
Install MFWD output shaft (17) seal guard (8) using JDG10482 MFWD Output Shaft Seal Installer (16).
MFWD Output Shaft Seal Installer
JDG10482
Installing Output Shaft Seal and Seal Guard
[25] - Install transmission filter assembly and cap screws. Tighten to specification.
Filter Assembly Cap Screw Torque 23 N·m
17 lb.-ft.
[26] - Install torque converter. See Torque Converter Remove and Install . (Group 0651.)
[27] - Install transmission. See Transmission Remove and Install . (Group 0300.)

Transmission Charge Pump Disassemble and Assemble

Essential Tools
ESSENTIAL TOOLS
Other Material
OTHER MATERIAL
Loctite ™ Klean ‘N Prime™ Primer
LEGEND:
1 O-Ring
2 Seal
3 Transmission Charge Pump
Transmission Charge Pump
[1] - Remove O-ring (1) and discard.
[2] - Remove seal (2) and discard.
[3] - Inspect and replace transmission charge pump (3), if necessary.
[4] - Apply Loctite ™ Klean ‘N Prime™ Primer and Loctite ™ High Flex Form-in-Place Gasket to new seal.
Number Name Use

Loctite ™ Klean ‘N Prime™ Speed the cure of Loctite anaerobic products
Number Name Use
Loctite ™ High Flex Form-In-Place Gasket Gasket maker
[5] -
→NOTE:
If transmission charge pump is left on transmission while installing new seal, JDG10478 Seal Installer will
not seat seal fully onto pump.
If transmission charge pump has been removed from transmission, install new seal using JDG10478 Seal Installer.
Seal Installer
JDG10478
To install seal on transmission charge pump
ENGINE (g) by Belgreen v2.0
[6] - If transmission charge pump has not been removed from transmission, install new seal using aftermarket seal installation
tool.
[7] - Install new O-ring.
[8] - Fill area between seal lip and dust cover lip with multipurpose grease.

Section 04 - ENGINE
Table of contents
John Deere Engine Operation ............................................................................................................... 1
Engine Remove .................................................................................................................................... 2
Engine Install ...................................................................................................................................... 19

Section 04 - ENGINE Group 0400: Removal and Installation

John Deere Engine Operation
This machine uses one of the following engines:
John Deere PowerTech™ E diesel engine model 4045HT054

John Deere PowerTech™ E diesel engine model 4045HT086
John Deere PowerTech™ diesel engine model 4045TT096
To identify engine model, see Engine Identification . (Group 9010-15.)

For theory of operation on John Deere PowerTech ™ engines not contained in this group, see the following:
Engine 4045HT054 and 4045HT086
See General Engine Operation . (CTM104).

See Head Gasket Joint Construction and Operation . (CTM104).
See Cooling System Operation . (CTM104).
See Lubrication System Operation . (CTM104).
See Fuel System Operation . (CTM502).
See Electronic Injector (EI) Operation . (CTM502).
See High-Pressure Fuel Pump Operation . (CTM502).
See High-Pressure Fuel System Operation . (CTM502).
See Low-Pressure Fuel Pump Operation . (CTM502).
See Low-Pressure Fuel System Operation . (CTM502).
See Air Intake and Exhaust System Operation . (CTM104).
See EGR Valve Operation . (CTM104).
For additional engine information on John Deere engines and components, see the following component technical manuals
(CTM).
See Powertech™ 4.5L & 6.8L Diesel Engines—Base Engine . (CTM104.)

See Powertech™ E 4.5L & 6.8L Diesel Engines—Level 16 Electronic Fuel System with Denso HPCR . (CTM502.)
Engine 4045TT096
See General Engine Operation . (CTM104).

See Head Gasket Joint Construction and Operation . (CTM104).
See Cooling System Operation . (CTM104).
See Lubrication System Operation . (CTM104).
See Fuel System Operation . (CTM331.)
See Electronic Injector (EI) Operation . (CTM331.)
See High-Pressure Fuel Pump Operation . (CTM331.)
See High-Pressure Fuel System Operation . (CTM331.)
See Low-Pressure Fuel Pump Operation . (CTM331.)
See Low-Pressure Fuel System Operation . (CTM331.)
See Air Intake and Exhaust System Operation . (CTM104).
For additional engine information on John Deere engines and components, see the following component technical manuals
(CTM).
See Powertech™ 4.5L & 6.8L Diesel Engines—Base Engine . (CTM104.)

See Powertech™ 4.5L & 6.8L Diesel Engines—Level 12 Electronic Fuel System with Stanadyne DE10 Pump . (CTM331.)

Engine Remove
Engines 4045HT054, 4045HT086, 4045HT087
Specifications
SPECIFICATIONS
247 kg
Transmission Weight (approximate)
545 lb.
483 kg
Engine Weight (approximate)
1065 lb.
Essential Tools
ESSENTIAL TOOLS
JDG244-1 Lifting Eye
D01043A Load-Positioning Sling
[1] - Raise loader boom and install service lock. See Loader Boom Service Lock . (Operator’s Manual.)
[3] - Disconnect battery negative (–) ground cable or turn battery disconnect switch (if equipped) to the OFF position. See
Battery Disconnect—If Equipped . (Operator’s Manual.)
[4] - Remove grille. See Grille Remove and Install . (Group 1921.)
[5] - Remove hood. See Hood and Engine Enclosure Disassemble and Assemble . (Group 1910.)
[6] - Remove cooling package. See Cooling Package Remove and Install . (Group 0510.)
[7] - Remove serpentine belt. See Serpentine Belt Remove and Install . (Group 0510.)
[8] -
LEGEND:
Y19 Air Conditioner Compressor Clutch Solenoid
Air Conditioner Compressor (if equipped)

Machines Equipped with Air Conditioning Only:
a. Tag and disconnect air conditioner compressor clutch solenoid (Y19) connector.
b. Remove cap screws (1) and lay compressor aside.

[9] -
LEGEND:
2 Battery Power Cable
3 Ground Strap
M1 Starter Motor
W1 Frame Ground Near Starter Motor
Starter Motor
Tag and disconnect battery power cable (2) and ground strap (3) from starter motor (M1).
[10] - Tag and disconnect frame ground near starter motor (W1). See Engine Harness (W10) Component Location . (Group
9015-10.)
[11] - Remove tool box. See Battery Box Remove and Install . (Group 1913.)
[12] -
LEGEND:
F1 Main 250 A Fuse
R5 CAN Termination Resistor 1
W10 Engine Harness
X101 MTG 3-Pin Connector (if equipped)
X102 MTG CAN 1 Connector (if equipped)
Modular Telematics Gateway (MTG) Connectors (with

JDLink ™ )

Modular Telematics Gateway (MTG) Connectors (without

JDLink ™ )
Machines Equipped with JDLink™
Tag and disconnect modular telematics gateway (MTG) 3-pin connector (X101) and modular telematics gateway (MTG) CAN 1
connector (X102).
Machines without JDLink™
Tag and disconnect modular telematics gateway (MTG) 3-pin connector (X101) and CAN termination resistor 1 (R5).
[13] - Tag and disconnect engine harness (W10) from main 250 A fuse (F1).
[14] - Remove cap screws (4).
[15] - Remove turbocharger and muffler. See Muffler Remove and Install . (Group 0530.)
[16] -
LEGEND:
14 Bracket
15 Low Pressure Fuel Line
16 Fuel Filter
B60 Water-in-Fuel Sensor
M17 Fuel Lift Pump
Fuel Lift Pump and Fuel Filter

Tag and disconnect fuel lift pump (M17) electrical connector and water-in-fuel sensor (B60) electrical connector.
[17] - Disconnect low pressure fuel line (15). Close all openings using caps and plugs.
[18] - Loosen cap screws (13), remove bracket (14), and lay fuel filter (16) assembly aside.
[19] -

LEGEND:
17 Heater Hose (2 used)
Heater Hoses
Disconnect heater hoses (17) and close all openings using caps and plugs.
[20] - Remove start aid solenoid (if equipped). See Start Aid Solenoid Remove and Install—If Equipped . (Group 0505.)
[21] -
Transmission Oil Fill Tube

Transmission Oil FIll Tube (detail view)

LEGEND:
20 Transmission Oil Fill Tube
Remove cap screws (18 and 19) and rotate transmission oil fill tube (20) away from engine.
[22] - Remove drive shaft. See Universal Joint and Drive Shaft Remove and Install . (Group 0230.)
[23] -
LEGEND:
22 Access Plate
23 Flywheel Housing
24 Plug
26 Flexplate-to-Flywheel Cap Screw (4 used)
27 Transmission-to-Flywheel Housing Cap Screw (12 used)

Flywheel Housing (bottom view)

Remove cap screws (21) and access plate (22) from bottom of flywheel housing (23).
[24] - Remove plug (24), located at right front side of flywheel housing, and insert JDG820 Flywheel Turning Tool (25).
JDG820
Used to turn flywheel when installing flexplate-to-flywheel cap screws.
[25] - Remove four flexplate-to-flywheel cap screws (26). Use flywheel turning tool to rotate flywheel as necessary.
[26] - Remove eight transmission-to-flywheel housing cap screws (27) from below the machine.
[27] -
CAUTION:
Support transmission using an appropriate lifting device.

545 lb.
[28] -

LEGEND:
30 Floor Access Plate
Floor Plates
Remove cab floor mat, cap screws (29), and floor access plates (30 and 31).
[29] - Remove the four remaining transmission-to-flywheel housing cap screws through front floor access.
[30] -
LEGEND:
X20 Engine Harness-to-Cab/Canopy Harness Connector
X49 Start Aid Switch Harness Connector
X86 Fuel Lift Pump Relay Harness Connector
Engine Harness Electrical Connections

Tag and disconnect engine harness-to-cab/canopy harness connector (X20), start aid switch harness connector (X49), and fuel
lift pump relay harness connector (X86).
[31] -
LEGEND:
33 Steering and Brake Valve Access Door
Steering and Brake Valve Access Door

Remove engine speed control pedal. See Engine Speed Control Pedal Remove and Install . (Group 0515.)
[32] - Remove cap screws (32) and open steering and brake valve access door (33).
[33] -

LEGEND:
34 Cap Screw
A2 ECU
K5 Starter Relay
X41 ECU 32-Pin Connector
Engine Control Unit (ECU)

Tag and disconnect engine control unit (ECU) 32-pin connector (X41) and ECU 48-pin connector (X42) from ECU (A2).
[34] - Remove cap screw (34 and 35). Lay starter relay (K5) aside.
[35] -
LEGEND:
36 JDG244-1 Lifting Eye
38 D01043A Load Positioning Sling
Lifting Eyes
Load Positioning Sling

Fasten JDG244-1 Lifting Eye (36) to right rear side and JDG244-2 Lifting Eye (37) to left front side of engine.
Lifting Eye
JDG244-1
Used to lift engine.
Lifting Eye
JDG244-2
[36] - Install D01043A Load Positioning Sling (38) to lifting eyes (36 and 37).

Load-Positioning Sling
D01043A
Used to remove and install engine.
[37] -
CAUTION:
Engine Weight (approximate) 483 kg
1065 lb.
Engine Mounts (exploded view)

LEGEND:
39 Nut (2 used)
40 Washer (2 used)
Remove engine mount nuts (39), washers (40), and cap screws (41).
[38] -
IMPORTANT:
Torque converter and flexplate damage may result. Make sure torque converter stays with transmission,
and take care not to damage torque converter flexplate as engine is being removed.
Carefully remove engine, checking for obstructions and missed disconnections.
Engine 4045TT096
Specifications
SPECIFICATIONS
483 kg
1065 lb.

Essential Tools
ESSENTIAL TOOLS
[6] - Remove cooling package. See Cooling Package Remove and Install . (Group 0510.)
[8] -
LEGEND:

a. Tag and disconnect air conditioner compressor clutch solenoid (Y19) connector.
b. Remove cap screws (1) and lay compressor aside.
[9] -

LEGEND:
3 Ground Strap
M1 Starter Motor
Starter Motor
Tag and disconnect battery power cable (2) and ground strap (3) from starter motor (M1).
[10] - Tag and disconnect frame ground near starter motor (W1). See Engine Harness (W10) Component Location . (Group
9015-10.)
[12] -
LEGEND:
F1 Main 250 A Fuse
W10 Engine Harness
Modular Telematics Gateway (MTG) Connectors

Tag and disconnect modular telematics gateway (MTG) 3-pin connector (X101) and CAN termination resistor 1 (R5).
[13] - Tag and disconnect engine harness (W10) from main 250 A fuse (F1).
[15] - Remove turbocharger and muffler. See Muffler Remove and Install . (Group 0530.)
[16] -

LEGEND:
14 Bracket
16 Fuel Filter
R26 Fuel Filter Heater (if equipped)
Fuel Filter Assembly

Tag and disconnect water-in-fuel sensor (B60) and fuel filter heater (R26) (if equipped) electrical connectors.
[17] - Disconnect low pressure fuel line (15). Close all openings using caps and plugs.
[18] - Loosen cap screws (13), remove bracket (14), and lay fuel filter (16) assembly aside.
[19] -
LEGEND:
Heater Hoses
Disconnect heater hoses (17) and close all openings using caps and plugs.
[20] - Remove start aid solenoid (if equipped). See Start Aid Solenoid Remove and Install—If Equipped . (Group 0505.)
[21] -


LEGEND:
Remove cap screws (18 and 19) and rotate transmission oil fill tube (20) away from engine.
[22] - Remove drive shaft. See Universal Joint and Drive Shaft Remove and Install . (Group 0230.)
[23] -
LEGEND:
22 Access Plate
23 Flywheel Housing
24 Plug
26 Flexplate-to-Flywheel Cap Screws (4 used)
Transmission-to-Flywheel Housing Cap Screws (12
27
used)


Remove cap screws (21) and access plate (22) from bottom of flywheel housing (23).
[24] - Remove plug (24), located at right front side of flywheel housing, and insert JDG820 Flywheel Turning Tool (25).
JDG820
[25] - Remove four flexplate-to-flywheel cap screws (26). Use flywheel turning tool to rotate flywheel as necessary.
[26] - Remove eight transmission-to-flywheel housing cap screws (27) from below the machine.
[27] -
CAUTION:
Support transmission using an appropriate lifting device.

545 lb.
[28] -

LEGEND:
Floor Plates
Remove cab floor mat, cap screws (29), and floor access plates (30 and 31).
[29] - Remove the four remaining transmission-to-flywheel housing cap screws through front floor access.
[30] -
LEGEND:

Tag and disconnect engine harness-to-cab/canopy harness connector (X20) and start aid switch harness connector (X49).
[31] -
LEGEND:

Remove engine speed control pedal. See Engine Speed Control Pedal Remove and Install . (Group 0515.)
[32] - Remove cap screws (32) and open steering and brake valve access door (33).
[33] -

LEGEND:
A2 ECU
K5 Starter Relay
X10 Engine Control Unit (ECU) Connector

Tag and disconnect engine control unit (ECU) connector (X10) from ECU (A2).
[34] - Remove cap screws (35) and lay starter relay (K5) aside.
[35] -
LEGEND:
Lifting Eyes

Lifting Eye
JDG244-1
Lifting Eye
JDG244-2
[36] - Install D01043A Load Positioning Sling (38) to lifting eyes (36 and 37).

D01043A
[37] -
CAUTION:
1065 lb.

LEGEND:
39 Nut (2 used)
40 Washer (2 used)
Remove engine mount nuts (39), washers (40), and cap screws (41).
[38] -
IMPORTANT:
Torque converter and flexplate damage may result. Make sure torque converter stays with transmission,
and take care not to damage torque converter flexplate as engine is being removed.
Carefully remove engine, checking for obstructions and missed disconnections.

Engine Install
Engines 4045HT054, 4045HT086, 4045HT087
Specifications
SPECIFICATIONS
483 kg
1065 lb.
73 N·m
Tansmission-to-Flywheel Housing Cap Screw Torque
54 lb.-ft.
73 N·m
Torque Converter Flexplate-to-Flywheel Cap Screw Torque
54 lb.-ft.
Essential Tools
ESSENTIAL TOOLS
[1] -
LEGEND:
Engine Lifting Eyes

Lifting Eye
JDG244-1
Lifting Eye
JDG244-2
[2] -
CAUTION:
1065 lb.

IMPORTANT:
Torque converter and flexplate damage may result. Make sure torque converter is fully seated on
transmission input shaft, and take care not to damage torque converter flexplate as engine is being
installed.
Carefully lower engine into position using appropriate lifting device. Adjust engine height and angle using D01043A Load
Positioning Sling (38), so front of oil pan clears frame and engine aligns with transmission.
D01043A
LEGEND:
[3] -


LEGEND:
24 Plug
27 Transmission-to-Flywheel Housing Cap Screws (12 used)
39 Nut (2 used)
40 Washer (2 used)
Install eight transmission-to-flywheel housing cap screws (25) from below machine.
[4] - Install engine mount cap screws (41), washers (40), and nuts (39).
[5] - Install remaining transmission-to-flywheel housing cap screws through floor access. Tighten to specification.
Tansmission-to-Flywheel Housing Cap Screw Torque 73 N·m
54 lb.-ft.
[6] - Use JDG820 (26) to rotate flywheel and install flexplate-to-flywheel cap screws (24). Tighten to specification.
Torque Converter Flexplate-to-Flywheel Cap Screw Torque 73 N·m
54 lb.-ft.
[7] - Remove transmission supporting device.
[8] -
LEGEND:
22 Access Plate
23 Flywheel Housing

Install access plate (22) and cap screws (21) at bottom of flywheel housing (23).
[9] - Remove JDG820 Flywheel Turning Tool and install plug (24).
JDG820
[11] -

LEGEND:
Rotate transmission oil fill tube (20) toward engine and install cap screws (18 and 19).
[12] - Install start aid solenoid (if equipped). See Start Aid Solenoid Remove and Install—If Equipped . (Group 0505.)
[13] -
LEGEND:
Heater Hoses
Connect heater hoses (17).
[14] -

LEGEND:
14 Bracket
16 Fuel Filter
M17 Fuel Lift Pump
Fuel Lift Pump and Fuel Filter

Install fuel filter (16) and bracket (14) on cap screws (13). Tighten cap screws.
[15] - Connect low pressure fuel line (15), fuel lift pump (M17) electrical connector, and water-in-fuel sensor (B60) electrical
connector.
[16] -
LEGEND:
34 Cap Screw
A2 ECU
K5 Starter Relay

Connect engine control unit (ECU) 32-pin connector (X41) and ECU 48-pin connector (X42) to ECU (A2).
[17] - Install starter relay (K5) and cap screws (34 and 35).
[18] -
LEGEND:
X86 Fuel Lift Pump Relay Harness Connector

Connect engine harness-to-cab/canopy harness connector (X20), start aid switch harness connector (X49), and fuel lift pump

relay harness connector (X86).
[19] -
LEGEND:

Close steering and brake valve access door (33) and install cap screws (32).
[20] - Install engine speed control pedal. See Engine Speed Control Pedal Remove and Install . (Group 0515.)
[21] -
LEGEND:
Floor Access Plates

Install floor access plates (30 and 31), cap screws (29), and cab floor mat.
[22] - Install muffler and turbocharger. See Muffler Remove and Install . (Group 0530.)
[23] -

LEGEND:
F1 Main 250 A Fuse
W10 Engine Harness
Modular Telematics Gateway (MTG) 3-Pin Connector
X101
(if equipped)
Modular Telematics Gateway (MTG) CAN 1 Connector
X102
(if equipped)
Modular Telematics Gateway (MTG) Connectors (with

JDLink ™ )
Modular Telematics Gateway (MTG) Connectors (without

JDLink ™ )
Machines Equipped with JDLink™:
Connect modular telematics gateway (MTG) 3-pin connector (X101) and modular telematics gateway (MTG) CAN 1 connector
(X102).
[24] - Machines without JDLink™:

Connect modular telematics gateway (MTG) 3-pin connector (X101) and CAN termination resistor 1 (R5).
[25] - Connect engine harness (W10) to main 250 A fuse (F1) and install cap screws (4).
[26] - Install tool box. See Battery Box Remove and Install . (Group 1913.)
[27] -

LEGEND:
3 Ground Strap
M1 Starter Motor
Starter Motor
Connect battery power cable (2) to starter motor (M1).
[28] - Connect ground strap (3) to starter motor and connect frame ground near starter motor (W1).
[29] -
LEGEND:

a. Install compressor and cap screws (1).

b. Connect air conditioner compressor clutch solenoid (Y19) connector.
[30] - Install serpentine belt. See Serpentine Belt Remove and Install . (Group 0510.)
[31] - Install cooling package. See Cooling Package Remove and Install . (Group 0510.)
[32] - Install hood. See Hood and Engine Enclosure Disassemble and Assemble . (Group 1910.)
[33] - Install grille. See Grille Remove and Install . (Group 1921.)
[34] - Connect battery negative (–) ground cable or turn battery disconnect switch (if equipped) to the ON position. See Battery
Disconnect—If Equipped . (Operator’s Manual.)
[35] - Remove service lock and lower loader boom. See Loader Boom Service Lock . (Operator’s Manual.)

Engine 4045TT096
Specifications
[1] - SPECIFICATIONS
483 kg
1065 lb.
73 N·m
Tansmission-to-Flywheel Housing Cap Screw Torque
54 lb.-ft.
73 N·m
Torque Converter Flexplate-to-Flywheel Cap Screw Torque
54 lb.-ft.
Essential Tools
ESSENTIAL TOOLS
LEGEND:
Engine Lifting Eyes

Lifting Eye
JDG244-1
Lifting Eye
JDG244-2
[2] -
CAUTION:
1065 lb.

IMPORTANT:
Torque converter and flexplate damage may result. Make sure torque converter is fully seated on
transmission input shaft, and take care not to damage torque converter flexplate as engine is being
installed.
Carefully lower engine into position using appropriate lifting device. Adjust engine height and angle using D01043A Load
Positioning Sling (38), so front of oil pan clears frame and engine aligns with transmission.
D01043A
LEGEND:
[3] -


LEGEND:
24 Plug
27 Transmission-to-Flywheel Housing Cap Screws (12 used)
39 Nut (2 used)
40 Washer (2 used)
Install eight transmission-to-flywheel housing cap screws (27).
[4] - Install engine mount cap screws (41), washers (40), and nuts (39).
[5] - Install remaining transmission-to-flywheel housing cap screws. Tighten to specification.

Tansmission-to-Flywheel Housing Cap Screw Torque 73 N·m
54 lb.-ft.
[6] - Use JDG820 (26) to rotate flywheel and install flexplate-to-flywheel cap screws (24). Tighten to specification.
Torque Converter Flexplate-to-Flywheel Cap Screw Torque 73 N·m
54 lb.-ft.
[7] - Remove transmission supporting device.
[8] -
LEGEND:
22 Access Plate
23 Flywheel Housing

Install access plate (22) and cap screws (21) at bottom of flywheel housing (23).
[9] - Remove JDG820 Flywheel Turning Tool and install plug (24).
JDG820
[11] -

LEGEND:
Rotate transmission oil fill tube (20) toward engine and install cap screws (18 and 19).
[12] - Install start aid solenoid (if equipped). See Start Aid Solenoid Remove and Install—If Equipped . (Group 0505.)
[13] -
LEGEND:
Heater Hoses
Connect heater hoses (17).
[14] -

LEGEND:
14 Bracket
15 Fuel Line
16 Fuel Filter
R26 Fuel Filter Heater (if equipped)
Fuel Filter Assembly

Install bracket (14) and fuel filter (16) assembly onto cap screws (13). Tighten cap screws (13).
[15] - Connect fuel line (15).
[16] - Connect water-in-fuel sensor (B60) and fuel filter heater (R26) (if equipped) electrical connectors.
[17] -
LEGEND:
A2 ECU
K5 Starter Relay
X10 ECU Connector

Connect engine control unit (ECU) connector (X10) to ECU (A2).
[18] - Install starter relay (K5) and cap screws (35).
[19] -

LEGEND:

Connect engine harness-to-cab/canopy harness connector (X20) and start aid switch harness connector (X49).
[20] -
LEGEND:

Close steering and brake valve access door (33) and install cap screws (32).
[22] -
LEGEND:
Floor Plates
Install floor access plates (30 and 31), cap screws (29), and cab floor mat.
[23] - Install muffler and turbocharger. See Muffler Remove and Install . (Group 0530.)
[24] -

LEGEND:
F1 Main 250 A Fuse
W10 Engine Harness
Modular Telematics Gateway (MTG) Connectors

Connect modular telematics gateway (MTG) 3-pin connector (X101) and CAN termination resistor 1 (R5).
[25] - Connect engine harness (W10) to main 250 A fuse (F1) and install cap screws (4).
[27] -
LEGEND:
3 Ground Strap
M1 Starter Motor
Starter Motor
Connect battery power cable (2) to starter motor (M1).
[28] - Connect ground strap (3) to starter motor and connect frame ground near starter motor (W1).
[29] -

ENGINE AUXILIARY SYSTEM (g) by Belgreen v2.0
LEGEND:

Machines Equipped with Air Conditioning:
a. Install compressor and cap screws (1).

b. Connect air conditioner compressor clutch solenoid (Y19) connector.
[31] - Install cooling package. See Cooling Package Remove and Install . (Group 0510.)
[35] - Disengage service lock and lower loader boom. See Loader Boom Service Lock . (Operator’s Manual.)

Section 05 - ENGINE AUXILIARY SYSTEM

Table of contents
Group 0505 - Cold Weather Starting Aids ............................................................................................ 1
Coolant Heater Remove and Install—If Equipped ................................................................................. 1
Starting Aid Nozzle Remove and Install—If Equipped ........................................................................... 2
Start Aid Solenoid Remove and Install—If Equipped ............................................................................. 3
Group 0510 - Cooling Systems ............................................................................................................... 4
Fan Remove and Install ........................................................................................................................ 4
Serpentine Belt Remove and Install ..................................................................................................... 5
Radiator Remove and Install ................................................................................................................ 8
Cooling Package Remove and Install .................................................................................................. 13
Group 0515 - Speed Controls ............................................................................................................... 17
Engine Speed Control Pedal Remove and Install ................................................................................ 17
Group 0520 - Intake System ................................................................................................................. 19
Air Cleaner Remove and Install .......................................................................................................... 19
Charge Air Cooler Remove and Install ................................................................................................ 20
Group 0530 - Exhaust Systems ............................................................................................................ 22
Muffler Remove and Install ................................................................................................................. 22
Group 0560 - External Fuel Supply Systems ..................................................................................... 25
Fuel Tank Remove and Install ............................................................................................................. 25

Section 05 - ENGINE AUXILIARY SYSTEM Group 0505: Cold Weather Starting Aids
Group 0505 - Cold Weather Starting Aids

Coolant Heater Remove and Install—If Equipped
LEGEND:
1 Power Cord
2 Cap
3 Lock Nut
4 Adapter
5 Gasket
6 O-Ring
7 Heater Element
Coolant Heater
Coolant Heater—Exploded View
Specifications
SPECIFICATIONS
34 N·m
Coolant Heater Lock Nut Torque
25 lb.-ft.
[3] - Raise engine hood to full open position.
[4] - Drain cooling system. See Draining the Cooling System . (Operator′s Manual.)
[5] - Disconnect power cord (1) from coolant heater assembly.
[6] - Loosen lock nut (3).
[7] - Remove adapter (4) and heater element (7) from engine block.
[8] -
CAUTION:
Prevent possible personal injury from bursting sheath. Test coolant heater in liquid only. Do not plug
coolant heater into electrical power unless heating element is immersed in coolant.
Inspect and replace parts as necessary.
[9] - Install heater element into engine block.

Section 05 - ENGINE AUXILIARY SYSTEM Group 0505: Cold Weather Starting Aids
[10] - Install and tighten adapter.
[11] - Turn heater element until it comes in contact with engine casting. Move heater element to centered position.
[12] - Hold heater element in centered position and tighten lock nut to specification.
Coolant Heater Lock Nut Torque 34 N·m
25 lb.-ft.
[13] - Connect power cord and secure with plastic tie bands.
[14] - Refill cooling system. See Filling the Cooling System . (Operator′s Manual.)
[15] - Start engine and check for leaks.
[16] - Close hood.
[17] - Disengage service lock and lower loader boom to ground.
Starting Aid Nozzle Remove and Install—If Equipped

[2] - Raise loader boom and install boom service lock. See Loader Boom Service Lock . (Operator’s Manual.)
[3] - Open engine hood.
Battery Disconnect—If Equipped . (Operator’s Station.)
[5] -
LEGEND:
1 Starting Aid Tube
2 Nozzle
3 Nozzle Holder
Starting Aid Nozzle (engine 4045HT054 shown)

Disconnect starting aid tube (1).
[6] - Remove nozzle holder (3) from air intake manifold.
[7] - Remove nozzle (2) from nozzle holder.
[8] - Clean or replace nozzle as required.
[9] - Install nozzle in nozzle holder.
[10] -

Section 05 - ENGINE AUXILIARY SYSTEM Group 0510: Cooling Systems
→NOTE:
Arrow on nozzle holder indicates direction of nozzle.
Install nozzle holder in air inlet with arrow pointing up.
[11] - Connect starting aid tube.
[12] - Turn battery disconnect switch (if equipped) to ON or connect the battery ground cable.
[13] - Close engine hood.
[14] - Disengage boom service lock and lower loader boom to ground.
Start Aid Solenoid Remove and Install—If Equipped

[3] - Open engine hood to full open position.
[4] -
LEGEND:
1 Start Fluid Container
2 Start Aid Tube
3 Cap Screw and Nut (2 used)
4 Electrical Connector
Y15 Start Aid Solenoid
Start Aid Solenoid

Loosen clamp and remove start fluid container (1).
[5] - Disconnect start aid tube (2).
[6] - Remove cap screws and nuts (3).
[7] - Disconnect electrical connector (4) and remove start aid solenoid (Y15).
[9] - Install start aid solenoid, cap screws and nuts.
[10] - Connect electrical connector.
[11] - Connect start aid tube.
[12] - Install start fluid container (1) and tighten clamp.
[13] - Close engine hood.
[14] - Disengage boom lock bar and lower loader boom to ground.

Group 0510 - Cooling Systems

Fan Remove and Install
[3] - Open hood to full open position.
[5] -
LEGEND:
2 Fan Guard
4 Grille Housing Support
Fan Guard and Grille Housing Support

Remove cap screws (1) and fan guard (2).
[6] - Remove cap screws (3) and remove grille housing support (4).
[7] -
LEGEND:
5 Hose Clamp
6 Charge Air Cooler Tube
Charge Air Cooler Tube (engine 4045HT054)

Engines 4045HT054, 4045HT072, 4045HT086, 4045HT087 Only:
Loosen hose clamp (5) and disconnect charge air cooler tube (6).

[8] -
LEGEND:
7 Fan Cap Screw (4 used)
8 Fan
9 Spacer Cap Screw (4 used)
10 Spacer
Engine Fan
Remove fan cap screws (7) and slide fan (8) toward engine.
[9] - Remove spacer cap screws (9) and remove spacer (10) with fan.
[10] - Inspect parts and replace as necessary.
[11] - Slide fan over spacer.
[12] - Install spacer and spacer cap screws.
[13] - Install fan and fan cap screws on spacer.
[14] - Connect charge air cooler tube and tighten hose clamp.
[16] - Install grille housing support and cap screws (3).
[17] - Install fan guard and cap screws (1).
[18] - Close hood.
[19] - Disengage boom service lock and lower loader to ground.
Serpentine Belt Remove and Install

[4] -

LEGEND:
1 Square Hole
2 Serpentine Belt Tensioner
Serpentine Belt Tensioner

Insert a 1/2 in. socket drive in square hole (1) and rotate serpentine belt tensioner (2) away from belt. Remove the serpentine
belt from fan and alternator pulleys.
[5] - Remove serpentine belt by sliding over fan blades.
[6] - Inspect and replace as necessary.
[7] - Slide serpentine belt over fan blades.
[8] -
Serpentine Belt Routing (with air conditioning)

Serpentine Belt Routing (without air conditioning)

Insert a 1/2 in. socket drive in square hole and rotate serpentine belt tensioner counterclockwise to install serpentine belt.
[9] - Close hood.
[10] - Disengage loader boom service lock and lower loader to ground.

Radiator Remove and Install

Specifications
SPECIFICATIONS
24 kg
Hydraulic/Transmission Radiator Weight (approximate)
64 lb.
28 kg
Radiator Weight (approximate)
75 lb.
[5] - Drain cooling system. See Draining the Cooling System . (Operator’s Manual.)
[6] -
LEGEND:
1 Latch (2 used)
2 Air Conditioner Condenser/Fuel Cooler Bracket
Air Conditioner Condenser

Unhook latches (1) and fold out air conditioner condenser/fuel cooler bracket (2).
[7] - Machines Equipped with Air Conditioning Only

Remove cap screws (3), remove any tie bands on air conditioner condenser lines and carefully lay condenser aside.
[8] -
LEGEND:
Air Conditioner Condenser/Fuel Cooler Bracket

Remove cap screws (5) and lay air conditioner condenser/fuel cooler bracket aside.
[9] - Machines Equipped with Engines 4045HT4054, 4045HT063, 4045HT072, or 4045HT073 Only.
Remove charge air cooler. See Charge Air Cooler Remove and Install . (Group 0520.)
[10] - Remove horn. See Horn Remove and Install . (Group 2004.)
[11] -

LEGEND:
8 Hydraulic/Transmission Radiator Vent Hose (2 used)
9 Hydraulic/Transmission Radiator Inlet Hose
10 Hydraulic/Transmission Radiator Outlet Hose
Radiator Vents and Coolant Hoses

Tag and Disconnect hydraulic/transmission radiator vent hoses (8), hydraulic/transmission radiator inlet hose (9), and
hydraulic/transmission radiator outlet hose (10). Close all openings using caps and plugs.
[12] -
CAUTION:
LEGEND:
12 Hydraulic/Transmission Radiator
13 Clip (2 used)
14 Lockout Bracket
15 Latch (2 used)
Hydraulic/Transmission Radiator
Remove clips (13) and lockout bracket (14).
[13] - Unhook latches (15).
[14] - Attach appropriate lifting device to hydraulic/transmission radiator (12).

Hydraulic/Transmission Radiator Weight (approximate) 24 kg
64 lb.
[15] - Remove cap screws (16) and hydraulic/transmission radiator.
[16] -

LEGEND:
18 Hose Clamp
19 Upper Radiator Hose
20 Radiator Vent Hose
Upper Radiator Hose

Loosen hose clamp (18), remove upper radiator hose (19), and radiator vent hose (20). Close all openings using caps and
plugs.
[17] -
LEGEND:
23 Fan Guard
24 Hose Clamp
25 Lower Radiator Hose
26 Radiator
28 Bracket (2 used)
Lower Radiator Hose

Remove cap screws (22) and fan guard (23).
[18] - Loosen hose clamp (24) and disconnect lower radiator hose (25). Close all openings using caps and plugs.
[19] -
CAUTION:
Attach appropriate lifting device to radiator (26).

Radiator Weight (approximate) 28 kg
75 lb.
[20] - Remove cap screws (27), bracket (28) and radiator.
[21] -
LEGEND:
30 Hose Clamp
31 Radiator Drain Hose
33 Washer (4 used)
34 Fan Shroud
35 Clip (4 used)
36 Pin (4 used)
37 Bracket (2 used)
Radiator
Loosen hose clamp (30) and remove lower radiator hose. Close all openings using caps and plugs.
[22] - Disconnect radiator drain hose (31). Close all openings using caps and plugs.
[23] - Remove cap screws (32), washers (33), and fan shroud (34).
[24] - Remove clips (35), push out pins (36), and remove brackets (37).
[26] - Install brackets, pins, and clips (35).
[27] - Install fan shroud, washers, and cap screws (32).
[28] - Connect radiator drain hose and lower radiator hose. Tighten hose clamp (30).
[29] -
CAUTION:
Attach appropriate lifting device to radiator.

Radiator Weight (approximate) 28 kg
75 lb.
[30] - Install radiator, bracket (28), and cap screws (27).
[31] - Connect lower radiator hose and tighten hose clamp (24)
[33] - Install radiator vent hose, upper radiator hose, and tighten hose clamp (18).
[34] -
CAUTION:

Attach appropriate lifting device to hydraulic/transmission radiator.

Hydraulic/Transmission Radiator Weight (approximate) 24 kg
64 lb.
[35] - Install hydraulic/transmission radiator and cap screws (16).
[36] - Connect latches (15), install lockout bracket, and clips (13).
[37] - Connect hydraulic/transmission radiator vent hoses, hydraulic/transmission radiator inlet hose, and
hydraulic/transmission radiator outlet hose.
[38] - Install horn. See Horn Remove and Install . (Group 2004.)
[39] - Machines Equipped with Engines 4045HT4054, 4045HT063, 4045HT072, or 4045HT073 Only.
Install charge air cooler. See Charge Air Cooler Remove and Install . (Group 0520.)
[40] - Install air conditioner condenser/fuel cooler bracket and cap screws (5).

Install air conditioner condenser/fuel cooler and cap screws (3).
[42] - Close air conditioner condenser/fuel cooler bracket, and hook latches (1).
[43] - Fill cooling system. See Filling the Cooling System . (Operator’s Station.)
[46] - Remove boom service lock and lower loader boom to ground. See Loader Boom Service Lock . (Operator’s Manual.)

Cooling Package Remove and Install

Specifications
SPECIFICATIONS
88 kg
Cooling Package Weight (approximate)
236 lb.
[5] - Drain cooling system. See Draining the Cooling System . (Operator’s Manual.)
[6] -
LEGEND:
1 Latch (2 used)
2 Air Conditioner Condenser/Fuel Cooler Bracket
Air Conditioner Condenser (if equipped)

Unhook latches (1) and fold out air conditioner condenser/fuel cooler bracket (2).

Remove cap screws (3), remove any tie bands on air conditioner condenser lines and carefully lay condenser aside.
[8] -
LEGEND:
Air Conditioner Condenser/Fuel Cooler Bracket

Remove cap screws (5) and lay air conditioner condenser/fuel cooler bracket aside.
[9] - Remove horn. See Horn Remove and Install . (Group 2004.)
[10] -

LEGEND:
9 Fan Gaurd (2 used)
11 Washer (8 used)
12 Grille Housing support (2 used)
Grille Housing Support

Remove cap screws (8) and fan guards (9).
[11] - Remove cap screws (10), washers (11), and grille housing supports (12).
[12] -
LEGEND:
14 Hose Clamp (4 used)
15 Charge Air Cooler Tube (2 used)
17 Air Intake Tube
19 Upper Radiator Hose
20 Thermostat Housing Vent Hose
B109 Air Filter Restriction Switch
Air Intake Tubes
Upper Radiator Hose

Engines 4045HT054, 4045HT072, 4045HT086, 4045HT087 Only:
Loosen hose clamps (14) and remove charge air cooler tubes (15). Close all openings with caps and plugs.
[13] - Tag and disconnect air filter restriction switch (B109).
[14] - Loosen hose clamps (16) and remove air intake tube (17). Close all openings with caps and plugs.

[15] - Loosen hose clamps (18) and remove upper radiator hose (19).
[16] - Disconnect thermostat housing vent hose (20).
[17] -
LEGEND:
22 Thermal Bypass Valve Supply Hose
23 Oil Cooler Supply Hose
24 Coolant Pump Supply Hose
25 Hose Clamp
26 Lower Radiator Hose
Coolant Hoses
Lower Radiator Hose

Disconnect hoses (22—24), loosen hose clamp (25), and disconnect lower radiator hose (26).
[18] -
LEGEND:
30 Washer (2 used)
31 Bushing (2 used)
33 Washer (4 used)
34 Nut (2 used)
35 Grille Housing
36 Cooling Package
Cooling Package
Remove cap screws (29), washers (30), and bushings (31).
[19] - Remove cap screws (32), washers (33), and nuts (34).
[20] -
CAUTION:
Section 05 - ENGINE AUXILIARY SYSTEM Group 0515: Speed Controls
Attach appropriate lifting device to grille housing (35).

Cooling Package Weight (approximate) 88 kg
236 lb.
[21] - Remove cooling package (36).
[23] - Install cooling package using appropriate lifting device.
[24] - Install cap screws (32), washers (33), and nuts.
[25] - Install bushings, washers (30), and cap screws (29).
[26] - Connect lower radiator hose, tighten hose clamp (25), and connect hose (22—24).
[27] - Connect engine interface-to-horn and coolant level harness connector.
[28] - Connect thermostat housing vent hose, install upper radiator hose, and tighten hose clamps (18).
[29] - Install air intake tube, tighten hose clamps (16), and connect air filter restriction switch.
[30] - Engines 4045HT054, 4045HT072, 4045HT086, 4045HT087 Only:

Install charge air cooler tubes and tighten hose clamps (14).
[31] - Install grille housing supports, washers (11), and cap screws (10).
[32] - Install fan guards and cap screws (8).
[33] - Install horn. See Horn Remove and Install . (Group 2004.)
[34] - Install air conditioner condenser/fuel cooler bracket and cap screws (5).

Install air conditioner condenser and cap screws (3).
[36] - Fold in air conditioner condenser/fuel cooler bracket and hook latches (1).
[37] - Fill cooling system. See Filling the Cooling System . (Operator’s Manual.)
[40] - Remove boom service lock and lower loader boom to ground. See Loader Boom Service Lock . (Operator’s Manual.)

Section 05 - ENGINE AUXILIARY SYSTEM Group 0515: Speed Controls
Group 0515 - Speed Controls

Engine Speed Control Pedal Remove and Install
[2] - Disconnect battery negative (–) ground cable or turn battery disconnect switch (if equipped) to OFF position. See Battery
[3] -
LEGEND:
1 Engine Speed Control Pedal Cover
B20 Engine Speed Control Pedal
Engine Speed Control Pedal

Remove cap screws (2) and engine speed control pedal cover (1).
[4] -
LEGEND:
3 Engine Speed Control Pedal Electrical Connector
B20 Engine Speed Control Pedal
Engine Speed Control Pedal (cover removed)

Disconnect engine speed control pedal electrical connector (3).
[5] - Remove cap screws (4) and engine speed control pedal.
[7] - Install engine speed control pedal and cap screws (4).

Section 05 - ENGINE AUXILIARY SYSTEM Group 0520: Intake System
[8] - Connect engine speed control pedal electrical connector.
[9] - Install engine speed control pedal cover and cap screws (2).
[10] - Turn battery disconnect switch (if equipped) to ON or connect battery ground cable.
[11] - Check operation of engine speed control pedal. See Engine Speed Check . (Group 9010-25.)

Group 0520 - Intake System

Air Cleaner Remove and Install
[4] -
LEGEND:
2 Fan Guard
4 Grille Housing Support
6 Turbocharger-to-Charge Air Cooler Tube
8 Air Cleaner-to-Turbocharger Tube
B109 Air Filter Restriction Switch
Fan Guard
Remove cap screws (1) and remove fan guard (2).
[5] - Remove cap screws (3) and remove grille housing support (4).
[6] -
→NOTE:
Machines with engine 4045TT096 are not equipped with a charge air cooler.
If equipped, loosen hose clamps (5) and remove turbocharger-to-charge air cooler tube (6).
[7] - Loosen hose clamps (7) and remove air cleaner-to-turbocharger tube (8).
[8] - Disconnect air filter restriction switch (B109).
[9] -
LEGEND:
9 Nut (2 used)
10 Thermal Bypass Valve
12 Washer (4 used)
13 Air Cleaner
14 Bolt (2 used)
15 Mounting Bracket
Thermal Bypass Valve (bottom view)

Thermal Bypass Valve (top view with air cleaner

removed)
Loosen nuts (9) and slide thermal bypass valve (10) toward cooling package until bolts (14) are free from mounting bracket
(15).
[10] - Set thermal bypass valve aside.
[11] - Remove cap screws (11), washers (12), and air cleaner (13).
[13] - Install air cleaner, cap screws (11), and washers.
[14] - Install thermal bypass valve, pressing bolts through mounting bracket holes.
[15] - Slide thermal bypass valve towards engine and tighten nuts (9).
[16] - Connect air filter restriction switch.
[17] - Install air cleaner-to-turbocharger tube and tighten hose clamps (7).
[18] - Install turbocharger-to-charge air cooler tube and tighten hose clamps (5).
[19] - Install grille housing support and cap screws (3).
[21] - Close hood, disengage service lock, and lower loader boom. See Loader Boom Service Lock . (Operator’s Manual.)
Charge Air Cooler Remove and Install

[2] - Park machine and prepare for service. See Park and Prepare for Service Safely . (Group 0001.)
[4] - Raise hood to full open position.
[5] -

Section 05 - ENGINE AUXILIARY SYSTEM Group 0530: Exhaust Systems
LEGEND:
1 Rubber Deflector (2 used)
2 Clamp (2 used)
3 Latch (2 used)
4 Cap Screw with Bushing (2 used)
5 Charge Air Cooler
Charge Air Cooler
Charge Air Cooler (rubber deflector removed)

Remove rubber deflectors (1).
[6] - Loosen clamps (2).
[7] - Unhook latches (3).
[8] - Remove cap screws with bushings (4) and charge air cooler (5).
[10] - Install charge air cooler and cap screws with bushings.
[11] - Install rubber deflectors.
[12] - Hook latches and tighten clamps.
[13] - Close hood and install grille.

Group 0530 - Exhaust Systems

Muffler Remove and Install
Specifications
SPECIFICATIONS
70 N·m
Turbocharger Cap Screws Torque
52 lb.-ft.
7.5 N·m
Muffler Clamp Torque
66 lb.-in.
24 N·m
Oil Inlet Line Torque
212 lb.-in.
24 N·m
Oil Return Line Cap Screw Torque
212 lb.-in.
6 N·m
Hose Clamp Torque
53 lb.-in.
[4] -
LEGEND:
1 Hose Clamp
2 Hose Clamp
3 Turbocharger Intake Tube
4 Turbocharger Outlet Tube
5 Muffler Clamp
6 Oil Inlet Line
8 Oil Return Line with Gasket
10 Turbocharger with Gasket
Engines 4045HT054, 4045HT086, 4045HT087
Engines 4045HT054, 4045HT086, 4045HT087

Engine 4045TT096
Loosen hose clamps (1 and 2).
[5] - Disconnect turbocharger intake tube (3) and turbocharger outlet tube (4).
[6] - Disconnect oil Inlet line (6), remove cap screws (7), and disconnect oil return line with gasket (8). Close all openings using
caps and plugs.
[7] - Remove and replace oil return line gasket.
[8] - Remove muffler clamp (5), cap screws (9), and turbocharger with gasket (10).
[9] - Remove and replace turbocharger gasket.
[10] -
LEGEND:
12 Muffler
Muffler
Remove cap screws (11), rotate muffler (12) clockwise, and remove.
[12] - Install muffler and cap screws (11).
[13] - Install turbocharger with gasket and cap screws (9). Tighten to specification.
Turbocharger Cap Screws Torque 70 N·m

Section 05 - ENGINE AUXILIARY SYSTEM Group 0560: External Fuel Supply Systems
52 lb.-ft.
[14] - Install muffler clamp and tighten to specification.

Muffler Clamp Torque 7.5 N·m
66 lb.-in.
[15] - Connect oil inlet line and tighten to specification.

Oil Inlet Line Torque 24 N·m
212 lb.-in.
[16] - Connect oil return line with gasket, and cap screws (7). Tighten to specification.
Oil Return Line Cap Screw Torque 24 N·m
212 lb.-in.
[17] - Connect turbocharger intake tube and turbocharger outlet tube. Tighten hose clamps to specification.
Hose Clamp Torque 6 N·m
53 lb.-in.
[18] - Close hood.
[19] - Disengage service lock and lower loader boom to ground. See Loader Boom Service Lock . (Operator’s Manual.)

Section 05 - ENGINE AUXILIARY SYSTEM Group 0560: External Fuel Supply Systems
Group 0560 - External Fuel Supply Systems

Fuel Tank Remove and Install
Specifications
SPECIFICATIONS
155 L
Fuel Tank Capacity (approximate)
41 gal.
56 kg
Fuel Tank Weight (approximate)
124 lb.
Other Material
OTHER MATERIAL
7649 LOCTITE ™ Cure Primer
242 LOCTITE ™ Thread Lock and Sealer (medium strength)
[2] -
CAUTION:
Prevent fire or explosion, handle fuel carefully. If engine is hot or running, DO NOT drain fuel tank. DO
NOT smoke while draining fuel tank or working on fuel system.
→NOTE:
To ensure that all of fuel drains properly, use right stabilizer to lift right rear wheel off ground.
LEGEND:
1 Drain Screw
Fuel Tank Drain

Remove drain screw (1) to drain fuel tank. See Handling and Storing Diesel Fuel . (Operator’s Manual.)
Fuel Tank Capacity (approximate) 155 L
41 gal.
[3] -
LEGEND:
2 Fuel Tank Vent Hose
3 Fuel Return Hose
4 Fuel Supply Hose
B8 Fuel Level Sensor

TORQUE CONVERTER (g) by Belgreen v2.0
Fuel Level Sensor

Tag and disconnect fuel tank vent hose (2), fuel return hose (3), and fuel supply hose (4). Close all openings using caps and
plugs.
[4] - Disconnect electrical connector (5) from fuel level sensor (B8).
[5] -
CAUTION:
Attach appropriate lifting device to fuel tank.

Fuel Tank Weight (approximate) 56 kg
124 lb.
LEGEND:
8 Washer (6 used)
9 Fuel Tank
Fuel Tank
[6] - Remove cap screws (7) and washers (8). Remove fuel tank (9) using appropriate lifting device.
[8] - Install fuel tank, washers, and cap screws.
[9] - Connect electrical connector to fuel level sensor.
[10] - Connect fuel tank vent hose, fuel return hose, and fuel supply hose.
[11] - Apply PM37509 Cure Primer and then PM37418 Thread Lock and Sealer (medium strength) to drain screw.
Number Name Use

• PM37509 (us)
Cure Primer Apply to threads of fuel tank drain screw
• PM37418 (us)
Thread Lock and Sealer (Medium Strength) Apply to threads of fuel tank drain screw.
[12] - Install drain screw and fill fuel tank to proper level. See Handling and Storing Diesel Fuel . (Operator’s Manual.)

Section 06 - TORQUE CONVERTER

Table of contents
Group 0651 - Turbine, Gears, and Shaft .............................................................................................. 1
Torque Converter Remove and Install .................................................................................................. 1

Section 06 - TORQUE CONVERTER Group 0651: Turbine, Gears, and Shaft
Group 0651 - Turbine, Gears, and Shaft

Torque Converter Remove and Install
Specifications
SPECIFICATIONS
46 N·m
Cap Screw Torque
34 lb.-ft.
Other Material
OTHER MATERIAL
Loctite ™ Klean ‘N Prime™ Primer
Loctite ™ 242® Threadlocker (medium strength)
[1] -
→NOTE:
Torque converter has no internal service parts. If replacement is necessary, install a new torque
converter.
Torque Converter and Flexplate

LEGEND:
2 Washer (8 used)
3 Flexplate (2 used)
4 Torque Converter
Remove transmission. See Transmission Remove and Install . (Group 0300.)
[2] - Remove cap screws (1), washers (2), and flexplate (3).
[3] - Slide torque converter (4) off transmission input shaft.
[5] - Apply Loctite ™ Klean ‘N Prime™ Primer and Loctite ™ 242® Threadlocker (medium strength) to threads of cap screws.

STEERING SYSTEM (g) by Belgreen v2.0
Number Name Use

• PM37509 (us)
Primer Enter the part use here.
• Loctite ™ Klean ‘N Prime™ (loctite)
• PM37418 (us)
Threadlocker (medium strength) Apply to cap screws threads.
• Loctite ™ 242® (loctite)
[6] - Install flexplate, washers, and cap screws. Tighten to specification.

Cap Screw Torque 46 N·m
34 lb.-ft.
[7] - Install transmission. See Transmission Remove and Install . (Group 0300.)

Section 09 - STEERING SYSTEM

Table of contents
Group 0960 - Hydraulic System ............................................................................................................. 1
Tilt Steering Column Remove and Install .............................................................................................. 1
Tilt Steering Wheel and Column Disassemble and Assemble ............................................................... 4
Steering Valve Remove and Install—Tilt Steering ................................................................................. 7
Steering Valve Disassemble and Assemble ........................................................................................ 10
Non-Powered Axle Steering Cylinder Remove and Install ................................................................... 17
Non-Powered Axle Steering Cylinder Disassemble and Assemble ...................................................... 19
Mechanical Front Wheel Drive (MFWD) Axle Steering Cylinder Remove and Install ........................... 21
Mechanical Front Wheel Drive (MFWD) Axle Steering Cylinder Disassemble and Assemble .............. 24

Section 09 - STEERING SYSTEM Group 0960: Hydraulic System

Tilt Steering Column Remove and Install
Specifications
SPECIFICATIONS
30 N·m
Steering Column Nut Torque
22 lb-ft.
[2] - Release hydraulic pressure. See Hydraulic Circuit Pressure Release . (Group 9025-25.)
[4] - Drain hydraulic reservoir or apply a vacuum to the reservoir. See Change Hydraulic Reservoir Oil . (Operator’s Manual.)
[5] - Remove front floor mat.
[6] - Remove front console. See Front Console Remove and Install . (Group 1810.)
[7] -
LEGEND:
X48 Transmission Control Lever (TCL) Connector
Steering Column Wiring

Disconnect transmission control lever (TCL) connector (X48).
[8] -

LEGEND:
1 Turn Signal Connector
2 Cap Screw
3 Upper Steering Column Cover
S30 Turn Signal Switch
Upper Steering Column Cover

Disconnect turn signal connector (1) from turn signal switch (S30).
[9] - Remove cap screw (2) and upper steering column cover (3).
[10] -
LEGEND:
5 Lower Steering Column Cover
Lower Steering Column Cover

Remove cap screws (4) and lower steering column cover (5).
[11] - Mark steering column for proper alignment to steering valve during assembly.
[12] -

LEGEND:
6 Nut (4 used)
Steering Column Removal

Remove nuts (6) and steering column assembly.
→NOTE:
If cap screws spin, the steering valve needs to be removed to secure cap screw head. See Steering Valve
Remove and Install—Tilt Steering . (Group 0960.)
[14] -
CAUTION:
If steering valve and steering column splines do not line up, loss of steering control will result. Check for
proper spline alignment and engagement.
Install steering column assembly and tighten nuts to specification.

Steering Column Nut Torque 30 N·m
22 lb-ft.
[15] - Install lower steering column cover and cap screws.
[16] - Install upper steering column cover and cap screw.
[17] - Install electrical connectors.
[18] - Install front console. See Front Console Remove and Install . (Group 1810.)
[19] - Install front floor mat.
[20] - Fill hydraulic reservoir to proper level or remove vacuum from reservoir. See Check Hydraulic Reservoir Oil Level .
(Operator′s Manual.)

Tilt Steering Wheel and Column Disassemble and Assemble

Specifications
SPECIFICATIONS
48 N·m
Steering Wheel Nut Torque
35 lb.-ft.
[1] -
Transmission Control Lever (TCL) Removal

LEGEND:
1 Nut (2 used)
3 Transmission Control Lever (TCL)
4 Steering Column
Remove nuts (1), cap screws (2), and transmission control lever (TCL) (3) from steering column (4).
[2] -

Cylinder and Steering Wheel Removal

LEGEND:
4 Steering Column
5 Cover
6 O-Ring
7 Steering Wheel
8 Nut
9 Lock Washer
10 Snap Ring
11 Pin
13 Cylinder Assembly
Remove cover (5) and O-ring (6) from steering wheel (7).
[3] - Remove nut (8), lock washer (9), and steering wheel.
[4] - Remove snap ring (10) and remove pin (11).
[5] - Remove cap screws (12) and cylinder assembly (13).
[6] -

Steering Column Disassembled

LEGEND:
4 Steering Column
5 Cover
6 O-Ring
7 Steering Wheel
8 Nut
9 Lock Washer
10 Snap Ring
11 Pin
13 Cylinder Assembly
Install cylinder assembly and cap screws (12).
[7] - Install pin and snap ring.
[8] - Install steering wheel, lock washer, and nut (8). Tighten to specification.
Steering Wheel Nut Torque 48 N·m
35 lb.-ft.
[9] - Install O-ring and cover.
[10] - Install TCL, cap screws (2), and nuts (1).

Steering Valve Remove and Install—Tilt Steering

Essential Tools
ESSENTIAL TOOLS
JDG1385 Snap-to-Connect (STC) ™ Hose and Line Fitting Tool
[2] -
CAUTION:
High Pressure Fluid

pressure.
Release hydraulic pressure. See Hydraulic Circuit Pressure Release . (Group 9025-25.)
[7] - Remove engine speed control pedal. See Engine Speed Control Pedal Remove and Install . (Group 0515.)
[8] -
LEGEND:
2 Front Floor Access Panel
Floor Access Panel

Remove cap screws (1) and front floor access panel (2).

[9] -
LEGEND:
Brake and Steering Valve Access Door

Remove cap screws (3) and open the steering and brake valve access door.
[10] -
LEGEND:
4 Steering Valve-to-Priority Valve Hose (yellow)
5 Steering Valve-to-Steering Cylinder Hose (green)
6 Steering Valve-to-Steering Cylinder Hose (orange)
7 Priority Valve-to-Steering Valve Hose (red)
8 Steering Valve-to-Hydraulic Oil Reservoir Hose (blue)
9 Nut (4 used)
124 Steering Valve
Escaping Fluid
Steering Valve Connections

Disconnect hose (8) from steering valve (124).
[11] - Disconnect hoses (4—7) using JDG1385 Disconnect Tool.
a. Clean area around the STC quick disconnect hose fittings.

IMPORTANT:
DO NOT pry against release sleeve or damage to fitting may result.
DO NOT force release sleeve beyond normal range of travel, otherwise, release sleeve may fall off
when hose is disconnected. If this happens and fitting is connected without the release sleeve
installed, fitting will not be able to be disconnected again.
→NOTE:
Cap and plug steering valve and hoses using special STC plugs, 62H1028 and 62H1029 and caps
62H1036 and 62H1035. Order caps and plugs through your authorized dealer.
Insert JDG1385 Disconnect Tool between release sleeve and shoulder of fitting.
Snap-to-Connect (STC) ™ Hose and Line Fitting Tool
JDG1385
Used to disconnect quick disconnect hoses.
c. Gently push, DO NOT PRY , release sleeve away from shoulder to disconnect the fitting.
d. Pull hose to disconnect.
[12] - Close all openings using caps and plugs.
[13] - Mark position of steering wheel.
[14] - Remove nuts (9) and steering valve.
[15] - Repair or replace steering valve. See Steering Valve Disassemble and Assemble . (Group 0960.)
[16] - Check position of steering wheel before installing steering valve.
[17] -
CAUTION:
Prevent possible injury or death. If steering valve and steering column splines do not line up, loss of
steering control will result. Check for proper spline alignment and engagement.
Install steering valve and nuts.
[18] - Connect hydraulic hoses to the steering valve following color coded guide on access door.
STC Quick Disconnect Lines
a. Make sure fitting halves are clean and free from contaminants.
b. Make sure release sleeve is on male half of fitting before connecting fitting halves together.
c. Push fitting halves together until a definite snap and solid stop is felt.
d. Pull back on hose to make sure fitting halves are locked together.
[19] - Close the steering and brake valve access door and install cap screws.
[20] - Install front floor access panel and cap screws.
[24] - Fill hydraulic reservoir to proper level or remove vacuum from reservoir. See Check Hydraulic Reservoir Oil Level .
(Operator′s Manual.)
Steering Valve Disassemble and Assemble

Specifications
SPECIFICATIONS
17 N·m
End Cap Mounting Cap Screw Initial Torque
150 lb.-in.
28—34 N·m
End Cap Mounting Cap Screw Final Torque
250—300 lb.-in.
50 N·m
Elbow (1) Torque
37 lb.-ft.
73 N·m
Priority Valve Supply Check Valve (2) Torque
54 lb.-ft.
24 N·m
Elbow (3) Torque
18 lb.-ft.
73 N·m
Adaptor (4) Torque
54 lb.-ft.
73 N·m
Elbow (5) Torque
54 lb.-ft.
21 N·m
Elbow (6) Torque
15 lb.-ft.
73 N·m
Elbow (7) Torque
54 lb.-ft.
[1] -
Steering Valve Fittings

LEGEND:
1 Elbow
2 Priority Valve Supply Check Valve
3 Elbow

4 Adaptor
5 Elbow
6 Elbow
7 Elbow
124 Steering Valve
Remove elbows (1,3, and 5—7), priority valve supply check valve (2), and adaptor (4) from steering valve.
[2] -
End Cap
Check and Anticavitation Valves

LEGEND:
8 Cap Screw
9 Cap Screw
10 Cap Screw
11 Pin
12 Ball
13 Pin (2 used)
14 Ball (2 used)
15 End Cap
16 Gerotor
17 Spacer
18 Housing
20 O-Ring
Remove cap screws (8—10) in sequential order. Identify holes to aid in assembly.
[3] - Remove pin (11) and manual steering ball (12) from cap screw (8) hole.
[4] - Remove pins (13) and steel balls (14) from cap screw (9 and 10) holes.
[5] - Mark outside of end cap (15), gerotor (16), spacer (17), and housing (18) to aid in assembly.
[6] - Remove remaining cap screws (19), end cap, and O-ring (20).
[7] -
End Cap and Gerotor

LEGEND:
16 Gerotor
21 Star
22 O-Ring
Remove gerotor, star (21), and O-ring (22).
[8] -

Spacer and Drive Spool

LEGEND:
17 Spacer
23 O-Ring
24 Drive Spool and Sleeve
Remove spacer (17) and O-ring (23).
[9] - Remove drive spool and sleeve (24).
[10] -
Bearing and Seals

LEGEND:
18 Housing
25 Bearing Race (2 used)
26 Bearing
27 O-Ring
28 Seal
29 Dust Seal
Remove bearing races (25) and bearing (26).
[11] - Remove O-ring (27) and seal (28).
[12] - Remove dust seal (29).

[13] -
→NOTE:
Only O-rings (20, 22, 23, and 27), seal (28), and dust seal (29) are serviceable.
Steering Valve Disassembled

LEGEND:
11 Pin
12 Ball
13 Pin (2 used)
14 Ball (2 used)
15 End Cap
16 Gerotor
17 Spacer
18 Housing
20 O-Ring
21 Star
22 O-Ring
23 O-Ring
24 Drive Spool and Sleeve
25 Bearing Race (2 used)
26 Bearing
27 O-Ring
28 Seal
29 Dust Seal
Inspect parts for contamination, wear, or damage. Replace as necessary.
[14] - Install dust seal.
[15] - Install seal and O-ring (27). O-ring (27) should rest on lip of seal.
[16] - Install bearing races and bearing.
[17] - Install drive spool and sleeve.
[18] - Install O-ring (23) and spacer.
[19] - Install O-ring (22), star, and gerotor.

[20] - Install pins and balls into correct holes.
[21] - Install O-ring (20) and end cap.
[22] -
Torque Pattern
LEGEND:
30 Cap Screw
31 Cap Screw
32 Cap Screw
33 Cap Screw
34 Cap Screw
35 Cap Screw
36 Cap Screw
Install cap screws (30—36). Tighten to initial specification.
End Cap Mounting Cap Screw Initial Torque 17 N·m
150 lb.-in.
[23] - Tighten cap screws in sequential order (30—36) to final specification.

End Cap Mounting Cap Screw Final Torque 28—34 N·m
250—300 lb.-in.
[24] -

Steering Valve Fittings

LEGEND:
1 Elbow
2 Priority Valve Supply Check Valve
3 Elbow
4 Adaptor
5 Elbow
6 Elbow
7 Elbow
124 Steering Valve
Install fittings (1—7). Tighten to specification.
Steering Valve Fitting

Elbow (1) Torque 50 N·m
37 lb.-ft.
Priority Valve Supply Check Valve (2) Torque 73 N·m
54 lb.-ft.
18 lb.-ft.
Adaptor (4) Torque 73 N·m
54 lb.-ft.
54 lb.-ft.
15 lb.-ft.
54 lb.-ft.

Non-Powered Axle Steering Cylinder Remove and Install

Specifications
SPECIFICATIONS
7440—12 143 kg
16 387—26 747 lb.
460 N·m
Steering Cylinder Mounting Cap Screw Torque
339 lb.-ft.
300 N·m
Tie Rod-to-Cylinder Rod Torque
221 lb.-ft.
Other Material
OTHER MATERIAL
271 LOCTITE ™ Thread Lock and Sealer (high strength)
→NOTE:
Steering cylinder must be removed from machine for service.
[3] -
CAUTION:
Prevent possible crushing injury from heavy component. Use appropriate lifting device and floor stands
for supporting machine.
Machine Weight (approximate) 7440—12 143 kg
16 387—26 747 lb.
[4] -
LEGEND:
1 Steering Cylinder Hose (2 used)
2 Tie Rod (2 used)
3 Cylinder Rod
Steering Cylinder Removal

Disconnect steering cylinder hoses (1). Close all openings using caps and plugs.
[5] - Disconnect tie rods (2) from cylinder rod (3).
[6] - Remove mounting cap screws (4) and steering cylinder (125).
[7] - Repair or replace as necessary. See Non-Powered Axle Steering Cylinder Disassemble and Assemble . (Group 0960.)
[8] - Apply PM37421 Thread Lock and Sealer (high strength) to threads of cylinder mounting cap screws, and install cylinder.
Tighten cap screws to specification.

Number Name Use

• PM37421 (us) Apply to threads of steering cylinder mounting cap
Thread Lock and Sealer (high strength)
• 271 LOCTITE ™ (loctite) screws.
Steering Cylinder Mounting Cap Screw Torque 460 N·m
339 lb.-ft.
[9] - Connect tie rods. Tighten to specification.

Tie Rod-to-Cylinder Rod Torque 300 N·m
221 lb.-ft.
[10] - Connect steering cylinder hoses.
[11] - If tie rod, spindle assembly, or steering cylinder are adjusted or serviced, perform the following procedures:
Adjust tracking angle. See Tracking Angle Check and Adjust . (Group 9020-20.)
Adjust toe-in. See Toe-In Check and Adjust . (Group 9020-20.)
Adjust steering angle. See Steering Angle Check and Adjust . (Group 9020-20.)

Non-Powered Axle Steering Cylinder Disassemble and Assemble

[1] -
LEGEND:
1 Rod Guide (2 used)
2 Cylinder Rod
3 Cylinder Body
Cylinder Housing (disassembled)

Remove rod guides (1) from cylinder body (3) and slide cylinder body off of cylinder rod (2).
[2] -
→NOTE:
To aid in assembly, note location of each seal before removal.
LEGEND:
4 External Wiper Seal (2 used)
5 Wear Ring (2 used)
6 Backup Ring (2 used)
7 Internal Wiper Seal (2 used)
10 Groove
Rod Guide
Inspect wiper seals (4 and 7) and rings (5, 6, 8, and 9) and replace if necessary.
[3] -
LEGEND:
12 Cylinder Rod Piston
13 O-Ring
14 Seal Ring
Cylinder Rod Seals

Inspect rings (11, 13, and 14) on cylinder rod piston (12) and replace if necessary.
[4] -

Steering Cylinder Cross Section

LEGEND:
1 Rod Guide (2 used)
2 Cylinder Rod
3 Cylinder Body
4 External Wiper Seal (2 used)
7 Internal Wiper Seal (2 used)
12 Rod Piston
13 O-Ring
14 Seal Ring
Install seals and rings in rod guides (1) and on cylinder rod piston (12).
[5] - Install rod into cylinder body.
[6] - Install rod guides onto cylinder rod (2) and into cylinder body (3).

Mechanical Front Wheel Drive (MFWD) Axle Steering Cylinder Remove

and Install
Specifications
SPECIFICATIONS
240 N·m
Steering Cylinder Cap Screw Torque
177 lb.-ft.
300 N·m
Steering Cylinder Rod Torque
221 lb.-ft.
Other Material
OTHER MATERIAL
TY24811 NEVER-SEEZ ™ Anti-Seize Lubricant
Loctite ™ Thread Lock and Sealer (medium strength)
[4] - Remove counterweights, if equipped.
[5] -
IMPORTANT:
To avoid damaging seals, do not overheat piston rod. Use a butane torch with low flame. Stop before
heat reaches seals.
→NOTE:
Wrench flats on left end of piston rod are covered by stop collar. Remove left ball joint first if stop collars
are installed on piston rod.
LEGEND:
1 Cylinder Rod
2 Tie Rod
Steering Cylinder Removal (non-powered axle shown)

Disconnect tie rods (1) from steering cylinder rod (2). Heat end of piston rod near ball joint to break down sealant on threads.
Hold ball joint of cylinder to loosen and disconnect tie rod from steering cylinder rod.
[6] -

Mechanical Front Wheel Drive (MFWD) Axle Steering Cylinder

LEGEND:
5 Steering Cylinder
Install identification tag and disconnect steering hoses (3). Close all openings with caps and plugs.
[7] - Remove cap screws (4) and steering cylinder (5).
[8] - Repair or replace as necessary. See Mechanical Front Wheel Drive (MFWD) Axle Steering Cylinder Disassemble and
Assemble . (Group 0960.)
[9] -
LEGEND:
6 Anti-Seize Location (2 used)
Anti-Seize Location
Number Name Use

• TY24811 (us)
NEVER-SEEZ ™ Anti-Seize Lubricant Used on mating parts of steering cylinder and front axle housing.
• TY24811 (canadian)
Apply TY24811 Anti-Seize Lubricant to the anti-seize locations (6) before installing cap screws.
[10] - Install steering cylinder and cap screws.

Steering Cylinder Cap Screw Torque 240 N·m
177 lb.-ft.
[11] - Connect steering hoses.
[12] - Apply PM37509 Klean ‘N Prime then PM37418 Thread Lock and Sealer (medium strength) to threads of tie rods.
Number Name Use

Loctite ™ Klean ‘N Prime Cleans threads
Number Name Use
Loctite ™ Thread Lock and Sealer (medium strength) Secure threads
[13] - Install tie rods to steering cylinder rod. Tighten to specification.

Steering Cylinder Rod Torque 300 N·m
221 lb.-ft.
[14] - Install counterweights, if removed.

Mechanical Front Wheel Drive (MFWD) Axle Steering Cylinder

[1] -
CAUTION:
pressure.
Steering Cylinder
LEGEND:
1 Snap Ring
2 Snap Ring
3 Seal
4 Seal
5 Seal
6 Plug
7 Piston Rod
8 Hydraulic Cylinder Barrel
9 Seal
10 Seal
11 Seal
12 Bushing
13 Plug (2 used)
15 Snap Ring
16 Flange
17 Seal
18 Seal
Remove snap rings (1 and 2).
[2] - Remove seals (3, 4, and 5).
[3] -

SERVICE BRAKES (g) by Belgreen v2.0
→NOTE:
Cylinder is full of oil. Use a container to catch oil.
Remove plug (6) and piston rod (7) from hydraulic cylinder barrel (8).
[4] - Remove seals (9, 10, and 11).
[5] - Remove bushing (12) and plugs (13).
[6] - Remove snap ring (15) from flange (16).
[7] - Remove hydraulic cylinder barrel from flange.
[8] - Remove seals (17 and 18) from hydraulic cylinder barrel.
→NOTE:
The piston seal can be made more pliable by warming it with your hands or by putting seal in hot water
for approximately 5 minutes.
[9] - Repair or replace as necessary.
[10] - Apply clean hydraulic oil to seals to aid in assembly of rod and plug.
→NOTE:
Once started, install piston seal as quickly as possible to keep the amount of time the seal is stretched to
a minimum.
[11] - Install seals (17 and 18) in hydraulic cylinder barrel.
[12] - Install flange to hydraulic cylinder barrel.
[14] - Install plugs (13) and bushing.
[15] - Install seals (11, 10, and 9).
[16] - Install piston rod and plug to hydraulic cylinder barrel.
[17] - Install seals (5, 4, and 3) and snap rings (2 and 1).

Section 10 - SERVICE BRAKES

Table of contents
Group 1011 - Active Elements ............................................................................................................... 1
Brake Disc and Pressure Plate Remove and Install ............................................................................... 1
Brake System Bleeding Procedure ....................................................................................................... 2
Power Boost Brake Valve Remove and Install ...................................................................................... 3
Brake Valve Disassemble and Assemble .............................................................................................. 6
Brake Pedal Adjustment ....................................................................................................................... 9

Section 10 - SERVICE BRAKES Group 1060: Hydraulic System

Brake Disc and Pressure Plate Remove and Install
→NOTE:
Service brakes are part of the rear axle.
For brake disc and pressure plate remove and install, see Rear Axle Remove and Install , see Rear Axle Disassemble , and see
Rear Axle Assemble . (Group 0250.)


Brake System Bleeding Procedure
For brake system bleeding procedure, see Service Brake Bleed Procedure . (Group 9020-20.)

Power Boost Brake Valve Remove and Install

Essential Tools
ESSENTIAL TOOLS
JDG1385 STC Line and Fitting Disconnect Tool
[7] - Remove engine speed control pedal. See Engine Speed Control Pedal Remove and Install . (Group 0515.)
[8] -
LEGEND:
2 Front Floor Access Panel
Floor Access Panel

Remove cap screws (1) and front floor access panel (2).
[9] -
LEGEND:
Brake and Steering Valve Access Door

Secure brake pedals into raised position.
[10] - Remove cap screws (3) and open the steering and brake valve access door.
[11] -

LEGEND:
4 Protective Boot (2 used)
5 Steering and Brake Valve Drain Line
6 Transmission-to-Brake Valve Line (2 used)
7 Brake Valve-to-Transmission Oil Cooler Line
76 Service Brake Valve
S26 Brake Light Switch 1
S27 Brake Light Switch 2
Brake Valve Connections

Remove protective boots (4) and disconnect electrical connectors to brake light switches (S26 and S27).
[12] - Tag and disconnect lines (5—7 and 77) from service brake valve (76). Remove lines with quick disconnect hose fittings
using JDG1385 Disconnect Tool.
a. Clean area around the STC quick disconnect hose fittings.

IMPORTANT:
DO NOT pry against release sleeve or damage to fitting may result.
DO NOT force release sleeve beyond normal range of travel, otherwise, release sleeve may fall off
when hose is disconnected. If this happens and fitting is connected without the release sleeve
installed, fitting will not be able to be disconnected again.
→NOTE:
Cap and plug steering valve and hoses using special STC plugs, 62H1028 and 62H1029 and caps
62H1036 and 62H1035. Order caps and plugs through your authorized dealer.
Insert JDG1385 Disconnect Tool between release sleeve and shoulder of fitting.
STC Line and Fitting Disconnect Tool
JDG1385
Used to disconnect quick disconnect hoses.
c. Gently push, DO NOT PRY , release sleeve away from shoulder to disconnect the fitting.
d. Pull hose to disconnect.
[14] - Turn out lower cap screws (8) as far as possible without removing cap screws.
[15] - Remove upper cap screws (9) and remove brake valve from pedals.
[16] - Disassemble and repair valve as needed. See Brake Valve Disassemble and Assemble . (Group 1060.)
[17] -
→NOTE:
Fill brake valve with oil and bleed out air before installing on machine.
Install brake valve.

[18] - Install upper cap screws.
[19] - Tighten lower cap screws.
[20] - Connect lines to appropriate valve port using color coding guide.
[21] - Install electrical connectors to brake light switches and protective boots.
[22] - Close the steering and brake valve access door and install cap screws.
[23] - Remove strap to allow brake pedals down.
[24] - Install floor access panel and cap screws.
[27] - Fill hydraulic oil reservoir to proper level or remove vacuum from hydraulic oil reservoir. See Check Hydraulic Reservoir
Oil Level . (Operator′s Manual.)
[28] - Bleed brake system. See Brake System Bleeding Procedure . (Group 1060.)
[29] - Connect battery negative (-) ground cable or turn battery disconnect switch (if equipped) to the ON position. See Battery

Brake Valve Disassemble and Assemble

Specifications
SPECIFICATIONS
44 N·m
Brake Adapter Valve Assembly Torque
33 lb.-ft.
71 N·m
Brake Valve Fitting and Reducer Torque
53 lb.-ft.
58 N·m
Brake Valve Plug Torque
43 lb.-ft.
34 N·m
Brake Valve Assembly Cap Screws Torque
24 lb.-ft.
[1] -
Brake Valve Assembly

LEGEND:


2 Washer (4 used)
3 Housing
5 Push Rod (2 used)
6 Wiper Seal (2 used)
7 Spring (2 used)
8 Retainer (2 used)
9 Seal (2 used)
10 Retainer (2 used)
11 O-Ring (2 used)
12 Spring (2 used)
13 Seal (2 used)
14 Ring (2 used)
15 Piston (2 used)
16 Piston Ring (2 used)
18 Lock Washer (2 used)
19 Ball (2 used)
20 Plug (2 used)
21 O-Ring (3 used)
22 Spring (2 used)
23 Washer (2 used)
24 Ring
25 Spool
26 Reducer
27 O-Ring (2 used)
28 Adapter Valve (2 used)
29 Housing
30 Fitting Plug
Housings (3 and 29) are under spring tension, to separate housing halves, position mounting flange on housing (29) face down
and clamp in a vise. Apply downward pressure on housing (3) while evenly loosening four cap screws (1) and washers (2) while
carefully separating housing halves.
[2] -
→NOTE:
Do not remove snap rings (4) from push rods (5).
→NOTE:
Note direction of seals (9) and wiper seals (6).
Remove push rods (5) and wiper seals (6).
[3] -
→NOTE:
Retainers (8) are held in position by Loctite. ™ It is not necessary to remove retainers (8) to service seals
(6 and 9).
Remove springs (7) and seals (9).
[4] - Check retainers (8) for wear; if necessary, remove snap rings (4) and seals (6 and 9). With housing (3) flange face down in
a vise, use a plastic or wooden dowel through housing (3) bore to evenly tap on retainers (8). An inside bearing puller from
housing (3) flange end can also be used to remove retainers (8).
[5] - Remove retainers (10), O-rings (11), springs (12), and seals (13).
[6] - Remove rings (14), pistons (15), and piston rings (16).
[7] - Remove snap rings (17), lock washers (18), and balls (19) from pistons.
[8] - Remove plugs (20), O-rings (21), springs (22), and washers (23).
[9] -

→NOTE:
Be careful not to scratch or damage spool (25) or housing bore.
Remove ring (24) and spool (25).
[10] - Remove reducer (26), fitting plug (30), O-ring (27), adapter valves (28), and O-rings (21) from housing (29).
[12] - Thoroughly clean housings and all parts with clean solvent and allow to dry before proceeding. Lubricate all rubber
components with clean fluid used in the system.
[13] -
→NOTE:
When servicing brake valve, install all of the brake valve kit parts.
Install O-rings (21) and adapter valves. Tighten adapter valves to specification.
Brake Adapter Valve Assembly Torque 44 N·m
33 lb.-ft.
[14] -
Install O-rings (27), reducer, and fitting plug to housing (29). Tighten fittings to specification.
Brake Valve Fitting and Reducer Torque 71 N·m
53 lb.-ft.
[15] - Install spool and ring (24).
[16] - Install washers (23), springs (22), O-rings (21), and plugs. Tighten plugs to specification.
Brake Valve Plug Torque 58 N·m
43 lb.-ft.
[17] - Install balls, lock washers, and plugs (20) to pistons.
[18] -
→NOTE:
Seals (13) will stretch and become oversized when being installed. These seals must be resized before
final assembly. To resize seals (13), lubricate seals (13), pistons, and housing (3) bores with clean type
fluid used in the system.
Install piston rings, rings (14), and seals (13) to pistons.
[19] - Install pistons to housing (3).
[20] - Install springs (12), O-rings (11), and retainers (10).
[21] - Install springs (7) into push rods.
[22] - Install seals (9) to housing (3).
[23] - Install push rods to housing (3).
[24] - Install wiper seals (6) to housing.
[25] - Install seals (13).
[26] - Install cap screws (1) and washers (2). Tighten to specification.

PARK BRAKE (g) by Belgreen v2.0
Brake Valve Assemblies Cap Screw Torque 34 N·m
24 lb.-ft.
Brake Pedal Adjustment

For brake pedal adjustment, see Service Brake Pedal Adjustment . (Group 9020-20.)

Section 11 - PARK BRAKE

Table of contents
Group 1111 - Active Elements ............................................................................................................... 1
Park Brake Remove and Install ............................................................................................................. 1

FRAME OR SUPPORTING STRUCTURE (g) by Belgreen v2.0

Park Brake Remove and Install
→NOTE:
Park brake is part of rear axle.
Remove and install park brake. See Rear Axle Remove and Install and see Park Brake Disassemble and Assemble . (Group
0250.)

Section 17 - FRAME OR SUPPORTING STRUCTURE

Table of contents
Group 1740 - Frame Installation ........................................................................................................... 1
Welding Repair of Major Structures ...................................................................................................... 1
RIVNUT® (KREMNUT) Fasteners Remove and Install ........................................................................... 2
Group 1749 - Chassis Weights ............................................................................................................... 5
Counterweight Remove and Install—If Equipped .................................................................................. 5

Section 17 - FRAME OR SUPPORTING STRUCTURE Group 1740: Frame Installation
Group 1740 - Frame Installation

Welding Repair of Major Structures
IMPORTANT:
Disconnect battery ground strap or turn battery disconnect switch to "OFF" to prevent voltage spikes
through alternator or monitor.
Have only a qualified welder do this job. Connect welder ground clamp close to each weld area so
electrical current does not pass through any bearings.
Remove or protect all parts that can be damaged by heat or weld splatter.
If machine is equipped with a controller (microprocessor) like Engine Controller (EC) or Pump and Valve
Controller (PVC) disconnect harness connector from controller to prevent voltage spikes through
microprocessor.
Connect welder ground clamp close to each weld area so electrical current does not arc inside any
bearings.
Use one of the following weld processes:

AWS-E-7018 covered electrode with shielded metal arc welding (SMAW) process.
AWS-ER-70S-3 wire electrode with gas metal arc welding (GMAW) process.
AWS-E70T-1 or E71T-1 wire electrode with flux core arc welding (FCAW) process.
Preheat area to be repaired to allow better weld penetration.
To repair weld metal failure, remove failed weld metal using arc or grinding equipment. Thoroughly clean area to be welded.
Preheat structural assemblies to a minimum of 38°C (100°F). Preheat ground engaging tools (cutting edges, skid shoes, and
teeth shanks) to 177°C (350°F).
To repair base metal failure remove enough material to allow weld to penetrate to the bottom of crack. Preheat structural
assemblies to a minimum of 38°C (100°F). Preheat ground engaging tools (cutting edges, skid shoes, and teeth shanks) to
177°C (350°F).

RIVNUT® (KREMNUT) Fasteners Remove and Install
Fastener Removal
[1] - Remove flange of RIVNUT ™ using a hammer and chisel. Use care not to damage equipment’s surface under the flange or
the hexagon hole.
Use a punch to remove threaded portion of fastener.
[2] -
LEGEND:
A Hexagon Hole
Hexagon Hole
Select the proper length fastener for the thickness of the material where the fastener will be installed. Fasteners are color-
coded as well as stamped on the flange surface. (Coding indicates the nominal plate thickness for which the fastener can be
used.)
Rivet Nut Length Selection
RIVET NUT LENGTH SELECTION
Material Thickness Flange Stamp Color Code
4.25—5.60 mm (0.167—0.220 in.) 4.5 Silver
5.74—7.09 mm (0.226—0.279 in.) 6 Yellow
7.75—9.09 mm (0.305—0.358 in.) 8 Red
9.75—11.10 mm (0.384—0.437 in.) 10 Black
11.73—13.08 mm (0.462—0.515 in.) 12 Olive Drab
[3] -
IMPORTANT:
DO NOT force or drive fastener into hole. Fastener can be damaged and will not hold securely.
Make sure the new fastener fits easily into the existing hexagon hole (A). If necessary, use a small file to clean the edges of the
hole.

[4] -
LEGEND:
A Large Threads
B Tool Shoulder
C Rivnut Fastener
D Small Threads
JDG894 Installation Tool

Lubricate the large threads (A) of the JDG894 Installation Tool.
RIVNUT ™ Installation Tool
JDG894
JDG894
Install RIVNUT ™ fasteners.
[5] - Install RIVNUT ™ fastener (C) on tool:
Small threads (D) of installation tool must extend past fastener.

Flange of fastener must contact shoulder (B) of tool.
[6] -
LEGEND:
A Socket Head Screw
B Nut
C Flange
Use Crowsfoot Wrench to Tighten Large Nut

Install fastener with installation tool in hexagon hole. Make sure flange (C) is flat against mounting surface.

Section 17 - FRAME OR SUPPORTING STRUCTURE Group 1749: Chassis Weights
[7] -
IMPORTANT:
NEVER turn or tighten JDG894 Installation Tool socket head screw. Damage to threads of fastener can
occur.
While holding socket head screw (A) stationary, tighten large (1-1/16 in.) nut (B) to specifications using a crowsfoot wrench.
RIVNUT ™ (KREMNUT) Fastener Torque 68—74 N˙m (50—55 lb-ft)
[8] - Loosen large nut to remove tool.

OPERATOR′S STATION (g) by Belgreen v2.0
Group 1749 - Chassis Weights

Counterweight Remove and Install—If Equipped
LEGEND:
2 Washer (4 used)
3 Front Counterweight
Front Counterweight
Specifications
SPECIFICATIONS
204—567 kg
Front Counterweight Weight (approximate)
450—1250 lb.
275 N·m
Front Counterweight Cap Screw Torque (lubricated)
205 lb.-ft.
[2] - Raise loader boom and engage service lock.
[3] -
CAUTION:
Front Counterweight Weight (approximate) 204—567 kg
450—1250 lb.
Install hoist to counterweight with straps.
[4] - Remove cap screws (1) and washers (2).
[5] - Remove front counterweight (3).
[7] - Install front counterweight. Tighten cap screws to specification.

Front Counterweight Cap Screw and Nut Torque 275 N·m
205 lb.-ft.
[8] - Remove straps from counterweight.
[9] - Disengage loader boom service lock and lower loader to ground.

Section 18 - OPERATOR′S STATION

Table of contents
Operator′s Station Remove and Install ................................................................................................. 1
Group 1810 - Operator Enclosure .......................................................................................................... 8
Front Window Wiper and Wiper Motor Remove and Install ................................................................... 8
Rear Window Wiper and Wiper Motor Remove and Install .................................................................. 11
Front Console Remove and Install (S.N. —000470) ............................................................................ 13
Fixed Window Remove and Install ...................................................................................................... 14
Non-Fixed Window Remove and Install .............................................................................................. 16
Non-Fixed Window Adjustment ........................................................................................................... 19
Non-Fixed Window Latch Adjustment ................................................................................................. 20
Cab Door Hinges and Latch Adjustment ............................................................................................. 22
Headliner Remove and Install (S.N. —000470) ................................................................................... 23
Cab Roof Remove and Install .............................................................................................................. 25
Group 1821 - Seat and Seat Belt ......................................................................................................... 27
Seat Assembly Remove and Install ..................................................................................................... 27
Mechanical Suspension Seat Disassemble and Assemble .................................................................. 28
Air Suspension Seat Disassemble and Assemble—If Equipped ........................................................... 37
Seat Belt Disassemble and Assemble ................................................................................................. 45
Group 1830 - Heating and Air Conditioning ...................................................................................... 46
R134a Refrigerant Cautions and Proper Handling .............................................................................. 46
R134a Compressor Oil Removal ......................................................................................................... 46
R134a Component Oil Charge ............................................................................................................ 47
Refrigerant Leakage Testing .............................................................................................................. 48
Refrigerant Hoses and Tubing Inspection ........................................................................................... 48
R134a Refrigerant Recover, Recycle, and Charge Station Installation Procedure .............................. 49
Recover R134a System ...................................................................................................................... 50
Evacuate R134a System ..................................................................................................................... 51
Charge R134a System ........................................................................................................................ 52
Air Conditioning System Cleaning Procedures .................................................................................... 52
Flush and Purge Air Conditioning System ........................................................................................... 54
Blower Mode Door Motor Remove and Install ..................................................................................... 56
Evaporator or Heater Core Remove and Install .................................................................................. 58
Expansion Valve Remove and Install .................................................................................................. 60
Air Conditioner Freeze Control Switch Remove and Install ................................................................. 62
Receiver-Dryer Remove and Install .................................................................................................... 64
Condenser Remove and Install ........................................................................................................... 66
Compressor Remove and Install ......................................................................................................... 68

Section 18 - OPERATOR′S STATION Group 1800: Removal and Installation

Operator′s Station Remove and Install
Specifications
SPECIFICATIONS
2.38 kg
Refrigerant Charge (actual) Capacity
5.25 lb.
34.8 qt.
Cooling System Capacity
32.9 L
746 kg
Cab Weight (approximate)
1645 lb.
420 N·m
Operator Station Mounting Cap Screw Torque
310 lb.-ft.
DFT1101 Cab and ROPS Lift Bracket
REMOVAL
[1] -
→NOTE:
Cab and canopy operator station remove and install procedures are similar. Cab is shown in illustrations.
[2] -
CAUTION:
pressure.
Relieve hydraulic system pressure. See Hydraulic Circuit Pressure Release . (Group 9025.)
[3] - Cab Machines:
Recover R134a refrigerant. See R134a Refrigerant Recover, Recycle, and Charge Station Installation Procedure and see
R134a Refrigerant Charge Capacity . (Group 1830.)
Drain coolant. See Draining the Cooling System . (Operator’s Manual.)
Refrigerant Charge (actual) Capacity 2.38 kg
5.25 lb.
Cooling System Capacity 34.8 qt.
32.9 L
[4] - Drain hydraulic reservoir or apply a vacuum. See Change Hydraulic Reservoir Oil (Operator’s Manual) or see Apply
Vacuum to Hydraulic Oil Reservoir . (Group 2160.)
[5] - Disconnect negative battery cable.

[7] - Remove front and middle floor plates (1, 2).

LEGEND:
1 Front Floor Plate
2 Middle Floor Plate
Floor Access Plate Removal
[9] - Disconnect hydraulic hoses (6—8) from steering valve (124).
Steering Valve and Brake Valve

LEGEND:
6 Steering Cylinder Work Hose (2 used)
7 Load Sense Hose
8 Steering Valve Supply Hose
10 Brake Valve-to-Hydraulic Oil Tank Hose
124 Steering Valve
129 Brake Valve
[10] - Disconnect hydraulic hoses (9, 10) from brake valve (129).
[11] - Disconnect ECU connectors (X5501—X5503).

LEGEND:
A2 Engine Control Unit (ECU)
X5501 ECU Connector 1
Engine Control Unit (S2 model shown)
[12] - Cab Machines Only: Disconnect heater hoses (11) and air conditioner lines (12) (if equipped).
LEGEND:
12 Air Conditioner Line (2 used)
13 Ground Strap
14 Cap Screw
15 Electrical Connector (up to 5 used)
Transmission Harness-to-Cab/Canopy Harness
X21
Connector
Cab Hoses, Lines, and Wire Harness Connections
[13] - Disconnect ground strap (13).
[14] - Remove cap screw (14) to disconnect air conditioner lines from bracket.
[15] - Disconnect electrical connectors (X20, X21).
[16] -
→NOTE:
There may be up to five electrical connectors (15) grouped together depending on machine options.
Disconnect all electrical connectors (15) mounted to bracket.
[17] - Disconnect linkage (16, 17) from loader and stabilizer control valve (190).

LEGEND:
16 Loader Linkage Rod (2—3 used)
17 Stabilizer Linkage Cable (2—3 used)
18 Bracket
190 Loader and Stabilizer Control Valve
Stabilizer and Loader Valve Linkage (five function with

EH auxiliary control valve shown)
[18] - Remove stabilizer linkage cables from bracket (18).
[19] - Manual Backhoe Controls: Disconnect backhoe lever linkage and auxiliary pedal(s) (if equipped) from backhoe control
valve.
See Backhoe Control Valve Linkage Remove and Install—Two Lever . (Group 3315.)
See Backhoe Auxiliary Pedal Remove and Install—Fifth and Sixth Functions . (Group 3315.)
[20] - Pilot Backhoe Controls:
Pilot Control Hose Connections

PEPS Manifold Solenoid Harness

LEGEND:
22 Return Hydraulic Hose (2 used)
23 Boom Hydraulic Hose (2 used)
24 Crowd Hydraulic Hose (2 used)
25 Supply Pressure Hose (2 used)
26 Swing Hydraulic Hose (2 used)
27 Bucket Hydraulic Hose (2 used)
137 Pilot Enable and Pattern Select (PEPS) Manifold
145 Backhoe Control Valve
X52 Pilot Control Console Harness Connector
X53 Pilot Enable Switch Harness Connector
→NOTE:
Cap and plug pilot control valve and hoses using 62H1028 and 62H1029 Snap-to-Connect (STC) ™ Plugs,
and 62H1036 and 62H1035 Caps. Order caps and plugs through your authorized dealer.
a. If equipped, disconnect auxiliary pedal linkage from backhoe control valve see Backhoe Auxiliary Pedal Remove and
Install—Fifth and Sixth Functions . (Group 3315.)
b. Disconnect hydraulic hoses (22—25) from pilot enable and pattern select (PEPS) valve (137).
c. Disconnect hydraulic hoses (26, 27) from upper and lower backhoe control valve (145).
d. Disconnect electrical connectors (X52, X53).
[21] - Disconnect cab power lead (35) from starter motor (M1).
LEGEND:
35 Cab Power Lead
M1 Starter Motor
Cab Power Lead
[22] - Remove boom lock hook (38) from rod (39).

LEGEND:
38 Boom Lock Hook
39 Rod
Boom Lock
[23] -
CAUTION:
Install DFT1101 Lift Bracket (40) using chains and lifting straps. See DFT1101 Cab and ROPS Lift Bracket . (Group 9900.)
Cab and ROPS Lift Bracket
DFT1101
Used to remove and install cab.
LEGEND:
40 DFT1101 Lift Bracket
41 Lifting Location
42 Lifting Location
DFT1101 Lift Bracket
a. Attach front lifting straps to exterior hand rails (41).

b. Open the rear side windows and attach rear lifting straps to upper window latch loop (42).
c. Remove slack from chains and lifting straps.
Cab Weight (approximate) 746 kg
1645 lb.
[24] -

Section 18 - OPERATOR′S STATION Group 1810: Operator Enclosure
→NOTE:
Remove upper half of rubber isolators (47 and 52) after cab is lifted from machine frame.
Remove operator station mounting hardware (45—52).

LEGEND:
45 Front Cap Screw (2 used)
46 Washer (2 used)
47 Front Rubber Isolator (2 sets used)
48 Large Washer (2 used)
49 Nut (2 used)
50 Rear Cap Screw (2 used)
51 Washer
52 Rear Rubber Isolator (2 sets used)
Front Cab Mounts
Rear Cab Mounts
[25] - Carefully remove cab. Support cab with shop stands.
INSTALLATION
[1] - Install operator station mounting hardware (45—52). Tighten cap screws to specification.
Operator Station Mounting Cap Screw Torque 420 N·m
310 lb.-ft.
[2] - Installation is reverse of removal procedure.
[3] - Fill hydraulic reservoir or remove vacuum. See Change Hydraulic Reservoir Oil (Operator’s Manual) or see Apply Vacuum
to Hydraulic Oil Reservoir . (Group 2160.)
[4] - Cab Machines Only:
If equipped, charge air conditioning system. See R134a Refrigerant Recover, Recycle, and Charge Station Installation
Procedure . (Group 1830.)
Fill radiator with proper coolant. See Heavy Duty Diesel Engine Coolant and see Filling the Cooling System (Operator’s
Manual.)

Group 1810 - Operator Enclosure

Front Window Wiper and Wiper Motor Remove and Install
Specifications
SPECIFICATIONS
Front Window Wiper Motor
20 N·m.
Jam Nut Torque
177 lb.-in.
10 N·m
Cap Screw Torque
88 lb.-in.
Front Window Wiper Arm
18 N·m
Wiper Arm Nut Torque
160 lb.-in.
[3] - Raise hood assembly and remove stationary hood from frame above hydraulic reservoir. See Hood and Engine Enclosure
Disassemble and Assemble . (Group 1910.)
[4] -
LEGEND:
1 Wiper Arm Nut
2 Wiper Arm
3 Pivot Shaft Jam Nut Cover
Wiper Arm
Remove wiper arm nut (1) and wiper arm (2).
[5] - Remove pivot shaft jam nut cover (3).
[6] -

LEGEND:
6 Jam Nut
7 Washer
Wiper Arm Pivot Shaft

Remove jam nut (6) and washer (7).
[8] -
LEGEND:
8 Wiper Motor Electrical Connector
M13 Front Wiper Motor
Wiper Motor
Disconnect front wiper motor electrical connector (8) and remove front wiper motor (M13).
[10] - Install front wiper motor and connect front wiper motor electrical connector.
[11] - Install cap screws, washer, and jam nut. Tighten to specification.
Front Window Wiper Motor

Jam Nut Torque 20 N·m
177 lb.-in.
88 lb.-in.

[12] - Install wiper arm and wiper arm nut. Tighten to specification.
Front Window Wiper Arm

Wiper Arm Nut Torque 18 N·m
160 lb.-in.
[13] - Install stationary hood and close hood assembly.
[14] - Install front console.

Rear Window Wiper and Wiper Motor Remove and Install

Specifications
SPECIFICATIONS
Rear Window Wiper Arm and Motor
18 N·m
Wiper Arm-to-Pivot Torque
160 lb.-in.
20 N·m
Pivot Shaft Jam Nut Torque
177 lb.-in.
10 N·m
Wiper Motor Mount Cap Screw Torque
88 lb.-in.
[1] - Remove interior headliner. See Headliner Remove and Install . (Group 1810.)
[2] - Remove cab roof. See Cab Roof Remove and Install . (Group 1810.)
[3] -
Rear Window Wiper

LEGEND:
1 Wiper Arm
2 Lock Nut
3 Drive Assembly
5 Tie Band
M14 Rear Wiper Motor
Rear Wiper Motor

Pop up bottom portion of wiper arm (1) and remove lock nut (2).
[4] - Remove wiper arm and remove drive assembly (3).
[5] - Remove tie band (5) and electrical connector (6).
[7] - Remove rear wiper motor (M14).
[8] - Inspect for worn or damaged parts and replace as necessary.
[9] - Install wiper motor and cap screws. Tighten to specification.

Rear Window Wiper Arm and Motor

Wiper Arm-to-Pivot Torque 18 N·m
160 lb.-in.

Pivot Shaft Jam Nut Torque 20 N·m
177 lb.-in.
Wiper Motor Mount Cap Screw Torque 10 N·m
88 lb.-in.
[10] - Connect electrical connector and install tie band.
[11] - Install drive assembly and wiper arm.
[12] - Install lock nut and close bottom portion of wiper arm.
[13] - Install headliner See Headliner Remove and Install (Group 1810.)
[14] - Install cab roof. See Cab Roof Remove and Install . (Group 1810.)

Front Console Remove and Install (S.N. —000470)

[2] -
LEGEND:
2 Upper Steering Console Cover
E75 Bucket Position Indicator
Steering Console Covers (non-TMC machines)
Steering Console Covers (TMC machines)

Remove cap screws (1) and remove upper steering console cover (2).
[3] - TMC Machines: Disconnect bucket position indicator (E75).
[4] - Cab Machines: Disconnect blower mode door motor harness connector (X47).

LEGEND:
Blower Mode Door Motor Harness Connector (if
X47
equipped)
Blower Mode Door Motor Harness Connector (cab

machine shown)
[6] -
LEGEND:
6 Front Console
Front Console (cab machine shown)

Remove cap screws (5) and front console (6).
[8] - Install front console and cap screws (5).
[9] - Cab Machines: Connect blower mode door motor harness connector.
[10] - Install cap screws (4).
[11] - TMC Machines: Connect bucket position indicator.
[12] - Install upper steering console cover and cap screws (1).

Fixed Window Remove and Install

→NOTE:
Use this procedure to replace cab front, rear side, and lower door windowpanes.
Use Quick Cure Primerless Autoglass Windshield Sealant or equivalent to hold windowpanes in place. DO NOT use any other
type of adhesive other than a urethane. It is also recommended that an auto glass dealer install windowpanes.
IMPORTANT:
Windowpanes must have an ultra-violet barrier around edge of glass since ultra-violet rays will
deteriorate adhesive. Windowpanes ordered through John Deere Parts have ultra-violet barrier. If
windowpane is purchased through a glass dealer, dealer must put an ultra-violet barrier on glass. DO
NOT apply paint to border of glass.
If an auto glass dealer is not installing windowpanes, use the following procedure:
[1] - Purchase urethane adhesive from your local auto glass dealer.
[3] - If window frame is removable, remove frame from cab.
[4] - Scrape broken glass off existing adhesive. DO NOT remove adhesive from window frame or cab.
[5] - Trim existing adhesive so it has a smooth surface.
[6] - Apply a 12.5 mm (1/2 in.) bead of adhesive on top of existing adhesive.
[7] - Place a new windowpane into position. Use light hand pressure to force windowpane down around edges until even with
metal frame. DO NOT over press adhesive.
[8] - If windowpane is installed directly on cab, use tape to hold it in place while adhesive cures.
[9] - Allow adhesive to cure for 24 hours before operating machine.

Non-Fixed Window Remove and Install
Rear Window Exploded View

LEGEND:
1 Window
2 Window
3 Window
4 Screw (10 used)
5 Rack Step (2 used)
6 Frame (2 used)
7 Weatherstrip (2 used)
8 Gasket (2 used)
9 Latch (4 used)
10 Seal
11 Upper Sliding Window
12 Middle Sliding Window
13 Lower Fixed Window
14 Window
15 Window
16 Stand-Off (22 used)
17 Washer (6 used)
18 Label
19 Label
20 Screw (6 used)
21 Window
22 Screw (6 used)

Specifications
SPECIFICATIONS
25 N·m
Window-to-Hinge Cap Screw Torque
221 lb.-in.
To remove and install rear side windows (14 and 15) see Fixed Window Remove and Install . (Group 1810.)
Upper and Lower Sliding Window (11 and 12)
[2] - Move middle sliding window (12) and upper sliding window (11) to full down position.
→NOTE:
When removing and installing middle sliding window (12) only. Upper sliding window (11) should be in
full up position. Middle sliding window will start in full down position.
[3] - Remove old flocked rubber from both sides, to just above top of upper and middle sliding windows (11 and 12). A screw
driver may help get end started. Cut rubber approximately 5 cm (2 in.) above top of upper and middle sliding windows.
→NOTE:
Upper sliding window can be removed by guiding side without lock into deep portion of channel until
other side clears the channel.
[4] - Starting with upper sliding window (11), remove one of the latches (9) and raise the upper sliding window until it clears
flocked rubber.
[5] - Repeat steps 3and 4 to remove middle sliding window (12).
[6] - Repair and replace parts as necessary
[7] - With lower portion of flocked rubber still in place install middle sliding window (12). Move middle sliding window to full
down position.
[8] - Install flocked rubber in upper portion of middle channel.
[9] - Install latch.
[10] - Repeat steps 7—9 to install upper sliding window (11).
Lower Rear Fixed Window (13)
[2] - Slide middle and upper sliding windows (11 and 12) to full up position.
[3] - Remove cap screws (22) and lower rack step (5) from each side of window.
→NOTE:
Lower fixed window (13) can be removed by guiding into deep portion of aluminum channel on one side
until opposite side is clear of frame.
[4] - Raise lower fixed window (13) until it clears flocked rubber.
[5] - Inspect for worn or damaged parts. Repair or replace as necessary.
[6] - Install lower fixed window (13) by sliding into flocked rubber installed in channel.
→NOTE:
A small rubber disk on bottom of each rack step is present to prevent direct contact between glass and
rack step.

[7] - Install lower rack step (5) to each side of window with cap screws (22).
Cab Door Upper Window and Side Window

LEGEND:
1 Window Latch (4 used)
3 Side Window
4 Cab Door Upper Window
Side Window and Cab Door Upper Window
[1] - Unlock window latches (1) on side window (3) and cab upper door window (4).
[2] - Remove cap screws (2), side window, cab upper door window, and hinges from machine.
[3] - Remove cap screws (5) and hinges from windows.
[5] - Install hinges to windows with cap screws (5) and tighten to specifications.
Window-to-Hinge Cap Screw Torque 25 N·m
221 lb.-in.
[6] - Install windows and hinges to cab with cap screws (2).
[7] - Lock latches on side window and cab upper door window.
[8] - Adjust cab door upper window and side window as necessary. See Non-Fixed Window Adjustment . (Group 1810.)
[9] - Repeat procedure for opposite side.

Non-Fixed Window Adjustment

Specifications
SPECIFICATIONS
25 N·m
Window-to-Hinge Cap Screw Torque
221 lb-in.
2.93 N·m
Window Open Lock Mount Torque
26 lb-in.
Cab Door Upper Window
→NOTE:
Cab door upper window must be adjusted prior to adjusting side window.
LEGEND:
1 Window Latch
Cab Door Upper Window
[2] - Unlock latches (1).
[3] - Loosen cap screws (2) and position window equally in door frame opening.

221 lb-in.
[5] - Lock window latches.
Side Windows
→NOTE:
Cab door upper window must be adjusted prior to adjusting side window.

[2] -
LEGEND:
1 Window Latch (2 used)
3 Window Open Lock Knob
Side Window
Unlock window latches (1).
[3] - Loosen cap screws (2) and position window equally in door frame opening.

221 lb-in.
[5] - Tighten window open lock knob (3) to allow knob to move freely.
[6] - Loosen window open lock knob mount in door window to adjust position to knob.
[7] - Tighten mount to specification.

Window Open Lock Mount Torque 2.93 N·m
26 lb-in.
[8] - Lock window latches.
Non-Fixed Window Latch Adjustment

LEGEND:
1 Latch
2 Seal
3 Striker
Window Latch
[1] - Close window and lock using latch (1).
[2] - Check for even compression of seal (2).
[3] - Open window. Bend striker (3) to obtain equal compression of seal.

Cab Door Hinges and Latch Adjustment

Specifications
SPECIFICATIONS
75 N·m
Cap Screws Torque
55 lb.-ft.
10—12 mm
Cab Frame-to-Door Frame Clearance
0.4—0.5 in.
65 N·m
Door Latch Striker Pin Nut Torque
48 lb.-ft.
[2] -
LEGEND:
Cab Door Hinge

Loosen cap screws (1) securing hinge to cab frame.
[3] - Move door and hinge to position door frame in cab frame front to rear.
55 lb.-ft.
[5] -
→NOTE:
Hinge mounting holes are slotted to provide adjustments. Hinges attached to cab frame have horizontal
slotted holes which provide forward and rearward adjustments. Hinges attached to door frame have
vertical slotted holes for upward and downward adjustments.
Loosen cap screws (2). Move door to position door frame in cab frame up and down.
55 lb.-ft.
[7] - Check door seal for proper compression. Seal should be evenly compressed around door to provide a seal between door
frame and cab frame.
[8] - If excessive clearance exists adjust latch strike pin.
[9] -

→NOTE:
It may be possible to view latch jaw engagement with latch cover in place. If not remove cover.
Latch and Striker Pin Adjustment

LEGEND:
6 Striker Pin
7 Latch Jaw Ends
8 Gap
Adjust latch and striker pin:
If gap (8) between latch jaw ends (7) is approximately 10 mm (0.4 in.) latch is only in first detent position. Adjust latch to
obtain second (primary) detent position. Loosen striker pin and move it forward approximately 0.8 mm (0.03 in.). Tighten
striker pin and check gap to make sure that jaws are in second detent as described. If necessary, repeat until second
detent engagement is obtained.
If gap between latch jaw ends is approximately 1—2 mm (0.04—0.08 in.) latch is in second (primary) detent position. To
decrease clearance at door center, loosen striker pin and move it rearward about 0.8 mm (0.03 in.). Tighten striker pin
and check clearance. If necessary, repeat until clearance of 10—12 mm (0.4—0.5 in.) exists between cab frame and door
frame.
Cab Frame-to-Door Frame Clearance 10—12 mm
0.4—0.5 in.
After making adjustment, tighten striker pin nut to specification.

Door Latch Striker Pin Nut Torque 65 N·m
48 lb.-ft.
Headliner Remove and Install (S.N. —000470)

[1] -

LEGEND:
1 Screw (3 used)
2 Sun Visor
3 Plug (9 used)
E20 Dome Light
Cab Headliner
Remove self-locking screws (1) and remove sun visor (2).
[2] - Remove dome light (E20).
[3] - Remove plugs (3).
[4] - Remove headliner through rear window.
[6] - Install headliner.
[7] - Locate retainers through headliner and cab frame support and install plugs.
[8] - Install dome light.
[9] - Install sun visor and self-locking screws.

Cab Roof Remove and Install

Specifications
SPECIFICATIONS
6.78 N·m
Cab Roof Cap Screw Torque
60 lb.-in.
[2] -
Cab Roof
LEGEND:
1 Cap Screw
3 Washer (8 used)
4 Sealing Washer (8 used)
5 Lock Nut (8 used)
W3 Roof Ground
W17 Roof Harness
X26 Cab/Canopy Harness-to-Roof Harness Connector
Remove cap screw (1) and disconnect roof ground (W3).
[3] - Disconnect cab/canopy harness-to-roof harness connector (X26) from roof harness (W17).
[4] - Disconnect antenna. See Antenna Remove and Install . (Group 2001.)
[5] - Remove cap screws (2), washers (3), sealing washers (4), and lock nuts (5).
[6] - Remove cab roof.
[7] - Inspect for worn or damaged parts. Replace if necessary.
[8] - Install cab roof.

Section 18 - OPERATOR′S STATION Group 1821: Seat and Seat Belt
[9] - Install cap screws (2), washers, sealing washers, and lock nuts. Tighten to specification.
Cab Roof Cap Screw Torque 6.78 N·m
60 lb-in.
[10] - Connect antenna. See Antenna Remove and Install . (Group 2001.)
[11] - Connect cab/canopy harness-to-roof harness connector to roof harness.
[12] - Connect roof ground and install cap screw (1).

Group 1821 - Seat and Seat Belt

Seat Assembly Remove and Install
LEGEND:
1 Seat Base
2 Seat Position Sensor Electrical Connector
3 Air Seat Motor Electrical Connector
Seat Assembly
Specifications
SPECIFICATIONS
66 kg
Seat Assembly with Base Weight (approximate)
145 lb.
[2] - Remove floor mat.
[3] - Tag and disconnect seat position sensor electrical connector (2) and air seat motor electrical connector (3).
[4] - Remove cap screws (4) from seat base (1).
[5] -
CAUTION:
Use appropriate lifting device and remove seat assembly with seat belts through left cab door or canopy opening.
Seat Assembly with Base Weight (approximate) 66 kg
145 lb.
[7] - Install seat assembly using lifting device through left cab door or canopy opening.
[8] - Install cap screws to seat base.
[9] - Connect seat position sensor electrical connector and air seat motor electrical connector.
[10] - Install floor mat.

Mechanical Suspension Seat Disassemble and Assemble

→NOTE:
If only seat position sensor (B9) removal is needed See Seat Position Sensor Remove and Install . (Group
9015-20.)
Armrests and Cushion Removal

LEGEND:
2 Washer (4 used)
4 Seat Cushion
5 Armrest ( 2 used)
[1] - Remove cap screws (1), washers (2), and armrests (5).
[2] - Remove cap screws (3) and seat cushion (4).
[3] -

Upper Seat Assembly

LEGEND:
7 Lock Nut (4 used)
8 Seat Swivel Cable
9 Washer (4 used)
Remove cap screws (6), washers (9), and lock nuts (7).
[4] - Disconnect seat swivel cable (8) from seat swivel latch. Remove upper seat assembly.
[5] -

Seat Swivel Assembly

LEGEND:
11 Front Plate
12 Rear Plate
B9 Seat Position Sensor
Remove cap screws (10), front plate (11), and rear plate (12).
[6] - Disconnect 6-pin connector from seat position sensor (B9).
[7] - Remove cap screws (13) and swivel assembly.
[8] -

Seat Position Sensor—Exploded View

LEGEND:
34 Socket Head Screw (2 used)
35 Base (guide)
36 Swivel Seat Assembly
37 Lever
38 Screw (with locking nut)
Mark position of seat position sensor (B9).
→NOTE:
Lever (37) and seat position sensor are keyed.
Lever and base (35) removal is not necessary to remove seat position sensor.
[9] - Remove socket head screws (34), and seat position sensor.
→NOTE:
Lever (37) is attached (inserted) into base (35) using a friction fit only. Lever can be separated by lightly
pulling lever and base apart by hand and out of the center diameter of swivel seat assembly.
[10] - If needed, remove remaining components (35, 37, 38) from swivel seat assembly (36) as shown.
[11] -

Boot Removal
LEGEND:
15 Plastic Fastener (27 used)
16 Boot
Remove plastic fasteners (15) and boot (16).
[12] -

Upper Suspension Tray

LEGEND:
18 Lock Nut
19 Lower Pivot Shaft
Remove lock nut (18) and lower pivot shaft (19).
[13] - Remove upper suspension tray by sliding back until rollers clear channel and lifting up.
[14] -

Seat Pedestal
LEGEND:
21 Lock Nut (4 used)
22 Washer (4 used)
24 Lower Suspension Tray
Remove lock nuts (21), washers (22), and cap screws (23) from lower suspension tray (24).
[15] - Remove lower suspension tray from seat pedestal.
[16] -

Lower Suspension Tray and Spring Assembly

LEGEND:
25 Adjustment Gear
26 Adjustment Knob Assembly
29 Spring Assembly
30 Pin
31 Adjustment Shaft
32 Adjustment Plate
Remove adjustment gear (25), and adjustment knob assembly (26).
[17] - Remove lock nuts (27) and cap screws (28).
[18] - Remove spring assembly (29), pin (30), adjustment shaft (31), and adjustment plate (32).
[20] - Install adjustment plate, adjustment shaft, pin, and spring assembly.
[21] - Install adjustment knob assembly and adjustment gear.
[22] - Install cap screws (28) and lock nuts (27).
[23] - Install seat pedestal, cap screws (23), washers (22), and lock nuts (21) to lower suspension tray.
[24] - Install upper suspension tray, lower pivot shaft, and lock nut (18).
[25] - Install boot and plastic fasteners.
[26] - If removed, install seat position lever (37), base (35), and screw (38)

[27] -
→NOTE:
Line up raised keyway strip on seat position sensor to slot in end of lever (37) for proper engagement
and orientation.
Install seat position sensor (B9) to base (35) in seat swivel assembly (36) with socket head cap screws (34).
[28] - Install swivel assembly and cap screws (13).
[29] - Connect 6-pin connector to seat position sensor (B9).
[30] - Install rear plate (12), front plate (11), and cap screws (10).
[31] - Connect seat swivel cable to seat swivel latch. Install upper seat assembly.
[32] - Install cap screws (6), washers (9), and lock nuts (7).
[33] - Install cap screws (3) and seat cushion (4).
[34] - Install cap screws (1), washers (2), and armrests.

Air Suspension Seat Disassemble and Assemble—If Equipped

→NOTE:
If only seat position sensor (B9) removal is needed See Seat Position Sensor Remove and Install . (Group
9015-20.)
Armrests and Cushion Removal

LEGEND:
2 Washer (4 used)
4 Seat Cushion
5 Armrest ( 2 used)
[2] - Remove cap screws (1), washers (2), and armrests (5).
[3] - Remove cap screws (3) and seat cushion (4).
[4] -

Upper Seat Assembly

LEGEND:
7 Lock Nut (4 used)
8 Seat Swivel Cable
9 Washer (4 used)
Remove cap screws (6), washers (9), and lock nuts (7).
[5] - Disconnect seat swivel cable (8) from seat swivel latch. Remove upper seat assembly.
[6] -

Seat Swivel Assembly

LEGEND:
11 Front Plate
12 Rear Plate
Remove cap screws (10), front plate (11), and rear plate (12).
[7] - Disconnect 6-pin connector from seat position sensor (B9).
[8] - Remove cap screws (13) and swivel assembly.
[9] -

Seat Position Sensor—Exploded View

LEGEND:
34 Socket Head Screw (2 used)
35 Base (guide)
36 Swivel Seat Assembly
37 Lever
38 Screw (with locking nut)
Mark position of seat position sensor (B9).
→NOTE:
Lever (37) and seat position sensor are keyed.
Lever and base (35) removal is not necessary to remove seat position sensor.
[10] - Remove socket head screws (34), and seat position sensor.
→NOTE:
Lever (37) is attached (inserted) into base (35) using a friction fit only. Lever can be separated by lightly
pulling lever and base apart by hand and out of the center diameter of swivel seat assembly.
[11] - If needed, remove remaining components (35, 37, 38) from swivel seat assembly (36) as shown.
[12] -

Boot Removal
LEGEND:
16 Boot
Remove plastic fasteners (15) and boot (16).
[13] -

Upper Suspension Tray

LEGEND:
18 Lock Nut
19 Upper Pivot Shaft
Remove lock nut (18) and upper pivot shaft (19).
[14] - Remove upper suspension tray by lifting and moving tray forward until rollers clear channel.
[15] -

Seat Pedestal
LEGEND:
23 Seat Pedestal
Remove cap screws (21), lock nuts (22), and seat pedestal (23) from lower suspension tray.
[16] -

Lower Suspension Tray and Scissor Frame Assembly

LEGEND:
25 Elbow Fitting
26 Air Spring
27 Cap Screw
28 Lock Nut
29 Lower Pivot Shaft
Remove elbow fitting (25) from air spring (26).
[17] - Remove cap screw (27).
[18] - Remove air spring.
[19] - Remove lock nut (28) and lower pivot shaft (29).
[20] - Remove scissor frame assembly by turning and lifting assembly until rollers clear channel.
[21] - Inspect scissor frame components. Repair or replace as necessary.
[22] - Clean all bushings, rollers, and pivots. Lubricate with multipurpose grease.
[23] - Install scissor frame assembly, lower pivot shaft, and lock nut (28).
[24] - Install air spring and cap screw (27).
[25] - Install elbow fitting to air spring.
[26] - Install seat pedestal, cap screws (21), and lock nuts (22) to lower suspension tray.
[27] - Install upper suspension tray, upper pivot shaft, and lock nut (18).
[28] - Install boot and plastic fasteners.

Section 18 - OPERATOR′S STATION Group 1830: Heating and Air Conditioning
[29] - If removed, install seat position lever (37), base (35), and screw (38)
[30] -
→NOTE:
Line up raised keyway strip on seat position sensor to slot in end of lever (37) for proper engagement
and orientation.
Install seat position sensor (B9) to base (35) in seat swivel assembly (36) with socket head cap screws (34).
[31] - Install swivel assembly and cap screws (13).
[32] - Connect seat position sensor (B9) on bottom of swivel assembly.
[33] - Install rear plate (12), front plate (11), and cap screws (10).
[34] - Connect seat swivel cable to seat swivel latch. Install upper seat assembly.
[35] - Install cap screws (6), washers (9), and lock nuts (7).
[36] - Install cap screws (3) and seat cushion (4).
[37] - Install cap screws (1), washers (2), and armrests.
Seat Belt Disassemble and Assemble

[1] -
LEGEND:
2 Washer
3 Seat Belt Buckle
4 Seat Belt
5 Seat
Seat Belt Assembly

Remove cap screws (1) and washer (2).
[2] - Remove seat belt buckle (3) and seat belt (4) from seat (5).
[4] - Install seat belt buckle (3) and seat belt (4).
[5] - Install washer and cap screws to seat.

Group 1830 - Heating and Air Conditioning

R134a Refrigerant Cautions and Proper Handling
CAUTION:
DO NOT allow liquid refrigerant to contact eyes or skin. Liquid refrigerant will freeze eyes or skin on
contact. Wear goggles, gloves and protective clothing.
If liquid refrigerant contacts eyes or skin, DO NOT rub area. Splash large amounts of COOL water on
affected area. Go to a physician or hospital immediately for treatment.
DO NOT allow refrigerant to contact open flames or very hot surfaces such as electric welding arc,
electric heating element and lighted smoking materials.
DO NOT heat refrigerant over 52 °C (125 °F) in a closed container. Heated refrigerant will develop high
pressure, which can burst the container.
Keep refrigerant containers away from heat sources. Store refrigerant in a cool place.
DO NOT handle damp refrigerant container with your bare hands. Skin may freeze to container. Wear
gloves.
If skin freezes to container, pour COOL water over container to free the skin. Go to a physician or
hospital immediately for treatment.
IMPORTANT:
To meet government standards relating to the use of refrigerants, R134a is used in the air conditioning
system. Because it does not contain chlorine, R134a is not detrimental to the ozone in the atmosphere.
However, it is illegal to discharge any refrigerant into the atmosphere. It must be recovered using the
appropriate recovery stations.
Use correct refrigerant recovery/recycling and charging stations. Never mix refrigerants, hoses, fittings,
components or refrigerant oils.
IMPORTANT:
Use only John Deere approved R134a refrigerant products. Mixing of products not compatible will cause
system damage and contaminate recovery/recycling and charging station equipment. Care must be taken
to identify and use equipment, refrigerant oil and refrigerant designed only for R134a refrigerant
systems. Refrigerant should be tested for type and purity before recovery, recycling or charging of
system. JT02167A Prism Pro Refrigerant Identification Instrument should be used before any testing or
repair to system is performed.
Prism Pro Refrigerant Identification Instrument

JT02167A
To safely identify type and check purity of refrigerant prior to recovery, recycling and recharging of A/C systems.
R134a Compressor Oil Removal

[2] - Remove compressor from machine. See Compressor Remove and Install . (Group 1830.)
[3] - Drain oil into graduated container while rotating compressor shaft.
[4] - Record measured oil and discard oil properly.
[5] - Install new oil. See R134a Component Oil Charge . (Group 1830.)
[6] - Install compressor. See Compressor Remove and Install . (Group 1830.)

R134a Component Oil Charge

Specifications
SPECIFICATIONS
306 mL
210K Backhoe—Total System Oil Volume
10.35 fl. oz.
363 mL
310K-410K Backhoe—Total System Oil Volume
12.3 fl. oz.
319 mL
710K Backhoe—Total System Oil Volume
10.8 fl. oz.
Other Material
OTHER MATERIAL
TY22101 U.S. Low Viscosity (ISO 40) R134a PAG Oil
CAUTION:
Liquid refrigerant will freeze eyes or skin on contact. Wear goggles, gloves, and protective clothing. See
Refrigerant Cautions and Proper Handling . (Group 1830.)
CAUTION:
All new compressors are charged with a mixture of nitrogen and TY22101 (R134a) Refrigerant Oil. Wear
safety goggles and discharge the compressor slowly to avoid possible injury.
IMPORTANT:
DO NOT leave system or R134a compressor oil containers open. Refrigerant oil easily absorbs moisture.
DO NOT spill R134a compressor oil on acrylic or ABS plastic. This oil will deteriorate these materials
rapidly. Identify R134a oil containers to eliminate accidental mixing of different oils.
IMPORTANT:
Avoid adding more oil than required, or maximum cooling will be reduced.
→NOTE:
A compressor from parts depot contains 160 mL (5.4 fl. oz.) of new oil.
1. Determine if R134a leakage was detected. Remove and repair, or replace component. See Air Conditioning System Leak
Test . (Group 9031-25.)
→NOTE: Anytime air conditioning system is discharged, a new receiver-dryer and accumulator (if
equipped) must be installed.
Remove and discard receiver-dryer. See Receiver-Dryer Remove and Install . (Group 1830.)
→NOTE: Flush and purge air conditioning system only if machine had a catastrophic air conditioner
compressor malfunction.
→NOTE: Air conditioner compressor is not to be flushed and purged.
→NOTE: Determine if condenser is continuous loop or parallel flow style. Continuous loop style has
either multiple round tubes or an extruded serpentine construction. Use an adapter and connect
hoses at a continuous loop condenser. If condenser is parallel flow style construction, do not flush, it
should be replaced. A parallel flow condenser with potential blockages probably will not flush
completely and could result in system malfunction.
Flush and purge air conditioning system, only if needed. See Flush and Purge Air Conditioning System . (Group 1830.)
→NOTE: Anytime air conditioning system is discharged, a new receiver-dryer and accumulator (if
equipped) must be installed.

Install new receiver-dryer. See Receiver-Dryer Remove and Install . (Group 1830.)
5. Add required amount of TY22101 Refrigerant Oil to air conditioning system according to vehicle platform requirements
and type of service performed. Determine vehicle platform requirements by engine code and serial number.
210K Backhoe—Total System Oil Volume 306 mL
10.35 fl. oz.
310K-410K Backhoe—Total System Oil Volume 363 mL
12.3 fl. oz.
710K Backhoe—Total System Oil Volume 319 mL
10.8 fl. oz.
Number Name Use

⚬ TY22101 (us) Low Viscosity (ISO 40) R134a PAG Oil Lubricate R134a air conditioning system.
6. Type of service to perform:
Oil charge required for acceptable circuit flushing. Compressor type total system oil charge minus compressor oil
volume.
Measure any oil captured during system recovery and add this quantity of new oil back to system along with oil
quantities for particular replacement components.
Compressor replacement, other than catastrophic malfunction, measure oil volume drained from old compressor.
Drain oil from new compressor and add back to new compressor new oil of same volume as old oil.
Condenser replacement oil charge. Use formula 1.5 percent of specified system total oil charge to add.
Evaporator replacement oil charge. Use formula 56 percent of specified system total oil charge to add.
Receiver-dryer replacement oil charge. Use formula 4.5 percent of specified system total oil charge to add.
→NOTE: Hoses = 3 mL per 30 cm (0.1 fl. oz. per ft.)
Hose replacement oil charge. If any section of hose is removed and flushed or replaced, measure length of hose and
use formula 3 ml per 30 cm (0.1 fl. oz. per ft.) to determine correct amount of oil to add.
7. Evacuate and charge system. See Evacuate R134a System and see Charge R134a System . (Group 1830.)
Refrigerant Leakage Testing

[1] - Inspect all lines, fittings, and components for oily or dusty spots. When refrigerant leaks from system, a small amount of
oil is carried out with it.
[2] - A soap and water solution can be sprayed on components in system to form bubbles at source of leak.
[3] - If a leak detector is used, move leak detector probe under hoses and around connections at specified rate.
Electronic Leak Detector
JT02081
Used to detect refrigerant leaks.
[4] - Some refrigerant manufacturers add dye to refrigerant to aid in leak detection.
Refrigerant Hoses and Tubing Inspection

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

Procedure
CAUTION:
IMPORTANT:
Use only John Deere approved R134a refrigerant products. Mixing of products not compatible will cause
system damage and contaminate recovery/recycling and charging station equipment. Care must be taken
to identify and use equipment, refrigerant oil and refrigerant designed only for R134a refrigerant
systems. Refrigerant should be tested for type and purity before recovery/recycling or charging of
system. JT02167A Prism Pro Refrigerant Identification Instrument should be used before any testing or
repair to system is performed.
JT02167A
To safely identify type and check purity of refrigerant prior to recovery, recycling and recharging of air
conditioning systems.
IMPORTANT:
Use only John Deere approved refrigerant recovery/recycling and charging stations. DO NOT mix
refrigerant, hoses, fittings, components, or refrigerant oils.
[2] -
LEGEND:
1 High Pressure Charge Port Cap
2 Red Hose
3 Blue Hose
4 High Pressure Relief Valve
5 Refrigerant Recovery/Recycling and Charging Station

Charging Station Installation

Close both high-side and low-side valves on refrigerant recovery/recycling and charging station (5).
HFC134a Deluxe Recovery/Recycling and Charging Station

JT02045
Used to remove refrigerant from system.
Charging Station
JT02046
[ Used with JT02050 Recovery and Recycling Station. ]
Servicing air conditioning system using R134a refrigerant.

Recovery and Recycling Station
JT02050
[ Used with JT02046 Charging Station. ]
Servicing air conditioning system using R134a refrigerant.
[3] - Remove cap from low pressure charge port and connect blue hose (3) from refrigerant recovery/recycling and charging
station (5).
[4] - Remove high pressure charge port cap (1) and connect red hose (2).
[5] - Follow manufacturer′s instructions when using refrigerant recovery/recycling and charging station.
Recover R134a System
CAUTION:
Liquid refrigerant will freeze eyes or skin on contact. Wear goggles, gloves, and protective clothing.
See Refrigerant Cautions and Proper Handling . (Group 1830.)
IMPORTANT:
Use correct refrigerant recovery/recycling and charging stations. DO NOT mix refrigerant, hoses, fittings,
components or refrigerant oils.
[1] - Run air conditioning system for 3 minutes to help in recovery process. Turn air conditioning system off before proceeding
with recovery steps.
[2] - With engine OFF, identify refrigerant type using JT02167A Refrigerant Identification Instrument.
JT02167A
To safely identify type and check purity of refrigerant prior to recovery, recycling, and recharging of air conditioning systems.
[3] - Connect refrigerant recovery system. See R134a Refrigerant Recover, Recycle, and Charge Station Installation Procedure
. (Group 1830.
[4] - Follow manufacturer’s instructions when using refrigerant recovery/recycling and charging station.

Evacuate R134a System
CAUTION:
See R134a Refrigerant Cautions and Proper Handling . (Group 1830.)
[1] - Connect refrigerant recovery, recycling, and charging station. See R134a Refrigerant Recovery, Recycling, and Charging
Station Installation Procedure . (Group 1830.)
R134a Refrigerant Recovery/Recycling and Charging Station
[ JT02046 and JT02050 recovery and charging stations can be substituted for the JT02045 station. ]
JT02045
Removes refrigerant from system, recycles it and recharges it.
[2] - Open low-side and high-side valves on refrigerant recovery/recycling and charging station.
[3] - Follow manufacturer instructions and evacuate system.
[4] -
→NOTE:
The vacuum specifications listed are for sea level conditions. Subtract 3.4 kPa (34 mbar) (1 in. Hg) from
98 kPa (980 mbar) (29 in. Hg) for each 300 m (1000 ft) elevation above sea level.
Evacuate system until low pressure gauge registers specified vacuum.

If specified vacuum cannot be obtained in 15 minutes, check system for leaks. Repair any leaks.
Vacuum Pressure at Sea Level 98 kPa
980 mbar
29 in. Hg
Pressure Above Sea Level Subtract 3.4 kPa from 98 kPa for each 300 m elevation
Subtract 34 mbar from 980 mbar for each 300 m elevation
Subtract 1 in. Hg from 29 in. Hg for each 1000 ft elevation
[5] - When vacuum reaches specified level, close low-side and high-side valves. Turn vacuum pump off.
[6] - If vacuum decreases more than specified amount in 5 minutes, there is a leak in system.
Leak Present Decrease in Vacuum 3.4 kPa
34 mbar
1 in. Hg
[7] - Locate and repair leak.
[8] - Evacuate system for 30 minutes after initial specified vacuum is reached.
[9] - Close low-side and high-side valves. Stop evacuation.
[10] - Charge air conditioning system. See Charge R134a System . (Group 1830.)

Charge R134a System
CAUTION:
See Refrigerant Cautions and Proper Handling . (Group 1830.)
IMPORTANT:
Use only John Deere approved refrigerant recovery/recycling and charging stations. DO NOT mix
refrigerant, hoses, fittings, components, or refrigerant oils.
[1] - Identify refrigerant type using JT02167A Refrigerant Identification Instrument.

JT02167A
To safely identify type and check purity of refrigerant prior to recovery, recycling and recharging of air conditioning systems.
[2] - Connect JT02045 R134a refrigerant recovery, recycling, and charging station. See R134a Refrigerant Recover, Recycle,
and Charge Station Installation Procedure . (Group 1830.)
R134a Refrigerant Recovery/Recycling and Charging Station
[ JT02046 and JT02050 recovery and charging stations can be substituted for the JT02045 station. ]
JT02045
Removes refrigerant from system, recycles it and recharges it.
[3] - Evacuate system. See Evacuate R134a System . (Group 1830.)
[4] -
→NOTE:
Before beginning to charge air conditioning system, the following conditions must exist: Engine
STOPPED, pump must be capable of pulling at least 28.6 in. Hg vacuum (sea level). Subtract 3.4 kPa (34
mbar) (1 in. Hg) from 98 kPa (980 mbar) (29 in. Hg) for each 300 m (1000 ft) elevation above sea level.
Follow manufacturer instructions and charge system.
[5] -
→NOTE:
Recommended specification charge includes additional 0.11 kg (0.25 lb) of R134a refrigerant remaining in
charge station hoses.
Add refrigerant until system is charged to specification.

Refrigerant Charge (recommended) Capacity 2.5 kg
5.50 lb.
Refrigerant Charge (actual) Capacity 2.38 kg
5.25 lb.
[6] - Perform Air Conditioner Check. See Operational Checkout Procedure . (Group 9005.)
Air Conditioning System Cleaning Procedures

IMPORTANT:
Determine if condenser is continuous loop or parallel flow style. Continuous loop style has either multiple
round tubes or an extruded serpentine construction. Use an adapter and connect hoses at a continuous
loop condenser.
If condenser is parallel flow style construction, do not flush, it should be replaced. A parallel flow
condenser with potential blockages will not flush completely and could result in system malfunction.
Flushing
Flushing a component is a cleaning process using a liquid solvent to remove oil and debris. Purging is always necessary after
flushing to remove solvent from system or component.
Flushing air conditioner components is only necessary after following have occurred:
Catastrophic compressor failure.

System was left open to atmosphere long enough for dirt, moisture, or debris to enter tubing or components.
System was contaminated with a mixture of refrigerant oils.
System has an internal blockage.
Oil drained from compressor appears or smells overheated.
TY25601 ACC-Flush-II Flushing Solution is recommended for flushing air conditioner system components. Use only solvents with
an equivalent MSDS.
Number Name Use

• TY25601 (us) ACC-Flush-II Flushing Solution Used to flush R134a air conditioning system.
Purging
Purging system or a component is a cleaning process using a gas to force liquid from system. Purging alone will not remove
refrigerant oil from system.
Following is a list of situations that require a purging procedure be done:
After flushing system with solvent, to prevent oil dilution.

System was contaminated with nitrogen or two refrigerants.
System was left open to atmosphere and flushing could not be performed.
Installation of new lines, condenser, or evaporator was required.
Evacuating
Evacuating system is a process to remove air and moisture from system by creating a vacuum. See Evacuate R134a System .
(Group 1830.)

Flush and Purge Air Conditioning System

This procedure should only be performed on machines that have had a catastrophic air conditioner compressor malfunction.
Cleanup procedure must be performed prior to returning machine air conditioning system back into service.
CAUTION:
→NOTE:
Anytime air conditioning system is discharged, a new receiver-dryer and accumulator (if equipped) must
be installed.
[1] - Recover R134a refrigerant. See Recover R134a System . (Group 1830.)
[2] -
IMPORTANT:
DO NOT attempt to flush through compressor or receiver-dryer. Flushing solution may not be completely
removed from these components and could cause system malfunction.
Remove air conditioner compressor. See Compressor Remove and Install . (Group 1830.)
[3] -
→NOTE:
be installed.
Remove and discard receiver-dryer. See Receiver-Dryer Remove and Install . (Group 1830.)
[4] - Remove and discard expansion valve. See Expansion Valve Remove and Install . (Group 1830.)
[5] -
→NOTE:
loop condenser.
condenser with potential blockages probably will not flush completely and could result in system
malfunction.
Divide system into evaporator or condenser circuits, including hoses. Flush and purge procedure is same for both circuits.
[6] - Flush and purge air conditioner continuous loop condenser circuit:
Connect flusher outlet hose to inlet end of air conditioner compressor discharge line using adapter JT02102 Adaptor.
Adapter, O-Ring Tube
JT02102
Adapter to connect flusher outlet hose to inlet end of compressor discharge line.
Connect hoses at continuos loop condenser with an adapter from JT02098 Air Conditioning Fitting Kit.
Air Conditioning Flushing Kit
JT02098
Adapter to connect hoses at continuos loop condenser.
Attach a return hose and aerator nozzle to end of receiver-dryer inlet hose using JT03197 Reducer. Put nozzle in
container to collect flushing solvent.
Reducer Fitting, Straight

JT03197
Attach a return hose and aerator nozzle to outlet end of receiver-dryer inlet hose.
Add TY25601 ACC-Flush-II Flushing Solution to system with JT02075 Air Conditioning Flusher using fittings from
JT02098 Air Conditioning Fitting Kit.
Number Name Use
▪ TY25601 (us) ACC-Flush-II Flushing Solution Used to flush R134a air conditioning system.
Air Conditioning Flusher
JT02075
To be used with air conditioning flushing kit.
Air Conditioning Flushing Kit
JT02098
Flush air conditioning system and adjust expansion valve.
Fill air conditioning system flusher tank with 4 L (1 gal) of solvent and tighten all connections.
Air Conditioning System Flusher Tank Capacity 4L
1 gal
→NOTE: Air pressure must be at least 620 kPa (6.2 bar) (90 psi) for flushing and purging.
Air Conditioning System Air Pressure (minimum for flushing and purging) 620 kPa
6.2 bar
90 psi
Connect supply line of moisture-free compressed air or dry nitrogen to flusher air valve.
Open air valve to force flushing solvent into air conditioner circuit. Flusher tank is empty when hose pulsing stops.
Disconnect flusher tank and connect to flushed circuit discharge hose end.
IMPORTANT: Additional flushing cycles are required if system is heavily contaminated with
burned oil or metal particles.
Fill flusher tank and repeat flushing procedure in reverse direction.
→NOTE: Purging takes 10—12 minutes to thoroughly remove solvent.
Disconnect hose from aeration nozzle to check circuit for solvent. Hold discharge hose close to a piece of cardboard.
Continue purging until cardboard is dry, and proceed to next step.
Flush and purge air conditioner evaporator:
a. Remove evaporator. See Evaporator or Heater Core Remove and Install . (Group 1830.)
b. Follow same flush and purge procedure used on condenser, using adapters from JT02098 Air Conditioning Fitting Kit.
Adapter, O-Ring Tube
JT02102
Adapter to connect flusher outlet hose to inlet end of compressor discharge line.
c. Install evaporator and proceed to next step. See Evaporator or Heater Core Remove and Install . (Group 1830.)
[7] -
→NOTE:
be installed.
Install new receiver-dryer. See Receiver-Dryer Remove and Install . (Group 1830.)
[8] - Install new expansion valve. See Expansion Valve Remove and Install . (Group 1830.)
[9] -

→NOTE:
loop condenser.
condenser with potential blockages probably will not flush completely and could result in system
malfunction.
Install new condenser, if needed. See Condenser Remove and Install . (Group 1830.)
[10] - Install new compressor. See Compressor Remove and Install . (Group 1830.)
[11] - Add required R134a refrigerant oil to air conditioning system. See R134a Component Oil Charge . (Group 1830.)
[12] - Evacuate and charge air conditioning system. See Evacuate R134a System and see Charge R134a System . (Group
1830.)
Blower Mode Door Motor Remove and Install

[2] -
LEGEND:
2 Cap Screw
3 Defrost Air Duct
4 Front Console
Defrost Air Duct

Remove front console (4). See Front Console Remove and Install . (Group 1810.)
[3] - Remove cap screws (1 and 2).
[4] - Separate defrost air duct (3) from front console.
[5] -
LEGEND:
M11 Blower Mode Door Motor
W40 Blower Mode Door Motor Harness
Blower Mode Door Motor

Disconnect blower mode door motor harness (W40) from blower mode door motor (M11).
[6] - Remove cap screws (6) and blower mode door motor.
[8] - Install blower mode door motor and cap screws (6).
[9] - Connect blower mode door motor harness.
[10] - Install defrost air duct on front console and install cap screws (1 and 2).

Evaporator or Heater Core Remove and Install

LEGEND:
2 Middle Cover
Middle Cover
LEGEND:
4 Refrigerant hose (2 used)
Heater and Refrigerant Hoses
[1] - Lower all equipment to ground.
[2] - With engine off operate all controls to relieve pressure.
[3] - Drain radiator See Draining the Cooling System . (Operator′s Manual.)
[4] - Remove the floor mats.
[5] - Remove cap screws (1) on middle cover (2).
[6] - Remove middle cover (2).
[7] - Disconnect heater hoses (3) at heater core connectors (below cab floor) and drain heater core.
[8] - Disconnect refrigerant hoses (4) below cab floor.
[9] - Remove seat. See Seat Assembly Remove and Install . (Group 1821.)
LEGEND:
5 Air Filter Grille
8 Stabilizer Cover
9 Lower Console Cover
Evaporator Housing
[10] - Remove air filter grille (5) from lower console cover (9).

[12] - Remove stabilizer cover (8) and lower console cover (9).
[13] -
LEGEND:
11 Air Duct
14 Refrigerant Hose (2 used)
15 Evaporator
Evaporator
Remove cap screws (10) and remove air duct (11).
[15] - Disconnect heater hoses (13 ) and refrigerant hoses.
[16] -
CAUTION:
Wear gloves when removing and installing heater core to prevent cuts from fins on heater core.
Carefully remove the evaporator (15).
[17] - Repair or replace evaporator.
[18] - Install evaporator.
[19] - Install heater hoses and refrigerant hoses.
[21] - Reinstall air duct and cap screws (10).
[22] - Install lower console cover and cap screws (7).
[23] - Install stabilizer cover and cap screws (6).
[24] - Connect heater hoses at heater core connectors (below cab floor).
[25] - Connect refrigerant hoses.
[26] - Fill radiator with proper coolant. See Heavy Duty Diesel Engine Coolant . (Operator′s Manual.) Fill radiator to proper
level. See Filling the Cooling System . (Operator′s Manual.)
[27] - Check for leaks.

Expansion Valve Remove and Install

IMPORTANT:
A new receiver-dryer must always be installed after system is flushed or purged. DO NOT use a flushed or
used receiver-dryer. Contamination of system will cause component malfunction.
[2] - Relieve pressure to hydraulics. See Hydraulic Circuit Pressure Release . (Group 9025.)
[3] - Disconnect negative (-) battery cable or turn battery disconnect switch to OFF position. See Battery Disconnect—If
Equipped . (Operator’s Manual.)
[4] - Recover R134a from air conditioning system. See R134a Refrigerant Recover, Recycle, and Charge Station Installation
Procedure . (Group 1830.)
[5] - Remove floor mats.
[6] -
LEGEND:
5 Air Filter Grille
8 Stabilizer Cover
Lower Console Cover

Remove air filter grille (5) from lower console cover (9).
[8] - Remove stabilizer cover (8) and lower console cover (9).
[9] -
LEGEND:
10 Refrigerant Hose (2 used)
11 Cap Screw
12 Expansion Valve
Expansion Valve
Disconnect and tag refrigerant hoses (10). Close all openings using caps and plugs.
[10] - Remove cap screw (11) and expansion valve (12).
[12] - Install expansion valve (12) and cap screw (11).Tighten cap screw (11) to specification.
Cap Screw Torque 5.2—6.2 N·m

46—55 lb-in.
[13] - Install refrigerant hoses.
[14] - Install lower console cover and stabilizer cover.
[15] - Install cap screws (7 and 6).
[16] - Install air filter grille to lower console cover.
[17] - Install floor mats.
[18] - Install new receiver-dryer. See Receiver-Dryer Remove and Install . (Group 1830.)
[19] - Evacuate and charge air conditioning system. See Evacuate R134a System and see Charge R134a System . (Group
1830.)
[20] - Connect negative (-) battery cable or turn battery disconnect switch to ON position. See Battery Disconnect—If Equipped
. (Operator’s Manual.)

Air Conditioner Freeze Control Switch Remove and Install

LEGEND:
2 Washer (3 used)
4 Stabilizer Linkage Access Cover
Stabilizer Linkage Access Cover
[2] - Remove cap screws (1), washers (2), and cap screws (3).
[3] - Remove stabilizer linkage access cover (4).
[4] -
LEGEND:
5 Air Filter Grille
7 Washer (8 used)
Lower Console Cover

Remove air filter grille (5) from lower console cover (8).
[6] - Remove lower console cover.
[7] -
LEGEND:
11 Washer (2 used)
12 Upper Housing
13 Rubber Grommet
Upper Housing
Remove cap screws (10) and washers (11).

[8] - Remove upper housing (12).
[9] - Remove rubber grommet (13).
[10] -
LEGEND:
15 Temperature Sensor
B2 Air Conditioner Freeze Control Switch
Air Conditioner Freeze Switch

Disconnect temperature sensor (15) and remove from evaporator.
[11] - Remove cap screws (16) and air conditioner freeze control switch (B2).
[13] - Install air conditioner freeze control switch and cap screws.
[14] - Install temperature sensor to evaporator and rubber grommet.
[15] - Install upper housing, washers, and cap screws.
[16] - Install lower console cover, washers (7), and cap screws (6).
[17] - Install air filter grille to lower console cover.
[18] - Install stabilizer linkage access cover and cap screws (3).
[19] - Install washers (2) and cap screws (1).

Receiver-Dryer Remove and Install

[2] -
IMPORTANT:
A new receiver dryer must always be installed after system is flushed or purged. DO NOT use a flushed or
used receiver dryer. Contamination of system will cause component malfunction.
Open engine hood. See Opening and Closing Engine Hood . (Operator’s Manual)
Schrader Valve Tool
JT03130 Schrader Valve Tool
JT02130
Use to replace Schrader valve in A/C high and low pressure switches
[3] - Recover refrigerant from system. See Recover R134a System . (Group 1830.)
[5] -
LEGEND:
1 Tube Nut (2 used)
2 Refrigerant Line
3 Refrigerant Line
4 Clamp (2 used)
5 Receiver-Dryer
Receiver-Dryer Location
Loosen tube nuts (1).
[6] - Disconnect refrigerant lines (2 and 3). Close all openings using caps and plugs.
[7] - Loosen clamps (4).
[8] - Remove receiver-dryer (5).
→NOTE:
If air conditioning system is flushed or purged a new receiver dryer must be installed.
[9] - Clean components See Air Conditioning System Cleaning Procedures . (Group 1830.) Flush components, if needed see
Flush and Purge Air Conditioning System . (Group 1830.) Purge components, if needed see Flush and Purge Air Conditioning
System . (Group 1830.)
[10] - Install receiver-dryer.
[11] - Connect refrigerant lines and tighten tube nuts.
[12] - Tighten clamps.
[14] - Charge system. See Charge R134a System . (Group 1830.)
[15] -
IMPORTANT:
Hood must be closed before lowering the loader boom or damage to hood will result.
Close engine hood. See Opening and Closing Engine Hood . (Operator’s Manual).
[17] - Remove boom service lock and lower loader boom to ground.

Condenser Remove and Install

[2] -
CAUTION:
Prevent injury from unexpected machine movement. Install boom lock bar before working on machine
with loader boom in raised position.
Condenser
LEGEND:
1 Condenser Outlet Line
2 Condenser Inlet Line
3 Condenser
4 Fuel Cooler
6 Hood
7 Latch (2 used)
Latch
Raise loader boom and install boom lock bar.
[5] - Disconnect condenser outlet line (1) and condenser inlet line (2). Close all openings using caps and plugs.
[6] - Open hood (6), unhook latches on both sides (7), and close hood.
[7] - Remove cap screws (5) and condenser (3).
[9] - Repair or replace condenser as necessary.
[10] - Flush and purge components, if needed. See Flush and Purge Air Conditioning System . (Group 1830.)
[11] - Install condenser and cap screws.
[12] - Connect condenser inlet line and condenser outlet line.
[13] - Open hood, hook latches on both sides, and close hood.
[14] -

IMPORTANT:
Avoid system contamination. A new receiver-dryer must be installed after system is flushed or purged.
Install new receiver-dryer if air conditioning system was flushed or purged. See Receiver-Dryer Remove and Install . (Group
1830.)
[16] - Evacuate system see Evacuate R134a System . (Group 1830.) Charge system. See Charge R134a System . (Group
1830.)
[17] - Remove boom lock bar and lower loader boom to ground.

Compressor Remove and Install

Specifications
SPECIFICATIONS
120 N·m
Air Conditioner Compressor Mount Torque
89 lb.-ft.
[2] -
→NOTE:
Battery is accessed by removing top cover on left side step.
Disconnect negative (-) battery cable or turn battery disconnect switch to OFF position. See Battery Disconnect—If Equipped .
(Operator’s Manual.)
[3] -
CAUTION:
Prevent injury from unexpected machine movement. Install boom lock bar before working on machine
with loader boom in raised position.
Raise loader boom and install boom lock bar.
[4] - Open engine hood to full open position. See Opening and Closing Engine Hood . (Operator’s Manual.)
[7] -
LEGEND:
1 Pressure Line (to condenser)
2 Suction Line (from expansion valve)
3 Electrical Connector from Y19
5 Lock Nut (2 used)
6 Washer (2 used)
8 Air Conditioning Compressor
Air Conditioning Compressor

Disconnect pressure line (1) and suction line (2). Close all openings using caps and plugs.
[8] - Disconnect electrical connector from Y19 (3).
[9] - Remove cap screws (4), lock nuts (5), and washers (6).
[10] - Remove cap screws (7) and compressor (8).
[12] -
SHEET METAL AND STYLING (g) by Belgreen v2.0
IMPORTANT:
If compressor is being replaced due to an internal failure, flush and purge each component in air
conditioning system individually. See Air Conditioning System Cleaning Procedures . (Group 1830.)
Flush components, if needed. See Flush and Purge Air Conditioning System . (Group 1830.)
[13] - Purge system, if needed. See Flush and Purge Air Conditioning System . (Group 1830.)
[14] - Install compressor. Tighten cap screws (7) to specification.

Air Conditioner Compressor Mount Torque 120 N·m
89 lb.-ft.
[15] - Install cap screws (4), washers, and lock nuts. Tighten to specification.
Air Conditioner Compressor Mount Torque 120 N·m
89 lb.-ft.
[16] - Connect electrical connector from Y19.
[17] - Connect pressure and suction lines.
[18] - Install fan belt. See Serpentine Belt Remove and Install . (Group 0510.)
[19] -
IMPORTANT:
Avoid system contamination. A new receiver-dryer must be installed after system is flushed or purged.
Install new receiver-dryer if air conditioning system was flushed or purged. See Receiver-Dryer Remove and Install . (Group
1830.)
[21] - Charge system. See Charge R134a System . (Group 1830.)
[22] - Connect negative (-) battery cable or turn battery disconnect switch to ON position. See Battery Disconnect—If Equipped
[23] -
IMPORTANT:
Avoid damage to hood. Hood must be closed before lowering loader boom or damage to hood will result.
Close engine hood. See Opening and Closing Engine Hood . (Operator’s Manual.)
[24] - Remove boom lock bar and lower loader boom to ground.

Section 19 - SHEET METAL AND STYLING

Table of contents
Group 1910 - Hood or Engine Enclosure .............................................................................................. 1
Hood and Engine Enclosure Disassemble and Assemble ...................................................................... 1
Group 1913 - Miscellaneous Shields ..................................................................................................... 3
Battery Box Remove and Install ........................................................................................................... 3
Group 1921 - Grille and Grille Housing ................................................................................................. 8
Grille Remove and Install ...................................................................................................................... 8
Grille Housing Remove and Install ........................................................................................................ 8

Section 19 - SHEET METAL AND STYLING Group 1910: Hood or Engine Enclosure
Group 1910 - Hood or Engine Enclosure

Hood and Engine Enclosure Disassemble and Assemble
Specifications
SPECIFICATIONS
45 kg
Hood Assembly (210K) Weight (approximate)
121 lb.
32 kg
Hood Assembly (310K—410K) Weight (approximate)
85 lb.
65 N·m
Hood Pivot Cap Screw and Nut Torque
48 lb.-ft.
[4] -
CAUTION:
LEGEND:
1 Hood
2 Extension Spring (2 used)
3 Gas Operated Cylinder
5 Washer (2 used)
6 Lock Nut (2 used)
8 Washer (2 used)
9 Guide
10 Prop Rod
Hood and Engine Enclosure
Prop Rod and Guide

Attach appropriate lifting device to hood (1).

Section 19 - SHEET METAL AND STYLING Group 1913: Miscellaneous Shields
Hood Assembly (210K) Weight (approximate) 45 kg
121 lb.
Hood Assembly (310K—410K) Weight (approximate) 32 kg
85 lb.
[5] - Disconnect extension springs (2) at upper hook.
[6] - Disconnect gas operated cylinder (3) at upper mount.
[7] - Remove cap screws (4), washers (5), and lock nuts (6).
[9] - Separate guide (9) and prop rod (10) by sliding prop rod roller to hole at back of guide.
[10] - Remove hood using appropriate lifting device.
[12] - Install hood using appropriate lifting device.
[13] - Install prop rod roller into hole at back of guide. Install washers (8) and cap screws (7).
[14] - Install washers (5), cap screws (4), and lock nuts. Tighten to specification.
Hood Pivot Cap Screw and Nut Torque 65 N·m
48 lb.-ft.
[15] - Connect extension springs and gas operated cylinder.
[16] - Close hood.
[17] - Lower loader boom and install service lock. See Loader Boom Service Lock . (Operator’s Manual.)

Group 1913 - Miscellaneous Shields

Battery Box Remove and Install
Specifications
SPECIFICATIONS
29 kg
Battery Weight (approximate)
64 lb.
44 kg
Battery Box Weight (approximate)
96 lb.
Dual Batteries
[3] -
LEGEND:
2 Washer (3 used)
3 Tool Box
Tool Box
[4] - Remove tool box (3).
[5] -

LEGEND:
4 Negative (–) Battery Cable
5 Positive (+) Battery Cable
6 Flange Nut
7 Nut (4 used)
8 Washer (4 used)
9 Bracket (2 used)
G1 Battery 1
G2 Battery 2
Batteries
Disconnect negative (–) battery cable (4) first, then disconnect positive (+) battery cable (5).
[6] - Remove flange nut (6).
[7] - Remove nuts (7) and washers (8).
[8] - Remove brackets (9).
[9] -
CAUTION:
Remove battery 1 and battery 2 (G1 and G2) using appropriate lifting device.
Battery Weight (approximate) 29 kg
64 lb.
[10] -
LEGEND:
13 Washer (4 used)
14 Battery Box
A6000 Modular Telematics Gateway (MTG) Control Unit
F1 Main 250 A Fuse
Battery Box
Remove cap screws (10) and set main 250 A fuse (F1) and bracket aside.

[11] - Remove cap screws (11) and set modular telematics gateway (MTG) control unit (A6000) aside.
[12] -
CAUTION:
Support battery box (14) using appropriate lifting device.

Battery Box Weight (approximate) 44 kg
96 lb.
[14] - Remove battery box.
[16] - Install battery box, washers (13), and cap screws (12).
[17] - Install MTG control unit and cap screws (11).
[18] - Install main 250 A fuse, bracket, and cap screws (10).
[19] - Install batteries, brackets, washers (8), and nuts (7).
[20] - Install positive (+) battery cable first, then install negative (–) battery cable.
[21] - Install flange nut.
[22] - Install tool box, washers (2), and cap screws (1).
[23] - Remove service lock and lower boom to ground.
Single Battery
[3] -
LEGEND:
2 Washer (3 used)
3 Tool Box
Tool Box
[4] - Remove tool box (3).
[5] -
LEGEND:
4 Negative (–) Battery Cable
5 Positive (+) Battery Cable
6 Flange Nut
7 Nut (2 used)
8 Washer (2 used)
9 Bracket
G1 Battery 1
Battery
Disconnect negative (–) battery cable (4) first, then disconnect positive (+) battery cable (5).
[6] - Remove flange nut (6).
[7] - Remove nuts (7) and washers (8).
[8] - Remove bracket (9) and lay aside.
[9] -
CAUTION:
Remove battery 1 (G1) using appropriate lifting device.

Battery Weight (approximate) 29 kg
64 lb.
[10] -

Section 19 - SHEET METAL AND STYLING Group 1921: Grille and Grille Housing
LEGEND:
12 Washer (4 used)
13 Battery Box
A6000 Modular Telematics Gateway (MTG) Control Unit
Battery Box
Remove cap screws (10) and set modular telematics gateway (MTG) control unit (A6000) aside.
[11] -
CAUTION:
Support battery box (13) using appropriate lifting device.

Battery Box Weight (approximate) 44 kg
96 lb.
[13] - Remove battery box.
[15] - Install battery box, washers (12), and cap screws (11).
[16] - Install MTG control unit and cap screws (10).
[17] - Install batteries, bracket, washers (8), and nuts (7).
[18] - Install positive (+) battery cable first, then install negative (–) battery cable.
[19] - Install flange nut.
[20] - Install tool box, washers (2), and cap screws (1).
[21] - Remove service lock and lower boom to ground.

SAFETY AND CONVENIENCE (g) by Belgreen v2.0
Group 1921 - Grille and Grille Housing

Grille Remove and Install
LEGEND:
2 Washer (4 used)
3 Grille
Grille Remove and Install
[4] - Remove grille (3).
[6] - Install grille, washers, and cap screws.
Grille Housing Remove and Install

For grille housing remove and install, see Cooling Package Remove and Install . (Group 0510.)

Section 20 - SAFETY AND CONVENIENCE

Table of contents
Group 2001 - Radio .................................................................................................................................. 1
Radio and Speakers Remove and Install .............................................................................................. 1
Antenna Remove and Install ................................................................................................................. 2
Group 2004 - Horn and Warning Devices ............................................................................................. 3
Horn Remove and Install ...................................................................................................................... 3
Backup Alarm Remove and Install ........................................................................................................ 3
Backup Alarm Volume Adjustment ....................................................................................................... 4

Section 20 - SAFETY AND CONVENIENCE Group 2001: Radio
Group 2001 - Radio

Radio and Speakers Remove and Install
[2] - Remove headliner. See Headliner Remove and Install . (Group 1810.)
[3] -
LEGEND:
1 Wire Harness Connector (2 used)
3 Speaker (2 used)
Speaker Location
Disconnect wire harness connectors (1) from speaker (3).
[5] - Remove speaker, repair or replace as necessary.
[6] - Install speakers and cap screws.
[7] - Connect wire harness connector to each speaker.
[8] -
LEGEND:
4 Antenna Coaxial Cable
5 Radio Connector
6 Cap Screw
7 Bracket
Radio Removal
Disconnect antenna coaxial cable (4) and radio connector (5).
[9] - Remove cap screws (6) from bracket (7).
[10] - Remove radio from bracket.
[12] - Install radio onto mounting bracket.
[13] - Install bracket and cap screws.
[14] - Connect antenna coaxial cable and radio connector.
[15] - Install headliner. See Headliner Remove and Install . (Group 1810.)

Section 20 - SAFETY AND CONVENIENCE Group 2004: Horn and Warning Devices
Antenna Remove and Install

LEGEND:
1 Cap Screw
2 Washer
3 Antenna
4 Antenna Cable
5 Grommet
Antenna Location
Specifications
SPECIFICATIONS
Antenna
1.3 N·m
Antenna Pivot Torque
12 lb.-in.
[2] - Loosen cap screw (1) and washer (2), and move antenna (3) to horizontal position.
[3] - Remove cap screw and washer, slide over antenna to remove antenna base from bracket.
[4] - Remove headliner. See Headliner Remove and Install . (Group 1810.)
[5] - Disconnect antenna cable (4) from radio.
[6] - From outside cab pull antenna cable through grommet (5) in cab.
[7] - Install antenna cable through grommet in cab and connect to radio.
[8] - Install headliner. See Headliner Remove and Install . ( Group 1810.)
[9] - Install antenna, washer, and cap screw.
[10] - Move antenna to upright position and tighten cap screw to specification.
Antenna
Antenna Pivot Torque 1.3 N·m
12 lb.-in.

Group 2004 - Horn and Warning Devices

Horn Remove and Install
Horn Location
LEGEND:
1 Electrical Connector (2 used)
2 Cap Screw
H40 Horn
[2] - Raise loader boom and install boom service lock.
[3] - Open engine hood to full open position. See Opening and Closing Engine Hood . (Operator’s Manual.)
[4] -
→NOTE:
Horn is located on left side above radiator in engine compartment.
Disconnect electrical connectors (1).
[5] - Remove cap screw (2) and horn (H40).
[7] - Install horn and cap screw.
[8] - Connect electrical connectors.
[9] - Close engine hood. See Opening and Closing Engine Hood . (Operator’s Manual.)
[10] - Remove boom service lock and lower loader boom to ground.
Backup Alarm Remove and Install

LEGEND:
1 Lock Nut (2 used)
3 Electrical Connector (2 used)
H3 Backup Alarm
Backup Alarm
→NOTE:
Backup alarm is located inside main frame on left-rear side.
[2] - Remove lock nuts (1) and cap screws (2).
[3] - Tag and disconnect electrical connectors (3).
[4] - Remove backup alarm (H3)
[6] - Reconnect electrical connectors and install backup alarm.
[7] - Install lock nuts and cap screws.
Backup Alarm Volume Adjustment

LEGEND:
1 Nut
2 Nut
4 Shorting Bar
5 Backup Alarm
Backup Alarm Volume Adjustment
IMPORTANT:
The backup alarm is set on high volume at the factory. It may be necessary to adjust the volume to meet
local regulations.
The procedure will change the factory set high volume to low volume.
[1] - Remove backup alarm. See Backup Alarm Remove and Install . (Group 2004.)
[2] - Remove nut (2) and electrical connector (3) from shorting bar (4).
[3] - Remove nut (1) and shorting bar from backup alarm.

MAIN HYDRAULIC SYSTEM (g) by Belgreen v2.0
[4] - Install electrical connector to terminal stud with existing nuts.
[5] - Install backup alarm. See Backup Alarm Remove and Install . (Group 2004.)

Section 21 - MAIN HYDRAULIC SYSTEM

Table of contents
General Oil Cleanup Procedure ............................................................................................................. 1
Apply Vacuum to Hydraulic Oil Reservoir ............................................................................................. 2
Hydraulic Pump Remove and Install ..................................................................................................... 4
Hydraulic Pump Disassemble and Assemble ........................................................................................ 6
Hydraulic Reservoir Remove and Install ............................................................................................... 9
Hydraulic and Transmission Oil Coolers Remove and Install .............................................................. 13
Hydraulic Filter Assembly Remove and Install .................................................................................... 16

Section 21 - MAIN HYDRAULIC SYSTEM Group 2160: Hydraulic System

General Oil Cleanup Procedure
Essential Tools
ESSENTIAL TOOLS
JDG10712 Super Caddy
This procedure is to be used on machines that have had hydraulic system repair without a catastrophic component failure.
Filter caddy procedure must be done prior to starting machine after a component has been repaired or replaced.
IMPORTANT:
Intermixing of oils can cause premature hydraulic component damage and oil contamination. Oil types
and filters must not be intermixed. Use filter element in same type oil to avoid intermixing of oils.
Oil contamination could result if filter caddy is used in dusty or wet conditions. Clean work practices and
cleanliness of filter caddy and attachments are critical when filtering oil.
→NOTE:
Filter oil should be at 27°C (80°F) or above for best Super Caddy ™ performance. Reduce flow rate to
filter oil below 27°C (80°F).
Super Caddy requires a 20-amp electric circuit. Use of electrical extension cord is not recommended.
[1] -
→NOTE:
Park machine in an area that will allow all hydraulic functions to be operated.
[2] - Clean exterior of oil fill cap and surrounding area to prevent contamination.
[3] - Remove hydraulic oil reservoir cap.
[4] -
→NOTE:
When installing suction and discharge wands into the hydraulic oil reservoir, locate the submerged ends
of the wands as far away from each other as possible to ensure maximum oil movement during cleanup
procedure.
Install suction and discharge wands from JDG10712 Super Caddy into the hydraulic oil reservoir through the oil fill tube.
Super Caddy
JDG10712
Used to clean hydraulic oil
[5] - Seal suction and discharge wands to oil fill tube to secure wands to hydraulic oil reservoir and prevent contamination.
[6] -
CAUTION:
Prevent possible personal injury from unexpected machine movement. Clear all persons from area before
operating machine.
Avoid entanglement and possible electrocution from filter caddy power cord. Do not operate machine
while filter caddy is connected to machine.
Use JDG10712 Super Caddy to remove oil contaminants. Refer to the Super Caddy operator′s manual or see Super Caddy in
Service ADVISOR ™ for operating procedure.

[7] - When cleaning process is done, disconnect Super Caddy from machine.
[8] - Fill hydraulic oil reservoir to operating level. See Check Hydraulic Reservoir Oil Level . (Operator′s Manual.)
[9] - Run machine at slow idle. Operate each circuit a minimum of 2 minutes in each direction to flush any remaining
contaminants back through hydraulic system filters.
[10] - Stop engine. Install Super Caddy to machine as before.
[11] - Repeat Super Caddy operation procedure until contaminant value is at specifications per Super Caddy operator′s manual
or see Super Caddy in Service ADVISOR for operating procedure.
[12] - When oil reaches an acceptable level of cleanliness, disconnect Super Caddy from machine.
[13] - Install new hydraulic oil filter. See Replace Hydraulic Oil Filter . (Operator’s Manual.)
[14] -
→NOTE:
Instrument cleanliness and clean work practices are critical when taking oil samples. Dust, wind, and
moisture, as well as contaminated sample pumps, bottles, and tubing, can affect results.
Obtain oil sample for fluid analysis. Oil sample must be taken from system before oil passes through the filter when oil is warm.
See Take Fluid Samples . (Operator′s Manual.)
[15] - Fill hydraulic oil reservoir to proper operating level. See Check Hydraulic Reservoir Oil Level . (Operator′s Manual.)
[16] - Return machine to service.
Apply Vacuum to Hydraulic Oil Reservoir

Essential Tools
ESSENTIAL TOOLS
D15032NU Vacuum Pump Kit
[2] -
LEGEND:
1 Vent Hose
2 Hydraulic Oil Reservoir Fill Tube
Hydraulic Oil Reservoir Fill Tube

Hydraulic Oil Reservoir Fill Tube Connection

Disconnect vent hose (1) from hydraulic oil reservoir fill tube (2).
[3] - Connect D15032NU Vacuum Pump Kit or equivalent to hydraulic oil reservoir fill tube as shown.
Vacuum Pump Kit
D15032NU
Create vacuum in hydraulic oil reservoir
[4] - Refer to pump instructions for operating information.

Hydraulic Pump Remove and Install

Specifications
SPECIFICATIONS
26 kg
Hydraulic Pump Weight (approximate)
57 lb.
130 N·m
Hydraulic Pump Mounting Cap Screw Torque
96 lb.-ft.
[2] -
CAUTION:
pressure.
[3] - Disconnect battery negative (-) ground cable or turn battery disconnect switch (if equipped) to the OFF position. See
[4] - Drain hydraulic oil reservoir. See Change Hydraulic Reservoir Oil . (Operator’s Manual.)
[5] - Remove rear drive shaft. See Universal Joint and Drive Shaft Remove and Install . (Group 0225.)
[6] -

Hydraulic Pump Removal

LEGEND:
1 Hydraulic Low Pressure Supply Hose
2 Hydraulic Pressure Supply Hose
70 Transmission
110 Hydraulic Oil Reservoir
113 Hydraulic Pump
Y56 Hydraulic Pump Control Solenoid
Tag and disconnect hydraulic hoses (1 and 2). Close all openings using caps or plugs.
[7] - Disconnect hydraulic pump control solenoid (Y56) electrical connector.
CAUTION:
Prevent possible crushing injury from heavy component. Use an appropriate lifting device.
[8] - Secure hydraulic pump (113) with appropriate lifting device.

Hydraulic Pump Weight (approximate) 26 kg
57 lb.
[9] - Remove cap screws (3) and hydraulic pump (113).
[10] -
→NOTE:
Only serviceable parts are seal kits and O-rings.
Repair or replace hydraulic pump as necessary.
[11] - Install new O-ring between hydraulic pump and transmission.
[12] -
CAUTION:
Prevent possible crushing injury from heavy component. Use an appropriate lifting device.
Install hydraulic pump with appropriate lifting device
[13] - . Install cap screws and tighten to specification.

Hydraulic Pump Mounting Cap Screw Torque 130 N·m
96 lb.-ft.
[14] - Connect hydraulic pump control solenoid (Y56) electrical connector.
[15] - Connect hydraulic hoses.
[16] - Install rear drive shaft. See Universal Joint and Drive Shaft Remove and Install . (Group 0225.)
[17] - Fill hydraulic reservoir. See Change Hydraulic Reservoir Oil . (Operator’s Manual.)

Hydraulic Pump Disassemble and Assemble

Specifications
SPECIFICATIONS
271 N·m
Nut-to-Stud Torque
200 lb.-ft.
61 N·m
Unloader Relief Valve Torque
45 lb.-ft.
181 N·m
Pump Section Cap Screw Torque
134 lb.-ft.
Other Material
OTHER MATERIAL
TY16135 Loctite ™ ULTRA BLUE ™ RTV Silicone Form-In-Place Gasket
[1] -

Hydraulic Pump Disassembled

LEGEND:
1 Port End Housing
2 Gear Housing
3 Unloader Valve
4 Gear Housing
5 Shaft End Cover
7 Washer (4 used)
8 Channel Backup Seal (2 used)
9 Channel Seal (2 used)
10 Thrust Plate (2 used)
11 Gasket Seal (2 used)
12 Matched Gear Set
13 Connecting Shaft
14 Check Valve
15 O-Ring
16 Relief Valve
17 Spring
18 Spool
19 Plug
20 Nut (4 used)
21 Washer (4 used)
22 Channel Backup Seal (2 used)
23 Channel Seal (2 used)
24 Thrust Plate (2 used)
25 Gasket Seal (2 used)
26 Matched Gear Set
27 Drive Shaft Seal
28 Air Vent
29 Fitting
Y56 Hydraulic Pump Control Solenoid
Clean outside of pump to prevent contamination to internal components.
[2] - Mark port end housing (1), gear housings (2 and 4), unloader valve (3), and shaft end cover (5) to aid in assembly.
[3] - Mount pump in bench vice with shaft pointing down and vice jaws camping pump mounting flanges.
[4] - Remove cap screws (6), washers (7), and port end housing.
[5] - Remove channel backup seals (8), channel seals (9), thrust plates (10), gasket seals (11), gear housing (2), matched gear
set (12), and connecting shaft (13).
[6] - Remove check valve (14) and O-ring (15).
[7] - Remove hydraulic pump control solenoid (Y56) and spool.
[8] - Remove relief valve (16), spring (17), spool (18), and plug (19).
[9] - Remove nuts (20), washers (21), and unloader valve.
[10] - Remove channel backup seals (22), channel seals (23), thrust plates (24), gasket seals (25), and matched gear set (26).
[11] - Remove drive shaft seal (27).
[12] - Remove air vent (28) and fitting (29).
[13] - Inspect parts for contamination, wear, or damage. Replace as necessary.
[14] - Install fitting and air vent.
[15] - Apply 58730 ULTRA BLUE RTV Silicone Form-in-Place gasket to drive shaft seal OD and bore ID.
Number Name Use

• TY16135 (us) 58730 Loctite ™ ULTRA BLUE ™ RTV Silicone Form-In-Place Gasket Form gasket around seal

[16] - Install drive shaft seal.
[17] - Install matched gear set (26), gasket seals (25), thrust plates (24), channel seals (23), and channel backup seals (22).
[18] - Install unloader valve, washers (21), and nuts (20). Tighten to specification in a cross pattern.
Nut-to-Stud Torque 271 N·m
200 lb.-ft.
[19] - Install plug, spool, and spring, and relief valve.
[20] - Install relief valve. Tighten to specification.

Unloader Relief Valve Torque 61 N·m
45 lb.-ft.
[21] - Install hydraulic pump control solenoid and spool.
[22] - Install O-ring and check valve.
[23] - Install connecting shaft, matched gear set (12), gear housing, gasket seals (11), thrust plates (10), channel seals (9),
and channel backup seals (8).
[24] - Install port end housing, washers (7), and cap screws. Tighten to specification in a cross pattern.
Pump Section Cap Screw Torque 181 N·m
134 lb.-ft.

Hydraulic Reservoir Remove and Install

Specifications
SPECIFICATIONS
32 kg
Hydraulic Oil Reservoir Weight (approximate)
70 lb.
JT01748 Lifting Bracket
LEGEND:
2 Engine Control Unit Mounting Plate
Engine Control Unit
[2] -
CAUTION:
pressure.
Release pressure in hydraulic system. See Hydraulic Circuit Pressure Release . (Group 9025-25.)
[3] - Switch battery disconnect to OFF (if equipped) or disconnect the battery ground cable. See Battery Disconnect—If
[5] - Remove cab or canopy. See Operator′s Station Remove and Install . (Group 1800.)
[6] - Remove cap screws (1) and engine control unit mounting plate (2) from hydraulic reservoir.
[7] -

Hydraulic Oil Reservoir Hoses and Isolator

LEGEND:
3 Hydraulic Pump Supply Hose
4 Attachment Coupler Return Hose (if equipped)
5 Ride Control Return Hose (if equipped)
6 Hydraulic Oil Filter Return Hose
7 Loader Auxiliary Manifold Return Hose (if equipped)
8 Brake Valve Return Hose
9 Hydraulic Oil Cooler Supply Hose
10 Hydraulic Oil Reservoir Drain Hose
13 Isolator
B10 Hydraulic Oil Temperature Sensor (if equipped)
Disconnect hoses (3—9). Close all openings using caps and plugs.
[8] - Disconnect electrical connector to hydraulic oil temperature sensor (B10), if equipped.
[9] - Remove plastic fasteners (11), cap screws (12), and isolator (13).
[10] -

LEGEND:
15 Hood Cowling
Cowling Removal
Remove cap screws (14) and hood cowling (15).
[11] -
LEGEND:
16 Vent Hose
18 Rear Hood Cowling Support
Rear Cowling Support

Disconnect vent hose (16) from hydraulic reservoir fill tube.
[12] - Remove cap screws (17) and rear hood cowling support (18).
[13] -
LEGEND:
19 Lift Point
Hydraulic Oil Reservoir Cap Screws and Lift Point

Install JT01748 Lifting Bracket to lift point (19).

Lifting Bracket
JT01748
Used to remove and install reservoir.
[15] -
CAUTION:
Raise hydraulic oil reservoir with hoist slightly to provide access to hydraulic oil reservoir drain hose (10).
Hydraulic Oil Reservoir Weight (approximate) 32 kg
70 lb.
[16] - Disconnect drain hose. Close all openings using caps and plugs.
[17] - Remove hydraulic oil reservoir.
[19] - Move hydraulic oil reservoir into position slightly above standard placement and connect hydraulic pump supply hose
and hydraulic oil reservoir drain hose.
[20] - Install hydraulic oil reservoir and cap screws.
[21] - Remove hoist and lifting bracket.
[22] - Install rear cowling support and cap screws.
[23] - Connect vent hose to hydraulic reservoir fill tube.
[24] - Install hood cowling and cap screws.
[25] - Install isolator, cap screws, and plastic fasteners.
[26] - Connect remaining hoses and hydraulic oil temperature sensor (if equipped).
[27] - Install engine control unit mounting plate and cap screws.
[28] - Install cab or canopy. See Operator′s Station Remove and Install . (Group 1800.)
[29] - Fill hydraulic oil reservoir. See Change Hydraulic Reservoir Oil . (Operator′s Manual.)
[30] - Switch battery disconnect to ON (if equipped) or connect the battery ground cable. See Battery Disconnect—If Equipped

Hydraulic and Transmission Oil Coolers Remove and Install

Hydraulic Oil Cooler Remove
[2] -
CAUTION:
pressure.
[4] - Drain coolant. See Draining the Cooling System . (Operator’s Manual.)
[6] -
Hydraulic and Transmission Oil Coolers

LEGEND:
2 Hydraulic Oil Cooler Return Hose
3 Coolant Hose
4 Coolant Hose
6 Coolant Hose
7 Transmission Hose (2 used)
39 Transmission Oil Cooler
120 Hydraulic Oil Cooler
Tag and disconnect hydraulic hoses (1 and 2) and coolant hoses (3 and 4). Close all openings using caps and plugs.
[7] - Remove cap screws (5) and hydraulic oil cooler (120).
Hydraulic Oil Cooler Install
[1] - Install hydraulic oil cooler and cap screws (5).
[2] - Connect hydraulic (1 and 2) and coolant hoses (3 and 4).
[3] - Fill hydraulic oil reservoir. See Change Hydraulic Reservoir Oil . (Operator’s Manual.)
[4] - Fill coolant system. See Filling the Cooling System . (Operator’s Manual.)
Transmission Oil Cooler Remove
[1] -
Hydraulic and Transmission Oil Coolers

LEGEND:
2 Hydraulic Oil Cooler Return Hose
3 Coolant Hose
4 Coolant Hose
6 Coolant Hose
7 Transmission Hose (2 used)
39 Transmission Oil Cooler
120 Hydraulic Oil Cooler
Remove hydraulic oil cooler, see Hydraulic Oil Cooler Remove at beginning of this procedure.
[2] - Tag and disconnect coolant hoses (3 and 6). Close all openings using caps or plugs.
[3] -
→NOTE:
If hose clamps are inaccessible from underneath machine, remove front floor mat and floor access panel
to access hose clamps.
Tag and disconnect transmission hoses (7). Close all openings using caps or plugs.
[4] - Remove cap screws (8) and transmission oil cooler (39).
Transmission Oil Cooler Install
[1] - Install transmission oil cooler and cap screws (8).
[2] - Connect transmission hoses.
[3] - Connect coolant hoses (3 and 6).
[4] - Install hydraulic oil cooler, see Hydraulic Oil Cooler Install at beginning of this procedure.
[5] - Check transmission oil level. See Check Transmission Oil Level . (Operator’s Manual.)

Hydraulic Filter Assembly Remove and Install

[2] -
CAUTION:
Avoid High Pressure Fluids

pressure.
[4] - Drain hydraulic oil reservoir or apply vacuum. See Change Hydraulic Reservoir Oil . (Operator’s Manual.)
[6] -
LEGEND:
2 Floor Access Panel
Floor Access Panel (310K floor access panel shown)

Remove cap screws (1) and floor access panel (2).
[7] -

Hydraulic Filter Assembly
Hydraulic Filter Assembly (view from access panel)

LEGEND:
3 Backhoe Control Valve-to-Hydraulic Oil Filter Hose
4 Loader and Stabilizer Control Valve-to-Hydraulic Oil Filter Hose
5 Hydraulic Oil Filter-to-Hydraulic Oil Cooler Hose
6 Hydraulic Oil Filter-to-Hydraulic Oil Reservoir Hose
118 Hydraulic Oil Filter

LOADER (g) by Belgreen v2.0
B12 Hydraulic Oil Filter Restriction Switch

Rotate hydraulic oil filter (118) counterclockwise to remove.
[8] - Tag and disconnect hoses (3—5). Close all openings using caps and plugs.
[9] - Disconnect hydraulic oil filter-to-hydraulic oil reservoir hose (6).
[10] -
IMPORTANT:
Hydraulic filter restriction switch (B12) connector is hidden. To prevent possible damage to wiring and
switch, support filter assembly when removing cap screws.
Support hydraulic filter assembly and remove cap screws (7).
[11] - Disconnect electrical connector from hydraulic oil filter restriction switch (B12) and remove hydraulic filter assembly.
[13] - Connect electrical connector to hydraulic oil filter restriction switch.
[14] - Install hydraulic oil filter assembly and cap screws.
[15] - Connect hoses.
[16] - Install floor access panel and cap screws.
[18] - Apply clean hydraulic oil to filter seal. Turn hydraulic oil filter clockwise until seal touches base and tighten additional 3/4
turn.
[19] - Fill hydraulic oil reservoir or remove vacuum.
[20] - Check hydraulic oil level. See Check Hydraulic Reservoir Oil Level . (Operator′s Manual)

Section 31 - LOADER
Table of contents
Group 3100 - Loader ................................................................................................................................ 1
Loader Boom Remove and Install ......................................................................................................... 1
Group 3102 - Bucket ................................................................................................................................ 4
Loader Bucket Remove and Install ....................................................................................................... 4
Welded Bucket Cutting Edges Replacement Procedure ....................................................................... 5
Group 3115 - Control Linkage ................................................................................................................ 6
Loader Control Valve Linkage Remove and Install—Two Function ....................................................... 6
Single Lever Loader Auxiliary Control Lever Remove and Install .......................................................... 8
Manual Third Function Loader Control Valve Linkage Remove and Install ......................................... 10
Stabilizer Linkage Remove and Install (S.N. —000470) ...................................................................... 13
Loader Bucket Cylinder Linkage Remove and Install .......................................................................... 15
Loader Bucket Self-Leveling Linkage and Return-to-Dig Switch Adjustment ...................................... 16
Loader and Stabilizer Control Valve Remove and Install .................................................................... 17
Loader and Stabilizer Control Valve Spool Disassemble and Assemble .............................................. 20
Loader and Stabilizer Control Valve Relief Valves Remove and Install ............................................... 32
Loader Boom Anticavitation Valve Disassemble and Assemble .......................................................... 34
Loader Boom Raise and Bucket Curl Circuit Relief Valve Disassemble and Assemble ........................ 37
Loader Bucket Dump Circuit Relief Valve With Anticavitation Disassemble and Assemble ................ 39
Loader Auxiliary Circuit Relief Valve Disassemble and Assemble ....................................................... 41
Loader Auxiliary Shutoff Plug Disassemble and Assemble ................................................................. 42
Loader Boom Cylinder Remove and Install ......................................................................................... 44
Loader Boom Cylinder Disassemble and Assemble ............................................................................ 45
Loader Bucket Cylinder Remove and Install ....................................................................................... 46
Loader Bucket Cylinder Disassemble and Assemble .......................................................................... 48
Loader Multi-Purpose Bucket Cylinder Disassemble and Assemble .................................................... 48
Loader Auxiliary Manifold Remove and Install .................................................................................... 50
Ride Control Valve Remove and Install ............................................................................................... 52
Ride Control Valve Disassemble and Assemble .................................................................................. 54
Ride Control Valve Solenoid Disassemble and Assemble ................................................................... 55
Ride Control Accumulator Remove and Install ................................................................................... 56

Section 31 - LOADER Group 3100: Loader
Group 3100 - Loader

Loader Boom Remove and Install
LEGEND:
1 Location (rear lifting point)
2 Cross Tube
3 Location (front lifting point)
Loader Lifting Points
Specifications
SPECIFICATIONS
399 kg
Loader Boom Weight (approximate)
880 lb.
57 kg
Boom Cylinder Weight (approximate)
126 lb.
[2] - Release pressure in hydraulic system. See Hydraulic Circuit Pressure Release . (Group 9025-25.)
[3] -
CAUTION:
Be careful when removing bucket linkage pins. Linkage can fall and cause bodily injury. If necessary,
support bucket linkage using blocks.
Remove loader linkage. See Loader Bucket Cylinder Linkage Remove and Install . (Group 3115.)
[4] - Remove bucket cylinder. See Loader Bucket Cylinder Remove and Install . (Group 3160.)
[5] - Remove bucket. See Loader Bucket Remove and Install . (Group 3102.)
[6] - Install lifting straps at locations (1) and (3). Make sure lifting straps are installed as follows:
Attach rear lifting straps to boom arms (1) using choker method.
Attach front lifting straps around each boom arm just in front of cross tube (2).
[7] -

Section 31 - LOADER Group 3100: Loader
LEGEND:
4 Return-to-Dig Switch Connector
6 Washer (as needed)
7 Pivot Pin
8 Hydraulic Hose
9 Hydraulic Hose
Loader Removal
Disconnect return-to-dig switch connector (4).
[8] - Tag and disconnect hydraulic hoses (8) and (9). Cap and plug all openings.
[9] - Support weight of loader with appropriate lifting device.
[10] - Remove snap rings (5), washers (6), and pin (7)
[11] -
CAUTION:
pressure.
LEGEND:
10 Cap Screw
11 Pin Retainer Plate
12 Pivot Pin
13 Lift Arm
Boom Cylinder Pivot Pin

At both sides of machine, position a 102 x 102 mm (4 x 4 in.) (minimum) wide block on the front axle directly under boom
cylinder.
[12] - Remove cap screw (10) and pin retainer plate (11).
[13] - Remove boom cylinder pivot pin (12) from lift arm (13). Lower rod end of boom cylinder and allow it to rest on the block.
[14] - Repeat for opposite cylinder.
[15] -
CAUTION:
Lift and remove loader boom using appropriate lifting device.

Section 31 - LOADER Group 3102: Bucket
Loader Boom Weight (approximate) 399 kg
880 lb.
[16] - Repair or replace loader boom as necessary.
[17] - Install boom cylinder pivot pin into lift arm.
[18] - Install pin retainer plate and cap screw.
[19] - Install hydraulic hoses.
[20] - Install pin, washers, and snap rings.
[21] - Connect return-to-dig switch connector.
[22] - Connect and adjust bucket self-leveling linkage. See Loader Bucket Self-Leveling Linkage and Return-To-Dig Switch
Adjustment . (Group 9025-20.)
CAUTION:
Boom Cylinder Weight (approximate) 57 kg
126 lb.
Loader Boom Weight (approximate) 399 kg
880 lb.
[23] - Install loader bucket. See Loader Bucket Remove and Install . (Group 3102.)
[24] - Install bucket linkage. See Loader Bucket Cylinder Linkage Remove and Install . (Group 3115.)
[25] - Install bucket cylinder. See Loader Bucket Cylinder Remove and Install . (Group 3160.)

Section 31 - LOADER Group 3102: Bucket
Group 3102 - Bucket

Loader Bucket Remove and Install
LEGEND:
3 Pin (2 used)
4 Bucket Cylinder
5 Bucket Linkage (2 used)
6 Lock Nut (2 used)
8 Pin (2 used)
9 Hydraulic Hose (2 used)
Loader Bucket (multi-purpose bucket shown)
CAUTION:
Prevent possible crushing injury from heavy component. Use appropriate lifting device. Be careful when
removing bucket linkage pins. Bucket cylinder and links will fall forward and cause bodily injury. If
necessary, support bucket linkage using blocks.
[2] - Lower loader to ground.
[3] - If equipped with multi-purpose bucket, disconnect hydraulic hoses (9).
[4] - Remove snap rings (1) and washers (2) from pins (3).
[5] -
Attach a hoist and lifting strap to bucket cylinder (4). Remove pins (3) from bucket cylinder and linkage (5).
[6] - Remove lock nuts (6), cap screws (7), and pins (8).
[7] - Remove loader bucket.
[8] - Repair or replace bucket as needed.
[9] - Align loader arms with bucket pin bosses.
[10] - Install pins (8), cap screws, and lock nuts.
[11] - Align bucket cylinder rod with bucket. Install pin (3), washers, and snap ring.
[12] - Align bucket linkage with bucket and install pin (3), washers, and snap ring.
Section 31 - LOADER Group 3115: Control Linkage
[13] - Install washers and snap rings.
Welded Bucket Cutting Edges Replacement Procedure

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


Loader Control Valve Linkage Remove and Install—Two Function
[3] -
LEGEND:
2 Middle Floor Panel
Middle Floor Panel

Remove cap screws (1) and middle floor panel (2).
[4] -
LEGEND:
4 Washer (4 used)
5 Cab Cover
Loader Control Cover

Remove cap screws (3), washers (4), and cab cover (5).
[5] -
LEGEND:
6 Cap Screw
7 Washer
8 Floor Plate
10 Cover
Loader Control Linkage

Remove cap screw (6) and washer (7) from floor plate (8).
[6] - Remove floor plate.

[7] - Remove cap screws (9) from cover (10).
[8] -
LEGEND:
11 Pin Retainer (2 used)
12 Pin Fastener (2 used)
Loader Linkage Lock Nuts

Remove pin retainers (11), pin fasteners (12) and linkage rods from loader and stabilizer control valve spools.
[9] -
LEGEND:
14 Ball Joint (2 used)
15 Loader Control Valve Linkage (2 used)
Control Linkage Removal

Remove lock nuts (13) and ball joints (14) to remove loader control valve linkages (15).
[10] - Repair or replace loader control valve linkage as necessary.
[11] - Install loader control valve linkage and lock nuts.
[12] - Install pin fasteners and pin retainers into control valve linkages.
[13] - Adjust linkage as necessary. See Loader and Stabilizer Lever Adjustment . (Group 9025.)
[15] - Install floor plate, cap screw (6), and washer (7).
[16] - Install cab cover, cap screws (3), and washers (4).
[17] - Install middle floor panel and cap screws (1).

Single Lever Loader Auxiliary Control Lever Remove and Install

[2] -
LEGEND:
4 Washer (4 used)
5 Loader Control Cover
Loader Control Cover

Remove cap screws (3), washers (4), and loader control cover (5).
[3] -
LEGEND:
X58 Loader Control Lever Connector
X58 Connector
Disconnect loader control lever connector (X58).
[4] -
LEGEND:
7 Boot
Single Lever Auxiliary Loader Control Lever Boot

Slide boot (7) down lever shaft.
[5] -
Single Lever Auxiliary Loader Control Lever Cap Screw Location

LEGEND:
10 Single Lever Auxiliary Loader Control Lever
Remove cap screws (9) and single lever auxiliary loader control lever (10).
[7] - Install single lever auxiliary loader control lever and cap screws (9).
[8] - Slide boot to original position.
[9] - Connect loader control lever connector to machine harness.
[10] - Install loader control cover, washers, and cap screws (3).

Manual Third Function Loader Control Valve Linkage Remove and Install
[3] -
LEGEND:
2 Middle Floor Panel
Middle Floor Panel

Remove cap screws (1) and middle floor panel (2).
[4] -
LEGEND:
4 Washer (4 used)
5 Cover
Manual Third Function Control Cover

Remove cap screws (3), washers (4), and cover (5).
[5] -

LEGEND:
6 Cap Screw
7 Washer
8 Floor Plate
10 Cover
Manual Third Function Linkage

Remove cap screw (6), washer (7), and floor plate (8).
[6] - Remove cap screws (9) from the cover (10).
[7] -
LEGEND:
12 Pin Fastener (3 used)
13 Linkage Rod (3 used)
Manual Third Function Linkage Clips

Remove pin retainers (11), pin fasteners (12), and linkage rods (13) from loader and stabilizer control valve spools.
[8] -
LEGEND:
14 Pivot Spacer
15 Linkage Rod Assembly

Manual Third Function Linkage Removal

Remove lock nuts (13) and pivot spacer (14).
[9] - Remove linkage rod assembly (15).
[10] - Repair or replace linkage rod assembly as necessary.
[11] - Install linkage rod assembly.
[12] - Install pivot spacer and lock nuts.
[13] - Install linkage rods, pin fasteners, and pin retainers.
[14] - Adjust linkage as necessary. See Loader and Stabilizer Lever Adjustment . (Group 9025.)
[15] - Install floor plate with cap screw (6) and washer (7).
[16] - Install cap screws (9) in cover.
[17] - Install cab cover with cap screws (3) and washers (4).
[18] - Install middle floor panel and cap screws (1).

Stabilizer Linkage Remove and Install (S.N. —000470)

[2] -
LEGEND:
2 Washer (3 used)
4 Stabilizer Linkage Access Cover
Stabilizer Linkages Access Cover

Remove cap screws (1) and washers (2) from stabilizer linkage access cover (4).
[3] - Remove cap screws (3) from control plate.
[4] -
LEGEND:
5 Retaining Ring (2 used)
6 Pivot Shaft
7 Cotter Pin (2 used)
8 Push/Pull Stabilizer Cable (2 used)
9 Stabilizer Lever (2 used)
10 Stabilizer Lever Mounting Tower
Stabilizer Levers
Remove retaining rings (5) from the pivot shaft (6).
[5] - Remove cotter pins (7) from the push/pull stabilizer cables (8).
[6] - Remove stabilizer lever (9) from pivot shaft (6).
[7] - Remove stabilizer levers and repair or replace as necessary.
[8] - Install stabilizer lever (9) on pivot shaft (6).
[9] - Install push/pull stabilizer cables and stabilizer levers with cotter pins.

[10] - Install retaining rings to pivot shaft.
[11] - Install cap screws (3) to control plate.
[12] - Install stabilizer linkage access cover, cap screws (1), and washers.

Loader Bucket Cylinder Linkage Remove and Install

Specifications
SPECIFICATIONS
45 kg
Loader Bucket Cylinder Weight (approximate)
100 lb.
D01045AA Bushing, Bearing and Seal Driver Set
[2] - Lower all equipment to ground and stop engine.
[3] -
CAUTION:
To avoid injury from escaping fluid under pressure, stop engine and relieve pressure in system before
disconnecting or connecting hydraulic or other lines. Tighten all connections before applying pressure.
[4] -
LEGEND:
1 Self-Leveling Rod
2 Snap Ring
3 Bucket Link (2 used)
6 Pin (3 used)
Loader Bucket Cylinder Linkage

If equipped, remove snap ring (2) and self-leveling rod (1) from bucket linkage.
[5] -

Section 31 - LOADER Group 3160: Hydraulic System
CAUTION:
Prevent possible injury from falling linkage. Bucket cylinder and links will fall when pins are removed.
Support or block linkage and cylinder before removing pins.
Support or block linkage from falling when disconnecting linkage.
[6] - Attach bucket cylinder to appropriate lifting device.
[7] - Remove snap rings (4), washers (5), pins (6), and bucket links (3) from machine.
Loader Bucket Cylinder Weight (approximate) 45 kg
100 lb.
[8] - Remove snap rings (4), washers (5), pin (6), and bucket links (7) from machine.
[9] - Inspect links. Repair or replace as needed. Remove and install bushings using D01045AA Bushing, Bearing and Seal
Driver Set.
Bushing, Bearing and Seal Driver Set
D01045AA
Used to remove and install loader bucket linkage bushings.
[10] -
IMPORTANT:
Do not use a graphite based grease on the synthetic bushings when assembling. Graphite will deteriorate
synthetic bushings.
Apply multipurpose grease to inside of all bushings before assembly.
[11] - Install bucket links to loader boom with pin, washers, and snap rings.
[12] - Install bucket links to bucket with pin, washers, and snap rings.
[13] - Align bucket links with cylinder and attach links to cylinder using washers and snap rings. Shim as required to reduce
looseness on bucket links and bucket links to cylinder.
[14] - Install self-leveling rod with snap ring.
Loader Bucket Self-Leveling Linkage and Return-to-Dig Switch

Adjustment
See Loader Bucket Self-Leveling Linkage and Return-To-Dig Switch Adjustment . (Group 9025-20).


Loader and Stabilizer Control Valve Remove and Install
[2] - Remove right rear wheel. See Rear Wheel Assembly Remove and Install . (Group 0110.)
[5] - Drain hydraulic oil reservoir or apply vacuum. See Change Hydraulic Reservoir Oil (Operator’s Manual) or see Apply
[6] -
Loader and Stabilizer Control Valve Cover

LEGEND:
2 Loader and Stabilizer Control Valve Cover
Remove cap screws (1) and loader and stabilizer control valve cover (2).
[7] - Remove loader control valve linkage. See Loader Control Valve Linkage Remove and Install—Two Function . (Group 3115.)
[8] -

Loader and Stabilizer Control Valve

LEGEND:
4 Stabilizer Linkage (2 used)
S12 Return-to-Dig Switch
Remove cotter pins (3) and disconnect stabilizer linkages (4) from loader and stabilizer control valve (190).
[9] - Tag and disconnect all hydraulic hoses. Close all openings using caps and plugs.
[10] - Disconnect electrical connector from return-to-dig switch (S12).
[11] -
CAUTION:
[12] - Attach and secure lifting device to loader and stabilizer control valve.
Loader and Stabilizer Control Valve Weight (approximate) 82 kg
181 lb.
[13] - Remove cap screws (5) and loader and stabilizer control valve.
[14] - Repair or replace loader and stabilizer control valve as necessary. See Loader and Stabilizer Control Valve Spool
[15] - Install loader and stabilizer control valve and cap screws (5).
[16] - Connect electrical connector to return-to-dig switch.
[17] - Connect hydraulic hoses to loader and stabilizer control valve.

[18] - Install stabilizer linkages and cotter pins.
[19] - Install loader control valve linkage. See Loader Control Valve Linkage Remove and Install—Two Function . (Group 3115.)
[20] - Fill hydraulic reservoir or remove vacuum. See Change Hydraulic Reservoir Oil . (Operator’s Manual.)
[22] - Start machine and check for leaks.
[23] - Install loader and stabilizer control valve cover and cap screws (1).
[24] - Install right rear wheel. See Rear Wheel Assembly Remove and Install . (Group 0110.)

Loader and Stabilizer Control Valve Spool Disassemble and Assemble

Specifications
SPECIFICATIONS
9.5 N·m
Spool End Screw Torque
84 lb.-in.
9.5 N·m
Retaining Plate Cap Screw (2 used) Torque
84 lb.-in.
Essential Tools
ESSENTIAL TOOLS
JDG734 Hydraulic Valve Seal Replacer
Other Material
OTHER MATERIAL
271 U.S. Loctite ™ Thread Lock and Sealer (high strength)
Stabilizer Spool Disassemble and Assemble
→NOTE:
Left stabilizer thermal relief valve is located in top of valve. Right stabilizer thermal relief valve is located
in bottom of valve.
→NOTE:
Stabilizer spool disassemble and assemble is identical for left and right stabilizers. Left stabilizer is
shown in illustrations.
[2] - Clean valve assembly to remove any dirt and debris.
[3] -
LEGEND:
1 Lock Nut (3 used)
2 Cap Screw
3 Bellcrank (2 used)
Stabilizer Valve Spool Bellcrank

Remove lock nuts (1) and cap screw (2) and bellcranks (3) from stabilizer valve spools (191 and 192).
[4] -

LEGEND:
5 Base
7 Spacer
8 Plate
9 Spool Wiper Seal
10 Lip Seal
12 Cap
13 Cap Screw
14 Retainer (2 used)
15 Spring
16 Plate
17 Seal
18 Seal
191 Left Stabilizer Spool
192 Right Stabilizer Spool
Stabilizer Valve Spool

Remove cap screws (4) and base (5).
[5] - Remove cap screws (6), spacer (7), and plate (8).
[6] - Use an O-ring pick to remove spool wiper seal (9) and lip seal (10).
[7] - Remove cap screws (11) and cap (12).
[8] - Remove cap screw (13), retainers (14), and spring (15).
[9] - Remove plate (16).
[10] - Remove left stabilizer spool from loader and stabilizer control valve (190).
[11] - Use an O-ring pick to remove seals (17 and 18).
[12] - Inspect parts for wear or damage. Replace as necessary.
[13] -
IMPORTANT:
Do not damage OD or ID of new seal during installation. JDG734 Hydraulic Valve Seal Replacer must be
used to install lip seal (10).
Lube seals with hydraulic oil prior to installation.

Installation Tool
LEGEND:
10 Lip Seal
28 Tool Sleeve
30 Tool Driver
Use
Hydraulic Valve Seal Replacer
JDG734
Install new seals
JDG734 Hydraulic Valve Seal Replacer and place lip seal (10) on end of tool driver (30) with open side of seal away from tool
driver.
[14] -
→NOTE:
Lip end of sleeve ID is cone-shaped to compress seal for installation.
Carefully slide tool sleeve (28) over lip seal and tool driver with raised lip of sleeve away from driver. Do not push seal through
tool sleeve.
[15] - Place tool assembly over end of spool with raised lip into counterbore of valve section.
[16] - Push tool driver to install lip seal into valve housing.
[17] - Spin tool driver 180 degrees and hold down for several seconds. This will allow air to escape and seal will seat in valve
counterbore.
[18] - Install spool wiper seal (9).

[19] - Repeat steps (12—19) for opposite end of spool.
[20] - Install left stabilizer spool (191).
[21] - Install plate (16), retainers (14), and spring (15).
[22] - Apply PM37509 and PM37421 Loctite ™ Thread Lock and Sealer (high strength) to threads of spool and cap screws.
Number Name Use

• 271 (us) Loctite ™ Thread Lock and Sealer (high strength) Thread lock and sealer
Number Name Use
• (us) Loctite ™ Klean ‘N Prime
[23] - Tighten spool end screw (13) to specification.

Spool End Screw Torque 9.5 N·m
84 lb.-in.
[24] - Install cap (12) and cap screws (11). Tighten cap screws to specification.
Retaining Plate Cap Screw (2 used) Torque 9.5 N·m
84 lb.-in.
[25] - Install spacer (7), plate (8) and cap screws (6). Tighten cap screws to specification.
Retaining Plate Cap Screw Torque 9.5 N·m
84 lb.-in.
[26] - Install bellcranks (3), cap screws (2) and lock nuts (1).
[27] - Check for correct seal installation by pushing down on stabilizer spool. Spool must return to neutral position.
Boom Spool Disassemble and Assemble
[1] -

LEGEND:
1 Filter
3 Cap
4 End
5 Valve Seat Insert
6 Spring
7 Valve Seat Insert
8 Ball (4 used)
9 Cam
10 Spring
11 Sleeve
12 Sleeve
13 Spool End Cap Screw (2 used)
14 Plate
15 Spool Wiper Seal
16 Lip Seal
17 Seal
18 O-Ring
19 Seat
20 O-Ring
21 Spring
22 Poppet
193 Loader Boom Spool
Boom Valve Spool

Check filter (1) and replace if necessary.
[2] - Remove cap screws (2), and cap (3).
[3] - Unscrew end (4) from valve seat insert (5).
[4] - Remove spring (6) from both valve seat inserts (5 and 7).
[5] - Remove balls (8), cam (9), and spring (10) from sleeves (11 and 12).
[6] - Remove spool end cap screws (13) and plate (14).
[7] - Remove loader boom spool (193).
[8] - Use an O-ring pick to remove spool wiper seal (15) and lip seal (16) from loader and stabilizer control valve (190).
[9] - Use an O-ring pick to remove seal (17) and O-ring (18) from loader and stabilizer control valve.
[10] - Remove seat (19), O-ring (20), spring (21), and poppet (22) from loader and stabilizer control valve.
[11] - Install seat, O-ring (20), spring (21), and poppet to loader and stabilizer control valve.
[12] - Install O-ring (18) to loader and stabilizer control valve.
[13] -
IMPORTANT:
used to install lip seal (16).

Installation Tool
LEGEND:
16 Lip Seal
23 Tool Sleeve
24 Tool Driver
Use
JDG734
Install new seals
driver.
[14] -
→NOTE:
Carefully slide tool sleeve (23) over seal and tool driver with raised lip of sleeve away from driver. Do not push seal through
tool sleeve.
counterbore.
[18] - Install seal (18), lip seal (16), and wiper spool seal (15) to loader and stabilizer control valve.

[19] - Install loader boom spool to loader and stabilizer control valve.
Number Name Use

Number Name Use
[21] - Install plate and spool end cap screws. Tighten spool end cap screws to specifications.
Spool End Cap Screw Torque 9.5 N·m
84 lb.-in.
→NOTE:
There should be a 1/8” gap between cap and loader and stabilizer control valve.
[22] - Install sleeves, spring, cam, and balls.
[23] - Install spring into both valve seat inserts and screw in end.
[24] - Install cap and cap screws.
Bucket Spool Disassemble and Assemble
[1] -
Remove lock nut (1), cap screw (2), and tube (3) from loader bucket spool (194).
[2] -
LEGEND:
1 Lock Nut
2 Cap Screw
3 Tube
5 Plate
6 Spacer
7 Spool Wiper Seal
8 Lip Seal
10 Magnet Housing
11 Magnet Assembly
12 Spacer
13 Ring
14 Clapper
15 Spool End
16 Plate
17 Spacer
18 Spring Seat
19 Ring
20 Spring
21 Spring Seat
22 Plate
23 Seal
24 Fitting Plug
25 O-Ring
26 Spring
27 Poppet
194 Loader Bucket Spool
Bucket Valve Spool

Remove spool end cap screws (4), plate (5), and spacer (6).
[3] - Use an O-ring pick remove spool wiper seal (7) and lip seal (8) from loader and stabilizer control valve.
[4] - Remove cap screws (9), magnet housing (10), and magnet assembly (11).
[5] - Remove spacer (12).
[6] - Remove ring (13), clapper (14), spool end (15), and plate (16).
[7] - Remove spacer (17), spring seat (18), and ring (19).
[8] - Remove spring (20), spring seat (21), and plate (22).
[9] - Remove loader bucket spool from loader and stabilizer control valve (190).
[10] - Use an O-ring pick to remove seal (23) from loader and stabilizer control valve.
[11] - Remove fitting plug (24), O-ring (25), spring (26), and poppet (27).
[12] - Install poppet, spring (26), O-ring (25), and fitting plug.
[13] -
IMPORTANT:
used to install lip seal.
Installation Tool
LEGEND:

8 Lip Seal
28 Tool Sleeve
29 Tool Driver
Use
JDG734
Install new seals
driver.
[14] -
→NOTE:
tool sleeve.
counterbore.
[18] - Install spool wiper seal (7), lip seal (8), and seal (23) to loader and stabilizer control valve.
[19] - Install loader bucket spool into loader and stabilizer control valve.
[20] - Install plate (22), spring seat (21), and spring (20).
[21] - Install ring (19), spring seat (18), and spacer (17).
[22] - Install plate (16), spool end (15), clapper (14), and ring (13).
[23] - Install spacer (12).
[24] - Install magnet assembly, magnet housing, and cap screws (9).
Number Name Use

Number Name Use
[26] - Install spacer (6), plate (5), and spool end cap screws (4). Tighten spool end cap screws to specifications.
84 lb.-in.
[27] - Install tube, cap screw (2), and lock nut.
Auxiliary Spool Disassemble and Assemble—If Equipped
[1] -

Auxiliary Valve Spool

LEGEND:
2 Plate
3 Spool Wiper Seal
4 Lip Seal
5 Retaining Screw (2 used)
6 Cap
7 Cap Screw
8 Retainer
9 Spring
10 Retainer
11 Plate
12 Seal
13 Seal
14 Fitting Plug
15 O-Ring
16 Fitting Plug
17 O-Ring
18 Spring
19 Poppet
195 Loader Auxiliary Spool
Remove spool end cap screws (1) and plate (2).
[2] - Use an O-ring pick to remove spool wiper seal (3) and lip seal (4).
[3] - Remove retaining screws (5) and cap (6).
[4] - Remove cap screw (7), retainers (8 and 10), and spring (9).
[5] - Remove plate (11).

[6] - Remove loader auxiliary spool (195) from loader and stabilizer control valve (190).
[7] - Use an O-ring pick to remove seals (12 and 13) from loader and stabilizer control valve.
[8] - Remove fitting plug (14) and O-ring (15).
[9] - Remove fitting plug (16), O-ring (17), spring (18), and poppet (19).
[10] - Install poppet, spring (18), O-ring (17), and fitting plug (16).
[11] - Install O-ring (15) and fitting plug (14).
[12] -
IMPORTANT:
used to install lip seal.
Installation Tool
LEGEND:
23 Tool Sleeve
4 Lip Seal
24 Tool Driver
Use
JDG734
Install new seals
driver.
[13] -
→NOTE:
tool sleeve.
counterbore.
[17] - Install seals (13 and 12) and plate to loader and stabilizer control valve.
[18] - Install seals (4 and 3) to loader and stabilizer control valve.
[19] - Install loader auxiliary spool to loader and stabilizer control valve.
[20] - Install retainers (10 and 8), spring (9), and cap screw (7).
Number Name Use

Number Name Use
[22] - Install cap and retaining screws (5). Tighten cap screws to specifications.
Retaining Screw Torque 9.5 N·m
84 lb.-in.
[23] - Install plate (2) and spool end cap screws (1). Tighten spool end cap screws to specifications.
84 lb.-in.

Loader and Stabilizer Control Valve Relief Valves Remove and Install
Specifications
SPECIFICATIONS
45 N·m
Relief Valve 22.35 mm (0.88 in.) Torque
33 lb.-ft.
61 N·m
Relief Valve 26 mm (1.06 in.) Torque
45 lb.-ft.
45 N·m
System Relief Valve Torque
33 lb.-ft.
Loader Control Valve Relief Valves

LEGEND:
150 System Relief Valve (310K only)
251 Boom Circuit Relief Valve (no anticavitation)
252 Boom Anticavitation Check Valve
253 Bucket Circuit Relief Valve (no anticavitation)
254 Bucket Circuit Relief Valve (with anticavitation)
255 Auxiliary Circuit Relief Valve (with anticavitation) (2 used)
[1] - To remove loader and stabilizer control valve, see Loader and Stabilizer Control Valve Remove and Install . (Group 3160.)

[2] -
→NOTE:
Relief valves must be installed in the correct ports for proper valve function.
To aid in assembly, put identification marks on relief valve and corresponding control valve port.
[3] - Remove relief valves as needed.
[4] - Repair or replace relief valves as necessary.
See Loader and Stabilizer Control Valve Spool Disassemble and Assemble . (Group 3160.)
See Loader and Stabilizer Control Valve System Relief Valve Disassemble and Assemble . (Group 3160.) (310K)
See Loader Boom Anticavitation Valve Disassemble and Assemble . (Group 3160.) (310K—325SK)
See Loader Boom Anticavitation Check Valve Disassemble and Assemble . (Group 3160.) (410K—710K)
See Loader Boom Raise and Bucket Curl Circuit Relief Valve Disassemble and Assemble . (Group 3160.)
See Loader Bucket Dump Circuit Relief Valve with Anticavitation Disassemble and Assemble . (Group 3160.)
See Loader Auxiliary Circuit Relief Valve Disassemble and Assemble . (Group 3160.)
See Loader Auxiliary Shutoff Plug Disassemble and Assemble . (Group 3160.)
[5] - Remove and inspect O-rings and backup rings for damage. If damaged, check housing for cause.
[6] -
IMPORTANT:
Avoid O-ring or component damage. Apply clean hydraulic oil to all internal parts before assembly and
petroleum jelly to O-rings and backup rings before installation.
Apply petroleum jelly to new O-rings and backup rings. Install new O-rings and backup rings.
[7] -
→NOTE:
Relief valve installation torque is port size specific. Verify diameter of port with specifications listed
below.
Install relief valves. Tighten relief valves to specification.

Relief Valve Torque

Relief Valve 22.35 mm (0.88 in.) Torque 45 N·m
33 lb.-ft.
Relief Valve 26 mm (1.06 in.) Torque 61 N·m
45 lb.-ft.
System Relief Valve Torque 45 N·m
33 lb.-ft.
[8] - To install loader and stabilizer control valve, see Loader and Stabilizer Control Valve Remove and Install . (Group 3160.)
[9] -
IMPORTANT:
To prevent possible hydraulic system damage, relief valves MUST be adjusted anytime they are
disassembled or replaced.
Adjust circuit relief valve pressures. See Circuit Relief Valve Test—With Remote Pump . (Group 9025-25.)
[10] - Adjust system relief valve. See System Relief Valve Pressure Test . (Group 9025-25.)

Loader Boom Anticavitation Valve Disassemble and Assemble

Specifications
SPECIFICATIONS
58—72 N·m
Loader Boom Anticavitation Valve Torque
43—52 lb.-ft.
[1] -
LEGEND:
1 Valve Body
2 O-Ring
3 Spring
4 O-Ring
5 Backup Ring
6 Poppet
Loader Boom Anticavitation Valve

Cross Section of Anticavitation Check Valve

LEGEND:
1 Valve Body
2 O-Ring
3 Spring
4 O-Ring
5 Backup Ring
6 Poppet
Remove valve body (1), O-ring (2), and spring (3).
[2] - Remove O-ring (4), backup ring (5), and poppet (6).
[4] - Put clean hydraulic oil on all parts before assembly.
[5] - Install poppet, backup ring, and O-ring (4).
[6] - Install spring, O-ring (2), and valve body.
[7] - Tighten to specification.

Loader Boom Anticavitation Valve Torque 58—72 N·m
43—52 lb.-ft.

Loader Boom Raise and Bucket Curl Circuit Relief Valve Disassemble
and Assemble
Specifications
SPECIFICATIONS
58—72 N·m
Circuit Relief Valve 26 mm (1.06 in.) Torque
43—53 lb.-ft.
[1] -
LEGEND:
1 Lock Nut
2 Adjustment Screw
3 O-Ring
4 Spring
5 Seal
6 O-Ring
7 Poppet
8 Relief Valve Body
9 O-Ring
10 Backup Ring
11 O-Ring
Circuit Relief Valve

Remove lock nut (1), adjustment screw (2), O-ring (3), and spring (4).
→NOTE:
If parts (1, 2, 7, and 8) need service, replace entire assembly.
→NOTE:
If seals are damaged, inspect port on control valve for wear or damage.
[2] - Remove seal (5), O-ring (6), poppet (7), and relief valve body (8).
[3] - Remove O-ring (9), backup ring (10), and O-ring (11).
[5] - Apply clean hydraulic oil on all parts before assembly.
[6] - Install O-ring (11), backup ring, O-ring (9), and relief valve body (8).
[7] - Install poppet (7), O-ring (6), seal, and spring.
[8] - Install O-ring (3), adjustment screw, and lock nut. Tighten to specification.
Circuit Relief Valve 26 mm (1.06 in.) Torque 58—72 N·m

43—53 lb.-ft.

Loader Bucket Dump Circuit Relief Valve With Anticavitation

Specifications
SPECIFICATIONS
58—72 N·m
Circuit Relief Valve With Anticavitation 26 mm (1.06 in.) Torque
43—53 lb.-ft.
[1] -
LEGEND:
1 Lock Nut
2 Adjustment Screw
3 O-Ring
4 Pilot Spring
5 Pilot Poppet
6 Valve Body
7 O-Ring (2 used)
8 Anticavitation Spring
10 O-Ring
11 Main Spring
12 Piston
13 Poppet
14 O-Ring
15 Backup Ring
16 Main Poppet
17 Valve Body
Loader Bucket Dump Circuit Relief Valve With

Anticavitation
Remove lock nut (1), adjustment screw (2), O-ring (3), and pilot spring (4).
→NOTE:
If parts (1, 2, 4—6,8,11—13,16, and 17) need service, replace entire assembly.
If seals are damaged, inspect port on control valve for wear or damage.
[2] - Remove pilot poppet (5), valve body (6), O-rings (7), anticavitation spring (8), and backup rings (9).
[3] - Remove O-ring (10), main spring (11), piston (12), poppet (13), and O-ring (14).
[4] - Remove backup ring (15), main poppet (16), and valve body (17).
[6] - Put clean hydraulic oil on all parts before assembly.
[7] - Install valve body (17), main poppet, backup ring (15), and O-ring (14).
[8] - Install poppet, piston, main spring, and O-ring (10).
[9] - Install backup rings (9), anticavitation spring, O-rings (7), valve body (6), and pilot poppet.

[10] - Install pilot spring, O-ring (3), and adjustment screw.
[11] -
IMPORTANT:
IMPORTANT:
below.
Install lock nut and tighten to specification.

Circuit Relief Valve With Anticavitation 26 mm (1.06 in.) Torque 58—72 N·m
43—53 lb.-ft.

Loader Auxiliary Circuit Relief Valve Disassemble and Assemble

Specifications
SPECIFICATIONS
58—72 N·m
Loader Auxiliary Circuit Relief Valve Torque
43—53 lb.-ft.
[1] -
LEGEND:
1 Valve Body
2 Spring
3 Retaining Ring (2 used)
4 O-Ring
6 O-Ring
7 Backup Ring
8 Adjusting Screw
9 Spring
10 Flat Washer (4 used)
11 Poppet
12 Valve Sleeve
13 O-Ring
Auxiliary Circuit Relief Valve

Remove valve body (1), spring (2), retaining rings (3), and O-ring (4).
[2] - Remove backup rings (5), O-ring (6), backup ring (7), and adjusting screw (8).
[3] - Remove spring (9), flat washers (10), poppet (11), valve sleeve (12), and O-ring (13).
[5] - Apply clean hydraulic oil on all parts before assembly.
[6] - Install O-ring (13), valve sleeve, poppet, flat washers, and spring (9).
[7] - Install adjusting screw, backup ring (7), O-ring (6), and backup rings (5).
[8] - Install O-ring (4), retaining rings, spring (2), and valve body.
[9] - Install loader auxiliary circuit relief valve and torque to specification.
Loader Auxiliary Circuit Relief Valve Torque 58—72 N·m
43—53 lb.-ft.

Loader Auxiliary Shutoff Plug Disassemble and Assemble

LEGEND:
1 Shutoff Plug
2 Seal
Shutoff Plug
Specifications
SPECIFICATIONS
58—72 N·m
Loader Auxiliary Shutoff Plug Torque
43—53 lb.-ft.
Essential Tools
ESSENTIAL TOOLS
[1] -
Loader Auxiliary Shutoff Plug Location

LEGEND:
3 Shutoff Plug Location
Remove shutoff plug (1) from shutoff plug location (3).
[2] - Remove seal (2) if necessary.
[3] - Apply clean hydraulic oil on seal before assembly.
[4] - Install seal using JDG1328 Seal Installer.

Seal Installer
JDG1328

To install special seal on shutoff plug.
[5] - Install shutoff plug. Torque to specification.

Loader Auxiliary Shutoff Plug Torque 58—72 N·m
43—53 lb.-ft.

Loader Boom Cylinder Remove and Install

Specifications
SPECIFICATIONS
Loader Boom Cylinder
36 kg
210K, 310K, 310SK, 315SK, 410K Weight (approximate)
80 lb.
64 kg
310SK TMC, 325K, 325SK, 410K TMC Weight (approximate)
141 lb.
55 kg
710K Weight (approximate)
122 lb.
[2] -
CAUTION:
pressure.
[4] -
LEGEND:
1 Snap Ring
2 Washer
3 Pin
4 Boom Cylinder Head End Hydraulic Hose
5 Clamp
6 Boom Cylinder Rod End Hydraulic Hose
7 Pin
8 Cap Screw
9 Plate
202 Boom Cylinder
Loader Boom Cylinder (310SK shown)

Remove clamp (5).
[5] - Tag and disconnect head end hydraulic hose (4) and rod end hydraulic hose (6) from boom cylinder (202). Close all
openings using caps and plugs.
[6] -
CAUTION:
Prevent crushing injury from heavy component. Use appropriate lifting device.
Attach appropriate lifting device to boom cylinder using lift straps.

Loader Boom Cylinder

210K, 310K, 310SK, 315SK, 410K Weight (approximate) 36 kg
80 lb.
310SK TMC, 325K, 325SK, 410K TMC Weight (approximate) 64 kg
141 lb.
710K Weight (approximate) 55 kg
122 lb.
[7] - Remove snap ring (1) and washer (2).
[8] - While supporting rod end of boom cylinder, remove cap screw (8), plate (9), and pin (7). Lower rod end of cylinder away
from loader arm and slide boom cylinder off pin (3).
[9] - Inspect and repair loader boom cylinder as necessary. See Loader Boom Cylinder Disassemble and Assemble . (Group
3160.)
[10] - Apply multipurpose grease to inside of all bushings before installing cylinder.
[11] -
CAUTION:
Attach appropriate lifting device to boom cylinder using lift straps.
[12] - Slide head end of boom cylinder onto pin (3). Install washer and snap ring.
[13] - Align hole in rod end of boom cylinder with pin boss holes in loader arm. Install pin (7), plate, and cap screw.
[14] - Connect hydraulic hoses to boom cylinder and install clamp. Tighten securely.
[15] - Connect battery negative (–) ground cable or turn battery disconnect switch (if equipped) to the ON position.
Loader Boom Cylinder Disassemble and Assemble

For loader boom cylinder repair information, see Cylinder Identification . (CTM120519.)

Loader Bucket Cylinder Remove and Install

Specifications
SPECIFICATIONS
Loader Bucket Cylinder
53 kg
210K, 310K, 310SK, 315SK, 410K Weight (approximate)
117 lb.
65 kg
310SK TMC, 325K, 325SK, and 410K TMC Weight (approximate)
144 lb.
75 kg
165 lb.
710K Loader Bucket Cylinder Links
44 kg
Front Link Weight (approximate)
97 lb.
26 kg
Rear Link Weight (approximate)
58 lb.
[4] -
LEGEND:
1 Bucket Cylinder Head End Hydraulic Hose
2 Bucket Cylinder Rod End Hydraulic Hose
3 Clamp
5 Washer (6 used)
6 Loader Bucket Cylinder Pivot
7 Loader Bucket Cylinder Rear Link (2 used)
8 Grease Fitting
9 Washer
11 Washer (2 used)
12 Loader Bucket Cylinder Rear Link-to-Loader Pin
13 Loader Bucket Leveling Linkage
203 Loader Bucket Cylinder
Loader Bucket Cylinder and Linkage

Remove clamp (3).
[5] -
CAUTION:
pressure.
Tag and disconnect head end and rod end hydraulic hoses (1 and 2) from loader bucket cylinder (203). Close all openings using
caps and plugs.
[6] -

CAUTION:
Attach appropriate lifting device to loader bucket cylinder.


210K, 310K, 310SK, 315SK, 410K Weight (approximate) 53 kg
117 lb.
310SK TMC, 325K, 325SK, and 410K TMC Weight (approximate) 65 kg
144 lb.
165 lb.
[7] - Remove grease fitting (8) and washer (9) from loader bucket leveling linkage (13).
[8] - Remove loader bucket leveling linkage from loader bucket rear link.
[9] - Remove snap rings (4 and 10) and washers (5 and 11).
[10] - Remove loader bucket cylinder rear link (7).
[11] -
CAUTION:
LEGEND:
5 Washer (6 used)
14 Loader Bucket Front Link
15 Snap Ring
16 Washer (2 used)
Loader Bucket Cylinder Front Link-to-Loader Bucket
17
Pin
Loader Bucket Front Linkage

Attach appropriate lifting device to loader bucket cylinder front link (14).
710K Loader Bucket Cylinder Links

Front Link Weight (approximate) 44 kg
97 lb.
Rear Link Weight (approximate) 26 kg
58 lb.

[12] - Remove snap ring (15) and washers (5 and 16).
[13] - Remove loader bucket cylinder front link.
[14] -
LEGEND:
5 Washer (6 used)
18 Snap Ring
Loader Bucket Cylinder Front Link-to-Loader Bucket
19
Pin

Remove snap ring (18), loader bucket cylinder-to-loader bucket pin (19), and washer (5).
[15] - Remove loader bucket cylinder.
[16] - Repair or replace loader bucket cylinder as necessary. See Loader Bucket Cylinder Disassemble and Assemble . (Group
3160.)
[17] - Apply multipurpose grease to inside of all bushings before assembly.
[18] -
CAUTION:
Attach appropriate lifting device to loader bucket cylinder.
[19] - Move loader bucket cylinder into position and install loader bucket cylinder-to-loader bucket pin (19) and snap ring (18).
[20] - Attach appropriate lifting device to loader bucket cylinder front link.
[21] - Install washer (5) onto loader bucket cylinder pivot (6).
[22] - Install loader bucket cylinder front link, washers (5 and 16), and snap ring (15).
[23] - Install loader bucket cylinder rear link, washers (5 and 11), and snap rings (4 and 10).
[24] - Install loader bucket leveling linkage, washer (9), and grease fitting.
[25] - Connect head end and rod end hydraulic hoses to loader bucket cylinder and install clamp. Tighten securely.
Loader Bucket Cylinder Disassemble and Assemble

For loader bucket cylinder repair information, see Cylinder Identification . (CTM120519.)

Loader Multi-Purpose Bucket Cylinder Disassemble and Assemble

For loader multi-purpose bucket cylinder repair information, see Cylinder Identification . (CTM120519.)

Loader Auxiliary Manifold Remove and Install

[2] - For location of loader auxiliary manifold (197), See Hydraulic System Component Location . (Group 9025-15.)
[3] - Drain hydraulic oil reservoir or apply a vacuum. See Change Hydraulic Reservoir Oil . (Operator’s Manual.)
[4] -
Loader Auxiliary Manifold

LEGEND:
Accumulator (manual controls) or Pilot Enable and Pattern Select (PEPS) Manifold (pilot controls)-to-Loader Auxiliary
1
Manifold Hose
2 Loader Auxiliary Manifold-to-Loader and Stabilizer Control Valve Hose (2 used)
3 Loader Auxiliary Manifold-to-Hydraulic Oil Reservoir Hose
197 Loader Auxiliary Manifold
Y20 Loader Auxiliary Extend Solenoid
Y21 Loader Auxiliary Retract Solenoid
Tag and disconnect hoses (1—3). Close all openings using caps and plugs.
[5] - Tag and disconnect electrical connectors to loader auxiliary extend solenoid (Y20) and loader auxiliary retract solenoid
(Y21).
[6] - Remove cap screws (4) and loader auxiliary manifold.
[7] - Repair or replace parts if necessary.
[8] - Install loader auxiliary manifold and cap screws.
[9] - Install electrical connectors to solenoids.

[11] - Fill hydraulic oil reservoir or remove vacuum. See Change Hydraulic Reservoir Oil . (Operator’s Manual.)
[12] - Start machine and operate auxiliary function.

Ride Control Valve Remove and Install

Specifications
SPECIFICATIONS
37 N·m
Ride Control Valve Mounting Cap Screw Torque
27 lb.-ft.
50 N·m
Ride Control Valve Hydraulic Hose Torque
37 lb.-ft.
[2] -
→NOTE:
Before performing service on ride control valve, see Ride Control Operation—If Equipped . (Group
9025-05.) See Hydraulic System Component Location . (Group 9025-15.)
CAUTION:
Prevent possible injury from unexpected boom or bucket movement when equipped with ride control.
Ride control accumulator energy must be discharged when working on hydraulic components.
Relieve pressure in ride control system. See Ride Control Accumulator Hydraulic Pressure Release Procedure . (Group 9025-20.)
[3] -
CAUTION:
To avoid injury from escaping fluid under pressure, stop engine and relieve hydraulic pressure in system
pressure.
Relieve hydraulic system pressure. See Hydraulic Circuit Pressure Release . (Group 9025-25.)
[4] -
→NOTE:
Ride control valve is located inside battery box.
Disconnect battery cables and remove battery box. See Battery Box Remove and Install . (Group 1913.)
[5] -

LEGEND:
1 Hydraulic Supply Hose
3 Ride Control Valve Mounting Cap Screw (2 used)
5 Hydraulic Return Hose
204 Ride Control Valve
205 Ride Control Accumulator
Y50 Ride Control Solenoid 1
Ride Control Valve and Accumulator

Tag and disconnect electrical connectors from ride control solenoids 1 and 2 (Y50 and Y51).
[6] - Tag and disconnect hydraulic hoses (1, 2, 4, and 5) from ride control valve. Close all openings using caps and plugs.
[7] - Remove ride control valve mounting cap screws (3) and ride control valve (204).
[8] - Repair or replace ride control valve as necessary. See Ride Control Valve Disassemble and Assemble . (Group 3160.)
[9] - Install ride control valve with ride control valve mounting cap screws. Tighten to specification.
Ride Control Valve Mounting Cap Screw Torque 37 N·m
27 lb.-ft.
[10] - Connect hydraulic hoses to ride control valve. Tighten to specification.

Ride Control Valve Hydraulic Hose Torque 50 N·m
37 lb.-ft.
[11] - Connect electrical connectors to ride control solenoids 1 and 2.
[12] - Install battery box and connect battery cables. See Battery Box Remove and Install . (Group 1913.)
[13] - Charge ride control accumulator. See Ride Control Accumulator Charge Procedure . (Group 9025-20.)

Ride Control Valve Disassemble and Assemble

[1] -
LEGEND:
1 O-Ring (4 used)
2 O-Ring (4 used)
3 Hydraulic Fitting (2 used)
4 Hydraulic Fitting
5 Hydraulic Fitting
Ride Control Valve

Disassemble parts as needed. Inspect O-rings (1 and 2) for damage.
[2] - If removal of ride control solenoids (Y50 and Y51) from ride control valve (204) is necessary, see Ride Control Valve
Solenoid Disassemble and Assemble . (Group 3160.)
[3] -
IMPORTANT:
Prevent component or O-ring damage. Apply clean hydraulic oil to all internal parts before assembling
and apply petroleum jelly to all O-rings before installation.
Apply petroleum jelly to all new O-rings. Install new O-rings.
[4] - Apply clean hydraulic oil to all internal parts. Assemble all parts. Tighten securely.

Ride Control Valve Solenoid Disassemble and Assemble

Specifications
SPECIFICATIONS
41 N·m
Solenoid Valve Spool Torque
30 lb.-ft.
5 N·m
Ride Control Solenoid Nut Torque
48 lb.-in.
[1] -
→NOTE:
Ride control valve solenoids can be serviced with ride control valve installed on machine.
→NOTE:
To remove ride control valve, see Ride Control Valve Remove and Install . (Group 3160.)
LEGEND:
1 O-Ring (2 used)
2 O-Ring (2 used)
3 Solenoid Valve Spool (2 used)
4 Nut (2 used)
5 Orifice (2 used)
Ride Control Valve Solenoid

Remove nuts (4).
[2] - Remove ride control solenoids (Y50 and Y51) from solenoid valve spools (3).
[3] - Remove solenoid valve spools from ride control valve (204).
[4] - Remove O-rings (1 and 2).
[5] - Inspect and clean all orifices (5).
[6] -
IMPORTANT:
Prevent O-ring or component damage. Apply clean hydraulic oil to all internal parts before assembly and
petroleum jelly to O-rings before installation.
Apply petroleum jelly to new O-rings. Install new O-rings.
[7] - Apply clean hydraulic oil to all internal parts. Install solenoid valve spool in ride control valve. Tighten to specification.
Solenoid Valve Spool Torque 41 N·m
30 lb.-ft.
[8] - Install ride control solenoids and nuts. Tighten to specification.

Ride Control Solenoid Nut Torque 5 N·m
48 lb.-in.
[9] - To install ride control valve (if removed), see Ride Control Valve Remove and Install . (Group 3160.)

Ride Control Accumulator Remove and Install

Specifications
SPECIFICATIONS
73 N·m
Ride Control Accumulator Mounting Strap Cap Screw Torque
54 lb.-ft.
37 N·m
Ride Control Accumulator-to-Ride Control Valve Hydraulic Hose Torque
27 lb.-ft.
[2] -
CAUTION:
Prevent possible injury from unexpected boom or bucket movement when equipped with ride control.
Ride control accumulator energy must be discharged when working on hydraulic components.
Relieve pressure in ride control system. See Ride Control Accumulator Hydraulic Pressure Release Procedure . (Group 9025-20.)
[3] - Relieve hydraulic system pressure. See Hydraulic Circuit Pressure Release . (Group 9025-25.)
[4] -
→NOTE:
Ride control accumulator is located inside battery box attached to left frame rail.
Disconnect battery cables and remove battery box. See Battery Box Remove and Install . (Group 1913.)
[5] -
CAUTION:
To avoid injury from escaping fluid under pressure, stop engine and relieve hydraulic pressure in system
pressure.
LEGEND:
2 Upper Mounting Strap
3 Lower Mounting Strap
Ride Control Accumulator-to-Ride Control Valve
5
Hydraulic Hose
205 Ride Control Accumulator
Ride Control Accumulator

Disconnect ride control accumulator-to-ride control valve hydraulic hose (5) from ride control accumulator (205).

BACKHOE (g) by Belgreen v2.0
[6] -
→NOTE:
The ride control valve (204) does not have to be removed from the lower mounting strap (3).
Remove cap screws (1 and 4) and upper and lower mounting straps (2 and 3) to remove ride control accumulator.
[7] -
→NOTE:
Ride control accumulator has no serviceable internal parts.
Inspect and replace ride control accumulator if necessary.
[8] - Install ride control accumulator. Fasten with upper and lower mounting straps. Tighten mounting strap cap screws (1 and
4) to specification.
Ride Control Accumulator Mounting Strap Cap Screw Torque 73 N·m
54 lb.-ft.
[9] - Connect hydraulic hose and tighten to specification.

Ride Control Accumulator-to-Ride Control Valve Hydraulic Hose Torque 37 N·m
27 lb.-ft.
[10] - Install battery box and connect battery cables. See Battery Box Remove and Install . (Group 1913.)
[11] - Charge ride control accumulator. See Ride Control Accumulator Charge Procedure . (Group 9025-20.)

Section 33 - BACKHOE
Table of contents
Group 3302 - Bucket ................................................................................................................................ 1
Backhoe Bucket and Bucket Links Remove and Install ......................................................................... 1
Backhoe Bucket Tooth Tips Remove and Install ................................................................................... 2
Bucket Tooth Shank Remove and Install .............................................................................................. 3
Backhoe Bucket Cutting Edge Remove and Install ............................................................................... 6
Group 3315 - Control Linkage ................................................................................................................ 8
Backhoe Control Valve Linkage Remove and Install—Two Lever .......................................................... 8
Backhoe Control Valve Linkage Disassemble and Assemble—Two Lever ........................................... 11
Backhoe Auxiliary Pedal Remove and Install—Fifth and Sixth Functions ............................................ 15
Backhoe Auxiliary Pedal Disassemble and Assemble—Fifth and Sixth Functions ............................... 19
Backhoe Pilot Control Valve Remove and Install ................................................................................ 25
Backhoe Pilot Control Valve Disassemble and Assemble .................................................................... 32
Backhoe Pilot Control Tower Remove and Install ............................................................................... 36
Backhoe Pilot Control Tower Disassemble and Assemble ................................................................... 42
Group 3340 - Frames ............................................................................................................................. 51
Dipperstick Remove and Install .......................................................................................................... 51
Backhoe Boom Remove and Install .................................................................................................... 54
Swing Frame Remove and Install ....................................................................................................... 56
Dipperstick Extension Remove and Install .......................................................................................... 58
Sideshift Frame Remove and Install ................................................................................................... 63
Backhoe Control Valve Remove and Install ........................................................................................ 66
Backhoe Control Valve Disassemble and Assemble ........................................................................... 78
Backhoe Control Valve Spool Seals Remove and Install ..................................................................... 81
Backhoe Control Valve Relief Valves Remove and Install ................................................................... 86
Backhoe Inlet Section Disassemble and Assemble ............................................................................. 88
Backhoe Boom Section Disassemble and Assemble ........................................................................... 91
Backhoe Bucket Section Disassemble and Assemble ......................................................................... 98
Backhoe Crowd Section Disassemble and Assemble ........................................................................ 104
Backhoe Swing Section Disassemble and Assemble ........................................................................ 111
Backhoe Auxiliary Section Disassemble and Assemble—If Equipped ............................................... 117
Backhoe Auxiliary Selective Flow Control Section Disassemble and Assemble—If Equipped ........... 121
Pilot Enable and Pattern Select Valve Remove and Install ............................................................... 125
Pilot Enable and Pattern Select Valve Disassemble and Assemble ................................................... 128
Backhoe Boom Cylinder Remove and Install .................................................................................... 130
Backhoe Boom Cylinder Disassemble and Assemble ....................................................................... 132
Backhoe Bucket Cylinder Remove and Install .................................................................................. 133
Backhoe Bucket Cylinder Disassemble and Assemble ...................................................................... 134
Backhoe Crowd Cylinder Remove and Install ................................................................................... 135
Backhoe Crowd Cylinder Disassemble and Assemble ....................................................................... 137
Backhoe Stabilizer Cylinder Remove and Install ............................................................................... 138
Backhoe Stabilizer Cylinder Disassemble and Assemble .................................................................. 139
Backhoe Swing Cylinder Remove and Install .................................................................................... 140
Backhoe Swing Cylinder Disassemble and Assemble ....................................................................... 142
Backhoe Extendable Dipperstick Cylinder Remove and Install ......................................................... 143
Backhoe Extendable Dipperstick Cylinder Disassemble and Assemble ............................................ 144
Backhoe Boom Lock Cylinder Remove and Install ............................................................................ 145
Backhoe Boom Lock Valve Remove and Install—(S.N. —232969) .................................................... 147
Backhoe Sideshift Lock Valve Remove and Install—(S.N. —232969) ................................................ 149
Backhoe Sideshift Lock Valve Disassemble and Assemble—(S.N. —232969) ................................... 152

Backhoe Sideshift Lock Valve Disassemble and Assemble—(S.N. 255930—) ................................... 154
Backhoe Sideshift Lock Piston and Bushing Remove and Install ...................................................... 157

Section 33 - BACKHOE Group 3302: Bucket
Group 3302 - Bucket

Backhoe Bucket and Bucket Links Remove and Install
LEGEND:
3 Pin
5 Pin (2 used)
8 Pin (2 used)
Pins, Snap Rings, and Washers
[2] - Lower bucket to ground.
[3] - Remove snap rings (1).
[4] - Remove washers (2) and pin (3).
[5] - Remove pin retainers (4) and pins (5).
[6] - Remove bucket links.
[7] - Remove cotter pins (6).
[8] - Remove washers (7) and pins (8).
[9] - Remove bucket links (9).
[11] - Inspect bushings and replace as necessary. For ease of removing bushings, weld three straight beads the inside length
of the bushing. Allow bushing to cool before removing with a punch. Install new bushings even with outside surface of bucket
using D01072AA Seal Driver Set.
Bushing, Bearing and Seal Driver Set
D01072AA
Used to install bushings in bucket links.
[12] - Install bucket links.
[13] - Install washers (7) and pins (8).
[14] - Install cotter pins.

[15] - Install bucket links.
[16] - Align bucket with pin boss holes. Install pins (5).
[17] - Install pin retainers.
[18] - Install washers, pin (3), and snap rings.
Backhoe Bucket Tooth Tips Remove and Install

There are two types of teeth used on the backhoe bucket.
For removal and installation information see one of the following:
Replacing Bucket Teeth—Flex Pin . (Operator’s Manual.)

Replacing Bucket Teeth—TK Series . (Operator’s Manual.)

Bucket Tooth Shank Remove and Install

[1] -
Top Weld
Remove top and bottom welds using air arc equipment or cutting torch.
[2] -
Bottom Weld
Grind all surfaces to a smooth finish.
[3] -
Smooth All Surfaces
IMPORTANT:
Shanks and cutting edge must be preheated to 177°C (350°F) to prevent under bead cracking in shank
and brittleness in cutting edge. Preheat each shank and cutting edge area just before welding. Use low
hydrogen E-7018 dry rods or E-70T-4 flux core process.
Position shanks on cutting edge. Preheat area to be welded just before welding to 177°C (350°F).
[4] -
Welding Front of Tooth Shank

LEGEND:
1 Bevel Weld and Fillet Weld
2 Angle Weld
3 Bevel Weld
4 Weld Free Area
6 Angle Weld
Start welds on top of shank, the long part. On corner shanks, weld area with a bevel weld (1). Penetrate 3 mm (0.12 in.) and
leave a 5 mm (0.20 in.) face. Fill entire area between shank and side cutter level with top of shank. Cap this area with a 9 mm
(0.35 in.) fillet weld (1). Weld all the way to edge of cutting edge.
[5] - Weld area of corner shank with an angle weld (2), 6 mm (0.24 in.) deep and 11 mm (0.43 in.) across face.
[6] - Weld area of corner shank with a bevel weld (3). Penetrate 3 mm (0.12 in.) and leave a 5 mm (0.20 in.) face. Cap that
weld with a 11 mm (0.43 in.) fillet weld. Leave area (4) free of weld for 19 mm (0.75 in.).
[7] - On center shanks, weld areas with a bevel weld (5). Penetrate 3 mm (0.12 in.) and leave a 5 mm (0.20 in.) face. Cover
with a 9 mm (0.35 in.) fillet weld (5).
[8] - Weld area with an angle weld (6), 6 mm (0.24 in.) deep and 11 mm (0.43 in.) across face.
[9] -

LEGEND:
10 Weld Free Area
11 Bevel Weld and Fillet
12 Angle Weld
Welding Back of Tooth Shank

Turn bucket over and weld bottom of shank to cutting edge. On corner shank, weld area with bevel weld (7). Penetrate 3 mm
(0.12 in.) and leave a 5 mm (0.20 in.) face. Cover with 11 mm (0.43 in.) fillet weld (7). Weld all the way to edge of cutting edge.
[10] - Weld area with bevel weld (8). Penetrate 3 mm (0.12 in.) and leave a 5 mm (0.20 in.) face. Cover with 9 mm (0.35 in.)
fillet weld (8).
[11] - Weld area of corner shank with bevel weld (9). Penetrate 3 mm (0.12 in.) and leave a 5 mm (0.20 in.) face. Cover with
11 mm (0.43 in.) fillet weld (9). Leave area (10) free of weld for 19 mm (0.75 in.).
[12] - On center shanks, weld areas with bevel weld (11). Penetrate 3 mm (0.12 in.) and leave a 5 mm (0.20 in.) face. Cover
with a 9 mm (0.35 in.) fillet weld (11). Leave area (10) free of weld for 19 mm (0.75 in.).
[13] - Weld area with angle weld (12). Penetrate 6 mm (0.24 in.) and leave a 11 mm (0.43 in.) face.

Backhoe Bucket Cutting Edge Remove and Install

[1] - Remove tooth shanks in corners. Remove all shanks if they are to be reused. See Bucket Tooth Shank Remove and Install
. (Group 3302.)
[2] -
Remove Welds
Use air arc equipment or cutting torch to remove welds. Remove all welds from cutting edge to side cutters.
[3] - Remove weld from cutting edge to bottom joint.
[4] -
Remove Weld from Cutting Edge to Bottom

Turn bucket over and remove weld from cutting edge to bottom. Do not blow through bottom.
[5] - Cut new cutting edge to proper length for bucket, approximately 11 mm (0.43 in.) protruding beyond side cutter on each
side.
[6] -
IMPORTANT:
Cutting edge must be preheated to 177°C (350°F) to prevent brittleness in cutting edge. Preheat area
just before welding. Use low hydrogen E-7018 dry rods or E-70T-4 flux core process.

Section 33 - BACKHOE Group 3315: Control Linkage
Weld Top First

Set bucket on bottom and weld top first. Position cutting edge and clamp. Preheat cutting edge to 177°C (350°F). Start at
center of cutting edge and weld toward side cutters. Use a 6 mm (0.24 in.) fillet weld.
[7] - Make 11 mm (0.43 in.) fillet weld outside bucket at cutting edge to side cutter joint. Continue weld down back edge.
[8] -
Weld Cutting Edge to Bottom

Turn bucket over and weld cutting edge to bottom with 6 mm (0.24 in.) fillet weld.
[9] - Install shanks. See Bucket Tooth Shank Remove and Install . (Group 3302.)


Backhoe Control Valve Linkage Remove and Install—Two Lever
[2] -
Control Console
LEGEND:
2 Console Cover
Remove rear floor mat.
[3] - Remove cap screws (1) and console cover (2).
[4] -

Lower Linkage Mounting Points

LEGEND:
3 Retainer (4 used)
4 Pin (4 used)
Remove retainers (3) and pins (4).
[5] -

Upper Linkage Mounting Points

LEGEND:
5 Nut (2 used)
6 Spacer (2 used)
7 Control Lever Assembly (2 used)
Remove nuts (5), spacers (6), and control lever assemblies (7).
[6] - Repair or replace parts as necessary. See Backhoe Control Valve Linkage Disassemble and Assemble—Two Lever . (Group
3315.)
[7] - Install control lever assemblies, spacers, and nuts.
[8] - Install pins and retainers.
[9] - Adjust valve linkage. See Backhoe Control Lever to Valve Linkage (Two Lever) Adjustment . (Group 9025-20.)
[10] - Install console cover and cap screws.
[11] - Install rear floor mat.

Backhoe Control Valve Linkage Disassemble and Assemble—Two Lever

Linkage Remove and Install
[1] -
→NOTE:
Follow same procedure to disassemble and assemble left control lever linkage.
Control Lever Linkage (right lever shown)

LEGEND:
1 Nut (2 used)
2 Linkage Assembly (2 used)
3 Lever Base
4 Nut
5 Link
6 Washer
7 Cap Screw
Remove nuts (1) and linkage assemblies (2) from lever base (3).
[2] - Replace parts as necessary. See Linkage Assembly Disassemble and Assemble at the end of this procedure.
[3] - Remove nut (4), link (5), washer (6), and cap screw (7) from lever base.
[4] - Replace parts as necessary. See Link Disassemble and Assemble at the end of this procedure.
[5] - Install cap screw, washer, link, and nut (4).
[6] - Install linkage assemblies and nuts (1).

Linkage Assembly Disassemble and Assemble
[1] -
Linkage Assembled
Linkage Disassembled
LEGEND:
1 Nut
8 Ball Joint
9 Yoke
11 Rod
Loosen lock nuts (10).
[2] - Remove ball joint (8), yoke (9), and lock nuts (10) from rod (11).
[4] - Install nuts, yoke, and ball joint to rod.
Link Assembly Disassemble and Assemble

[1] -
Link Assembled
Link Disassembled
LEGEND:
4 Nut
5 Link

6 Washer
7 Cap Screw
12 Nut
Remove nut (12) from link (5).
[3] - Install nut (12) to link.

Backhoe Auxiliary Pedal Remove and Install—Fifth and Sixth Functions

Manual Controls
[1] -
→NOTE:
Pedal remove and install is the same for fifth and sixth function pedal assemblies. This procedure utilizes
the fifth function pedal to describe remove and install steps.
[2] -
Control Lever Console

LEGEND:
2 Console Cover
3 Fifth Function Pedal Assembly
4 Sixth Function Pedal Assembly
[3] - Remove cap screws (1) and console cover (2).
[4] -

Pedal Linkage (fifth function pedal assembly shown)

LEGEND:
5 Retainer
6 Pin
7 Nut
Remove retainer (5) and pin (6).
[5] - Remove nut (7) and pedal linkage assembly.
[6] - Repair or replace parts as necessary. See Backhoe Auxiliary Pedal Disassemble and Assemble—Fifth and Sixth Functions .
(Group 3315.)
[7] - Install pedal linkage assembly and nut.
[8] - Install pin and retainer.
[9] - Install console cover and cap screws.
Pilot Controls
[1] -
→NOTE:
Pedal remove and install is the same for fifth and sixth function pedal assemblies. This procedure utilizes
the sixth function pedal to describe remove and install steps.

[2] -
Auxiliary Pedals
LEGEND:
1 Cap Screw (4 used) (if equipped)
2 Fifth Function Pedal
3 Sixth Function Pedal (if equipped)
5 Linkage Cover
[3] - Remove cap screws (1) and fifth and sixth function pedals (2 and 3).
[4] - Remove cap screws (4) and linkage cover (5).
[5] -

Pedal Linkage
LEGEND:
6 Retainer
7 Pin
9 Pedal Linkage Assembly
Remove retainer (6) and pin (7).
[6] - Remove cap screws (8) and pedal linkage assembly (9).
[7] - Repair or replace parts as necessary. See Backhoe Auxiliary Pedal Disassemble and Assemble—Fifth and Sixth Functions .
(Group 3315.)
[8] - Install pedal linkage assembly and cap screws (8).
[9] - Install pin and retainer.
[10] - Install linkage cover and cap screws (4).
[11] - Install fifth and sixth function pedals and cap screws (1).

Backhoe Auxiliary Pedal Disassemble and Assemble—Fifth and Sixth

Functions
Manual Controls
[1] -
→NOTE:
Pedal disassemble and assemble is the same for fifth and sixth function pedal assemblies. This procedure
utilizes the fifth function pedal to describe disassemble and assemble steps.
Pedal Assembly
LEGEND:
1 Nut
2 Linkage Assembly
3 Pedal
Remove nut (1) and linkage assembly (2) from pedal (3).
[2] - Replace linkage assembly parts as necessary. See Linkage Disassemble and Assembleat end of this procedure.
[3] -

Pedal Assembled
Pedal Disassembled
LEGEND:
3 Pedal
4 Nut
5 Spring Washer (2 used)
6 Bushing (2 used)
7 Washer
8 Cap Screw
9 Grommet
Remove nut (4), spring washers (5), bushings (6), washer (7), and cap screw (8) from pedal (3).
[4] - Remove grommet (9) from pedal.
[6] - Install grommet to pedal.
[7] - Install cap screw, washer, bushings, spring washers, and nut (4) to pedal.
[8] - Tighten nut (4) until spring washers are to specification.

Spring Washer Clearance 1.5 mm
0.06 in.
[9] - Install linkage assembly and nut (1).
Pilot Controls
[1] -
→NOTE:
Pedal disassemble and assemble is the same for fifth and sixth function pedal assemblies. This procedure
utilizes the fifth function pedal to describe disassemble and assemble steps.
Pedal Base Assembly

LEGEND:
10 Nut
11 Linkage Assembly
12 Pedal Pivot
Remove nut (10) and linkage assembly (11) from pedal pivot (12).

[2] - Replace linkage assembly parts as necessary. See Linkage Disassemble and Assemble.
[3] -
Pedal Base and Pivot Assembled
Pedal Base and Pivot Disassembled

LEGEND:
12 Pedal Pivot
13 Nut
14 Washer
15 Bushing (2 used)
16 Cap Screw
17 Mounting Bracket

Remove nut (13), washer (14), bushings (15), pedal pivot, and cap screw (16) from mounting bracket (17).
[5] - Install cap screw, pedal pivot, bushings, washer, and nut (13) to mounting bracket.
[6] - Install linkage assembly and nut (10).
Linkage Disassemble and Assemble
[1] -
Linkage Assembled
Linkage Disassembled
LEGEND:
18 Ball Joint
19 Yoke
21 Rod
Loosen lock nuts (20).
[2] - Remove ball joint (18), yoke (19), and lock nuts, from rod (21).

[4] - Install nuts (20), yoke, and ball joint to rod.

Backhoe Pilot Control Valve Remove and Install

Essential Tools
ESSENTIAL TOOLS
Right Pilot Control Remove and Install
[4] - Remove protective boot from controller.
[5] -
Right Pilot Control Tower

LEGEND:
2 Lower Control Tower Cover
Remove cap screws (1) and lower control tower cover (2).
[6] -


LEGEND:
4 Upper Control Tower Cover
S52 Pilot Enable Switch
Disconnect electrical connector to pilot enable switch (S52).
[7] - Remove cap screws (3) and upper control tower cover (4).
[8] -

Right Pilot Controller

LEGEND:
136 Pilot Control (right)
Tag and disconnect all hoses to pilot control (136).
Disconnect STC hose fitting by performing the following:
a. Clean around the STC fittings.

IMPORTANT:
Do not pry against release sleeve or damage to fitting could result.
Do not force release sleeve beyond normal range of travel, otherwise release sleeve could fall off
when hose is disconnected. If damaged fitting is connected without the release sleeve installed,
fitting will not disconnect again.
Insert JDG1385 STC Hose and Line Fitting Tool between release sleeve and shoulder of fitting.
JDG1385
Disconnect Snap-to-Connect® Fittings.
c. Gently push, do not pry, release sleeve away from shoulder to disconnect the STC fitting.
d. Pull hydraulic hose to disconnect.
Close all openings using caps and plugs.
[9] - Remove cap screws (5) and pilot controller.

[10] - Repair or replace pilot controller as necessary. See Backhoe Pilot Control Valve Disassemble and Assemble . (Group
3315.)
[11] - Install pilot controller and cap screws (5).
[13] - Install upper control tower cover and cap screws (3).
[14] - Connect electrical connector to pilot enable switch.
[15] - Install lower control tower cover and cap screws (1).
[16] - Install protective boot.
Left Pilot Control Remove and Install
[4] - Remove protective boot from controller.
[5] -
Left Pilot Control Tower

LEGEND:
2 Lower Control Tower Cover
Remove cap screws (1) and lower control tower cover (2).
[6] -

LEGEND:
4 Upper Control Tower Cover
Remove cap screws (3) and upper control tower cover (4).
[7] -

Left Pilot Controller

LEGEND:
135 Pilot Control (left)
Tag and disconnect all hoses to pilot control (135).
Disconnect STC hose fitting by performing the following:

IMPORTANT:
when hose is disconnected. If damaged fitting is connected without the release sleeve installed,
JDG1385
d. Pull hydraulic hose to disconnect.
[8] - Repair or replace pilot controller as necessary. See Backhoe Pilot Control Valve Disassemble and Assemble . (Group
3315.)

[9] - Install pilot controller and cap screws (5).
[11] - Install upper control tower cover and cap screws (3).
[12] - Install lower control tower cover and cap screws (1).
[13] - Install protective boot.

Backhoe Pilot Control Valve Disassemble and Assemble

Specifications
SPECIFICATIONS
34 N·m
Hex Nut-to-Universal Joint Torque
25 lb.-ft.
45 N·m
Universal Joint-to-Housing Torque
33 lb.-ft.
24 N·m
Adapter-to-Housing Torque
18 lb.-ft.
[1] -
→NOTE:
There is one orifice used for each pilot control valve. Left pilot control valve uses an orifice in work port 2
and right pilot control valve used an orifice in work port 3.
The orifices function one-way, they restrict flow only for oil returning to the pilot control valve. Flow out
of the pilot control valve is free flowing.

Backhoe Pilot Control Valve

LEGEND:
1 Fitting
2 O-Ring (5 used)
3 Adapter (5 used)
4 O-Ring (5 used)
5 Orifice (2 used)
6 Housing
7 Spring (4 used)
8 Spool (4 used)
9 Retainer Ring (8 used)
10 Spring (4 used)
11 Seat (4 used)
12 Plunger (4 used)
13 O-Ring (4 used)
14 Bearing (4 used)
15 Seal (4 used)
16 Plate
17 Washer (4 used)
19 Universal Joint
20 Plate
21 Nut
22 Handle
Plunger Assembly
LEGEND:
12 Plunger
13 O-Ring (4 used)
14 Bearing
15 Seal (4 used)
Remove fitting (1), O-rings (2), adapters (3), O-rings (4), and orifice (5).
[2] - Remove housing (6), springs (7), spools (8), retainer rings (9), and springs (10).
[3] - Remove seats (11), plungers (12), O-rings (13), and bearings (14).
[4] - Remove seals (15), plate (16), cap screws (18), washers (17), and universal joint (19).
[5] - Remove plate (20), nut (21), and handle (22).
[6] - Lubricate all seals and O-rings with hydraulic oil before assembly.
[7] - Install seals (15), bearings (14), and O-rings (13).
[8] - Install handle, nut, plate, and universal joint.
[9] - Install washers, cap screws, and plate.
[10] - Install bearings, O-rings (13), plungers, seats (11), and springs (10).
[11] - Install retainer rings, spools, springs (7), and housing.
[12] - Install orifice (5) in proper work port as needed, depending on right or left side valve.
[13] - Install O-rings (4), adapters, O-rings (2), and fitting.
[14] - Tighten nut (21), adapters (3), and universal joint (19) to specification.
Hex Nut-to-Universal joint Torque 34 N·m
25 lb.-ft.
Universal Joint-to-Housing Torque 45 N·m
33 lb.-ft.

Adapter-to-Housing Torque 24 N·m
18 lb.-ft.

Backhoe Pilot Control Tower Remove and Install

Right Pilot Control Remove and Install
[4] - Drain hydraulic oil reservoir or apply vacuum. See Change Hydraulic Reservoir Oil (Operator′s Manual) or see Apply
[5] -
Floor Plate, Boom Lock Lever, and Auxiliary Controls

LEGEND:
1 Cap Screw (if equipped, 4 used)
2 Auxiliary Control Pedal (if equipped, 2 used)
3 Backhoe Boom Lock Control Lever Knob
5 Console Cover
6 Backhoe Boom Lock Control Lever
8 Rear Floor Access Plate
[6] - If equipped, remove cap screws (1) and auxiliary control pedals (2).
[7] - Remove backhoe boom lock control lever knob (3).

[9] - Remove console cover (5) by sliding it over backhoe boom lock lever (6).
[10] - Remove cap screws (7) and rear floor access plate (8).
[11] -

LEGEND:
11 Right Pilot Control Tower
Install identification tags and disconnect hydraulic hoses (9).
Disconnect Snap-to-Connect (STC) ™ fitting lines by performing the following:

IMPORTANT:
when hose is disconnected. If damage fitting is connected without the release sleeve installed,
STC Hose and Line Fitting Tool
JDG1385

d. Pull hydraulic line to disconnect.
[12] - Disconnect pilot enable switch harness connector (X53).
[13] - Remove cap screws (10) and right pilot control tower (11).
[15] - Install right pilot control tower and cap screws (10).
[16] - Connect pilot enable switch harness connector.
[18] - Install rear floor access plate, console cover, and cap screws (4 and 7).
[19] - Install backhoe boom lock control lever knob.
Left Pilot Control Remove and Install
[4] - Drain hydraulic oil reservoir or apply vacuum. See Change Hydraulic Reservoir Oil (Operator′s Manual) see Apply Vacuum
to Hydraulic Oil Reservoir . (Group 2160.)
[5] -


LEGEND:
1 Cap Screw (if equipped, 4 used)
2 Auxiliary Control Pedal (if equipped, 2 used)
5 Console Cover
[6] - If equipped, remove cap screws (1) and auxiliary control pedals (2).
[9] - Remove console cover (5) by sliding it over backhoe boom lock control lever (6).
[11] -

LEGEND:
10 Washer (3 used)
12 Stabilizer Console Cover
Stabilizer Control Cover

[12] - Remove cap screws (11) and stabilizer console cover (12).
[13] -

LEGEND:
15 Left Pilot Control Tower
Install identification tags and disconnect hydraulic hoses (13).

Disconnect STC fitting lines by performing the following:

IMPORTANT:
JDG1385
[14] - Remove cap screws (14) and left pilot control tower (15).
[16] - Install left pilot control tower and cap screws (14).
[18] - Install stabilizer console cover, washers, and cap screws (9 and 11).
[19] - Install rear floor access plate, console cover, and cap screws (4 and 7).
[20] - If equipped, install auxiliary control pedals and cap screws (1).

Backhoe Pilot Control Tower Disassemble and Assemble

Right Pilot Control Tower Disassemble and Assemble
[1] - Remove pilot control valve and shields. See Backhoe Pilot Control Valve Remove and Install . (Group 3315.)
[2] -
Hydraulic Hoses and Guide

LEGEND:
2 Hose Guide
W31 Pilot Enable Switch Harness (right control tower only)
Remove plastic fasteners (1) and hose guide (2).
[3] - Remove hydraulic hoses (3).
[4] - Remove pilot enable switch harness (W31).
[5] -

Wrist Support
LEGEND:
4 Adjustment Lever
5 Washer
6 Cap Screw
7 Washer
8 Spring Washer
9 Nut
10 Wrist Support
Remove adjustment lever (4) and washer (5).
[6] - Remove cap screw (6), washer (7), spring washer (8), nut (9), and wrist support (10).
[7] -

Cylinder Removal
LEGEND:
11 Cap Screw
12 Washer (3 used)
13 Nut
14 Cap Screw
15 Washer (4 used)
16 Spacer
17 Nut
18 Shock
Remove cap screw (11), washers (12), and nut (13).
[8] - Remove cap screw (14), washers (15), spacer (16), nut (17), and shock (18).
[9] -

Arm Removal
LEGEND:
19 Snap Ring
20 Washer
21 Arm
22 Bearing (2 used)
24 Washer (2 used)
25 Spacer
26 Nut (2 used)
27 Bushing
Remove snap ring (19), washer (20), and arm (21).
[10] - Remove bearings (22).
[11] - Remove cap screws (23), washers (24), spacer (25), nuts (26), and bushing (27).
[12] - Inspect parts for excessive wear or damage. Replace as necessary.
[13] - Install bushing, spacer (25), nuts (26), washers (24), and cap screws (23).
[14] - Install bearings.
[15] - Install arm, washer (20), and snap ring.
[16] -
→NOTE:
Shock should be installed rod end down to extend shock life.
Install shock, nuts (13 and 17), spacer, washers (12 and 15), and cap screws (11 and 14).

[17] - Install wrist support, nut (9), spring washer, washer (7), and cap screw (6).
[18] - Install washer (5), and adjustment lever.
[19] - Install pilot enable switch harness (W31).
[21] - Install hose guide and plastic fasteners.
[22] - Install pilot control valve and shields. See Backhoe Pilot Control Valve Remove and Install . (Group 3315.)
Left Pilot Control Tower Disassemble and Assemble
[1] - Remove pilot control valve and shields. See Backhoe Pilot Control Valve Remove and Install . (Group 3315.)
[2] -
Hydraulic Hoses and Guide

LEGEND:
2 Hose Guide
Remove plastic fasteners (1) and hose guide (2).
[3] - Remove hydraulic hoses (3).
[4] -

Wrist Support Removal

LEGEND:
4 Adjustment Lever
5 Washer
6 Cap Screw
7 Washer
8 Spring Washer
9 Nut
10 Wrist Support
Remove adjustment lever (4) and washer (5).
[5] - Remove cap screw (6), washer (7), spring washer (8), nut (9), and wrist support (10).
[6] -

Shock Removal
LEGEND:
11 Cap Screw
12 Washer (3 used)
13 Nut
14 Cap Screw
15 Washer (2 used)
16 Shock
Remove cap screw (11), washers (12), and nut (13).
[7] - Remove cap screw (14), washers (15), and shock (16).
[8] -

Arm Removal
LEGEND:
17 Snap Ring
18 Washer
19 Arm
20 Bearing (2 used)
22 Spacer (2 used)
23 Washer (2 used)
24 Nut (2 used)
Remove snap ring (17), washer (18), and arm (19).
[9] - Remove bearings (20).
[10] - Remove cap screws (21), spacers (22), washers (23), and nuts (24).
[11] - Inspect parts for excessive wear or damage. Replace as necessary.
[12] - Install nuts (24), washers (22), spacers, and cap screws (21).
[13] - Install bearings.
[14] - Install arm, washer (18), and snap ring.
[15] -
→NOTE:
Shock should be installed rod end down to extend shock life.
Install shock, washers (12 and 15), cap screws (11 and 14), and nut (13).

Section 33 - BACKHOE Group 3340: Frames
[16] - Install wrist support, nut (9), spring washer, washer (7), and cap screw (6).
[17] - Install washer (5) and adjustment lever.
[18] - Install hydraulic hoses, hose guide, and plastic fasteners.
[19] - Install pilot control valve and shields. See Backhoe Pilot Control Valve Remove and Install . (Group 3315.)

Group 3340 - Frames

Dipperstick Remove and Install
Specifications
SPECIFICATIONS
204 kg
Dipperstick with Bucket Cylinder and Links Weight (approximate)
450 lb.
620 N·m
Dipperstick-to-Boom Connecting Pin Cap Screw Torque
460 lb.-ft.
[2] -
High Pressure Fluid

LEGEND:
1 Bucket Cylinder Line (2 used)
2 Crowd Cylinder-to-Dipperstick Pin
3 Boom-to-Dipperstick Pin
Dipperstick Remove and Install

Extend boom and dipperstick straight out. Put a floor stand under outer end of boom. Support dipperstick with a hoist.
[3] - Stop engine. Place transmission control lever (TCL) in neutral and set park brake.
[4] - Release hydraulic system pressure. See Hydraulic Circuit Pressure Release . (Group 9025.)
[5] - Remove backhoe bucket and bucket links. See Backhoe Bucket and Bucket Links Remove and Install . (Group 3302.)
[6] -

CAUTION:
pressure.
Tag and remove bucket cylinder lines (1). Close all openings using caps and plugs.
[7] - Remove crowd cylinder-to-dipperstick pin (2).
[8] -
CAUTION:
→NOTE:
If bucket links are removed, fasten rod end of bucket cylinder to dipperstick.
Remove boom-to-dipperstick pin (3), washers, and shims.Remove dipperstick using a hoist.
Dipperstick with Bucket Cylinder and Links Weight (approximate) 204 kg
450 lb.
[10] -
Dipperstick Adjustment
LEGEND:
3 Boom-to-Dipperstick Pin
6 Outer Plate
8 Cap Screw
9 Washer
11 Washer
Install boom to dipperstick with pin (5).
[11] - Adjust dipperstick and boom
Use shims (10) if pin (6) does not extend to surface of outer plate (6). Shim until flush with outer plate surface.
Use shims (7) if pin (6) extends beyond surface of outer plate. Shim until flush with end of pin.
[12] - Install cap screw (8) and washer (9). Tighten cap screw to specifications.
Pin Cap Screw Torque 620 N·m
460 lb.-ft.
[13] - Align crowd cylinder; install pin, shims, washer, and cap screw.
[14] - Connect bucket cylinder lines.
[15] - Install backhoe bucket and bucket links. See Backhoe Bucket and Bucket Links Remove and Install . (Group 3302.)

Backhoe Boom Remove and Install

Specifications
SPECIFICATIONS
385 kg
Boom with Cylinders Weight (approximate)
850 lb.
[1] - Park and prepare machine for service. See Park and Prepare for Service Safely (Group 0001.)
[2] - Stop engine. Place transmission control lever (TCL) in neutral and set park brake.
[4] - Remove dipperstick. See Dipperstick Remove and Install . (Group 3340.)
[5] -
CAUTION:
Support boom with a hoist.

Boom with Cylinders Weight (approximate) 385 kg
850 lb.
[6] -
CAUTION:
High Pressure Fluid

pressure.

LEGEND:
1 Hydraulic Line (4 used)
2 Pivot (2 used)
4 Collar (2 used)
5 Pin
Boom Remove and Install

Tag and disconnect hydraulic lines (1). Close all openings using caps and plugs.
[7] - Remove pivots (2) and boom cylinder rod end pin.
[9] - Remove snap rings (6), pin (5), and collars (4).
[10] - Remove boom.
[11] - Repair or replace boom, as necessary.
[12] - Install boom and cap screws.
[13] - Install pivots, boom cylinder rod end pin, collar, and snap rings.
[14] - Connect hydraulic lines to backhoe control valve.
[15] - Install dipperstick to boom. See Dipperstick Remove and Install . (Group 3340.)

Swing Frame Remove and Install

Specifications
SPECIFICATIONS
129 kg
Swing Frame (310K-410K) Weight (approximate)
284 lb.
298 kg
Swing Frame (710K) Weight (approximate)
657 lb.
[2] -
Swing Frame
LEGEND:
1 Swing Frame
2 Boom Lock Rod
3 Boom Lock Hook
4 Cap screw (2 used)
5 Washer (2 used)
6 Hose Guard
7 Swing Cylinder Locking Snap Ring and Rod
8 Pin (2 used)
9 Upper Pivot Locking Cap Screw
11 Lower Pivot Locking Cap Screw
12 Upper Pivot Pin
13 Thrust Washer
Lower Pivot Joint
14 Lower Shim
Remove dipperstick. See Dipperstick Remove and Install . (Group 3340.)
[3] - Remove boom. See Backhoe Boom Remove and Install . (Group 3340.)
[4] -
CAUTION:
Connect swing frame (1) to hoist using a lift strap.

Swing Frame (310K-410K) Weight (approximate) 129 kg
284 lb.
Swing Frame (710K) Weight (approximate) 298 kg

657 lb.
[5] - Remove boom lock rod (2) from boom lock hook (3).
[7] - Remove hose guard (6) from swing frame.
[8] - Remove swing cylinder locking snap ring and rod (7) from swing frame.
[9] - Remove pin (8) from swing frame.
[10] - Remove upper pivot locking cap screw (9) and lock nut (10) from the swing frame.
[11] - Remove lower pivot locking cap screw (11) and lock nut (10) from the swing frame.
[12] - Remove upper pivot pin (12), thrust washer (13), and lower shim (14) from both the top and lower mainframe pivot boss
of the swing frame.
[13] - Remove swing frame.
[15] -
→NOTE:
Weight of backhoe is supported at the lower pivot. There must be clearance between upper main frame
pivot boss and the ears of the swing frame.
Install thrust washer on top of lower mainframe pivot boss.
[16] -
→NOTE:
Install swing frame pins so that cross-drilled holes align with holes in swing frame to ease hardware
installation.
Position swing frame and install upper pivot pin. Secure in position with upper pivot locking cap screw and nut.
[17] - Align thrust washer with pin bore. Install lower pivot pin and secure in position with lower pivot locking cap screw and
nut.
[18] - Align swing cylinders and install pins from the bottom. Top of pins should be even with casting. Secure in position with
swing cylinder locking snap ring and rod.
[19] - Install hose guard, washers, and cap screws.
[20] - Install boom lock rod into boom lock hook.
[21] - Install boom. See Backhoe Boom Remove and Install . (Group 3340.)
[22] - Install dipperstick. See Dipperstick Remove and Install . (Group 3340.)

Dipperstick Extension Remove and Install

Specifications
SPECIFICATIONS
385 kg
Dipperstick Extension Weight (approximate)
850 lb.
73 N·m
Rod End Hose-to-Fitting Torque
54 lb.-ft.
73 N·m
Head End Hose-to-Elbow Fitting Torque
54 lb.-ft.
100 N·m
Elbow Fitting-to-Extendable Cylinder Head End Torque
74 lb.-ft.
22—27 N·m
Extendable Dipperstick Hex Socket Cap Screws for Internal Wear Plates Torque
16—20 lb.-ft.
104 N·m
Extendable Cylinder Head End 90° Fitting Torque
76 lb.-ft.
47—54 N·m
Extendable Dipperstick Hex Socket Cap Screws for Outer Pads Torque
35—40 lb.-ft.
Other Material
OTHER MATERIAL
LOCTITE ™ Klean ‘N Prime™
242 LOCTITE ™ Thread Lock and Sealer (medium strength)
[1] -
LEGEND:
1 Bucket Cylinder
2 Lifting Strap
3 Dipperstick (extending member)
4 Extension Locking Pin
5 Extending Cylinder Rod End Pin
Dipperstick Extension in Vertical Position

Park machine on level surface. Extend boom and extendable dipperstick to maximum reach with bucket dumped and lowered
to ground.
[3] - Remove bucket and bucket links. See Backhoe Bucket and Bucket Links Remove and Install . (Group 3302.)

[5] -
CAUTION:
Tag and disconnect hydraulic hoses from bucket cylinder (1). Close all openings using caps and plugs.
[6] - Secure bucket cylinder to dipperstick. Let hoses and lines hang to side.
[7] -
CAUTION:
Prevent possible crushing injury from heavy component. Use appropriate lifting device. Make sure hoist
is attached to dipperstick extension. When extendable cylinder rod end pin is removed, dipperstick
extension can drop suddenly.
Install proper lifting strap (2) to dipperstick extending member (3).

Dipperstick Extension Weight (approximate) 385 kg
850 lb.
[8] - Remove extension locking pin (4) and extending cylinder rod end pin (5).
[9] - Extend stabilizers fully, raise boom, and place dipperstick extension in vertical position. While raising boom and moving
dipperstick toward machine with extension supported on ground, raise boom until extension can be removed.
[10] - Lower dipperstick to the ground.
[11] -
Extendible Dipperstick Removal

LEGEND:
8 Hose, Rod End
9 Hose, Head End
10 Snap Ring
11 Pin
Disconnect rod end hose (8) and head end hose (9) from top of dipperstick.
[12] - Remove snap ring (10) and pin (11).
[13] - Slowly raise dipperstick and support extendible dipperstick cylinder with appropriate lifting device.
[14] -
Wear Plate Removal

LEGEND:
14 Lock Nut (3 used per wear plate)
15 Washer (3 used per wear plate)
16 Cap Screw (3 used per wear plate)
17 Wear Plate (2 used)
18 Shim (as needed)
Remove lock nuts (14), washers (15), and cap screws (16).
[15] - Remove wear plates (17 and 19) and shims (18) (if equipped).
[16] - Inspect internal dipperstick wear plates.
[18] -

Extendable Dipperstick Cylinder

LEGEND:
8 Hose, Rod End
9 Hose, Head End
24 O-Ring (2 Used)
25 Fitting
26 O-Ring
27 Elbow Fitting
28 O-Ring
29 Extendable Cylinder
Remove rod end hose (8) and head end hose (9).
[19] - Remove O-rings (24) and fitting (25) from rod end hose.
[20] - Remove O-rings (26 and 28) and elbow fitting (27) from head end hose.
[22] - Install O-rings (26 and 28) and elbow fitting to head end hose, tighten to specifications.
Head End Hose-to-Elbow Fitting Torque 73 N·m
54 lb.-ft.
[23] - Install fitting to extendable cylinder head end.

Elbow Fitting to Extendable Cylinder Head End Torque 100 N·m
74 lb.-ft.
[24] - Install O-rings (24) and fitting (25) to rod end hose, tighten to specifications.
Rod End Hose-to-Fitting Torque 73 N·m
54 lb.-ft.
[25] -
IMPORTANT:
It is important to maintain running clearance between pad, inner, and outer members of extension.
Do not damage shims. Only put in enough shims to fill clearance, then remove one shim.
Locking nuts should be replaced if removed to prevent loosening.
Install shims as required, to fill clearance and remove one shim. For every three shims added, remove a washer from under

head of cap screws to allow adequate thread engagement.
[26] - Install wear plates (17 and 19) with cap screws (16), washers (15), and lock nuts (14).
[27] - Apply PM37509 Klean ‘N Prime™ and PM37418 Thread Lock and Sealer to threads of cap screws.
[28] -
IMPORTANT:
Do not over tighten cap screws or wear plate deformation may result.
Tighten cap screws to specification.
Number Name Use

• PM37509 (us)
Klean ‘N Prime™ Apply to cap screws threads.
• PM37418 (us)
Thread Lock and Sealer (Medium Strength) Apply to threads of cap screws.
Extendable Dipperstick Cap Screws for Internal wear plates Torque 22—27 N·m
16—20 lb.-ft.
Extendable Dipperstick Cap Screws for Outer Pads Torque 47—54 N·m
35—40 lb.-ft.
[29] - Apply a light film of grease on wear pads.
[30] - Install extendible dipperstick cylinder to dipperstick. Install pin and snap ring.
[31] - Connect rod end hose and head end hose to fittings at top dipperstick.
[32] -
CAUTION:
Using proper lifting device, lift extension to vertical position. With stabilizers fully extended, raise boom and install dipperstick
into extension.
Dipperstick Extension Weight (approximate) 385 kg
850 lb.
[33] - Install extension locking pin (4) and extending cylinder rod end pin (5).
[34] - Connect all hydraulic hoses.
[35] - Remove proper lifting device from dipperstick extending member.
[36] - Install bucket cylinder. See Backhoe Bucket Cylinder Remove and Install . (Group 3360.)
[37] - Install bucket, links, and quick couplers (if equipped). See Backhoe Bucket and Bucket Links Remove and Install . (Group
3302.)
[38] - Cycle extension in and out to ensure proper operation.

Sideshift Frame Remove and Install

Specifications
SPECIFICATIONS
363 kg
Sideshift Frame with Swing Cylinders Weight (approximate)
800 lb
[2] - Lower stabilizers and backhoe to the ground. Stop engine and release pressure in the system. See Hydraulic Circuit
Pressure Release . (Group 9025-25.)
[3] -
CAUTION:
pressure.
Tag and disconnect hydraulic hose supplying pressure oil to boom lock cylinders.
[4] - Tag and disconnect hydraulic hose supplying pressure oil to sideshift lock piston circuit (four pistons total).
[5] - Remove backhoe boom. See Backhoe Boom Remove and Install . (Group 3340.)
[6] - Remove swing frame. See Swing Frame Remove and Install . (Group 3340.)
[7] -
Sideshift Frame
LEGEND:
1 Swing Cylinder Plumbing Line
2 Lock Valve Line
3 Extendible Dipper, Supply Line
4 Extendible Dipper, Return Line
5 Crowd, Supply Line
6 Crowd, Return Line

Section 33 - BACKHOE Group 3360: Hydraulic System
7 Bucket Cylinder, Supply Line

8 Bucket Cylinder, Return Line
9 Boom, Supply Line
10 Boom, Return Line
11 Boom Lock Valve Line
Disconnect and tag hoses (2—10) on the backhoe side only. Leave hoses connected to bulkhead on the machine side. Remove
bulkhead assembly with hoses from trunnion plate and lay aside.
[8] -
CAUTION:
LEGEND:
14 Lock Bar
15 Cap Screw
16 Sideshift Frame
17 Shim (as needed)
Sideshift Frame
Attach a lifting strap and hoist to frame.
Sideshift Frame with Swing Cylinders Weight (approximate) 363 kg
800 lb
[9] - Remove lock bar (14) by removing cap screws (15) and shims (17).
[10] - Lift sideshift frame (16) with hoist to remove.
[11] - Inspect lock pistons, pivot bushing, and lock bar for wear.
[12] - Repair and replace parts as necessary.
[13] - Install frame. Frame must fit completely on top and bottom rail.
[14] - Install lock bar with as many shims (17) as possible. Use as many shims as necessary for each side.
[15] - Remove 2.0 mm (0.08 in.) thickness of shims. Check to see if frame slides without binding. Add or subtract shims as
necessary.
[16] - Install hose bulkhead assembly.
[17] - Install boom. See Backhoe Boom Remove and Install . (Group 3340.)
[18] - Install swing frame. See Swing Frame Remove and Install . (Group 3340.)
[19] - Connect boom lock and sideshift hoses.
[21] - Operate sideshift functions for proper operation.



Backhoe Control Valve Remove and Install
Specifications
SPECIFICATIONS
50 kg
Backhoe Control Valve and Mount Plate (manual) Weight (approximate)
110 lb.
68 kg
Backhoe Control Valve and Mount Plate (pilot) Weight (approximate)
150 lb.
129 N·m
Frame Mount Cap Screw Torque
95 lb.-ft.
Essential Tools
ESSENTIAL TOOLS
Manual Controls
[4] - Drain hydraulic oil reservoir or apply vacuum. See Change Hydraulic Reservoir Oil (Operator′s Manual.) or see Apply
[5] - Remove rear window. See Non-Fixed Window Remove and Install . (Group 1810.)
[6] - Remove rear floor mat.
[7] -

Manual Controls and Floor Plate (two lever shown)

LEGEND:
1 Control Lever (2 used)
2 Fifth Function Control Pedal (if equipped)
3 Sixth Function Control Pedal (if equipped)
4 Backhoe Boom Lock Lever
Remove backhoe control valve control levers (1) and linkage. See Backhoe Control Valve Linkage Remove and Install—Two
Lever . (Group 3315.)
[8] - Remove fifth and sixth function control pedals (2 and 3), if equipped. See Backhoe Auxiliary Pedal Remove and
Install—Fifth and Sixth Functions . (Group 3315.)
[9] - Remove backhoe boom lock lever (4) and linkage.
[11] -

Backhoe Control Valve Rear Connections (310SK six function shown)

LEGEND:
7 Extendible Dipperstick Cylinder Hose (2 used)
8 Crowd Cylinder Hose (2 used)
9 Bucket Cylinder Hose (2 used)
10 Boom Cylinder Hose (2 used)
11 Swing Cylinder Hose (2 used)
12 Auxiliary Hose (2 used) (if equipped)
13 Auxiliary Selective Flow Control Pressure Hose (if equipped)
14 Attachment Coupler Hose (2 used) (if equipped)
B16 Load Sense Pressure Sensor (if equipped)
Y53 Selective Flow Control Solenoid (if equipped)
Tag and disconnect hoses (7—14) from backhoe control valve (145). Close all openings using caps and plugs.
[12] - Tag and disconnect load sense pressure sensor (B16) and selective flow control solenoid (Y53) electrical connectors, if
equipped.
[13] -

Backhoe Control Valve Front and Side Connections (310SK six function shown)
LEGEND:
15 Loader Auxiliary Manifold Supply Hose (if equipped)
18 Loader and Stabilizer Hydraulic Supply Hose
20 Hose Guide (2 used)
21 Backhoe Control Valve Mounting Plate
22 Auxiliary Selective Flow Control Return Hose (if equipped)
Tag and disconnect hoses (15—18). Close all openings using caps and plugs.
[14] - Remove cap screws (19) to remove hose guides (20) from backhoe control valve mounting plate (21).
[15] - Disconnect hose (22), if equipped, and route out of backhoe control valve mounting plate. Close all openings using caps
and plugs.
[16] -
CAUTION:
Prevent possible crushing injury. Use appropriate lifting device.

Backhoe Control Valve Removal

LEGEND:
23 Lift Point
Attach and secure control valve to hoist at lift point (23).
Backhoe Control Valve and Mount Plate (manual) Weight (approximate) 50 kg
110 lb.
[18] - Move backhoe control valve and mounting bracket toward front of machine and carefully remove assembly.
[19] - Repair backhoe control valve as necessary. See Backhoe Control Valve Disassemble and Assemble . (Group 3360.)
[20] - Move backhoe control into proper position and install cap screws (24). Tighten to specification.
Frame Mount Cap Screw Torque 129 N·m
95 lb.-ft.
[21] - Route hose (22) through backhoe control valve mounting plate and connect.
[22] - Install hose guides and cap screws (19) to backhoe control valve mounting plate.
[23] - Connect all remaining hoses.
[24] - Connect load sense pressure sensor (B16) and selective flow control solenoid (Y53) electrical connectors, if equipped.
[25] - Install rear floor access plate and cap screws (5).

[26] - Install backhoe boom lock lever and linkage.
[27] - Install fifth and sixth function control pedals if equipped. See Backhoe Auxiliary Pedal Remove and Install—Fifth and
Sixth Functions . (Group 3315.)
[28] - Install backhoe control valve levers and linkage. See Backhoe Control Valve Linkage Remove and Install—Two Lever .
(Group 3315.)
[30] - Install rear window. See Non-Fixed Window Remove and Install . (Group 1810.)
[31] - Refill or remove vacuum to hydraulic oil reservoir. See Change Hydraulic Reservoir Oil . (Operator′s Manual.)
Pilot Controls
[4] - Drain or apply vacuum to hydraulic oil reservoir. See Change Hydraulic Reservoir Oil (Operator′s Manual.) or see Apply
[5] - Remove rear window. See Non-Fixed Window Remove and Install . (Group 1810.)
[7] -


LEGEND:
1 Fifth Function Control Pedal (if equipped)
2 Sixth Function Control Pedal (if equipped)
3 Backhoe Boom Lock Lever
Remove fifth and sixth function control pedals (1 and 2), if equipped. See Backhoe Auxiliary Pedal Remove and Install—Fifth
and Sixth Functions . (Group 3315.)
[8] - Remove backhoe boom lock lever (3) and linkage.
[10] -

Backhoe Control Valve Rear Connections (310SK six function shown)

LEGEND:
6 Extendible Dipperstick Cylinder Hose (2 used) (if equipped)
7 Crowd Cylinder Hose (2 used)
8 Bucket Cylinder Hose (2 used)
9 Boom Cylinder Hose (2 used)
10 Swing Cylinder Hose (2 used)
11 Auxiliary Hose (2 used) (if equipped)
12 Auxiliary Selective Flow Control Pressure Hose (if equipped)
13 Attachment Coupler Hose (2 used) (if equipped)
B16 Load Sense Pressure Sensor (if equipped)
Y53 Selective Flow Control Solenoid (if equipped)
Tag and disconnect hoses (6—13) from backhoe control valve (145). Close all openings using caps and plugs.
[11] - Tag and disconnect load sense pressure sensor (B16) and selective flow control solenoid (Y53) electrical connectors, if
equipped.
[12] -

Backhoe Control Valve Front and Side Connections (310SK six function shown)
LEGEND:
14 Pilot Enable and Pattern Select (PEPS) Manifold Supply Hose
17 Loader and Stabilizer Control Valve Supply Hose
18 Swing Spool Pilot Control Hose
19 Boom Spool Pilot Control Hose
20 Bucket Spool Pilot Control Hose
21 Crowd Spool Pilot Control Hose
22 Crowd Spool Pilot Control Hose
23 Bucket Spool Pilot Control Hose
24 Boom Spool Pilot Control Hose
25 Swing Spool Pilot Control Hose
27 Hose Guide (2 used)
28 Backhoe Control Valve Mounting Plate
29 Auxiliary Selective Flow Control Return Hose (if equipped)
Tag and disconnect hoses (14—25). Disconnect pilot enable and pattern select valve STC fitting lines by performing the
following:

IMPORTANT:


JDG1385
[13] - Remove cap screws (26) to remove hose guides (27) from backhoe control valve mounting plate (28).
[14] - Disconnect hose (29), if equipped, and route out of backhoe control valve mounting plate. Close all openings using caps
and plugs.
[15] -
PEPS Connections (hoses to backhoe control valve not shown)

LEGEND:
30 Left Pilot Control Hose (4 used)
31 Right Pilot Control Hose (4 used)
32 Hyraulic Return Hose
33 Loader Auxiliary Manifold Supply Hose (if equipped)
Tag and disconnect STC hoses (30—33) from pilot enable and pattern select (PEPS) manifold (137). Close all openings using
caps and plugs.
[16] -

Control Valve Mounting Assembly Removal

LEGEND:
X52 Pilot Control Console Harness Connector
Tag and disconnect pilot control console harness connector (X52) and pilot enable switch harness connector (X53).
[17] -
CAUTION:
Prevent possible crushing injury. Use appropriate lifting device.
Attach and secure control valve to hoist.

Backhoe Control Valve and Mount Plate (pilot) Weight (approximate) 68 kg
150 lb.
[19] - Move backhoe control valve mounting assembly toward front of machine and carefully remove assembly.
[20] - Repair backhoe control valve as necessary. See Backhoe Control Valve Disassemble and Assemble . (Group 3360.)
[21] - Move backhoe control valve into proper position and install cap screws (34) to frame. Tighten to specification.
Frame Mount Cap Screw Torque 129 N·m
95 lb.-ft.

[22] - Connect pilot control console harness connector and pilot enable switch harness connector.
[23] - Route hose (29) if equipped, through backhoe control valve mounting plate and connect.
[24] - Install hose guides and cap screws (26) to backhoe control valve mounting plate.
[25] - Connect all remaining hoses.
[26] - Connect load sense pressure sensor (B16) and selective flow control solenoid (Y53) electrical connectors, if equipped.
[27] - Install rear floor access plate and cap screws (5).
[28] - Install backhoe boom lock lever and linkage.
[29] - Install fifth and sixth function control pedals if equipped. See Backhoe Auxiliary Pedal Remove and Install—Fifth and
Sixth Functions . (Group 3315.)
[31] - Install rear window. See Non-Fixed Window Remove and Install . (Group 1810.)
[32] - Fill hydraulic oil reservoir or remove vacuum. See Change Hydraulic Reservoir Oil . (Operator′s Manual.)

Backhoe Control Valve Disassemble and Assemble
Backhoe Control Valve (manual shown)

LEGEND:
1 Nut (6 used)
2 Washer (6 used)
3 Tie Rod 1/2 in.
4 Tie Rod 7/16 in. (2 used)

5 Inlet Section
6 Auxiliary Selective Flow Control Section (if equipped)
7 Auxiliary Section (if equipped)
8 Swing Section
9 Boom Section
10 Bucket Section
11 Crowd Section
12 Extendable Dipperstick Section or Auxiliary Section (if equipped)
13 O-Ring (as needed)
14 Load Check (4 used)
15 Spring (4 used)
16 Load Check
17 Spring
Specifications
SPECIFICATIONS
Backhoe Control Valve
50 kg.
Manual Controls Weight (approximate)
110 lb.
68 kg.
Pilot Controls Weight (approximate)
150 lb.
100 N·m
Nut (1/2 in. tie rod) Torque
74 lb.-ft.
65 N·m
Nut (7/16 in. tie rod) Torque
48 lb.-ft.
[1] -
CAUTION:
Set backhoe control valve (145) vertically on work table.

Backhoe Control Valve

Manual Controls Weight (approximate) 50 kg.
110 lb.
Pilot Controls Weight (approximate) 68 kg.
150 lb.
[2] - Mark individual sections to aid in assembly.
[3] - Remove nuts (1) and washers (2) from top of backhoe control valve.
[4] -
IMPORTANT:
Prevent possible damage to backhoe control valve. Keep all components for an individual section
together as a set.
Carefully remove sections (5—12). Take care to not lose or damage O-rings (13), load checks (14 and 16), and springs (15 and
17).
[6] - For complete section disassembly and assembly, see corresponding procedures:

Disassemble and Assemble Procedures
Inlet Section (5) See Backhoe Inlet Section Disassemble and Assemble . (Group 3360.)
Auxiliary Selective Flow Control Section (6) See Backhoe Auxiliary Selective Flow Control Section Disassemble and Assemble—If Equipped . (Group 3360.)
Auxiliary Section (7) See Backhoe Auxiliary Section Disassemble and Assemble—If Equipped . (Group 3360.)
Swing Section (8) See Backhoe Swing Section Disassemble and Assemble . (Group 3360.)
Boom Section (9) See Backhoe Boom Section Disassemble and Assemble . (Group 3360.)
Bucket Section (10) See Backhoe Bucket Section Disassemble and Assemble . (Group 3360.)
Crowd Section (11) See Backhoe Crowd Section Disassemble and Assemble . (Group 3360.)
Extendable Dipperstick Section or Auxiliary Section

See Backhoe Auxiliary Section Disassemble and Assemble—If Equipped . (Group 3360.)
(12)
[7] -
IMPORTANT:
Prevent possible damage to hydraulic components. Load check (16) must be installed after spring (17).
This is a different style check and should not be used in other sections.
Assemble sections in marked order. Ensure O-rings, load checks, and springs remain in correct position.
[8] - Install washers and nuts to rods; snug to tight.
[9] - Lay backhoe control valve horizontally on work table.
[10] -
IMPORTANT:
Prevent possible damage to backhoe control valve. Tighten rods evenly in several steps to prevent valve
spool binding or leakage between sections.
Tighten nuts in steps to specification.

Nut (1/2 in. tie rod) Torque 100 N·m
74 lb.-ft.
Nut (7/16 in. tie rod) Torque 65 N·m
48 lb.-ft.

Backhoe Control Valve Spool Seals Remove and Install

[1] -
Wiper Ring and Lip Seal

LEGEND:
1 Spool
2 Lip Seal
3 Spool Wiper Ring
4 Retainer Plate
Clean valve assembly to remove any dirt and debris.
[2] - Remove two socket head cap screws (5) and retainer plate (4) from top of valve section.
[3] - Use an O-ring pick to remove spool wiper ring (3) and lip seal (2).
[4] -

Valve Spool Seal Repair

LEGEND:
7 Lip Seal
8 Spool Wiper Ring
9 Spring
10 Retainer Plate
11 Spool
12 Spool End Screw
13 Spring Seat (2 used)
14 Cap
Remove two screws (6) and cap (14) from bottom of valve section.
[5] - Remove spool end screw (12) to remove spring seats (13), spring (9), and retainer plate (10).
[6] - Use an O-ring pick to remove spool wiper ring (8) and lip seal (7).
[7] -
IMPORTANT:
Do not damage OD or ID of new seal during installation. Installation tool JDG734 must be used to install
lip seal.

Installation Tool
LEGEND:
15 Tool Sleeve
16 Lip Seal
17 Tool Driver
Use
JDG734
Install new seals
JDG734 Hydraulic Valve Seal Replacer to install new lip seal at each end of spool.
[8] - Place lip seal (16) on end of tool driver (17) with open side of seal away from tool driver.
[9] -
→NOTE:
Lip end of sleeve ID is cone-shaped to compress lip seal for installation.
Carefully slide sleeve (15) over lip seal (16) and tool driver (17) with raised lip of sleeve away from driver. Do not push lip seal
(16) through sleeve (15).
[11] - Push tool driver (17) to install lip seal (16) into valve housing.
counter bore.
[13] -

Valve Spool Seal Repair

LEGEND:
7 Lip Seal
8 Spool Wiper Ring
9 Spring
10 Retainer Plate
11 Spool
12 Spool End Screw
14 Cap
Install spool wiper ring (8).
[14] - Repeat steps (7 —13) for opposite end of spool.
[15] - Install retainer plate (10), spring seats (13) and spring (9).
[16] - Torque Spool End Screw (12) to specification.

84 lb-in.
[17] - Install cap (14) and cap screws (6). Torque screws to specification.
Retaining Screw (2 used) Torque 9.5 N·m
84 lb-in.
[18] -

Wiper Ring and Lip Seal

LEGEND:
1 Spool
2 Lip Seal
3 Spool Wiper
4 Retainer Plate
5 Screw (2 used)
Install retainer plate (4) and screws (5). Tighten screws to specification.
84 lb-in.
[19] - Check for correct installation of seals by pushing down on spool (1). Spool must return to neutral position.

Backhoe Control Valve Relief Valves Remove and Install

Specifications
SPECIFICATIONS
45 N·m
Relief Valve Torque 22.35 mm (0.88 in.)
33 lb.-ft.
61 N·m
Relief Valve Torque 26 mm (1.06 in.)
45 lb.-ft.
45 N·m
33 lb.-ft.
Backhoe Circuit Relief Valves (six function control valve shown)

LEGEND:
1 Extendible Dipperstick Head End Plug
2 Extendible Dipperstick Rod End Plug
150 System Relief Valve
229 Auxiliary Selective Flow Relief Valve (no anticavitation)
230 Swing Circuit Relief Valve (with anticavitation) (2 used)
232 Boom Circuit Relief Valve (with anticavitation)
233 Bucket Circuit Relief Valve (with anticavitation)
235 Crowd Circuit Relief Valve (with anticavitation)
236 Crowd Circuit Relief Valve (no anticavitation)
[1] - For removal of backhoe control valve, see Backhoe Control Valve Remove and Install . (Group 3360.)
[2] -
→NOTE:
Relief valves must be installed in the correct ports for proper valve function performance.
To aid in assembly, put identification marks on the relief valves and corresponding control valve ports.
[3] - Remove relief valves as needed.
[4] - Remove and inspect O-rings and backup rings for damage. If damaged, check housing for cause.

See Backhoe Inlet Section Disassemble and Assemble . (Group 3360.)

See Backhoe Boom Section Disassemble and Assemble . (Group 3360.)
See Backhoe Bucket Section Disassemble and Assemble . (Group 3360.)
See Backhoe Crowd Section Disassemble and Assemble . (Group 3360.)
See Backhoe Swing Section Disassemble and Assemble . (Group 3360.)
See Backhoe Auxiliary Section Disassemble and Assemble—If Equipped . (Group 3360.)
See Backhoe Auxiliary Selective Flow Control Section Disassemble and Assemble—If Equipped . (Group 3360.)
[6] -
IMPORTANT:
Avoid O-ring or component damage. Apply clean hydraulic oil to all internal parts before assembly and
petroleum jelly to O-rings and backup rings before installation
Apply petroleum jelly to new O-rings and backup rings. Install new rings.
[7] -
→NOTE:
below.
Apply clean hydraulic oil to all internal parts. Install and tighten relief valves to specification.
Circuit Relief Valves

Relief Valve 22.35 mm (0.88 in.) Torque 45 N·m
33 lb.-ft.
45 lb.-ft.
33 lb.-ft.
[8] - For installation of backhoe control valve, see Backhoe Control Valve Remove and Install . (Group 3360.)
[9] -
IMPORTANT:
Some relief valves are adjustable. Adjustable relief valves MUST be adjusted after they are disassembled
or replaced. Failure to do so can cause damage to hydraulic system components.
Adjust relief valves. See Circuit Relief Valve Test—With Remote Pump and see System Relief Valve Pressure Test . (Group
9025-25.)

Backhoe Inlet Section Disassemble and Assemble

Specifications
SPECIFICATIONS
65 N·m
Plug Torque
48 lb.-ft.
45 N·m
33 lb.-ft.
Inlet Section Disassemble and Assemble
[1] -
Inlet Section—Exploded View

LEGEND:
1 Plug
2 O-Ring
3 Plug
4 O-Ring

5 Spring
6 Spool
150 System Relief Valve
Remove system relief valve (150). Repair or replace as necessary. See System Relief Valve Disassemble and Assemble.
[2] - Remove plug (1) and O-ring (2).
[3] - Remove plug (3), O-ring (4), spring (5), and spool (6).
[4] -
→NOTE:
Spool is not serviceable individually.
Inspect parts for wear or damage. Replace as necessary.
[5] - Apply clean hydraulic oil to all parts.
[6] - Install spool, spring, O-rings (2 and 4), and plugs (1 and 3). Tighten to specification.
Plug Torque 65 N·m
48 lb.-ft.
[7] - Install system relief valve. Tighten to specification.

33 lb.-ft.
[8] -
IMPORTANT:
Prevent possible damage to hydraulic components. Relief valves must be adjusted after they are
disassembled or replaced.
After installation of backhoe control valve to machine, adjust system relief valve pressure. See System Relief Valve Pressure
Test . (Group 9025-25.)
System Relief Valve Disassemble and Assemble
[1] -
System Relief Valve—Exploded View

LEGEND:

1 Plug
2 Valve Body
3 O-Ring
4 Nut
5 Spring
6 Washer
7 Poppet
8 Plug
9 O-Ring
10 O-Ring
12 Seal
Separate plug (1) from valve body (2).
[2] - Remove O-ring (3) and nut (4) from plug (1).
[3] - Remove spring (5), washer (6), and poppet (7).
[4] - Remove plug (8), O-rings (9 and 10), and backup rings (11).
[5] - Remove seal (12).
[7] - Install seal.
[8] - Install backup rings, O-rings (9 and 10), and plug (8).
[9] - Install poppet, washer, and spring.
[10] - Install nut and O-ring (3) to plug.
[11] - Install plug to valve body.

Backhoe Boom Section Disassemble and Assemble

Specifications
SPECIFICATIONS
9.5 N·m
Spool Detent Cap Screw Torque
84 lb.-in.
9.5 N·m
Detent Body Cap Screw Torque
84 lb.-in.
5.5 N·m
Plate Cap Screw Torque
48 lb.-in.
9.5 N·m
Spool Detent Cap Screw and Plug Torque
84 lb.-in.
9.5 N·m
End Cap, Cap Screw Torque
84 lb.-in.
65 N·m
Plug Torque
48 lb.-ft.
61 N·m
Relief Valve Torque
45 lb.-ft.
Other Material
OTHER MATERIAL
271 Loctite ™ Thread Lock and Sealer (high strength)
Backhoe Boom Section Disassemble and Assemble—Manual Controls
[1] -

Boom Section With Manual Controls—Exploded View

LEGEND:
1 Plug
2 O-Ring
3 Washer
4 Spring
5 Poppet
7 Plate
8 Wiper
9 O-Ring
11 O-Ring
12 Wiper
13 Plate
14 Spool
15 Detent Body
16 Cap Screw
17 O-Ring

19 Spring
Remove boom circuit relief valve (no anticavitation) (231). Repair or replace as necessary. See Relief Valve Disassemble and
Assemble—No Anticavitation.
[2] - Remove boom circuit relief valve (with anticavitation) (232). Repair or replace as necessary. See Relief Valve Disassemble
and Assemble—With Anticavitation.
[3] - Remove plug (1), O-ring (2), washer (3), spring (4), and poppet (5).
[4] - Remove cap screws (6), plate (7), wiper (8), and O-ring (9).
[5] - Remove cap screws (10) and parts (11—19) as an assembly.
[6] - Remove O-ring (11), wiper (12), and plate (13) from spool (14).
[7] - Remove detent body (15).
[8] - Secure spool in vice using a protective cover or wood blocks.
[9] - Remove cap screw (16), O-ring (17), spring seats (18), and spring (19).
[10] -
→NOTE:
Washer, poppet, and spool are not serviceable individually.
[11] - Apply clean hydraulic oil to all internal components.
[12] - Apply PM37509 Loctite Klean ′N Prime and PM37421 Loctite Thread Lock and Sealer (high strength) to threads of spool
and cap screw (16).
Number Name Use

• PM37509 (us) Loctite ™ Klean ‘N Prime Clean threads
• PM37421 (us) 271 Loctite ™ Thread Lock and Sealer (high strength) Secure threads
[13] - Install spring seats, spring (19), O-ring (17), and cap screw (16) to spool. Tighten to specification.
Spool Detent Cap Screw Torque 9.5 N·m
84 lb.-in.
[14] - Install plate (13), wiper (12), and O-ring (11) to spool.
[15] - Instal spool assembly, detent body, and cap screws (10). Tighten to specification.
Detent Body Cap Screw Torque 9.5 N·m
84 lb.-in.
[16] - Install O-ring (9), wiper (8), plate (7), and cap screws (6). Tighten to specification.
Plate Cap Screw Torque 5.5 N·m
48 lb.-in.
[17] - Install poppet, spring (4), washer, O-ring (2), and plug. Tighten to specification.
Plug Torque 65 N·m
48 lb.-ft.
[18] - Install relief valves. Tighten to specification.

Relief Valve Torque 61 N·m
45 lb.-ft.
Backhoe Boom Section Disassemble and Assemble—Pilot Controls
[1] -
Boom Section With Pilot Controls—Exploded View

LEGEND:
1 Plug
2 O-Ring
3 Washer
4 Spring
5 Poppet
21 Cap
22 O-Ring
24 O-Ring

25 Spool
26 Cap
27 Cap Screw
29 Spring
30 Retainer
31 Plug
32 O-Ring
33 O-Ring
Remove boom circuit relief valve (no anticavitation) (231). Repair or replace as necessary. See Relief Valve Disassemble and
Assemble—No Anticavitation.
[2] - Remove boom circuit relief valve (With Anticavitation) (232). Repair or replace as necessary. See Relief Valve
Disassemble and Assemble—With Anticavitation.
[4] - Remove cap screws (20), cap (21), and O-ring (22).
[6] - Remove O-ring (24) from spool (25).
[7] - Remove cap (26).
[8] - Secure spool in vice using protective cover or wood blocks.
[9] - Remove cap screw (27), spring seats (28), spring (29), retainer (30), plug (31), and O-rings (32 and 33).
[10] -
→NOTE:
[12] - Apply PM37509 Loctite Klean ′N Prime and PM37421 Loctite Thread Lock and Sealer (high strength) to threads of spool,
plug (31), and cap screw (27).
Number Name Use

[13] - Install O-rings (32 and 33), plug (31), retainer, spring (29), spring seats, and cap screw (27) to spool. Tighten to
specification.
Spool Detent Cap Screw and Plug Torque 9.5 N·m
84 lb.-in.
[14] - Install spool assembly, O-rings (22 and 24), caps, and cap screws (20 and 23). Tighten to specification.
End Cap, Cap Screw Torque 9.5 N·m
84 lb.-in.
[15] - Install poppet, spring (4), washer, O-ring (2), and plug (1). Tighten to specification.
Plug Torque 65 N·m
48 lb.-ft.

45 lb.-ft.
Relief Valve Disassemble and Assemble—With Anticavitation
[1] -
Relief Valve (with anticavitation)—Exploded View

LEGEND:
1 O-Ring
2 Valve Body
3 Sleeve Assembly
4 Spring
5 O-Ring
6 Backup Ring
Remove O-ring (1) from valve body (2).
[2] - Remove sleeve assembly (3) and spring (4).
[3] - Remove O-ring (5) and backup ring (6).
[4] -
IMPORTANT:
Prevent possible damage to hydraulic components. Do not disassemble sleeve assembly. Relief is not
adjustable. Internals of sleeve assembly are not serviceable individually.
→NOTE:
Only valve body, spring, backup ring and O-ring are serviceable.
[5] - Install backup ring and O-ring (5).
[6] - Install spring and sleeve assembly to valve body.
[7] - Install O-ring (1) to valve body.
Relief Valve Disassemble and Assemble—No Anticavitation
[1] -

Relief Valve (No Anticavitation)—Exploded View

LEGEND:
1 Nut
2 Adjustment Screw
3 O-Ring
4 Valve Body
5 Spring
6 Sleeve
7 O-Ring
8 Poppet
9 O-Ring
10 O-Ring
11 Backup RIng
Remove nut (1), adjustment screw (2), and O-ring (3) from valve body (4). Note number of revolutions for removal of
adjustment screw.
[2] - Remove spring (5), sleeve (6), O-ring (7), and poppet (8).
[3] - Remove O-rings (9 and 10) and backup ring (11) from valve body.
[5] - Apply clean hydraulic oil to internal components.
[6] - Install backup ring and O-rings (9 and 10).
[7] - Install poppet, sleeve, O-ring (7), and spring.
[8] - Install O-ring (3), adjustment screw, and nut.

Backhoe Bucket Section Disassemble and Assemble

Specifications
SPECIFICATIONS
9.5 N·m
84 lb.-in.
9.5 N·m
84 lb.-in.
5.5 N·m
48 lb.-in.
9.5 N·m
Spool Detent Cap Screw and Plug Torque
84 lb.-in.
9.5 N·m
84 lb.-in.
61 N·m
Relief Valve Torque
45 lb.-ft.
Other Material
OTHER MATERIAL
Bucket Section Disassemble and Assemble—Manual Controls
[1] -

Bucket Section With Manual Controls—Exploded View

LEGEND:
2 Plate
3 Wiper
4 O-Ring
6 O-Ring
7 Wiper
8 Plate
9 Spool
10 Detent Body
11 Cap Screw
13 Spring
234 Bucket Circuit Relief Valve (no anticavitation) (2 used)
Remove bucket circuit relief valves (no anticavitation) (234). Repair or replace as necessary. See Relief Valve Disassemble and
Assemble.

[7] - Remove cap screw (11), spring seats (12), and spring (13).
[8] -
→NOTE:
and cap screw (11).
Number Name Use

[11] - Install spring seats, spring, and cap screw (11) to spool. Tighten to specification.
84 lb.-in.
84 lb.-in.
48 lb.-in.

45 lb.-ft.
Bucket Section Disassemble and Assemble—Pilot Controls
[1] -
Bucket Section With Pilot Controls—Exploded View

LEGEND:
21 Cap
22 O-Ring
24 O-Ring
25 Spool
26 Cap
27 Cap Screw
29 Spring
30 Retainer
31 O-Ring
Remove bucket circuit relief valves (no anticavitation) (234). Repair or replace as necessary. See Relief Valve Disassemble and
Assemble.
[7] - Remove cap screw (27), spring seats (28), spring (29), retainer (30), and O-ring (31).
and cap screw (27).
Number Name Use

[11] - Install O-ring (31), retainer, spring (29), spring seats, and cap screw (27) to spool. Tighten to specification.
Spool Detent Cap Screw and Plug Torque 9.5 N·m
84 lb.-in.
84 lb.-in.

45 lb.-ft.
Relief Valve Disassemble and Assemble
[1] -
Relief Valve (no anticavitation)—Exploded View

LEGEND:
1 Nut
2 Adjustment Screw
3 O-Ring
4 Valve Body
5 Spring
6 Sleeve
7 O-Ring
8 Poppet
9 O-Ring
10 O-Ring
11 Backup RIng
adjustment screw.
Backhoe Crowd Section Disassemble and Assemble

Specifications
SPECIFICATIONS
9.5 N·m
84 lb.-in.
9.5 N·m
84 lb.-in.
5.5 N·m
48 lb.-in.
65 N·m
Plug Torque
48 lb.-ft.
45 N·m
Relief Valve 22 mm (0.88 in.) Torque
33 lb.-ft.
61 N·m
Relief Valve 26 mm (1 in.) Torque
45 lb.-ft.
9.5 N·m
84 lb.-in.
24 N·m
Relief Valve Nut Torque
18 lb.-ft.
Other Material
OTHER MATERIAL
Backhoe Crowd Section Disassemble and Assemble—Manual Controls
[1] -
Crowd Section Disassembly—Manual Controls

LEGEND:
1 Relief Valve 22 mm (0.88 in.)
2 Relief Valve 26 mm (1 in.)
3 Plug
4 O-Ring
5 Washer
6 Spring
7 Poppet
9 Plate
10 Wiper
11 O-Ring
13 O-Ring
14 Wiper
15 Plate
16 Spool
17 Detent Body
18 Cap Screw

20 Spring
21 Spool End
22 O-Ring
Remove relief valves (1 and 2). Repair or replace as necessary. See Relief Valve 22 mm (0.88 in.) Disassemble and Assembleor
see Relief Valve 26 mm (1 in.) Disassemble and Assemble.
[9] - Remove spool end (21) and O-ring (22).
[10] -
→NOTE:
Inspect parts for wear and damage. Replace as necessary.
[12] - Install O-ring (22) and spool end.
and cap screw (18).
Number Name Use

[14] - Install spring seats, spring (20), and cap screw (18) to spool. Tighten to specification.
84 lb.-in.
[16] - Install spool assembly, detent body, and cap screws (12). Tighten to specification.
84 lb.-in.
48 lb.-in.
[18] - Install poppet, spring (6), washer, O-ring (3), and plug. Tighten to specification.
Plug Torque 65 N·m
48 lb.-ft.

33 lb.-ft.
Relief Valve 26 mm (1 in.) Torque 61 N·m
45 lb.-ft.
Backhoe Crowd Section Disassemble and Assemble—Pilot Controls
[1] -
Crowd Section Disassembly—Pilot Controls

LEGEND:
1 Relief Valve 22 mm (0.88 in.)
2 Relief Valve 26 mm (1 in.)
3 Plug
4 O-Ring
5 Washer
6 Spring
7 Poppet
26 Cap
27 O-Ring
29 O-Ring
30 Spool
31 Cap
32 Cap Screw
34 Spring
35 Retainer
36 O-Ring
37 O-Ring
Remove relief valves (1 and 2). Repair or replace as necessary. See Relief Valve 22 mm (0.88 in.) Disassemble and Assembleor
see Relief Valve 26 mm (1 in.) Disassemble and Assemble.
[8] - Remove cap screw (32), spring seats (33), spring (34), retainer (35), and O-rings (36 and 37).
[9] -
→NOTE:
and cap screw (32).
Number Name Use

[12] - Install O-rings (36 and 37), retainer, spring (34), spring seats, and cap screw (32) to spool. Tighten to specification.
84 lb.-in.
84 lb.-in.
[14] - Install poppet, spring (6), washer, O-ring (4), and plug (3). Tighten to specification.
Plug Torque 65 N·m
48 lb.-ft.
33 lb.-ft.
Relief Valve 26 mm (1 in.) Torque 61 N·m
45 lb.-ft.
Relief Valve 22 mm (0.88 in.) Disassemble and Assemble
[1] -
Relief Valve—Exploded View

LEGEND:
1 Seal
2 Valve Body
3 Nut
4 Nut
5 O-Ring (2 used)
6 Adjustment Screw
7 Shim
8 Spring
9 Retainer
10 Poppet
Remove seal (1) from valve body (2).
[2] - Remove nuts (3 and 4) and O-rings (5).
[3] - Mark orientation of adjustment screw (6) to valve body.
[4] - Remove adjustment screw, noting number of revolutions for removal.
[5] - Remove shim (7), spring (8), retainer (9) and poppet (10).
[6] -
→NOTE:
Only nuts, O-rings, and seal are serviceable.
[7] - Install retainer, poppet, spring, and shim.
[8] - Install adjustment screw, using alignment marks and noted revolutions.
[9] - Install nuts and O-rings. Tighten to specification.

Relief Valve Nut Torque 24 N·m
18 lb.-ft.
[10] - Install seal to valve body.
Relief Valve 26 mm (1 in.) Disassemble and Assemble
[1] -
Relief Valve (no anticavitation)—Exploded View

LEGEND:
1 Nut
2 Adjustment Screw
3 O-Ring
4 Valve Body
5 Spring
6 Sleeve
7 O-Ring
8 Poppet
9 O-Ring
10 O-Ring
11 Backup RIng
adjustment screw.
Backhoe Swing Section Disassemble and Assemble

Specifications
SPECIFICATIONS
9.5 N·m
84 lb.-in.
9.5 N·m
84 lb.-in.
5.5 N·m
48 lb.-in.
9.5 N·m
84 lb.-in.
61 N·m
Relief Valve Torque
45 lb.-ft.
Other Material
OTHER MATERIAL
Backhoe Swing Section Disassemble and Assemble—Manual Controls
[1] -
Swing Section Disassembly—Manual Controls

LEGEND:
2 Plate
3 Wiper
4 O-Ring
6 O-Ring
7 Wiper
8 Plate
9 Spool
10 Detent Body
11 Cap Screw
12 O-Ring
14 Spring
15 Spool End
16 O-Ring
230 Swing Circuit Relief Valve (2 used)
Remove swing circuit relief valves (230). Repair or replace as necessary. See Swing Circuit Relief Valve Disassemble and
Assemble.
[7] - Remove cap screw (11), O-ring (12), spring seats (13), and spring (14).
[8] - Remove spool end (15) and O-ring (16).
[9] -
→NOTE:
[11] - Install O-ring (16) and spool end.
and cap screw (11).
Number Name Use

[13] - Install spring seats, spring (14), O-ring (12), and cap screw (11) to spool. Tighten to specification.
84 lb.-in.
[15] - Install spool assembly, detent body, and cap screws (5). Tighten to specification.
84 lb.-in.
48 lb.-in.

45 lb.-ft.
Backhoe Swing Section Disassemble and Assemble—Pilot Controls
[1] -
Swing Section Disassembly—Pilot Controls

LEGEND:
21 Cap
22 O-Ring
24 O-Ring
25 Spool
26 Cap
27 Cap Screw
29 Spring
30 Retainer
31 O-Ring
32 O-Ring
33 Plug
34 O-Ring
230 Swing Circuit Relief Valve (2 used)
Remove swing circuit relief valves (230). Repair or replace as necessary. See Swing Circuit Relief Valve Disassemble and
Assemble.
[7] - Remove cap screw (27), spring seats (28), spring (29), retainer (30), and O-rings (31 and 32).
[8] - Remove plug (33) and O-ring (34).
[9] -
→NOTE:
[11] - Apply PM37509 Loctite Klean ′N Prime and PM37421 Loctite Thread Lock and Sealer (high strength) to threads of spool,
cap screw (27), and plug.
Number Name Use

[12] - Install O-ring (34) and plug.
[13] - Install O-rings (31 and 32), retainer, spring, spring seats, and cap screw (27) to spool. Tighten to specification.
84 lb.-in.
84 lb.-in.

45 lb.-ft.
Swing Circuit Relief Valve Disassemble and Assemble
[1] -

LEGEND:
1 O-Ring
2 Valve Body
3 Sleeve Assembly
4 Spring
5 O-Ring
6 Backup Ring
[4] -
IMPORTANT:
→NOTE:
Only valve body, spring, backup ring, and O-ring are serviceable.
Backhoe Auxiliary Section Disassemble and Assemble—If Equipped

Specifications
SPECIFICATIONS
9.5 N·m
84 lb.-in.
9.5 N·m
84 lb.-in.
5.5 N·m
48 lb.-in.
65 N·m
Relief Valve or Plug Torque
48 lb.-ft.
Other Material
OTHER MATERIAL
→NOTE:
This procedure covers backhoe auxiliary hydraulic sections and extendable dipperstick section in the
backhoe control valve.
Auxiliary Section Disassemble and Assemble
[1] -
Auxiliary Section Disassembly

LEGEND:
1 Relief Valve (2 used) (if equipped)
2 Plug (2 used) (if equipped)
3 O-Ring (2 used) (if equipped)
5 Plate
6 Wiper
7 O-Ring
9 O-Ring
10 Wiper
11 Plate
12 Spool
13 Detent Body
14 Cap Screw
16 Spring
Remove relief valves (1) (if equipped) or remove plugs (2) and O-rings (3) (if equipped). Repair or replace relief valve as
necessary. See Relief Valve Disassemble and Assemble.
[8] -
→NOTE:
and cap screw (14).
Number Name Use

[11] - Install spring seats, spring, and cap screw (14) to spool. Tighten to specification.
84 lb.-in.
84 lb.-in.
48 lb.-in.
[15] - Install relief valves (if equipped) or install plugs and O-rings (3) (if equipped). Tighten to specification.
Relief Valve or Plug Torque 65 N·m
48 lb.-ft.
[1] -

LEGEND:
1 O-Ring
2 Valve Body
3 Sleeve Assembly
4 Spring
5 O-Ring
6 Backup Ring
[4] -
IMPORTANT:
→NOTE:
Only valve body, spring, backup ring and O-ring are serviceable.
Backhoe Auxiliary Selective Flow Control Section Disassemble and

Assemble—If Equipped
Specifications
SPECIFICATIONS
34 N·m
Solenoid Valve Torque
25 lb.-ft.
65 N·m
Selective Flow Spool Plug Torque
48 lb.-ft.
5 N·m
Selective Flow Knob Nut Torque
48 lb.-in.
65 N·m
Poppet Plug Torque
48 lb.-ft.
45 N·m
Relief Valve Torque
33 lb.-ft.
24 N·m
Relief Valve Nut Torque
18 lb.-ft.
Auxiliary Selective Flow Control Section Disassemble and Assemble
[1] -
Auxiliary Selective Flow Control Section Disassembly

LEGEND:
1 Relief Valve
2 Plug
3 O-Ring
4 Spring
5 Poppet
6 Nut
7 Plunger
8 Nut
9 Selector Knob
10 Selector Nut
11 O-Ring
12 O-Ring
13 O-Ring
14 O-Ring
15 Selector
16 Plug
17 O-Ring
18 Spring
19 Spool
20 Nut
21 Solenoid Coil
22 Solenoid Spool
Remove relief valve (1). Repair or replace as necessary. See Relief Valve Disassemble and Assemble.
[2] - Remove plug (2), O-ring (3), spring (4), and poppet (5).
[3] - Remove nut (6) and plunger (7).
[4] - Remove nut (8) and selector knob (9).
[5] - Remove selector nut (10), O-rings (11—14), and selector (15).
[6] - Remove plug (16), O-ring (17), spring (18), and spool (19).
[7] - Remove nut (20), solenoid coil (21), and solenoid spool (22).
[8] - Inspect parts for wear or damage. Repair or replace as necessary.
[9] - Install O-rings (23—25), backup rings, and solenoid spool. Tighten to specification.
Solenoid Valve Torque 34 N·m
25 lb.-ft.
[10] - Install solenoid coil and nut.
[11] - Install spool, spring (18), O-ring (17), and plug (16).
Selective Flow Spool Plug Torque 65 N·m
48 lb.-ft.
[12] - Install selector, O-rings (11—14), and selector nut.
[13] - Install selector knob, plunger, and nuts (6 and 8). Tighten to specification.
Selective Flow Knob Nut Torque 5 N·m
48 lb.-in.
[14] - Install poppet, spring (4), O-ring (3), and plug (2). Tighten to specification.
Poppet Plug Torque 65 N·m
48 lb.-ft.
[15] - Install relief valve. Tighten to specification.

33 lb.-ft.
[1] -
Relief Valve—Exploded View

LEGEND:
1 Seal
2 Valve Body
3 Nut
4 Nut
5 O-Ring (2 used)
6 Adjustment Screw
7 Shim
8 Spring
9 Retainer
10 Poppet
Remove seal (1) from valve body (2).
[2] - Remove nuts (3 and 4) and O-rings (5).
[3] - Mark orientation of adjustment screw (6) to valve body.
[4] - Remove adjustment screw, noting number of revolutions for removal.
[5] - Remove shim (7), spring (8), retainer (9), and poppet (10).
[6] -
→NOTE:
Only nuts, O-rings, and seal are serviceable.
[7] - Install retainer, poppet, spring, and shim.
[8] - Install adjustment screw, using alignment marks and noted revolutions.
[9] - Install nuts and O-rings. Tighten to specification.

Relief Valve Nut Torque 24 N·m
18 lb.-ft.
[10] - Install seal to valve body.
Pilot Enable and Pattern Select Valve Remove and Install

Essential Tools
ESSENTIAL TOOLS
[3] - Drain hydraulic oil reservoir or apply vacuum. See Change Hydraulic Reservoir Oil . (Operator′s Manual.) or see Apply
[5] -
Rear Floor Access Plate

LEGEND:
1 Cap Screw (4 used) (if equipped)
2 Auxiliary Control Pedal (2 used) (if equipped)
5 Console Cover
Remove cap screws (1) and auxiliary control pedals (2), if equipped.
[8] - Remove console cover (5) by sliding it over backhoe boom lock control lever (6).
[10] -
LEGEND:
140 Pilot Control Accumulator
Y52 Pilot Enable Solenoid
Y58 Pattern Select Solenoid 1
Pilot Enable and Pattern Select (PEPS) Manifold
PEPS Manifold Electrical Connections

Tag and disconnect all hoses connected to pilot enable and pattern select (PEPS) manifold (137). Disconnect STC fitting lines by
performing the following:

IMPORTANT:
JDG1385
Disconnect Snap-to-Connect Fittings.
[11] - Tag and disconnect pilot enable solenoid (Y52), pattern select solenoid 1 (Y58), and pattern select solenoid 2 (Y59)
electrical connectors.
[12] - Secure PEPS manifold and remove cap screws (9).
[13] - Remove PEPS manifold.
[14] - Repair or replace pilot enable and pattern select valve as required. See Pilot Enable and Pattern Select Valve
[15] - Install PEPS manifold and cap screws (9).
[16] - Connect solenoid electrical connectors.
[17] - Connect all hoses using identification tags and hose port identification decal on top of PEPS manifold.
[18] - Install rear floor access plate, console cover, and cap screws (7).
[19] - Install auxiliary control pedals and cap screws (4), if equipped.
[22] - Fill hydraulic oil reservoir or remove vacuum. See Change Hydraulic Reservoir Oil . (Operator′s Manual.)
Pilot Enable and Pattern Select Valve Disassemble and Assemble

[1] -
LEGEND:
2 Nut (2 used)
3 Spool (2 used)
4 Check Valve
5 O-Ring
138 Pilot Control Pressure Reducing Valve
140 Pilot Control Accumulator
Pilot Enable and Pattern Select Valve

Remove cap screws (1) and pilot enable solenoid (Y52).
[2] - Remove nuts (2), pattern select solenoids (Y58 and Y59), and spools (3).
[3] - Remove pilot control pressure reducing valve (138).
[4] - Remove check valve (4).
[5] - Remove pilot control accumulator (140) and O-ring (5).
[6] -
LEGEND:
2 Nut (2 used)
3 Spool (2 used)
4 Check Valve
138 Pilot Control Pressure Reducing Valve
Pilot Enable Solenoid
Pattern Select Solenoid
Pilot Control Pressure Reducing Valve
Check Valve
Inspect O-rings and seals for damage. Replace as necessary.
[7] - Inspect and test solenoids. See Electrical Component Specifications . (Group 9015-20.) Replace as necessary.
[8] - Install O-ring (5) and pilot control accumulator.
[9] - Install check valve.
[10] - Install pilot control pressure reducing valve.
[11] - Install spools, pattern select solenoids, and nuts.
[12] - Install pilot enable solenoid and cap screws.
Backhoe Boom Cylinder Remove and Install

Specifications
SPECIFICATIONS
Boom Cylinder
86 kg
190 lb.
100 kg
310SK, 310SK TMC, 315SK, 325K, 325SK Weight (approximate)
220 lb.
125 kg
410K, 410K TMC Weight (approximate)
275 lb.
230 kg
505 lb.
[1] - Park and prepare machine for service. See Park and Prepare for Service Safely . (Operator’s Manual.)
[2] -
CAUTION:
pressure.
High Pressure Fluid

[3] - Turn battery disconnect switch to the OFF position or remove battery negative (-) cables. See Battery Disconnect—If
[4] -
LEGEND:
1 Head End Hydraulic Hose
2 Rod End Hydraulic Hose
3 Head End Pin
5 Washer (4 used)
162 Backhoe Boom Cylinder
Backhoe Boom Cylinder and Pins
Backhoe Boom Cylinder

Tag and disconnect hydraulic hoses (1 and 2) from backhoe boom cylinder (162). Close all openings using caps and plugs.
[5] -
CAUTION:
Connect appropriate lifting device to backhoe boom cylinder using lifting straps.
Boom Cylinder
190 lb.
310SK, 310SK TMC, 315SK, 325K, 325SK Weight (approximate) 100 kg
220 lb.
410K, 410K TMC Weight (approximate) 125 kg
275 lb.
505 lb.
[6] - Remove snap rings (4) and washers (5) from head end pin (3).
[7] - Remove head end pin.
[8] -
LEGEND:
6 Pin
7 Boom Lock Pivot
8 Pin
10 Washer (2 used)
11 Rod End Pin
Boom Lock Pivot and Pins

Remove pins (6 and 8) to remove boom lock pivot (7).
[9] - Remove snap rings (9) and washers (10) from backhoe boom cylinder rod end pin (11).
[10] - Remove rod end pin.
[11] - Remove backhoe boom cylinder.
[12] - Repair or replace backhoe boom cylinder as necessary. See Backhoe Boom Cylinder Disassemble and Assemble . (Group
3360.)
[13] - Install backhoe boom cylinder.
[14] - Install rod and head end pins.
[16] - Install backhoe boom lock pivot and pins (6 and 8).
[17] - Connect backhoe boom cylinder hydraulic hoses (1 and 2).
[18] - Turn battery disconnect switch to ON or connect battery negative (-) cables.
[19] - Operate backhoe to check for leaks and proper backhoe boom cylinder operation.
Backhoe Boom Cylinder Disassemble and Assemble

For backhoe boom cylinder repair information, see Cylinder Identification . (CTM120519.)
Backhoe Bucket Cylinder Remove and Install

Specifications
SPECIFICATIONS
Backhoe Bucket Cylinder
45 kg
99 lb.
59 kg
310SK, 310SK TMC, 315SK, 325K, 325SK Weight (approximate)
130 lb.
66 kg
145 lb.
105 kg
230 lb.
[1] - Extend bucket to bucket dump position and lower to the ground.
[3] -
CAUTION:
pressure.
High Pressure Fluid

[5] -
LEGEND:
1 Hose Clamp
3 Washer (3 used)
4 Rod End Pin
5 Head End Pin
163 Backhoe Bucket Cylinder
Backhoe Bucket Cylinder Removal

Remove hose clamp (1) from backhoe bucket cylinder (163).
[6] - Tag and disconnect hydraulic hoses from backhoe bucket cylinder. Close all openings using caps and plugs.
[7] -
CAUTION:
Install appropriate lifting device to backhoe bucket cylinder using lifting straps.
Backhoe Bucket Cylinder

99 lb.
310SK, 310SK TMC, 315SK, 325K, 325SK Weight (approximate) 59 kg
130 lb.
145 lb.
230 lb.
[8] - Remove snap ring (2) and washer (3) from rod end pin (4).
[9] - Remove rod end pin.
[10] - Remove snap rings and washers from head end pin (5).
[12] - Remove backhoe bucket cylinder.
[13] - Repair or replace backhoe bucket cylinder as necessary. See Backhoe Bucket Cylinder Disassemble and Assemble .
(Group 3360.)
[14] - Install backhoe bucket cylinder.
[15] - Install pins at head and rod ends of backhoe bucket cylinder.
[17] - Connect backhoe bucket cylinder hydraulic hoses and install hose clamp.
[19] - Operate backhoe to check for leaks and proper bucket cylinder operation.
Backhoe Bucket Cylinder Disassemble and Assemble

For backhoe bucket cylinder repair information, see Cylinder Identification . (CTM120519.)
Backhoe Crowd Cylinder Remove and Install

Specifications
SPECIFICATIONS
Backhoe Crowd Cylinder
58 kg
127 lb.
84 kg
310SK, 310SK TMC, 315SK Weight (approximate)
186 lb.
186 lb.
310SK, 310SK TMC, 315SK
98 kg
98 kg
325K, 325SK Weight (approximate)
216 lb.
96 kg
212 lb.
156 kg
344 lb.
[1] - Extend dipperstick and lower boom to the ground.
[3] -
CAUTION:
pressure.
High Pressure Fluid

[5] -
LEGEND:
1 Head End Hydraulic Hose
2 Rod End Hydraulic Hose
4 Washer (11 used)
6 Spacer (2 used)
7 Rod End Pin
8 Head End Pin
164 Backhoe Crowd Cylinder
Backhoe Crowd Cylinder Removal

Tag and disconnect backhoe crowd cylinder (164) hydraulic hoses (1 and 2). Close all openings using caps and plugs.
[6] -
CAUTION:
Install appropriate lifting device to crowd cylinder using lifting straps.


127 lb.
310SK, 310SK TMC, 315SK Weight (approximate) 84 kg
186 lb.
325K, 325SK Weight (approximate) 98 kg
216 lb.
212 lb.
344 lb.
[7] - Remove snap ring (3) and washers (4) from rod end pin (7).
[8] - Remove rod end pin, wear plates (5) and spacers (6).
[9] - Remove snap rings and washers from head end pin (8).
[11] - Remove backhoe crowd cylinder.
[12] - Repair or replace backhoe crowd cylinder as necessary. See Backhoe Crowd Cylinder Disassemble and Assemble .
(Group 3360.)
[13] - Install backhoe crowd cylinder.
[14] - Install rod end pin, spacers, and wear plates.
[15] - Install washers and snap ring.
[16] - Install head end pin, washers, and snap rings.
[17] - Connect backhoe crowd cylinder hydraulic hoses (1 and 2).
[18] - Turn battery disconnect switch to the ON position or connect battery negative (-) cables.
[19] - Operate backhoe to check for leaks and proper backhoe crowd cylinder operation.
Backhoe Crowd Cylinder Disassemble and Assemble

For backhoe crowd cylinder repair information, see Cylinder Identification . (CTM120519.)
Backhoe Stabilizer Cylinder Remove and Install

Specifications
SPECIFICATIONS
Stabilizer Cylinder Weight 28 kg

(approximate) 61 lb.
LEGEND:
1 Cap Screw
2 Stabilizer Cover
4 Snap Ring
5 Washer (10 used)
6 Pin
201 Stabilizer Cylinder
Backhoe Stabilizer Cylinder Removal
Backhoe Stabilizer Cylinder Removal
Backhoe Stabilizer Cylinder
[1] - Lower stabilizer to the ground and remove foot. Retract cylinder.
[3] -
CAUTION:
pressure.
[4] - Turn battery disconnect switch to OFF or remove battery negative (-) cables. See Battery Disconnect—If Equipped .
(Operator’s Manual.)
[5] - Remove cap screw (1) and stabilizer cover (2).
[6] - Tag and disconnect hydraulic hoses (3). Close all openings using caps and plugs.
[7] -
CAUTION:
Install appropriate lifting device to stabilizer cylinder (201).

Stabilizer Cylinder Weight (approximate) 28 kg
61 lb.
[8] - Remove snap ring (4), pin (6), and washers (5).
[9] - Remove stabilizer cylinder.
[10] - Repair or replace stabilizer cylinder as necessary. See Backhoe Stabilizer Cylinder Disassemble and Assemble . (Group
3360.)
[11] - Install stabilizer cylinder.
[12] - Install washers, pin, and snap ring.
[13] - Connect hydraulic hoses. See Hydraulic System Component Location . (Group 9025-15.)
[15] - Extend cylinder to install foot.
[16] - Install stabilizer cover and cap screw.
[17] - Operate backhoe to check for leaks and proper stabilizer cylinder operation.
Backhoe Stabilizer Cylinder Disassemble and Assemble

For backhoe stabilizer cylinder repair information, see Cylinder Identification . (CTM120519.)
Backhoe Swing Cylinder Remove and Install

Specifications
SPECIFICATIONS
Backhoe Swing Cylinder
39 kg
86 lb.
45 kg
315K, 325K, 325SK, 410K Weight (approximate)
99 lb.
66 kg
146 lb.
Swing Cylinder Hydraulic Fittings Torque 34 N·m
Swing Cylinder Hydraulic Fittings 25 lb.-ft.
[2] - Swing backhoe to one side and lower backhoe bucket to ground.
[4] -
CAUTION:
pressure.
LEGEND:
2 Washer (2 used)
3 Pin
5 Washer (2 used)
6 Hose Guard
7 Pin (2 used)
Swing Cylinder-Hose Guard Side

Remove snap rings (1), washers (2), and pin (3).
[5] - Remove snap rings (4) and washers (5).
[6] - Remove hose guard (6) and pins (7).
[7] -
CAUTION:
Attach cylinder to a hoist using a lifting strap.
Backhoe Swing Cylinder

86 lb.
315K, 325K, 325SK, 410K Weight (approximate) 45 kg
99 lb.
146 lb.
[8] -
LEGEND:
11 Washer (8 used)
12 Trunnion
13 Swing Cylinder
Swing Cylinder-Trunnion Side

Tag and disconnect hydraulic hoses (9). Close all openings with caps and plugs.
[10] - Remove trunnion (12) and swing cylinder (13).
[11] - Repair or replace swing cylinder as necessary.
[12] -
LEGEND:
14 Swing Cylinder Bushing (2 used)
Swing Cylinder Bushing

Inspect swing cylinder bushings (14). Replace as necessary.
[13] - Install new bushings flush with trunnion using 49 mm and 59 mm disks.
[14] - Inspect upper and lower trunnion block bushings. Replace as necessary using 60 mm and 69 mm disks.
[15] - Install new bushings with 60 mm and 69 mm disks. Align grease passages in trunnion block and frame with passage in
bushing. Be sure lower trunnion bushing is pushed into seat flange.
[16] - Press upper bushing even with top of trunnion block.
[17] -
IMPORTANT:
Be sure hydraulic fittings in swing cylinder are tightened to specification. Cylinder movement and
hydraulic pressure can loosen fittings and cause a leak.
If hydraulic fittings were removed from cylinder, install and tighten fittings to specification.
Swing Cylinder Hydraulic Fittings Torque 34 N·m
25 lb.-ft.
[18] - Install swing cylinder and trunnion.
[19] - Install cap screws (10) and washers (11).
[21] - Install pins (7) and hose guard.
[22] - Install cap screws (4) and washers (5).
[23] - Install pin (3), washers (2), and snap rings.
Backhoe Swing Cylinder Disassemble and Assemble

For backhoe swing cylinder repair information, see Cylinder Identification . (CTM120519.)
Backhoe Extendable Dipperstick Cylinder Remove and Install

Specifications
SPECIFICATIONS
32 kg
70 lb.
41 kg
310SK, 315SK, 325K, 325SK, 410K Weight (approximate)
90 lb.
59 kg
129 lb.
[1] -
LEGEND:
1 Pin
160 Backhoe Extendable Dipperstick
165 Backhoe Extendable Dipperstick Cylinder
Extendable Dipperstick Cylinder Removal

Remove backhoe extendable dipperstick (160). See Dipperstick Extension Remove and Install . (Group 3340.)
[4] -
CAUTION:
pressure.
[5] - Remove hose clamps (2).
[6] - Tag and disconnect hydraulic hoses from backhoe extendable dipperstick cylinder (165). Close all openings using caps
and plugs.
[7] -
CAUTION:
Attach a hoist to backhoe extendable dipperstick cylinder.


70 lb.
310SK, 315SK, 325K, 325SK, 410K Weight (approximate) 41 kg
90 lb.
129 lb.
[8] - Remove backhoe extendable dipperstick cylinder head end pin (1) and slowly remove cylinder.
[9] - Repair or replace backhoe extendable dipperstick cylinder as necessary.
[10] - Position backhoe extendable dipperstick cylinder in place and install backhoe extendable dipperstick cylinder head end
pin.
[11] - Connect backhoe extendable dipperstick cylinder hydraulic hoses and install hose clamps.
[12] - Install backhoe extendable dipperstick. See Dipperstick Extension Remove and Install . (Group 3340.)
[13] - Turn battery disconnect switch to the ON position or install battery negative (-) cables.
[14] - Operate backhoe to check for leaks and proper backhoe extendable dipperstick operation.
Backhoe Extendable Dipperstick Cylinder Disassemble and Assemble

For backhoe extendable dipperstick cylinder repair information, see Cylinder Identification . (CTM120519.)
Backhoe Boom Lock Cylinder Remove and Install

Battery Disconnect—If Equipped . (Operator’s Manual)
[4] -
CAUTION:
To avoid injury from escaping fluid under pressure, stop engine and relieve pressure in the system
pressure.
LEGEND:
1 Hydraulic Hose
2 Snap Ring
3 Washer
4 Pin
5 Return Spring
6 Washer (2 used)
7 Cap Screw
8 Nut
168 Boom Lock Cylinder
Boom Lock Cylinder

Disconnect hydraulic hose (1) from boom lock cylinder (168). Close all openings using caps and plugs.
[5] - Remove snap ring (2), washer (3), and return spring (5) from pin (4).
[6] - Remove nut (8), cap screw (7), washers (6), and return spring.
[7] - Remove boom lock cylinder .
[8] - Inspect parts and repair or replace as necessary.
[9] - Install boom lock cylinder rod end onto pin (4).
[10] - Install boom lock cylinder head end, washers (6), return spring, cap screw, and nut. Tighten securely.
[11] - Install return spring, washer (3), and snap ring onto pin.
[12] - Retract boom lock cylinder and connect hydraulic hose to boom lock cylinder.
[14] - Start engine and cycle boom lock several times. Raise boom and engage boom lock to check for proper operation.
Backhoe Boom Lock Valve Remove and Install—(S.N. —232969)

[4] -
CAUTION:
Backhoe Boom Lock Valve Location

LEGEND:
Y35 Boom Lock Solenoid
LEGEND:
167 Boom Lock Solenoid Valve
Y35 Boom Lock Solenoid
Backhoe Boom Lock Valve

Tag and disconnect hydraulic hoses (1) from boom lock solenoid valve (167). Close all openings using caps and plugs.
[5] - Disconnect 2-pin connector from boom lock solenoid (Y35).
[6] - Remove cap screws (2) and boom lock solenoid valve (167).
[7] - Inspect parts and repair or replace as necessary.
[8] - Install boom lock solenoid valve and cap screws.
[9] - Connect 2-pin connector to boom lock solenoid.
[10] - Connect hydraulic hoses to boom lock solenoid valve.
[12] - Start engine and cycle boom lock several times. Raise boom and engage boom lock to check for proper operation.
Backhoe Sideshift Lock Valve Remove and Install—(S.N. —232969)

[2] - Relieve hydraulic system pressure. See Hydraulic Circuit Pressure Release . (Group 9025-25.)
[4] -
LEGEND:
1 Rear Floor Mat
2 Cap Screw
3 Washer
4 Foot Pedal (if equipped)
Backhoe Lever Console

Remove cap screw (2), washer (3), and foot pedal (4) (if equipped).
[5] - Remove rear floor mat (1).
[6] -
→NOTE:
Lever assembly bracket and levers do not have to be removed.
LEGEND:
6 Console Cover
8 Cab Floor Rear Access Panel
Cab Floor Rear Access Panel

Remove cap screws (5) and console cover (6).
[7] - Remove cap screws (7) and cab floor rear access panel (8).
[8] -
LEGEND:
12 Nut (2 used)
169 Sideshift Lock Solenoid Valve
Y34 Sideshift Lock Solenoid
Sideshift Lock Solenoid Valve

Disconnect electrical connector from sideshift lock solenoid (Y34).
[9] -
CAUTION:
pressure.
Disconnect hydraulic hoses (9—11) from sideshift lock solenoid valve. Close all openings using caps and plugs.
→NOTE:
A bracket attaches boom lock valve to sideshift lock solenoid valve. Bracket and boom lock valve will
hang free when cap screws are removed.
[10] - Remove nuts (12) and cap screws (13) to remove boom lock valve, bracket, and sideshift lock solenoid valve (169).
[11] - Repair or replace sideshift lock solenoid valve as necessary. See Backhoe Sideshift Lock Valve Disassemble and
Assemble—(S.N. —232969) . (Group 3360.)
[12] - Install boom lock valve, bracket, and sideshift lock solenoid valve using cap screws and nuts. Tighten securely.
[13] - Connect hydraulic hoses (9—11) to sideshift lock solenoid valve. Tighten securely.
[14] - Connect electrical connector to sideshift lock solenoid.
[15] - Connect battery negative (–) ground cable or turn battery disconnect switch (if equipped) to the ON position. See
[16] -
LEGEND:
15 Backhoe Sideshift Frame Hydraulic Hose
16 Backhoe Sideshift Frame
Backhoe Sideshift Frame

Bleed air from boom lock circuit as follows:
Start engine and operate at slow idle.

Carefully loosen backhoe sideshift frame hydraulic hose (15) at sideshift frame (16).
Tighten hose connection when oil flows clear from hose connection (no air bubbles).
Tighten hose connection.
Check for leaks.
[17] - Check hydraulic oil level and add if necessary. See Check Hydraulic Reservoir Oil Level . (Operator′s Manual.)
[18] - Install cab floor rear access panel with cap screws (7). Tighten securely.
[19] - Install console cover using cap screws (5). Tighten securely.
[21] - Install foot pedal (if equipped) using cap screw (2) and washer.
Backhoe Sideshift Lock Valve Disassemble and Assemble—(S.N.

—232969)
[1] -
Sideshift Lock Valve Disassembled
Spool O-Rings
LEGEND:
1 Nut
2 Spool
3 Relief Valve
5 O-Ring
6 O-Ring
7 O-Ring
8 O-Ring
10 O-Ring
Remove nut (1) and sideshift lock solenoid (Y34).
[2] - Remove spool (2).
[3] - Remove relief valve (3).
[5] - Install relief valve.
[6] - Install spool.
[7] - Install sideshift lock solenoid and nut.
Backhoe Sideshift Lock Valve Disassemble and Assemble—(S.N.

255930—)
[1] -
Sideshift Lock Valve Disassembled
Spool O-Rings
Sideshift Lock Valve Orifice Plug

LEGEND:
1 Nut
2 Spool
3 Relief Valve
5 O-Ring
6 O-Ring
7 O-Ring
8 O-Ring
10 O-Ring
12 Orifice Plug
Remove nut (1) and sideshift lock solenoid (Y34).
[2] - Remove spool (2).
[3] - Remove relief valve (3).
[5] - Install relief valve.
[6] - Install spool.
[7] - Install sideshift lock solenoid and nut.
→NOTE:
It is not recommended to remove orifice plug (12). If removal is necessary apply Loctite ™ 272
Threadlocker and tighten to specification.
Orifice Plug Torque 13.6 N·m
10 lb.-ft.
Backhoe Sideshift Lock Piston and Bushing Remove and Install

[3] - Remove backhoe sideshift frame. See Sideshift Frame Remove and Install . (Group 3340.)
[4] -
→NOTE:
Put cardboard or rags under pistons to avoid damage.
Lay sideshift frame down so pistons point towards the ground.
[5] -
CAUTION:
To avoid injury from escaping fluid under pressure, stop engine and relieve hydraulic pressure in the
system before disconnecting or connecting hydraulic or other lines. Tighten all connections before
applying pressure.
LEGEND:
1 Hydraulic Supply Hose (3 used)
2 Hydraulic Fitting (4 used)
3 Sideshift Frame
4 Bushing (4 used)
Sideshift Frame
Disconnect hydraulic supply hoses (1) and remove hydraulic fittings (2) from bushings (4). Close all openings using caps and
plugs.
[6] -
LEGEND:
4 Bushing (4 used)
5 Opening
170 Sideshift Lock Piston (4 used)
Sideshift Lock Piston

Use compressed air in opening (5) to force sideshift lock piston (170) out of bushing.
[7] -
LEGEND:
3 Sideshift Frame
4 Bushing (4 used)
6 Seal (2 used)
170 Sideshift Lock Piston (4 used)
Sideshift Lock Piston and Bushing

Remove seals (6) from bushing.
[8] - Inspect seals and piston for damage or wear. Replace as necessary.
[9] - Use D01044AA Bushing, Bearing, and Seal Driver Set to remove bushing (4).
[10] - Inspect bushing condition and replace as necessary.
[11] -
IMPORTANT:
Avoid O-ring or component damage. Apply clean hydraulic oil to seals and all internal parts before
assembly.
Apply clean hydraulic oil to all internal parts. Install seals into bushing.
[12] - Use D01044AA Bushing, Bearing, and Seal Driver Set to install bushing.
[13] - Install sideshift lock piston.
[14] - Install hydraulic fitting into bushing and connect hydraulic supply hose. Tighten securely.
[15] - Install backhoe sideshift frame. See Sideshift Frame Remove and Install . (Group 3340.)
[16] -
LEGEND:
15 Backhoe Sideshift Frame Hydraulic Hose
16 Backhoe Sideshift Frame
Backhoe Sideshift Frame

Bleed air from sideshift lock circuit as follows:
Start engine and operate at slow idle.

DEALER FABRICATED TOOLS (g) by Belgreen v2.0
Carefully loosen backhoe sideshift frame hydraulic hose (15) at sideshift frame (16).
Tighten hose connection when oil flows clear from hose connection (no air bubbles).
Tighten hose connection.
Check for leaks.
Section 99 - DEALER FABRICATED TOOLS

Table of contents
Group 9900 - Dealer Fabricated Tools .................................................................................................. 1
DFRW20 Compressor Holding Fixture ................................................................................................... 1
DFT1101 Cab and ROPS Lift Bracket .................................................................................................... 2
DFT1285 Engine Support Bracket ......................................................................................................... 3
DFT1286 Backlash Measurement Tool .................................................................................................. 8
DFT1163 MFWD Snap Ring Removal and Installation Tool ................................................................... 9

Section 99 - DEALER FABRICATED TOOLS Group 9900: Dealer Fabricated Tools
Group 9900 - Dealer Fabricated Tools

DFRW20 Compressor Holding Fixture
DFRW20 Compressor Holding Fixture

LEGEND:
A 102 mm (4 in.)
B 76 mm (3 in.)
C 70 mm (2.75 in.)
D 6.4 mm (0.25 in.)
E 19 mm (0.75 in.)
F 152 mm (6 in.)
G 254 mm (10 in.)
H 114 mm (4.5 in.)
I 178 mm (7 in.)
J Fillet Weld
K Two Holes
This tool is used to hold the air conditioning compressor during disassembly and assembly.
Compressor Holding Fixture
DFRW20
Used to hold the air conditioning compressor during disassembly and assembly.
MATERIALS:
Two pieces of steel plate, approximately 70 x 120 mm (2-3/4 x 4 in.) and 152 x 254 mm (6 x 10 in.)
Two pieces of threaded rod, 13 mm (1/2 in.) threads x 178 mm (7 in.) long
Four lock washers and nuts


LEGEND:
A Drill Six Holes (0.625 in.)
B Weld
C U46161 Lift Eyes Welded to Tube with 0.25 in. Fillet Weld
Used to remove and install cab or ROPS.
Material:
2.0 in. x 2.0 in. x 0.250 in. Square Tube

U46161 U-Bolts (4 used)
JT01748 Lift Brackets (2 used)
0.625 in. x 3.00 in. "F" Grade Cap Screws (2 used)

DFT1285 Engine Support Bracket

DFT1285A Engine Support Bracket
→NOTE:
If available, DFT1285 Engine Support Bracket (B) can be used to make DFT1285A Engine Support Bracket
(A).

DFT1285A Cross Bar

LEGEND:
A DFT1285A Engine Support Bracket
B DFT1285 Engine Support Bracket

DFT1285A Spacers
DFT1285A Engine Support Bracket supports engine while transmission is being removed and installed.
MATERIALS:
C-Channel Steel (C4 x 7.25)

Cap Screw (10.0 mm x 1.5 mm x 80.0 mm, 8 used)
Spacer (31.7 mm x 6.3 mm x 54.0 mm, 2 used)
Spacer (31.7 mm x 6.3 mm x 52.3 mm, 2 used)
DFT1285 Engine Support Tool

DFT1285 Cross Bar

DFT1285 Spacers
Used to support engine during while transmission is being removed and installed.
MATERIALS:
C Channel Steel (C4 x 7.25)

4 Cap Screws (10 mm x 1.5 mm x 80 mm)

Used to measure backlash between ring gear and pinion.

MATERIALS:
2 Cap Screws (7/16 x 30)

3/8 in. 1020 Steel


LEGEND:
A 3 in. Inside Diameter x 6 in. Long Pipe
Used to remove and install snap rings in MFWD shaft assembly.
Material required:
3 in. Inside Diameter x 6 in. Long Pipe

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315SK Backhoe Loader

REPAIR TECHNICAL MANUAL

Backhoe Loaders (T3/S3A) models 315SK (PIN: 1T0315SK**D229820-;

TM12472 27 DEC 15 (ENGLISH)

For complete service information also see:

John Deere Construction and Forestry

<- Go to Global Table of contents 315SK Backhoe Loader Repair

<- Go to Global Table of contents 315SK Backhoe Loader Repair

Manual Identiﬁcation—READ THIS FIRST!

Choosing the Correct Supporting Manuals

PIN Plate Location

Example of PIN Plate

<- Go to Global Table of contents 315SK Backhoe Loader Repair

PIN Identiﬁcation Table

17 Digit PIN Example

(3) (4) (5) (4) (6) (7) (8) (9)

(3)—World Code —Identiﬁes location where machine is manufactured.

1T0 .......... World Code (manufacturing location)

1DW .......... Davenport Works

1T8 .......... Thibodaux Works

1T0 .......... Dubuque Works

315_K .......... Machine Model Identiﬁer

S .......... Machine Option Code

X .......... Base Machine

S .......... Super Duty

E .......... Easy Power (EP)

T .......... Total Machine Control (TMC) Conﬁguration

_ .......... Check Letter (variable)

_ .......... Manufacturing Year Code (variable)

C .......... Engine Emission Code

C .......... Tier 2 and Stage II

D .......... Tier 3 and Stage III A

E .......... Interim Tier 4 and Stage III B

G .......... Interim Tier 4 and Stage III A (19-56 kW)

219607 .......... Machine Serial Number

<- Go to Section TOC Section 00 page 2 315SK Backhoe Loader Repair

Section 00 - GENERAL INFORMATION

<- Go to Global Table of contents 315SK Backhoe Loader Repair

<- Go to Global Table of contents 315SK Backhoe Loader Repair

Group 0001 - Safety

Safety alert Symbols

Safety Alert Symbols

Follow Safety Instructions

<- Go to Section TOC Section 00 page 1 315SK Backhoe Loader Repair

Operate Only If Qualiﬁed

<- Go to Section TOC Section 00 page 2 315SK Backhoe Loader Repair

Wear Protective Equipment

Avoid Unauthorized Machine Modiﬁcations

<- Go to Section TOC Section 00 page 3 315SK Backhoe Loader Repair

Inspect machine carefully each day by walking around it before starting.

Stay Clear of Moving Parts

Stay Clear of Moving Parts

Entanglements in moving parts can cause serious injury.

Avoid High-Pressure Fluids

<- Go to Section TOC Section 00 page 4 315SK Backhoe Loader Repair

Avoid High-Pressure Oils

Avoid High Pressure Oils

Avoid High-Pressure Oils

Work In Ventilated Area

<- Go to Section TOC Section 00 page 5 315SK Backhoe Loader Repair

Engine exhaust fumes

Handle Fuel Safely

Clean Machine Regularly