John Deere 410B, 410C, 510B, 510C Backhoe Loaders Repair TECHNICAL MANUAL TM-1469 (Dec-88) SS| FOREWORD | This manual is written for an experienced technician. | Eoocntial toolo roquired in performing certain sorvioe work are identified in this manual and are recom- mended for use. | live with safety Read tha safety messages in the | introduction of this manual and the cautions presented throughout the text of the manual. ‘This is the safety-alert symbol. When you see this symbol on the machine or in this ‘manual, be alert to the potential for per- sonal injury. Technical manuals are divided in two parts: repair and diagnostics. Repair sections tell how to repair the ‘components. Diagnostic sections help you identify the ‘majority of routine failures quickly Information is organized in groups for the various ‘components requiring service instruction. At the begin- ning of each group are summary listings of all applica- | ble essential tools, service equipment and tools, other materials needed to do the job, service parts Kits, specifications, wear tolorances, and torque values. Binders, binder labels, and tab sets can be ordered by John Deere dealers direct from the John Deere Distribution Service Center Litho in USA, This manual is part ofa total product support program. FOS Manuals-reterence Technical Manuals-machine service Component Manuals-component service Fundamentals of Service (FOS) Manuals cover basic theory of operation. fundamentals of troubleshooting, general maintenance, and basic types of failures and their causes, FOS Manuals are for training new person: nel and for reference by experienced technicians. Technicals Manuals are concise guides for specitic machines. Technical manuals are on-the-job guides containing only the vital information needed for diagno- sis, analysis, testing, and repair. Component Technical Manuals are concise service {guides for specific components. Component technicals. manuals are written as stand-alone manuals covering rmuliple machine applications. TMA1468 (Dec-88)_JOHN DEERE DEALERS IMPORTANT: Please remove this page and route through your service department. This is a complete revision for TM-1964, 410B/410C and 510B/510C Backhoe Loaders. ‘TM-1468 (Operation and Test) and TM-1469 (Repair) replace TM-1364. ‘The new pages are dated (Dec-86). Listed below is a brief explanation of "WHAT" was changed and "WHY" it was changed. This manual was revised: 1. Update hydraulic cylinder torque-turn specifications. 2. New procedure for repair of axle and integral steering cylinder. 8, Update to include unitized stroke control valve on the 3000 series hydraulic pump. 4, Update repair section to utlize CTM’s 5. Update repair and adjustment procedure of cab windows, 6. Update electrical and hydraulic sections. ~ ~ TM-1469 (Dec-88) Litho in USA.Lithe in USA. 410B AND 510B BACKHOE LOADER 410C AND 510C BACKHOE LOADER SECTION AND GROUP CONTENTS NOTE: This manual covers machine repair. For Opera- tion and Test information, see TM-1468. SECTION I—GENERAL INFORMATION Group | Introduotion and Satoty Information Group ll—General Specifications Group Ill Torque Values Group 1V—Lubrication Group V—Inspection Procedures SECTION 01—WHEELS Group 0110—Powered Wheels and Fastenings Group 0120—Non-Powered Wheels and Fastenings SECTION 02—AXLES AND SUSPENSION SYSTEMS Group 0230—Non-Powered Wheel Axles Group 0250—Axie Shafts, Bearings and Reduction Gears SECTION 03—TRANSMISSION Group 0300—Removal and Installation Group 0315—Controls Gioup 0325—Input Drive Shafts and Usioints Group 0350—Gears, Shatts, Housings, Bearings, Diffor- tential Lack, Brake and Park Brake Group 0360—Hydraulic System, Control Valve, Suction ‘Screen, Oil Pump, and Lubrication System All information. illustrations and specifications contained in this technical manual are based on the latest information available at the time of publication. The right is reserved to make changes at any time without notice. TECHNICAL MANUAL TM-1469 (DEC-88) SECTION 04—ENGINE Group 0400—Removal and Installation Group 0413_Fual Injection System Group 0414—Intake Manifold Group 0416—Turbocharaor Group 0417—Wator Pump Group 0418—Thermostats, Housing and Water Piping Group 0413—-iI Cooler Group 0420—Fuel Filter Group 0421—Tuel Teanster Pump Group 0422—Starting Motor and Fastenings SECTION 05—ENGINE AUXILIARY SYSTEMS Group 0605—Cold Weather Starting Aids Group 0510—Coaling Systems Group 0515—Speed Controls ) Group 0520—Intake System Group 0560—External Fuel Supply Systene | SECTION 09—STEERING SYSTEM Group 0960—Hydraulie System Steering Valve and ylinder SECTION 10—SERVICE BRAKES Group 1011—Acive Elements, Brake Disks and Contro! Linkage Group 1080—Hydraulie System Broke Valve Continued an next page TM-1469 (Dee-AA)SECTION 11—PARK BRAKES Group 1111—Active Elements, Group 1115—Controls Linkage SECTION 16—ELECTRICAL SYSTEMS Group 1671—Batteries, Support and Cablos Group 1672—Alterator, Regulator and Charging System Wiring Group 1678—Lighting System Group 1674—Wiring Harness and Switches Group 1675—System Controls Group 1676—Instruments, Indicators and Senders Group 1677—Motors and Actuators SECTION 17—FRAME, CHASSIS, OR SUPPORTING STRUCTURE Group 1740—Frame Installation Group 1749—Chassis Weights SECTION 18—OPERATOR’S STATION Group 1800—Removal and Installation Group 1810—Operator Enclosure Wiper Motor and Windshield Washer Group 1821—Seat and Seat Belt Group 1830—Heating and Air Conditioning SECTION 20—SAFETY, CONVENIENCE AND MISCELLANEOUS Group 2004—Horn and Warning Devices SECTION 21—MAIN HYDRAULIC SYSTEM Group 2160—Hydraulic System Main Hydraulic Pump, Pump Drive, Main Hydraulic Filter, Oil Cooler, Oil Cooler Bypass Valve, and System Relief Valve SECTION 31—LOADER Group 3100—Removal and installation Group 3102—Buckets Group 3115—Controls Linkage Group 3140—Frames Group 3160—Hydraulic System Control Valve and Cylinders SECTION 33—BACKHOE Group 3302—Buckets Group 9815—Controls Linkage Group 3340—Frames Group 9360. Hydraulic Syetom Control Valve and Cylinders Litho in U.S.A. ‘TM-1469 (Deo-88)Group | | Safety Information HANDLE FLUIDS SAFELY—AVOID FIRES When you work around fuel, do not smoke or work near VA here or othr fre Hazara Make sure machine is clean of trash, grease, and debris. Do not store oily rags; they can ignite and burn spontaneously visa? ospruaie ens PREVENT BATTERY EXPLOSIONS ‘Keep sparks, lighted matches, and open flame away from tho top of battery. Battory gae can explode. Never check battory charge by placing a motal object across the posts. Use a volt-meter or hydrometer. Do notcharge a frozen battery; it may explode. Warm battery to 16°C (60°F). LH PREPARE FOR EMERGENCIES 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 vour telephone. Litho in USA FFA a ~TM1469 (Deo-88)Safety information PREVENT ACID BURNS Sulfuric acid in battery electrolyte is poisonous. It is strong enough to burn skin, eat holes in clothing, and cause blindness if splashed into eyes. Avoid the hazard by: 1. Filling batteries in a well-ventilated area. 2. Wearing eye protection and rubber gloves. 3. Avoiding breathing fumes when electrolyte is added 4, Avoiding sping or dripping electrolyte, 5. Use proper jump start procedure. tt you spill acid on yoursett: 4. Flush your skin with water. 2. Apply baking Soda or lime to help neutralize the acid. 3, Flush your eyes with water for 10-15 minutes. Get medical attention immediately. It acid 1s swallowed: 1, Drink large amounts of water or milk. 2. (nen drink mik of magnesia, beaten eggs, or vegetable oil 3, Get meaical attention immediately | AVOID HIGH-PRESSURE FLUIDS Eecaping fhid under pressure ean penstate the skin Causing serous iy. Releve pressure before unhookng hydraulo or ether nee. Tighton all sonnoations bolore Hs | applying pressure. Keep hands and body away from pinholes. a | and nozzles which eject fluids under high pressure. Use a 1 piece of cardboard to search for leaks. | | IT ANY fluid is injacted into the skin, it must be surgically removed within a few hours by a doctor familiar with this typo injury or gangrene may result PARK MACHINE SAFELY Betore working on the machine: | * Lower all equipment to the ground, * Stop the engine and remove the key. ** Disconnect the battery ground strap. ‘= Hang a “DO NOT OPERATE” tag in operator station. ‘TM-1469 (Dec-88)Satety Information SUPPORT MACHINE PROPERLY Aways lower the attachment or implement to the ground | botore you work on the machin, i you must work on a ited | machine or attachment, securely Support the machine or attachment 1 not support the machine on cinder blocks, hollow tes, (2) or props that may crumble under continuous load. Do not work under a machine that is supported solely by a jack. Follow recommended procedures in this manual. | WEAR PROTECTIVE CLOTHING D ‘Wear close fitting clothing and safety equipment appropriate ; tomneoo. | Prolonged exposure to loud nolo cen cause Impainnent or ® | lose heen Wear a suitable hearing protective devce such as earmutts — “B or earplugs to protect against objectionable or uncomfort- shi oud nace @ i | SERVICE MACHINE SAFELY Tie long hair behind your head. Do not wear a necktie, scarf, loose clothing, or necklace when you work near machine tools or moving parts. If these items were to get caught, severe injury could result. Remove rings and other jewelry to prevent electrical shorts and entanglement In moving parts, WORK IN VENTILATED AREA Engine exhaust furnes can cause sickness or death. I itis necessary to run an engine in an enclosed area, remove the | exhaust fumes from the area with an exhaust pipe extension, you do net have an exhaust pipe extension, open the doors and get outside air into the area. TM-1469 (Dec-88) Litho in USASafety information UNDERSTAND CORRECT SERVICE lluminate your work area adequately but safely. Use a Portable safety light for working inside or under the machine. Make sure the bulb is enclosed by a wire cage. The hot filament of an accidentally broken bulb can ignite spilled fuel oa orl BZ Catch draining fue, oo othe ids in utabe containers, | | bo not use ood or beverage contaners that may mislead | ‘someone into drinking from them. Wipe up spills at once. REPLACE SAFETY SIGNS —_ Vo Replace missing or damaged safety signs. See the machine — Operators manal for caret safely sgn placement sa DEATSIOL OSSIGUSE 22:27 | USE PROPER LIFTING EQUIPMENT j | Litting heavy components incorrectly can cause severe | injury or machine damage. | Follow recommended procedure for removal andinstallation | of components in the manual | | | KEEP ROPS INSTALLED PROPERLY Make certain all parts are rainstallad correctly ifthe rollqver protective structure (ROPS) is loosened or removed for any reason. Tighten mounting bolts to proper torque. The protection offered by ROPS will be impaired it ROPS | is subjected to structural damagg, is involved in an overturn incident. orisin any way altered by welding, bending. ding. ‘or cuiting. A damaged ROPS should be replaced, not | reused l Utho in U.S.A. 14Safety Information SERVICE TIRES SAFELY Explosive separation of a tire and rim parts can cause serious injury or death. Do nat 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. When inflating ties, use a clip-on chuck and extension hose ong 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 wneels for low pressure, cuts, bubbles, damaged rims (or missing lug botts and nuts. AVOID HARMFUL ASBESTOS DUST ‘Avoid breathing dust that may be generated when handling components containing asbestos fibers. Inhaled asbestos fibera may cause lung canoer. Components in John Deere products that may contain asbestos fibers are brake pads, brake band and lining assemblies, clutch plates, and soma gaskets. The asbestos used in these components is usually found in a resin or sealed in some way. Normal handling is not hazardous as Jong as airborne dust containing asbestos is not generated. Avoid creating dust. Never use compressed air for cleaning. Avoid brushing or grinding of asbestos containing materials. When servicing, wear an approved respirator. A special vacuum cleaner is recommended to clean asbestos. if not available, wet the asbestos containing matenals with a mist of oil or water. Keep bystanders away from the area. Litho in USA, ‘TM-1469 (Dec-88)Satety information | PRACTICE SAFE MAINTENANCE | Understand service procedure before doing work. Keep area lean and dry. | Never lubricate or service machine while itis moving. Keep | hands, feet, and clothing from power-driven parts. Disen- gage all power and operato controle to roliove prossuto. | Lower equipment to the ground. Stop the engine. Remove @ the koy. Allow machine to cool. ‘Securely support any machine elements that must he raised for service work. Keep all parts in good condition and properly installed. Fix damage immediately. Replace worn or broken parts. Re- move any buildup of grease, oil, or debris. Disconnect battery ground cable (-) before making adjust- ments on electrical systems or welding on machine. STORE ATTACHMENTS SAFELY Stored attachments such as dual wheels, cage wheels, and loaders can fall and cause serious injury or death, Securely store attachments and implements to prevent falling. Keep playing children and bystanders away from storage area. 1 WORK IN CLEAN AREA 8 | | bot staring ao: © Goan wot re and machi 1 Moh Se youhav al coon tol todo your Hite torah pos on hen 1 Absu ah noruton hteghy; do ret attempt ~ shorts ‘N Litho in U.S.A, 16 ‘TM-1469 (Dec-88)Safety Information USE TOOLS PROPERLY Use tools appropriate to the work. Makeshift tools, parts, and procedures will not make good repairs. Use pneumatic and electric tools only to Inasen threaded parts and fasteners. Never use such tools to tighten fasteners, especially on light alloy parts. Use only replacement parts meeting John Deere specifications. DISPOSE FLUIDS PROPERLY ‘Be mindful of the environment and ecology. Before you drain fluids, find out the proper way to dispose of the oil Do not pour oil onto the ground, down a drain, or into a stream, pond, or lake. Consult local ordinances that govern the disposal of wastes. LIVE WITH SAFETY Before retumning machine to customer, make sure machine is functioning properly, especially the safety systems. Install all guard and shiolds, Litho in USA. 7 TM-1469 (De0-88)Safety information Litho in USA, TB TWw-1469 (Dec-88)Group II General Specifications | 410C BACKHOE LOADER (Specifications and design subject to change without notice. Wherever applicable, specifications are in accordance with ICED and SAE Standards. Except where otherwise noted, these specifications are based on a standard machine with 17.5L-24, 10PR, Ré4 rear tires; 11L-15, 10PR, F3 front tires with; 1.0 cu. yd. (0.76 m3) loader bucket; 24-in. (610 mm) backhoe bucket; ROPS/FOPS; full fuel tank and 175-lb. (79 kg) operator). Power (@ 2200 engine pm) sae DIN Final Drives Panetary inboard Ne 75 he 602 KH) 80 np (60 KY) Service Brakes: Engine: Manual ber, ape wth separate peas: hycauenly es Join Deere turbocharged (oplona 4-oynder dese, va inheed zed when Soh pedals ae depressed Wet sks an acng ara Uy ‘stroke cyte encased and sot-ajusing (108% 127 mm) Steering: Hydrostatic Power Displacement 276... Turning radius (brake aooled) Jon 9in 12m (52) Gearance exes 2911 8.86 m) Compression rata ces 188101 Stoocing whoo turns Tet 0 right 20 Mesemom torque @ 1300 rpm be ‘ioe a3 ieo1 Nm) ain oetings 5. yaraule System: Cosod contr variable om, constant pressure) Lubrication Pressure sysiem wititiow Standby Pressure 2785 pi (19.000 Ka} fier and cooler Pump 8 radal pistons, variable ow cooing Pressurized w/thermostat and Faw @ 200 pal (15 170 KPa) 35 gpm ‘red bypass eziuy Fan sce Sutton Fier, retun of 10 miron sto! enclose, replacosbie A cloanor Dy oment Elect! sys ‘avo screen, pressure oil 0/n. 20Vem) mash Aerator St ane Fine 115'eeth Hydraulic Cylinder: Bore stroke Rod Ltader boom (2) ais 208m AT in Torque converter: (GOmm) 57 mm) Gb mm) Single sage, dial phase, overuning stator, t1n. (280 mm) Loader bucket (1) ast, 282m, 177 in Anmate, sa ena 229 0 4 (omm)@18 mm) AS om) Backtoe boom (1) “son 385m, 240 in Reverse (118 mm) (@78. nm) (Om) OUUatd, Ku powe sh wi UHL weIDR EN ONE —gacknoe crowd (t) ... “Bun, au Surin ‘eco lver a lel of storing wheel Reverse speeds are 16% (200mm) (@36 mm) (60 mm) faster than forward speeds Bache bckat askin 31Dim arin (60mm) (787 mm) Om) ‘Transaie: Backtoe suing (2) 40m 95m, 20, Marva Sat wy st an Seu pets levy sy ore mm @ermmy gue mm engagements and thi and fourth speeds engeged wih core‘ype _Sackhoe exendole Sinetronaor. Siro hit lover, Noor mounts ner) 25m Bin, 4.25, (64mm) (1220 mm) @2 mm) Travel Speeds: Forward Reverse Backhoe stbazers 2). Sahm 2031187 in sop myhome kh (oom —wiemm — Gomm ‘without MFWO Steering (1) regular Gert 300 48s 88 me tern 95in, 00810 2 51 828s (600mm) etm) @50mn) a 0978803 Tres: © 139 gat oss Front {20 NOT ww wits MFO) 111 x15 10FA FO {00 NOT use with MFWD) 11 16 12PR F with MEWD (Use wth MFWD) 12 165 8 PR Fa Gert 93538 (00 NOT use wih MWD) 125 C18. PR it 2 57 8) 68108 (00 NOT use with MEWO) 145/75 x 161 10 PR FS 88138 toa Rea {DONOT use with MIWO) 0x24 07NINA 4 Bi 3868 {00 NOT uso win MWD) 175 24, 10PR, Ra (CO NOT vse wih MFWO) 12.5 L x24 10 FRAG Mechanical Front Wheel Drve:—if Equipped) {Use with MEWD) 21 Lx 26 10 PR AS Engaged on the-gohysrauial. Automate soeckng ferent Continued on next page ithe in USA TM-1469 (Dec-88)General Specifications 410C BACKHOE LOADER ‘Whoo! Treads: Frnt (witout MFO) (tn MEW) Fear (witout PWD) (win MEWO) Wheelbase: (without MEWO) (ovth EW) ‘Axle Ratings: (SAE 48) Front oar Buckets: wien Loader: In, (mm) (Long Up) 99.4 (2270) 92 eaa7) 82 (337) Backhoe: In. (mm) Standard 12 (905) 18 (408) Buen 2 (610) 30 (ree) 3814) Hewwy uty 18 (97) 24 10) 90 (0a) High 2 (610), Capacty 96014) Transporting: ‘struck Capacity cu. im) va. 1.05 (0.80) 08s (087) 107 (082) Cu. FL. (my 26 (007) 37 (10) 42 wre) 58 (0.17) 15 @2i) 75 (21) 42 012) 59.17) 76 (wat) 72 (020) 12 039) ‘SAE operating weight with ROPS Litho in U.S.A. 09, (1797 wm) 68 in. (1727 mm) (6 in. (1085 mm) 691n, (1757 mm) 227 in (2100 em) 833 in (2116 mm) 11-700 tb (6300 ko) 15 400 fb (7000 ka) Heaped Capacity cu. (m va. 125 (098) 10 (078) 13° (100) Cu. FL (mi) 30 (0.08) 45 0.19) br (19) 75 (21) yoo (028) 100 (028) 51 018) 75 (21) 100 (020) 88 (025) 146 (040) 6550 kg (14.400 1) He? ‘TM-1469 (Dec-88)| General Specitications Drain and Refit Capacities: 4100 BACKHOE LOADER us. Mate Erin colt ro hese) wa BL | Erde colt win estes WBqh SL Erane ol (houdng fen v-evcs/-Dgt OSL | Torque convertor ord rveser including fier) wat nL | ‘Transaxle-tydraulic system } (witout MEWO) Og a | tw MWD) Hee aL | ut ane Beat | Ay Wotan Fete)... tod TL Front ave EVO) Te 8st | | Front ned paneer WWE) Ft OL Tho in USA Tw.1468 (Dec-88)General specitications 410C BACKHOE LOADER Litho in USA. ~~ TW1489 (Dee 68)General Specifications 410C BACKHOE LOADER Key: \- Loading height, truck loading position Reach from center of swing mast Reach from canter of rear axle . Digging depth (SAE): (1) 2 ft. (610 mm) flat bottom (2) 8 ft. (2440 mm) flat bottom E. Maximum digging depth F. Ground clearance, minimum G. Bucket rotation H. Transport height J. K, Lu M, pomp Overall length, transport Stabilizer width—transport Stabilizer spread—operating ‘Overall width (less loader bucket) Digging force, bucket cylinder (Power aig position) Digging force, crowd cylinder ‘Swing are Operator control Bucket positions Stabilizer angle rearward Lifting capacity, maximum boom @ 65° NOTE: Backhoe specications aro with 24 jn, (610 mm) 7-5 cu ft (0.21 mi) standard bucket Backhoe* with Long Dipperstick 11 ft. 10 in, (3.62 m) 18 ft 5 in, (6.62 m) 22 ft Bin (6.76 m) 15 ft. 3 in, (4.64 m) 14 ft 2 in. (4.92 m) 15 ft. 4 in, (4.68 m) 12 in. (805 mm) 160° and 180° 41 ft 5 in. (8.49 m) 23 ft. Sin, (7.14 m) 7 ft. B in. (2.34 m) 9 ft. 10 in. (3.0 m) 82 in, (2070 mm) 11700 Ib (5310 kg) {6300 Ib (2860 kg) 180" Two lovers: 8° and 10° rollback 145° A100 lb (1860 kg) Extondible Dipperstick Retrected 11 ft.6 in, (2.51 m) 17 ft 9 in, (5.42 m) 21 ft Bin (6.8 m) 14 ft. 6 in, (4.42 m) 19 ft. 5 in. (4.09 m) 14 ft. 8 in, (4.46 m) 12 in, (805 mm) 160° and 180° 11 ft 8 in. (8.57 m) 23 ft. (7.01 m) 7 ft. 8 in, (2.34 m) 9 ft. 10 in, (3.0 m) 82 In, (2070 mm) 11700 Ib (5310 kg) {6800 Ib (8080 kg) 180" ht foot treadle 9° and 17° rollback 145° 4100 tb (1860 kg) 13 ft 11 in, (4.24 m) 21 ft. 5 in, (6.52 m) DB ft in. (7.88 mm) 18 ft. 4 in. (6.59 m) 17 ft 6 in, (6.34 m) 18 ft. 5 in. (6.62 m) 12 in. (805 men) 160° and 180° 41 ft 8 in. (8.57 m) 28 ft. (7.01 m) 7 ft 8 in. (2.84 m) 9 fL. 10 in. (8.0 m) 82 n, (2070 mm) 11700 Ib (6310 kg) | 4600 Ib (2090 kg) 180° Right foot treadle 412" and 22" rollback 14s 2700 Ib (1220 kg) Litho in USA ‘TM-1469 (Deo-88)General Specitications 410C BACKHOE LOADER LIFTING CAPACITIES Backhoe With Long Dipperstick NOTE: Lifting capacity ratings are made from bucket hinge pin, loader bucket and stabilizers on firm, level ground, Litting capacities are 87 percent of the maximum lft over any point on the swing arc and do not exceed 76 percent of the tipping load. Angle between boom and ground is 65 degrees. Machine is equipped with 21 in. (610 mm) etandard bucket, long, short or extendible dipporstiok (a9 indicated), and standard ‘equipment. Lifting capacity ratings are based on SAE J31 (except with loader bucket on ground.) Loader bucket on ground significantly improves side stability, therefore improving lift capacity to the side. Lith capacity over the rear is not affected. Reach (Bucket Hinge Pin to Center of Swing Frame) 10.5 ft (3.20 m) 10.8 ft. (@.20 m) 11.1 ft 38 m) 126 ft (@84 m) 11.0 ft (835 m) 139 ft (424m) 10.2 ft 11 m) 147 ft (4.48 m) 8.3 ft (259 m) 15.2 ft (4.64 m) 1544 ft (4.69 m) 18.3 ft (4.67 m) 14.9 f (4.54 m) 14.2 ft (4.38 m) 18.1 ft (8.99 m) 11.6 ft (54 m) 92 ft (2.81 m) 47 ft. (143 m) Height ‘Above (A) oF Below (B) Ground Line 12 ft (8.66 m) (A) 42 tt (2.68 m) (A) 10 ft. (3.05 m) (A) 40 ft (2.08 m) (A) 8 ft. (2.44 m) (A) Aft (244 m) (A) 6 ft. (1.83 m) (A) 6 ft. (1.83 m) (A) 4 ft. (1.22 m) (A) 4 (1.22 m) (A) 2 ft. (0.81 m) (A) 0 ft. (Ground Line) 2 ft. (0.61 m) (B) 4 ft (1.22 m) B) 6 ft (—1.83 m) (8) 8 ft. (—2.44 m) (B) 10 ft. (—3.05 m) (8) ~12 ft. (—3.66 m) (8) 2060 Ib. (995 ka) 12000 Ib, (950 ka) 2060 Ih. (980 kg) 2010 Ib. (910 kg) 1950 Ib. (885 ka) 1890 Ib. (855 kg) 1840 Ib. (835 kg) 1790 Ib. (810 kg) 1750 Ib. (795 kg) 1720 Ib. (780 kg) 1710 Ib. (775 kg) 1770 Ib. (805 kg) 2310 lb. (1050 kg) Dipperstick 9570 Ib. (1690 ka) 3300 Ib. (1495 kg) 8920 Ib. (1505 kg) 3630 Ib, (1695 kg) 4760 Ib. (2160 kg) Litho in USA TM-1469 (Dec-88)General Specitications 410C BACKHOE LOADER Backhoe With Short Dipperstick Reach Height {Bucket Hinge Pinto ‘Above (A) or ‘Center of Swing Frame) Below (B) Ground Line Boom Dipperstck 0.7 tt (2.06 mm) 12 ft (8.68 m) (A) 4010 tb. (1820 kg) 9.8 ft (2.99 m) 42 ft. (8.68 m) (A) 3860 tb. (1025 kg) 10.4. (2.17 m) 10 ft. (3.05 m) (A) 3850 Ib. (1655 kg) 11.8 ft. (@.60 m) 410 ft. (8.05 m) (A) £2300 Ib. (1045 ka) 10.9 ft. (9.14 m) B ft (2.44 m) (A) 9670 Ih. (1685 kg) 13.1 ft. (8.99 m) B ft (2.44 m) (A) 2270 Ib. (1030 kg) 9.4 ft (287 m) 6 ft (1.83 m) (A) 4190 Ib. (1875 ka) 14 ft (4.27 m) 6 ft (1.83 m) (A) £2200 Ib. (1000 kg) 67 ft (2.04 m) 4 ft (1.22 m) (A) 6410 Ib, (2810 kg) 448 ft (4.42 m) 4 ft. (1.22 m) (A) 2130 Ib. (965 ka) | 14.7 ft. (4.48 m) 2 ft. (0.61 m) (A) 2070 Ib. (940 kg) | 14.6 ft. (4.48 m) 0 ft. (Ground Line) 2000 Ib. (905 kg) | 142 ft. (4.33 m) 2 it. (—0.61 m) (B) 1950 Ib. (885 kg) 13.5 ML (4.12 m) 4 tt (=1.22 m)(B) 1800 1D. (BED kg) 12. ft. (8.75 m) 6 ft. (1.83 m) (B) 1870 Ib. (850 kg) 10.8 f. (8.23 m) =8 tt. (—244 mm) (B) 1870 Ib. (880 kg) 7.9 ft (241 m) =10 ft. (=3.05 m) (B) 1960 Ib. (890 kg) 410 BACKHOE LOADER Backhoe With Extendible Dipperstick, Retracted (Bucket Hinge Pin to Center of Swing Frame) Boom Dipperstck 9.7 ft (2.96 m) 12 ft. (8.66 m) (A) 3720 Ib. (1690 kg) 2.0 ft (2.99 m) 42 ft (0.00 m) (A) 1990 Ib. (905 kg) | 10.4 ft. (3.17 m) 10 ft. (3.05 m) (A) 3370 Ib. (1530 kg) 11.8 ft. (2.60 m) 410 ft. (8.05 m) (A) 1080 Ib. (000 kg) | 10.3 ft. (8.14 m) 8 ft. (2.44 m) (A) 3980 Ib. (1535 kg) | 13.1 ft. (3.99 m) 8 ft (2.44 m) (A) 1920 Ib. (870 kg) 9.4 ft (287 m) 6 ft (1.83 m) (A) 3790 Ib. (1720 kg) 14 ft. (4.27 m) 6 ft. (1.83 m) (A) 1830 Ib. (830 kg) 67 ft. 2.04 m) 4 ft (1.22 m) (A) 5920 Ib. (2685 kg) | 14.5 ft. (4.42 m) 4, ft. (1.22 m) (A) 1750 Ib. (795 ka) 14.7 ft. (4.48 m) 2 ft. (0.61 m) (A) 1660 Ib. (755 kg) | 14.6 ft. (4.45 m) 0 ft. (Ground Line) 1580 Ib. (715 kg) 14.2 ft. (4.33 m) 2 ft. (—0.61 m) (B) 1510 Ib. (685 kg) 49.5 ft. (4.12 m) 41. (1.22 m) (B) 1440 Ib. (655 ka) 12.3 ft. (3.75 m) <6 ft (1183 m) (B) 1990 Ib. (630 ka) 10.6 ft. (3.23 m) —8 ft. (—2.44 m) (B) 1350 Il. (610 kg) 7.9 tt (2.47 m) —1W ft. (—3.05 m) (6) 1870 Ib, (620 kg) Lithe in USA. 1-7 TM-1469 (Dec-88)General Specifications each (Bvoket Hinge Pin to Center of Swing Frame) 14 ft. (4.27 m) 148 ft (4.51 m) 1433 ft. (4.96 m) 16.1 f. (4.91 m) 1433 ft. (4.36 m) 17.4 f. 6.22 m) 19.8 ft. (4.21 m) 178 ft. (6.43 m) 128 ft. (@.90 m) 182 ft (6.55 m) 41 ft. (8.36 m) 18.3 ft. (6.58 m) 18.2 fl. (6.55 m) 17.9 ft. (6.46 m) 174 Ht (6.38 m) 165 ft. 6.03 m) 153 th (4.67 m) 13.7 ft (4.18 m) 11.5 ft (2.51 m) 8 ft. (2.44 m) 410C BACKHOE LOADER | Backhoe With Extendible Dipperstick, Extended Holght Above (A) or Below (8) Ground Line 12 ft. (3.66 m) (A) 42 ft (8.66 m) (A) 10 ft. (3.05 m) (A) 10 ft (3.05 m) (A) 8 ft. (2.44 m) (A) 8 ft. (2.44 m) (A) 6 ft. (1.83 m) (A) 6 ft. (1.83 m) (A) 4 tt (1:22 m) (A) 4. ft. (1.22 m) (A) 2 ft. (0.61 m) (A) 2 ft. (0.61 m) (A) 0 ft. (Ground Line) —2 ft. (—0.61 m) (8) —4 ft (—1.22 m) (8) —6 ft (1.83 m) (8) —8 ft (—2.44 m) (6) —10 ft. (—3.05 m) (8) 12 ft. (—3.66 m) (8) =14 ft (4.27 m) (@) 1250 Ib. (565 kg) 1270 Ib, (575 ka) 1270 Ib, (575 ka) 1260 Ib. (570 ka) 4290 Ib, (560 ka) 1210 Ib. (650 kg) 1180 Ib. (595 kg) 1150 Ib. (620 kg) 1130 1D. (818 kg) 1110 tb, (505 kg) 1110 1b. (505 kg) 1110 Ib. (605 kg) 1160 1b. (525 kg) 1350 Ib. (610 kg) Dipperstick 2250 Ib. (1020 kg) 2150 Ib. (975 ka) 2160 Ib. (975 kg) 2240 Ib. (1015 kg) 2480 Ib. (1125 kg) 3020 Ib (1970 kg) Lino in USA. TW-1469 (Dec-88)Goneral Spoottications 510C BACKHOE LOADER (Specifications and design subject fo change without notice. Wherever applicable, specifications are in accordance with ICED and SAE Standards. Excopt where otherwise noted, these specifications are based on a standard ‘machine with F/19.5 L x 24 12 PR Ré rear tres; 14.5/75-16.1, 10 PR, F3 front tires with 75 percent CaC'2 fil 1.5 cu yd. (1.15 m3) lnader bucket; 24-in. (610 mm) backhoe bucket: ROPS full fuel tank and 175-lb. (79 kg) operator) Power Service Brakes: (@ 2200 engine rpm SAE DIN Manial hte, apes with seperate eds haul ecu Net 85 hp (0 kw) 80; (7 Kw) tea when bom pedals re oopresuoa, Wet asks ana crys aul) enciosed and se-adhstng Engine: Join Deore turbocharged 4-cylnder eso, valve in head 4sttoke Mechanical Frnt Wheel Drive: Equipped) ode Engaged onthe go hyarauicaly, Automate stoking ferent Bore and stroke 4.10 x5.00 in (106% 127 mm) Steering: Hydrostatic Power Dipecement 276.cu in Turina radius (brake eooed) fof 3in (12 m (6520) Clearance ate 231 8m. (699m Compression rato 168101 Stoerng whoo tus, tt igh 23 Norm torque @ 1200 rm 260 bf va te couiies iosewm | Main bearings 5 tyrautie system: Closed cone (arabe tow, constant pressure) Uubcaton Pressure eystam wit iow Standby Pressure 2785 ps (18.000 KPa) fiter and cooler Pump 8 radial stone, variabie tow | Costing Pressurzed wrinementat and Flow @ a0 fal (18 170K 35 gom ‘ee bypass eats Fan Suction Fite, rum ot 10 micron steel enclosed, replaceable A cleaner by emer Elocticalsystam ‘volt Screen, peste ol -. S0yin.20/em) mesh tert Bt amos Fyne 115 eet Hyer Cyr Bore stroke Rod Leader boom @) asin asin 77 torque conver (Gomm) (57mm) Sm) Single sage, dul phase, overuning stator, 11-280 mm) Loader bucket (1) Jorn 82m 197m diameter sal ao 223 0 1 00mm) 18mm Gm) Backhoe boom (1) som “warm 280i Reverser: (127 am) (1084 mm) (68.5 mm) Meche, power st ape werk cess. Dhevton —Backhoo coud (1) asm samen Selector lover a tof soang whee, Reverse speeds ae 18% (118mm) (678mm) (629) {aster than forward speeds acon bket (0) Asin 910In 187m (60mm) 87mm) GO Transaxe Backhoe swing (2) 40m 950i 200m | Maat sit wit ft aid sewurl spends having sing cll fouemm germ Goa mm ‘engagements and thie and fouth speeds engaged with cone-type Backhoe extendible | svetvoncers, Sra shit lover, foor mount. sino (8) 25in goin, hain | (@4 mm) (1528 mm) 2m Travel Speeds: Forward Reverse Baciroo sais 2). Gaim 203i akin | men km/h mph kmh (oom rem 499 without MEW Stoerng (1) regular | cert 32008158 axle 17 95in 098 in 2 55 saa 103 (600mm) (est mm) (260mm) a N70 ete at 4 4 gees an es Front (00 NOT use wih MFWO) 11 Lx 16 12.R ES with MWD (Use wit MEWD) 12 18.5 8 PR FS Ger 9383 wk {20 NOT use wth MWD) 14.5/75—16.1 10 PR FO 2 57 83 bBo Fear... (OO NOT vse with MFWO)F/12.5 Ux 2610 PRG 2 wi eso ae {CO NOT ose win MPWO) F708 Lx Be 12 OR Re 4 mi 58 Bt (Uoo nih MEWD) 21 C24 10 PRA Continued on next page _ in cv oan | Litho in USA, 9 TM-1469 (Dec-88)510C BACKHOE LOADER Whee! Treads: Front (tht MEWN) (wth MEWD) Far (without MFWND) wan MEW) Without MFWO wth MEWO Axle Ratings: (SAE J Rear Buckets: Loads (Gong Lip) 884 82 82 Backhoe: In Standard 12, 19) (ram) (2270) (ess7) (eas) (om) (205) (406) as) 10) (72) (or) sr) (610) (762) (10) (1) Struck capacity ou. Ya. (m) ‘198 | (0.80) 088 (067) 107 (0.82) CuFt (a) 28 (on 37 (010) 42 (012) 50 (17) 73 (21) 75 (021) 42 0.12) 50 @17) 75 21) 72 (20) 12 (032) SAE operating weight with ROPS Genera! Specifications A in (1797 me) 68 in, (1727 mm) 66 in. (1675 mm) eu (757 mm) £827 in (2100 mm) 833 in, (2118 mm) 11.700 200) 16.200 lo (7400 kg) Hoaped Capacity cu. Ya. (m) 125 (0.96) 10 (076) 13 (1.00) cu. FL (m) 30 (0.08) 45 (0.13) 51 (0.14) 75 (21) 100 (0.28) 100 (0.28) 51 (18) 75 @20 100 (0.28) 88 (025) 45 (041) 7000 kg (15,400 1) Litho in US.A. ~~ TM-1469 (Dee-68)General Specitications 510C BACKHOE LOADER Drain and Refil Capacities: us. Metric Engine coolant (no heater) qt 18 Engine coolant (with heater) tea 15L Engine ol (ncluding fier) De BBL “Torque convertor and reversor (eluding fit) atk ‘Transanle-hydraulic system (thou MEWD) toga gab (th MEWD) ane 98 ML Foal tank Bgl BTL ‘Aupiary fuel tank Steal 87k Front axo (MPD) Ta 65 Front wheel planetary (MFWo) tq 10k Litho in USA. Tw.1489 (Dec-AA)General Specifications 510C BACKHOE LOADER Hiet2 Uitho in USA, TN-1469 (De0-88)General Specitications 510C BACKHOE LOADER | Kove Loading height, tnick Inading pasition Reach from center of swing mast Reach from center rear axle . Digging depth (SAE): (1) 2 ft. (610 mm) flat bottom (2) 8 ft. (2440 mm) flat bottom Maximum digging depth Ground clearance, minimum Bucket rotation |. Transport height Overall length, transport Stabilizer width—transport . Stabilizer spread—operating M. Overall width (less loader bucket) Digging force, bucket cylinder (power aig position) Digging force, crowd cylinder Swing are Operator contro! uucket positions Stabilizer angle rearward iting capacity, maximum boom @ 65° PASEZO™M COpE increase. Tithe in USA. Back 42 ft 4 in. (375 m) 19 ft. 3 in, (5.88 m) 29 ft. (7.02 m) 15 Bin. (6.77 m) 14 fe Bin, (4.46 m) 15 ft 9 in. (4.81 m) 43 in, (880 mm) 160" and 180° 7211 1n. (9 m) 22.11 in. (697 m) 7h. 8 In. (234 m) 9 f. 10 in. (3.0 m) 66 in. (2185 mm) 11000 Ib (4980 kg) 8100 Ib (9670 kg) 180° Two levers 8° and 17° rollback 145° $5500 Ib (2500 ka) Extendible Dipperstick Rotracted 12 ft 4 in. (8.75 m) 19 ft. 3 in. (6.88 m) 28 ft. (7.02 m) 16 ft. 8 in. (4.77 m) 14 ft 8 in, (4.46 m) 16 ft. 9 in. (4.81 m) 19 in, (830 mm) 160° and 180° 12 tt 8 in. (3.87 mM) 23 ft. (7.00 m) 7M Bin. (234 m) 9 ft. 10 in. (8.0 m) 0G in, (2105 mm) 11000 Ib (4990 kg) 8100 Ib (9670 kg) 400" Right foot treadle 8° and 18° rollback 145° 5400 Ib (2450 ka) NOTE: Backhoe specifications are with 24-in. (610 mm) 8.8 cu. ft. (0.25 m®) high capacity bucket. With 24 in, (610 mm) 7.5 cu ft (0.21 m3) standard bucket, the digging forces increase and the depth and reach 15 ft 3 in. (4.85 m) 23 ft. 11 in. (7.30 m) 27 ft. 8 in. (8.44 m) 20 ft. 7 in. (6.26 mm) 49 ft. 10 in. (6.04 m) 20 ft. 8 in. (6.90 m) 49 in. (880 mm) 160° and 180° | 12M 8 in, (3.8/ m) 23 ft. (7.00 m) 7 te 8 in, (234 m) 9 ft 10 in. (8.0 m) 06 in. (2105 mm) 11000 tb (4990 kg) | 5900 tb (2400 kg) 1180" Right foot treadie | 42° and 21° rollback 145° 2400 tb (1090 ka) ‘TM-1469 (Deo-88)General Specifications 510C BACKHOE LOADER LIFTING CAPACITIES Backhoe With Standard Dipperstick NOTE: Lifting capacity ratings are made from bucket hinge pin, loader bucket and stabilizers on im level ground. Liting capacities are 07 percent of the maximum lit over any point on the swing arc and do not exceed 75 percent ofthe tipping load. Angle between boom and ground is 65 degrees. Machine is equipped with 24 in, (610 mm) high capacity bucket, standard or extendible alpperatick (as indicated), and standard equipment. Lifting capacity ratings are based on SAE J31 (except with loader bucket on ground.) Loader bucket on ground signiticantly improves side stability, therefore improving It capacity to the side, 1ift capacity over the rear is not affected. Reach (Bucket Hinge Pin to Center of Swing Frame) 11 ft (3.95 m) 11.9 ft. (8.63 m) 14.4 ft. (8.62 m) 19.5 ft. (4.12 m) 14.2 ft. (8.42 m) 146 ft (445 m) 10.2 ft. (3.11 m) 15.4 ft. (4.70 m) 76 ft. (2.32 m) 15.9 ft. (4.85 m) 16 ft (4.88 m) 18.9 ft. (4.85 m) 18.5 ft (4.72 m) 14.8 ft (4.51 m) 19.8 ft (4.21 m) 12.2 ft (9.72 m) 40 ft. (3.05 mm) 6.2 ft. (1.89 m) Height Above (A) or Below (B) Ground Line 12 ft, (8.66 m) (A) 12 ft. (8.66 m) (A) 40 ft (8.05 m) (A) 10 ft. (3.05 m) (A) 8 ft. (2.44 m) (A) Aft (244 m) (A) 6 ft. (1.89 m) (A) 6 ft. (1.83 m) (A) 4 ft. (1.22 m) (A) 4 ft (1.22 m) (A) 2 ft. (0.61 m) (A) 0 ft. (Ground Line) ~2 ft (—0.61 m) (B) —4 fl (—1.22 m) @) 6 ft (—1.83 m) (8) 8 ft. (2.44 m) (B) =10 ft. (—3.05 m) (B) =12 ft. (—8.66 m) (B) 3240 Ib, 9290 Ib, 9170 tb 090 Ib. 8010 Ib. 2920 Ib. 2850 Ib, 2780 Ib. 2720 Ib 2880 Ib. 2670 Ib. 2730 Ib. 9150 Ib. (1470 kg) (1485 ke) (1440 kg) (1400 ka) (1985 ka) (1825 ka) (1295 ka) (1260 ka) (1235 kg) (1215 kg) (1210 ka) (1240 kg) (1480 ka) Dipperstck 4780 Ib, (2170 kg) 4820 Ib. (2190 kg) 4940 Ib. (2240 kg) 5550 Ib, (2515 ka) 8070 Ib. (9660 kg) TM-1469 (Dec-88)| 510C BACKHOE LOADER Backhoe With Extendible Dipperstick, Retracted Reach Ht {Gucket Hinge Pinto ‘Above (A) or Center of Swing Frame) Below (8) Ground Line Boom Dipperstick 14 ft, 28 m) 12 Mt (8.68 m) (A) 4740 tb. (2150 kg) 11.9 ft. (3.63 m) 12 ft. (3.66 m) (A) 2930 Ib. (1330 kg) 114 1 @.52 m) 10 ft. (3.05 m) (A) ‘A540 tb. (2080 kg) | 19.5 ft. (4.12 m) 10 ft. (3.05 m) (A) 2890 Ib. (1310 kg) 44.2 f (42 m) Bit 2.44 m) (A) 44650 Ih (21410 kg) | 446 ft (4.45 m) 8 ft (2.44 m) (A) 2810 Ib. (1275 ka) 10.2 ft. (@.11 m) 6 ft. (1.83 m) (A) £5280 lb. (2870 ka) 15.4 ft. (4.70 m) 6 ft. (1.83 m) (A) 2720 Ib. (1235 kg) 7.6 ft. (2.32 m) 4 ft (1.22 m) (A) 7630 Ib. (3460 kg) 15.9 ft. (4.85 m) 4, ft. (1.22 m) (A) 2630 Ib. (1195 kg) 16 ft. (4.88 m) 2 ft. (0.61 m) (A) 2530 tb (1150 kg) 15.9 ft. (4.85 m) 0 ft. (Ground Line) 2440 Ib. (1105 kg) 15.5 ft. (4.72 m) —2 ft. (—0.61 m) (B) 2360 Ib. (1070 kg) 148 tt (4.51 m) 41 (1.22 m) (8) 2200 I. (1040 kg) 13.8 fe (4.21 m) 6 ft. (=1.83 m) (B) 2240 Ib. (1018 kg) 122 n. (3.72 m) 8 tt (—2.44 m) (8) 2210 Ib. (1000 kg) 10 ft. (8.05 m) =10 ft. (—3,05 m) (8) 2280 Ib. (1010 kg) | G.2 ft. (1.89 m) 12 ft. (—3.06 m) (8) 2520 Ib. (1145 kg) Litho in USA Vet ‘TM-1469 (Dac-88)General Specifications 510C BACKHOE LOADER Backhoe With Extendible Dipperstick, Extended Reach (Bucket Hinge Pin to ‘Genter of Swing Frame) 186 1 (4.76 m) 16.2 tt (4.96 m) 164 Nt (6.00 mn) 16.2 tt. (4.94 m) 16.7 f. (4.70 mm) 44.8. (1.64 mm) 49. ft. (5.99 m) 10.7 ft (8.26 m) Height ‘Above (A) oF Below (8) Ground Line 141 (4.27 m) (A) 14 ft. (4.27 m) (A) 12 Mt (3.66 m) (A) 42 ft (8.66 m) (A) 10 £1.05 m) (A) 10 ft. (8.05 m) (A) 8 tt (2.44 m) (A) 8 ft (2.44 m) (A) 6 ft (1.88 m) (A) 6. ft. (1.83 m) (A) 4°86 (1.22 mm) (A) 4 ft (1.22 m) (A) 2 ft (0.81 m) (A) 2 ft. (0.61 m) (8) 6 (Ground) 0 (Ground) =2 ft. (—0.61 m) (®) 4 ft (=1.22 m) (8) =6 ft. (-1.83 m) (8) 8 ft. (—2.44 m) (8) =10 ft. (3.05 m) (8) =12 ft. (—3.66 m) (8) =14 ft. (4.27 m) @) 16 ft. (4.88 m) (8) 1780 Ib. (805 kg) 1840 Ib. (895 kg) 1850 Ib. (640 kg) 1850 Ib. (640 kg) 1840 Ib. (695 kg) 1810 Ib. (620 kg) 1790 tb. (810 kg) 1760 Ib, (800 kg) 4740 Ib. (790 ka) 1720 Ib. (780 kg) 4710 Ib. (775 ka) 1700 Ib. (770 kg) 1710 tb, (775 kg) 1750 Ib. (795 ka) 1850 Ib. (840 kg) 2170 Ib, (985 kg) Dipperstick 2060 Ib. (984 kg) | 2470 Ib. (1120 kg) 2770 Ib (1286 kg) 2020 tb, (1279 kg) | £2040 Ib, (1904 kg) 2180 lb (1442 kg) 9670 Ib, (1665 kg) 4850 Ih. (2200 kg) Litho in USA. HI "TM-1469 (Dec-88)Gonoral Spocitioations 410B BACKHOE LOADER (Specifications and design subject to change without notice. Wherever applicable, specifications are in accordance with ICCD and SAC Standards. Cxcept where otherwise noted, these specifications are based on @ standard ‘machine with 17.51-24, 10PR, PA rear tres; 111-15, 10PR, F3 front tres with; 1.0-cu.-yd, (0.76 m’) loader bucket; 21 in, (610 mm) backhoo bucket; ROPS/FOPS; full fuol tank and 175-1b. (79 kg) operator). Power (@ 2500 engine rpm): SAE DIN Gross 88 hp (49.2 kw) Net 22 hp (40.2 KH) 00 np (49 KW) [Net engine fwwhosl power is for an engine equipped wit fan ar clan, water pump, lubseating ol pump uel pup, alternator, and ‘muffler. Gross engine power is without fan, Flywheel power ratings te under SAC standard condtons of 500-1. (160 rm) etude and {85°F (28.5°C) temperature and DIN 70 020 standard conditions of 760 mm Hg barometer (Gea lovel) and 20°C temparature Engine: John Deere 4-cyinder diesel, valve in head 4-sroke cycle Dore and aroko 4.02 4.33 in (102 x'140 mm) Displacement 219 cu. in (3.589 L) Compression ratio 162001 Maxum torque @ 1200 rom 460 Ibi (217 Nm } NAC or AMA (U,S. Tax) horsepower 25.05 Main bearings coos Lubricator ‘ressuré sysiom w/tutiow fiter and cooler Coating Pressurized withermostat and fixed bypass Fan coos Suction ‘ar Gear» Ory Electrical system ‘2.0 ‘Altanatoe 51 arpa web, 95 amps regular Fiynneel "42 Teeth Torque converter: ‘Single stage, dual phase, overrunning satr, 11-280 m) diameter, ‘tall ratio 2.83 Reverser: Modulated, tu power sit wit mule wet sk cuts, Reverse ‘operating lever a left of steering weet ‘Tranemission: Manual shit with first and second speeds having siding colar ‘rgagemcnis i itd an fourth speeds engaged with cone-type ‘sypchronizers. Single shit lever, floor mounted, ‘Travel Speeds: Forward Reverse mph km/h mph ksh ear 4 bos 55 not 2 O79 17088137 3 0133 Bd OS 24 4 0218 © 9800253407 Service Brakes: ‘Manual hydaule, applied with separate pedals; hydraulically equal- laed when aoth pedals are depressed. Wet disks and facings are fully ‘onelocod and eal adueting Litho in US.A. LL-17 Steering: Hydrostatic Power “Turing radius brake apelod) 10 3 in. @.12 m) Cearance ercle aan 201 6in. (0m) Steenng wee! tums, ia 0 Aght 29 Fight tet 39 Hydraulic System: Closed centor(varlable flow, constant pressure) Proseure ... 2500 psi (17 238 KPa) Pump 1 rad pstons, variable ow Flow @ 2200 psi (18 170 kPa) 90 gpm (1.89 Lis) Fite, return oi 10 micron steo! enclosed, replaceable element Stree, pressure ail Sorin. (20rem) mesh Hydraule Cylinders: Bore stroke Rod Loader boom (2) a25in, 300i. 1.78in, (3mm) (162mm) (44 mm) Loader bucket 1) Sin Ati .75 in (@9 mm) (620mm) (45 mm) Backhoe boom (1) 445i 985in, 225i (114 mm) (980 mm) 67 mm) Backhoe crow (1) 440i, 330in 20 (102 mm) (@40 mm) (4 mm) Backhoe bucket (1) 35m 27din 255 (88mm) 696mm) (64 mm) Backhoe swing (2) 40in 835i 201m (202 mm) (281 ram) tm) Backhoe extendible dip per (). 25in Bin 1.285, (64mm) (1220 mm) (@2 mm) Backhoe stables (2) 40m 203i, 20K (102mm) (616 mm) 1 mm) ‘Stocring (1) regular ‘ale 20 851.018 (Simm @ét mm) 254 mm) (00 NOT use with MWD) 11L-15, 1ORR. £3 (00 NOT use with MFWD) 11L-18, 12PR, F3 (Use with MEWD) 12.1665, PR, F3 Hear (00 NOT use win MFO) 17-51-24, 10PR, Ra (Use with MFWD) 19.51-24, 10PR, Ra ‘Wheel Treads: Frost e+ 09 (1750 rm) Rear... 4 in. (1620 mm) Wheelbase 29 in, (2110 mm) ‘ate Ratings: (SAE J43) Front 19,000 tp, (4080 ka) Roar 412,590 lb, (5680 ka) ‘TM-1469 (Dec-88)General Specifications 410B BACKHOE LOADER OPERATING INFORMATION Ate nga ee | Ralesk @ gourd io “0 dog sxcieoe Beato ce "00 ara porte cont Tw taen Bebo Doane sep n025) Daina son 4 100 mn) toe Ye Bin (eae alae ooo aro KD) 2 (610 mm) fat boxor Tosi fees) Heigr to bucket hinge pin, max tf fe (2.38 my) (20 fat oto Fh Sin oem Haha ct neo cee oes aro jae 100 dog. (Dump clesrance, bucket @ 45 degrees of 274m) | 1g capac Reach at full height, bucket @ 45 degrees 28 in. (710 mm) ‘Boom lifting, dipper extended 2000 Ib. (910 kg) Fach at ful height e we ‘peer, sooo 8104) suckers apg toe Soci cinder in powerdp sua w usavo stuck Heaped | position width Capaci ‘Capacity ows ar 6001029409) once nam cure Or) Cute een reset GB io Or) | cme oy a mete ga 2 2 o ee From centt of rar ue FI pace oon ee ee, beste pesiion (Ot eG zm ty (0) 28 (oor 30 (08) Transport eight $1 Sin, a8 my) 406) 87 10) 45 (013) Buckotren |... Adib fr 8,127 er 65 depress ten tz ay Se Gig Behe posters 1210 20 ogres romact cm ss em 73 oan (0r 6 degrees forward 2) 75 (2 100 (020) pen Gi) 7s 2n tas oan exrENDIBLE Joa ut Ws) 42 faa) Bt (oa) Operate cont Fight oot weacle — Meavy duty om cs Gn te Gan png sop 24 i iB eh eee Extended tone REnGorm — yy 30 (782) (oan ance un7inidim MO on iy re aa) ak aH) Reach from center of swing mast 36 (914) 1.2 (0.32) 145 (0.81) Stoned nn IRTn GSM sey oo) 4s Way ae GN faected ihtomestm Loading rah, tk tang psion caracmes us tate Caro en ronosrm apace, nr Retracted A + 10 A. 5 in, (3.18 m) Engine oil including filter oq ask Digg fre, cond ender Tanne comerrandravesa’ wee ek Extended ns Seore Gesiny — Taneale and yas tytn AB gal 2 rane * 6teo a3 wn) arse an yer coat Fe Sowa conve animes TRANSPORTING. eno ‘Transport width ‘Tht. 8 in. (2.34 m) ‘SAE operating wei ~ (14,100 Ib.) poet opera postion Pi om om) mj rewnard ‘a oyect | t — - ~TW-1469 (Dec-88) Lino in U.410B BACKHOE LOADER | | . | | | | | | | | | | | | | \ | | Litho in U.S.A.General Specifications 510B BACKHOE LOADER (Specifications and design subject to change without notice. Wherever applicable, specifications are in accordance with ICED and SAE Standards. Except where otherwise noted, these specifications are based on a standard machine with 211-24, 16PR, A rear tres; 14.5/75-16.1, 12PR, F3 front tires with 75 percent CaClp il, 1.5-cu.-yd. (1.19 m9 loader bucket; 24-in. (610 mm) backhoe bucket; ROPS/FOPS; full fuel tank and 175:lb. (79 ky) operator). Power steering: Hyarostatic Power (@ 2200 engine rpm SAE om “Turning race (rake appbad) fon. sin 12m) Gras 76 hp (78 Kw) Glearance circa 2010 6 in. @m Net . TORTS KW) 74 hp (544 KW) ‘Steorng wheel turns, et ight 29 ight to ltt 39 [Net engine nyneel power i Yor an engine equpped win Tan, a cleaner, water pump, luresting ol pump, ful pum, alternator, and ‘fle Genes angina power ix witha an. Flywe pow Faint fare under SAE standard constions of S00-f. (150m) attede and Hydraute System: Ciosod conto variable low, constant pressure) Pressure 2500 pel (17 298 KPa} Pump ' radial pistons, variable flow 15°F (205°C) temeprature and DIN 70 020 standard condtons of Flow @ 2200 psi (15 170 KPa) 35 gpm 760 mim Hg Barometer (G08 level ane 20"U temperature, ezits) Filter, rtura of 40 micron stee! enclosed, repaceable Engine: John Deore 4cyindr desl, value in head data yea clement Bore and stoke 419% 5.00 in, Screen, pressure ol 0/in.20/em) mesh (108 x 127 mn) Displacement 276cuIn. —_Hyarauue cyunaers: Bore stroke oa (48241) Loader boom (2)... 35in, 300in 178 in Compression ato $eP tat (@amm) (782 mm) (4k mm) Maxamum torque @ 1200 rpm 285 ost Loader bucket (1) 40m, 2a 20im (225 Nm) (102 mmm) (620 mm) (61 mm) [NAOO or AMA (U.S. Tax) horsepower - 28 wacknoe boom (1) Sum azn 25 Main bearings 5 (127 mm) (1085 mm) (64 mim) Lubrication Pressure eysom w/utow Backhoe ere (1) 45in Main 725i titer and cooler (145 em) (678 rom) ST mm) Coating Presourzed w/thermostat and Backhoe bucket (1) 38h, asin, 225in, fixed bypass, (eam — (eam) GF MM Fan Suction Backhoe swing (2) 40m," 88in —-20in Air Cleaner Bry (102 mm) (2A em) (BA mm) Electrical system : ‘Yawok Backhoe extendible dip. ‘Alternator 1°51 amps w/b, 35 amps regular per (). 25in ein, 1.25 (e4 mm) (1525 mm) (SE mm ‘Torque Converter: Backhoe stabilizers (2) 40in, 208in 20 ingle stage dual phaco, ovrunning eater. 1 n- (280m) ameter, (102 mm) (SAB mm) SE mm) stall rato 28:1 Stooring (1) rogue ae 20 851.0% Roverser: Gimm) wet mm @s4 mm Modulated ul power shit with multiple wet-disk clutches. Reverser| ‘operating lover at lof of storing whoo. ‘Tires: ‘Transmission Front (00 NOT use with MEWD) 111-18, 1PR, F9 Manual shit with trst and second speeds hving siding collar ‘engagements and thd and fourth speeds engaged with cone-type synetontzers Gngle hil lever, Noor mounted (00 NOT use with MFWO) 11L-16, 12PR, FS (Use with MEWD) 12-185, 8A, FS Roar (©0 NOT use with MEWO) 17.524, 10PR, Ra (Use with MEWD) 195-26, 1OPR, Rd Travel Speeds: Forward Reverse mph kmh mph km/h ‘Wheel Treads: Gear + 03383 3B Front 169i. (1750 mm) 2 ore M8084 198 oar SEIT 6 in (1875 am) 3 OnS1 zit ons 248 4 ogee ona aot Wheelbase 89 In. (2110 my Service Brakes: ‘ale Ratings: (SAE J#3) Manual iyuaule, applied wth separate pedals; hyéreuicaly equa Front «| 40,600 b. (4760 ka) |aod when both pedals are depressed. Wetdisks and facings.are uly Reer 13,4001. (6080 ka) enclosed and soltadlusng Litho in U.S.A. Ll-20 TM-1469 (Dec-88)General Specifications 510B BACKHOE LOADER (OPERATING INFORMATION ‘BACKHOE: Operator contol. Digging vey CED), Maximum . 2 (610 mn) fat bottom (2440 mm) flat bottom ‘Swing are ‘Boom iting, dipper extondod Dipper iting, boom @ 85" Digging force: ‘Bucket cylinder in poweraig postion Crowd eyiindr Reach: From center of swing mast From canter of rar aslo Lacing height, ruck loading ‘ection “Transpoct height Bucket rotation Bucket postions EXTENDIBLE DIPPERSTICK ‘Operator conto coe Digging depin, 2 (610 mm) flat bottom Rowacted each trom center of swing mast Extended Relracted Leading height, Wack leading positon Extended Rowactes Digging force, crowd cylinder Exiended Revected STABILIZERS: Operator contol ‘Transport width Spread in opocating positon ‘Angle rearward Two lovers 15 ft. Bin. (4:78 m) 15 ft Bin. (4.72 m) 14 ft 8in. (4.40 m) 180 deg, £2500 tb. (1195 kg) 5000 tb. (2270 ka) 10,200 b. (454 KI) 700 Ib. (242 KN) 19 ft. 2in. 84 m) 22 Bin (675 m) 10 110 in. (90 m) 12 (85m) ‘Adjustable for 123, 127 or 155 degrees 12 to 20 degrees rollback (oF G degrees forward Fight foot treadle £011 in. (6.00 m) 15 6in (C72) 24. (750 m) 19 680m) 13 A 10. (422 m) 11 RR tin (45 m) 4895 b. 21.9 KN) 7570 Ib. (98.7 KN) sess Two levers 7h. Bin, (294 m) OR ADin Om) +19 degrees Loaver: Operator contro! Single lever Roiback @ gouna level "20 009 Broakout force 9,200 I. (40.9 KN) Digging deoth below ground Bucket level 4 in, (100 mm) iting capacity, fui height 6180 Ib. (2810 kg) Height To bucket hinge pi, max hin. (3.98 a) Bucket dump angle, max 50 dogrees Dump clearance. bucket @ 45 deoreas ..... 8 ft 8 in. (267 m Reach at ful height, bucket @ 48 degrees ..... 90 in. (762 mm) BUCKETS, Struck Heaped wit Capacity Capacity Loader in (mm) CuFt (me) Cu.Yd(m) 82 2340) 13 (1.00) Backhoe: cu. (my Standard duty 12 (905) 28 (007 $0 (008) 18 (408) 87 1) 45 (019) jes) 2 ote) 1 8) 2% 610) 58 O17) 75 2H) 20 (762) 75 2H 100 (028) 36 1) «75 21) 100 (28) Heaw duty 18 (457) 42.12) BA (014) 2 0) «58 O37) 73 (RH) 90 (782) 75 21) 100 028) High capacity 2 (610) 72 (020) 88 (0.25) 3 @14) 12 (032) 148 (O41) Ejector 26 GI) 48 O13) 87 0.18) ‘cAaPacies: Us. Metric Engine coolant qe tea. Engine of including iter og BSL Torque converter and rverser sean 1920 “Transanie and hydroule aystom erga 705. Foal tank 23ga ara ‘TRANSPORTING: SAE operating weight with ROPS 6340 kg (45,900 8) Litho in U.S.A ‘TM-1469 (Deo-88)General Specifications 510B BACKHOE LOADER r0F 1010 198. 2, (584m) ‘Stun cesrance (insur) Great lang ranspor poss) vert wat (08 lense Bucket) T 22 11a. (6.98) sig cso nm) Benn 0.1. (S080 eT) 1g Gin, (472m) 28.1610 mm) it Botom 2 SACO UF PER SAE ST 108 aAcanOE UF Pen SAE Litho in U.S.A, ‘TM-1469 (Dec-88)Group III Torque Values HARDWARE TORQUE SPECIFICATIONS Check cap screws and nuts to be sure they are tight. If hardware is loose. tighten to torque shown on the following charts unless a special torque is specified. TM-1469 (Doc-88)_ Litho in US.A.Tighten wheel cap screws. 10 Front: 11 Lx 15 10PR FS 41016 12 BRO 12x 1858 PA FS 125 x16 8PR 145/75 —16.1 10 PR FS 16.0248 PARE (975 Lx 24 10 PR Re) 195 Lx 24 10 PR RE 21x 24 10 PR RA s10¢ Front: 11x16 12 PR FS 421650 PR FS Rear F/I9S Lx 24 10 PRE F/i98 Lx24 12 PR RA Litho in U.S.A. CHECK WHEEL CAP SCREW TORQUE tm 198 +20 -27 00 +110 40 98 420-27 198 +20 27 578 +170 —118 575 +170 —118 575 4170 —118 575 4170 118 Nm 498 +20 ~27 300 + 110 —40 Wm 575 4170 —118 575 4170 118 876 4170 —146 (ios (100 4-15 ~20) (400 116 20) (eat +81 ~29) (400 415 —20) (100 415 —20 (omy) (424 4-125 —86) (428 +125 —85) (424 4125 —85) (424 +125 — 85) (ost) {100 +15 20) (21 +81 —68) (G0 +15 —20) (ott (424 4125 85) (za +125 —85) (es +125 05) ‘TM-1469 (Dec-88)Torque Values } INCH SERIES TORQUE CHART | | DO NOT use these values if a different torque value or | tightening procedure is listed for a specific application. Torque values listed are for general use only. Check sig se-8 age tightness of cap screws periodically. Ep @ oO Q & Shear bolte are dosigned to fail under prodotormined loade. ‘Always replace shear bolts wih identical grade. Sa ana aT | Fasteners shouldbe replaced with the same orhigher rade. _[adstw) xa [aes [un] — aa I higher grade fantaners are ined, tess shaw oatybe eee ee eee | tightened to the strength of the original. 387 woo Poa on | ow ag | oa eles) ea | Make sure fastener threads are clean and you property start thread engagement, This will prevent them from faiingwhen | $2°" | (2s) gg | 12 om | am gy tightening ae |e | fe | abe | Sous | se es | eS eto | see om | com fes ‘Tighten cap screws with plastic insert or crimped steel-ype lock nuts to approximately 60 percent of amount shown in. chart. Tighten toothed or serratedtyped lock nuts to full torque value. METRIC SERIES TORQUE CHART | CAUTION: Use only metric tools on metric hard- ware. Other tools may not fit properly. They may slip and cause injury. DO NOT use these values if a different torque value or | tightenina procedure is listed for a specific application BOLT TORQUE CHART Torque values listed are for general use only. Check Tarting on tightness of cap screws periodically. oetteg | wrench [ay ry | | ment| ke ‘Shear bolts are designed to fail under predetermined loads. Nem_oo-F) | Nem (ef ‘Always replace shear bolts with identical grade. com] emm | 6 aay oe emm | 10mm | 0 7s) | as GD Fasteners should be replaced with the same or higher grade. Som | 13mm | 25 a) | 3 Ge) If higher grade fasteners are used, these should only be i re ronm | sem | 2 on | 75 oo tightened to the strength of the original am | ywm | go | sg iemm | 2am | 215 189 | 315 sq ‘Make sure tastener threads are clean and you property start thread engagement. This willpreventthem from failing when | zomm | gomm | 435 Gan} e20 457) tightening. zemm | 20mm | 790 59) | 1070 oH somm | 46mm | 1495 (108) | 23900571 | Tighten cap sorews with plastic inserl or imped stevbtype | lock nuts to approximately 0 percent of amount shown in | chart. Tighten toothed or serratedtype lock nuts to full | torque value. | } averse osnoRge, cs Litho in U.S.A. Hll-3 ‘TM-1469 (Dec-88)Torque Values | CHECK OIL LINES AND FITTINGS DA CAUTION: Escaping tid under pressure can penetrate the skin causing serious injury. Re= lieve pressure before disconnecting hydraulic “ or other lines. Tighten all connections before , applying pressure. Keep hands and body away from pinholes and nozzice which oject fluids under high pressure. Use a piece of cardboard or paper to search for leaks. DO NOT use your hand. If ANY fluid is injected into the skin, it must be surgically removed within a few hours by a doctor familiar with this type injury or gangrene may result. Check all oil lines, hose and fitings reqularty for leaks or damage. Make sure all clamps are in position and tight. Make sure hoses are not twisted or touching machine parts which are moving Tubing with dents may cause the oil to overheat. If you find ‘tubing with dents, install new tubing immediately. IMPORTANT: Tighten fittings as specified in torque cnart. ‘When you tighten connections, use two wrenches to prevent bending or breaking tubing and fittings. Litho in USA FIN-@ TM-1469 (Dec-88)Torque Values SERVICE RECOMMENDATIONS FOR O-RING BOSS FITTINGS Straight Fitting 1. Inspect O-ring hase seat for dirt ar 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. 8. Tighten fitting to torque value shown on chart. Angle Fitting 4. Back-off lock nut (A) and back-up washer (B) completely 10 head-end (C) of tittng. 2. Turn fitting into threaded boss until back-up washer (B) contacts face of boss. 3. Turn fitting head-end (C) counterclockwise to proper index (maximum of one tum). 4. Hold fitting head-end (0) with a wranch and tighten locknut (A) and back-up washer (8) to proper torque value. NOTE: Do not allow hoses to twist when tightening fittings. ‘TORQUE VALUE CHART Thread Torque Size Nm (ty 3/8-24 UNF 8 © 716-20 UNF. Wee ° 172-20 UNF 16. 2) 9716-18 UNF a «) 3/416 UNF. 46. @) FOAM UNF oon 08, 0) 4-1/16:12 UN 102 75) 49/18 12 UN, sas (0) 45/1612 UN 142 (108) 4-5/8.42 UN, 100 (say 4.7/8-12 UN. 217, (160) NOTE: Torque tolerance is + 10%. Litho in U.S.A. ‘TM.1489 (Dec-88)Torque Values SERVICE RECOMMENDATIONS FOR FLAT FACE O-RING SEAL FITTINGS. 1. Inspect the fiting sealing surfaces. They must be free of dirt or defects. 2. Inspect the O-ring, t must be free of damage or defects. 8. Lubricate O-rings and install into groove using petroleum jolly to hold in place. 4. Push O.ting into tha groove with plenty of petroleum jally 80 O-ting is not displaced during assembly. 6. Index angle fittings and tighten by hand pressing joint together to insure O-ring remains in place, 6. Tighten fitting or nut to torque value shown on the chart per dash size stamped on the fiting. Do not alow hoses to twist when tightening fitings. Nominal Thread Tube OD. Dash Size mm (in) Size in 635 0260. 4 enese 052 0376. 6 Hies8 1270 0.500. 8 13/1648 1528 0.90. 40. 144, 1908 0.760 2, yanet2... 2222 0875, 14. 4s nt6.12. 3175 1.250. 20, 1 1triese 3810 1500, 24 aaa NOTE: Torque tolerance is +15 ~20%. FLAT FACE O-RING SEAL FITTING TORQUE ‘Swivel Nut Nm (lost) 62 a ot 102 75 102 75 190140. 217 160. Buinend sor torque on ty so as m0 tas 70 12s | 0 12s m0 12s 1012s 1012s esas ope wr. omits | Litho in USA. TM-1469 (Dec-88)Torque Values | SERVICE RECOMMENDATIONS FOR 37° FLARE AND 30° CONE SEAT CONNECTORS 4. Inspect flare and flare seat. They must be free of dirt or obvious defects. 2, Detects in tube flare cannot be repaired. Over- tightening a defective flared fitting will not stop leaks. 3. Align tube wih tting betore attempting to start nut Litho in USA. 4. Lubricate male threads with hydraulic fluid or petro- eum jelly 5. Index angle fittings and tighten by hand. 6. Tighten iting or nut to torque value shown on chart Do not allow hoses to twist when tightening fittings. STRAIGHT FITTING OR SPECIAL NUT TORQUE Thread Torque Size Nem (ot 3/824 UNF 8 © 716-20 UNF 2 ® 172-20 UNF 6 (2) 9/16-18 UNF 2 (8) 4“ (24) 62 (46) 102 5) 12 (20) 1+5/16-12 UN 4a 105) 4570-42 UN 100 (140) 4-7/0-12 UN 27 (180) NOTE: Torque tolerance is + 10%.Torque Values ‘A-Sealing Surface B-Spiit Flange 1. Clean sealing surfaces (A). Inspect. Scratches cause leaks. Roughness causes seal wear. Out-of-lat 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 (8) halves. Make sure split is centrally located and perpen- dicular to port. Hand tighten cap screws to hold parts In place. Do not pinch O-ring (C). Nominal Nm Flange Size (cap Serow size! Min ve. 5/16 - 18 UNC 20 1 3/8 = 16 UNC. a7 vila 7/16 - 14 UNG. a nie Shue 19 une 8 2 1/2 - 1S UNC. 73 aie 2 = 19 UNG 107 3 5/8 = 17 UNC. 458, 34/8 5/8 = 11 UNG. 158 4 5/8 = 11 UNG. 188 5 5/8 - 11 UNC. 158 1. Metre standard tread. c-Pinched o-Ring D-Single Piece Flange 4, Single piece flange (0): 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 chart below. DO NOT use air wrenches. DO NOT tighten one cap screw fully before tightening the others. DO NOT overtighten, tt Max Mi Max a 6 2 5 2 Pi 85 35 63 131 6 97 131 56 97 286 Ww 195 268 Ww 195 24 7 195 258 a7 195 2. Tolerance + 10%. The torques given are enough forthe given size connection withthe recommended working pressure. Increasing cap ‘Screw forque beyond these amount wil result in ange and cap Screw bending and connection fares. Litho in U.S.A. ‘TM-1469 (Dec-88)Torque Values ‘A-Sealing Surface B-Spiit Flange 1. Clean sealing surfaces (A). Inspect. Scratches cause leaks. Roughness causes seal wear. Out-oflat 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 tlange: Loosely assemble split flange (8) halvos. Make suro spit is contrally located and porpen- dicular to port. Hand tighten cap screws to hold parts in placa. Ro nat pinch Oxing (0) 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 sorew. Tighten two remaining cap screws. Tighten all cap screws as specified in chart below. DO NOT use air wrenches. DO NOT tighten one cap screw fully before tightening the others. DO NOT overlighten, LT Litho in USA c-Pinehed O-Ring D-Single Piece Flange Torquet Thread Nm eat Me ar ® Me. 90 22 mi 95 70 kia a7 a8 Mas 27 160 ms. 334 268 me an ave 1. Metric standerd thread. 2. Tolerance + 10%. The torques given are enough for the given ‘820 connection wn ihe raconmendea working pressure. crossing cap screw torque beyond these amounts wil result in lange and cap sorew bending and connection talus. TM-1469 (De0-88)Torque Values lino in USA TH-10 TW-1468 (Dec-88)FUEL SPECIFICATIONS Use ONLY clean, high-quality fuel. Use Grade No. 2-0 fuel above 4°C (40°F), Use Grade No. 1-D fuel below 4°C (40°F), Use Grade No. 1-D fuel for all air temperatures at altitudes above 1 500 m (5000 ft) IMPORTANT: If fuel sulfur content exceeds 0.5 per cent, change the engine all at one- half the normal interval. Use fuel with less than 1.0 per cent sulfur. It possible, use fuel with less than 0.5 per cent sulfur. Fuels and Lubricants | For maximum fiter life, sediment and water should not be more than 0.10 per cent. Tho cotane number ehould be 40 minimum. If you operate your machine where air temperatures are | normally low or whara altitudes are high, you may need fuel with a higher cetane number. Cloud Point—For cold weather operation, cloud point should be 6°C (10°F) below lowest normal air ‘temperature. Group IV FUEL STORAGE NOTE: Diesel fuels stored fora fong time may form gum or bacteria and plug fiters. Keep fuel in a clean container in a protected area. Water and sedimont must be romoved before fuel gets to tho engine. Do not use de-icers to remove water from fuel. Do rat dapand an fuel filters to ramave water. If possible, install a water separator at the storage tank ‘outlet. (See your John Deere dealer). IMPORTANT 1 Keep all dirt, scale, water or other foreign material out of fuel. Store fuel drums on their sides with plug up. Litho in USA, TM.1489 (Dee-A8)Fuels and Lubricants FUEL TANK CAUTION: Handle fuel carefully. f engine is hot | or running, do not fill the fuel tank. Do not smoke while you fill fuel tank or work on fuel system. O77 ‘To avoid condensation, fil fuel tank atthe end of each day's ~O poration. Capcty ef min lnk in aprsiatl 67 (2 9 wm @) me Capacity of auniliary furl tank is approximately 5681 (15 gal). Both tanks are filled through the main tank. The fuel gauge (A) will eaister fue! level in elther the main or auxiliary tank, depending on the position of the toggle switch below the gauge. ‘TM-1469 (Dec-88) Litho in USA.ENGINE OIL Depending upon the expected air temperature range: between oil changes, use cil viscosity shown on the temperature chart ahove. ‘Additives are not required nor recommended. John Deere TORG-GARD SUPREME® engine oil is recommended because its a specifically balanced formulation to provide maximum engine life. It provides excellent protection against mechanical wear, carbon deposits, and lacquer formation, plus providing superior cold weather starting pertormance, It other olls are used, they must have one of the following specifications: (Ot Specification Use API Service: CD/SF. CD/SE, CD/SD, CD/SC. or MIL-L21040, MIL-L-21040 Recommended For SAE 5W20, SAE SW30 and arctic oil only, use if *API Service OC/SF, CC/SE, CC/SD, CC/SC or recommended oil is not TMIL-L-46152, available. *MIL-L-461528 *MIL-L-46167A For arctic oll only *Change oil at one-half the normal interval. ithe in USA, iV-3 TM-1469 (Dec-68)_Fuels and Lubricants MECHANICAL FRONT WHEEL DRIVE OIL Rik TEMPERATURE RANGE ET 40-30 20-70. Fanroohen CA] “67 | Depending on the expected air temperature range between oil changes, use oil viscosity shown on the chart above. The following oils are recommended: John Deere API GL-5 Gear Oil Oils meeting API Service GL-S (MIL-L-2108B or MIL-2105C) il meeting MIL-L-10324A may be used as arctic ol Litho in USA. 1V-4 TW-1469 (Dec-88)Fuels and Lubricants TRANSMISSION HYDRAULIC—DIFFERENTIAL OIL AIR TEMPERATORE RANGE Fanrennent CF] [Getetus Cod Depending on the expected air temperature range between il changes, use oil viscosity shown on the chart above. John Deere HY-GARD® transmission and hydraulic Is recommended because it is specifically formulated to minimize brake chatter, provide optimum clutch engage- ment, and to provide maximum protection against mechani- cal wear, rust, corrosion, and foaming. You may also use QUATROL® oils, which are oils that meet minimum John Deere standards, or other oils meeting John Deere Standard JDM J20A or J20B, lls meeting MIL-L-46167A may be used as arte oll. ithe in USA TM.1489 (Dee-AA)Fuels and Lubricants GREASE "AIR TEMPERATURE RANGE, 7 00 Tanrenhen CT) Geiss °C a t T _ 1 | | | = 70 Depending on the expected air temperature range during use, use grease shown on chart above. Greases recommended are: John Deere Moly High Temperature/EP grea: (preterred). SAE Multipurpose Grease with Extreme Pressure {EP) performance and containing 9 to 5 per cent molybdenum disulfide (preferred). ‘SAE multi-purpose EP grease. Grease meeting MIL-G-10924C specifications may be used as arctic groase. Litho in US.A. GREASE FOR EXTENDIBLE DIPPERSTICK SAE Multipurpose Grease with Extreme Pressure (EP) performance and containing 3 to 5 per cent molybdenum disulfide (preferred), LV-6 "TM-1469 (De0-88)ALTERNATIVE LUBRICANTS ‘Additional information on cold weather operation is available from your John Deore dealer. Conditions in certain geographical aroas may require special | lubricants and lubrication practices which do not appear in this operator's manual If you have any questions, consult your John Deere dealer to obtain the latest information and recommendations. LUBRICANT STORAGE Your equipment can operate at top efficiency only if clean lubricants are used. Use clean containers to handle all lubricants | Store lubricants and containers in an area protected from dust, moisture, and other contamination. Litho in U.S.A FIV-7 TW-1469 (Dec-86).Fuels and Lubricants Gthoin USA, VV-8 TM-1469 (Dec-88)PLANNED INSPECTION PROGRAM | (PIP 1) ‘When you doliver the machine, explain to the customer the advantages of the Planned Inspection Program | (PIP I): ‘Top production from the machina Minimum downtime Lower long-term operating costs Overall greater satisfaction PLANNED INSPECTION PROGRAM II (PIP II) PIP Il is a continuation of PIP | This program tests critical machine systems and will enable the customer to keep the machine in the best possible condition, Prepare a contract with the customer specifying the number of field inspections by your service technician and the cost. Use the PIP Il Inspection Checkiist in this group as a guide in preparing the contract. Group V | _Inspection Procedures | Prepare a contract with the customer specifying the number of field inspections by your service technician and the cost. Use the PIP | Inspection Checklists in this group as a guide in preparing the contract. | USING THE CHECKLISTS Do an inspection procedure only if there is a “box” behind the procedure in the service column which you are following. Mark the box with an "x" when the procedure is done. For specific instructions on how to do each procedure, refer to the operator's manual or the technical manual, Ha box is not marked, write an explanation in the ‘comments column. For example: If engine oil level is low, note amount of oil needed. to fil crankcase. I the machine Is not lubricated according to the Periodic Maintenance Chart, note this. When the inspection is done, put the checklist in the customer's file. Use the same checklist for additional | inspections, corm cs zoee | Litho in USA, FV-T ‘TM-1469 (Dec-88)Inspection Procedures DELIVERY SERVICE Use the operator’s manual as a guide. Discuss the following points thoroughly with the customer: ‘The importance of safety. Controls and instruments All functions of the hydraulic system. How to start and stop the engine. The importance of the break-in period The importance of lubrication and periodic maintenance. Have the owner sign the Delivery Receipt. Give the owner the operator’s manual. Litho in USA ~~ TM-1469 (Deo-88)CHECK LIST FOR PLANNED INSPECTION PROGRAM | (PIP |) — Feld inspections contracted with the owner. NOTE: ilustrated planned inspection program checks can be found in SP656. Inspection 1 Inspection 2 Inspection 3 Inapection 4 Machine Hours Performed by Mochanie Signature Date ‘Owner's Name Adress ) Signature 7 Dealership — | | | JOHN DEERE 4108/4106 ana 5108/510C BACKHOE LOADERS | | | | | tem ox comments 1. Coolant level and freeze-protection 2. Radiator ara 4, Engine compartment 5. Exhaust system 6. Engine oil level 7. Engine oll conatton 8, Fuel Filer | | L naroiat rn te ne) Litho in USA TM-1469 (Oee-88)Inspection Procedures 10. 1" 12, 13. 14, 16. 16. 17. 23 24, 25. 26. 27. 28. 29. 30. st. 32, 33, Litho Fuel tank sump Transmission-hydraulc oil level Transaxle-hydraulic oil condition Reverser oil level Reverser oil condition MEWD axle oil level MEWD axle oil condition EWU planetary oil level MFWOD planetary oil condition . Battery level and terminals, . Battery electrolyte concentration . Air restriction indicator Prooloaner Air intake hose Starting aid tine Toon Tire pressure Whee! cap screw torque Hardware tightness Grease fitings Extendible dipperstick bearing strips Safety equipment and welds Engine valve lash (clearance) Reverser oil fiter element Hydraulic oil filter element inUSA. FV-4 0DondoOnDnoOnDnDAnDADoOoOonaoooOoOoeE onDoaooadgaagd Comments M1469 (Dsc-88)34, 35, 36. 37. 38. 33. 40. a 46. 47. 49, Bt. 52, 53 54. 56. 56. Litho tem Seat adjustment Neutral start system Gauges and indicators Engine speeds ‘Speed control linkage Air flow pre-test Radiator air flow Clutch pedal operation . Transaxle operation 1. Revereor operation MEWD operation . Reverse warning alarm Brakes Steering . Differential lock Park Brake Lights Bucket level return-to-dig Bucket sel-leveling linkage Cycle times Change engine oil and fiter Fiuid leakage Clean the machine inUSA. DoaondonnAnnonOoOnDnAnAnDnAnDAADALoAoOanoS 1V-5 Comments, ‘TM-1469 (Deo-88)Inspection Procedures JOHN DEERE 410B/410C and 510B/510C BACKHOE LOADERS CHECK LIST FOR PLANNED INSPECTION PROGRAM II (PIP iI) — Field inspections contracted with the owner. NOTE: tilustrated planned inspection program checks can be found in SP659. Inspection 1 Machine Houre Performed by Mechanic Signature Date (Owner's Name Address Signature —— Dealership — Item Engine speeds Slow idle Fast idle |urbo Boost Pressure—tt Equipped (Charge Pump Pressure Main Pump Standby Pressure Priority Valve ycle Time Hydraulio System Neutral Leakage: Litho in U.S.A, Inspection 2 LV6 booaoooood Inspection 3 Comments ‘TM-1469 (Dec-88)Inspection Procedures tom 8. Steering System Leakage 9. MFWD Clutch Pressure—if Equipped 10. Steering Valve Neutral Drit 11, Gytinder Dat 12, Reverser System Pressure Litho in U.S.A. oooog: ‘Comments TM-1469 (Deo-88)| Inspection Procedures Litho in U.S.A 1-8 TM-1469 (Dec-88)Section 01 WHEELS CONTENTS Page Page GROUP 0110 - POWERED WHEELS AND GROUP 0120 - NON-POWERED WHEELS AND FASTENINGS FASTENINGS Service Equipment and Tools . 0110-1 Service Equipment and Tools 0120-1 Specifications 0110-1 Specifications 0120-1 Rear Wheel Assembly Front Wheel Assembly Remove and install on02 Flemove and Install 0120-1 Tre Tire Feemove are Install 0110-2 Remove arid Install 0120-2 | Litho in U.S.A. 01-1 TM-1364 (Mar-86)Litho in USA, O12 "TM-1364 (Mar-86)Group 0110 | POWERED WHEELS AND FASTENINGS | SERVICE EQUIPMENT AND TOOLS NOTE: Order tools from your SERVICE-GARD™ Catalog. Some tools may be available from a local supplier. Name Floor Stand Heavy Duty Wheel Lift Use To support unit while removing and installing wheels. To remove and install wheels. SPECIFICATIONS tem Rear whoo! assombly Without Fluid With Fluid Rear wheel to axle cap scraws 4408 and 4100 Tire Size (Rear) 1691x248 PRR4. 17.5 Lx 24 10 PR R4 195 Lx 24 10 PR R4 21 Lx 24 10 PR R4 510B and 5100 Tire Size (Rear) F/19.5 Lx 24 10 PR F/19.5 Lx 2412 PR 21Lx2410PR RA. Measurement Specification 141 kg (810 Ib) 420 kg (030 Ib) 575 4 170 4115 Nem (424 + 125 -85 lb-ft) Tire operating pressure ......... 221 kPa (2.2 bar) (92 psi) Tire operating pressure ......... 221 kPa (2.2 bar) (82 psi) Tite operating pressure .......... 193 kPa (1.9 bar) (28 psi) Tire operating pressure ......... 179 kPa (1.8 bar) (26 psi) Tire operating pressure Tire operating pressure ... Tire operating pressure .. 193 kPa (2 bar) (28 psi) 189 kPa (2 bar) (28 psi) 179 kPa (1.8 bar) (26 psi) NOTE: Change tire pressures to suit working conditions according to tire manufacturer's recommendations. Litho in USA. 0110-1 ~~ TM-1364 (Mar-88)Powered Wheels and Fastenings REMOVE AND INSTALL WHEEL ASSEMBLY CAUTION: Rear wheel weighs approximately 197 kg (435 Ib). 4. Use a wheal it (A) to ald in removing and installing wheel 2. Remove cap screws (A) to remove wheel 3. Thoroughly clean the cap screw. washers, and the tapped holes in the tianged axle. Use compressed air to dry all parts and tapped holes. 4, Install wheel and cap screws. IMPORTANT: If a power wrench Is used, be sure that the cap screws are engaged to prevent stripping. Operate the wrench slowly to Prevent thread damage. 5. Cross tighten cap screws to 575 + 170 — 115 Nm (424 + 125 — 85 Ib-tt), REMOVE AND INSTALL TIRE 41. The tire can be removed without removing the wheel from the machine. See the John Deere Off-The-Road Tire Maintenance Manual to remove the tire from the wheel. CAUTION: Failure to follow proper procedures when demounting or mounting a tire from a ‘wheel or rim can produce an explosion which may result In serious bodily injury. DO NO attempt to demount or mount a tire unless you have the proper equipment and experience to perform the job safely. Have it done by a qualified tire repair servic 2. Always completely deflate the tire by removing the valve core (A) from valve before attempting any demounting ‘operation. Check the valve stem by running a probe through ito make sure the valve stemis not plugged. Remove valve rut (B). 3. Inspect all parts for damage; replace parts as necessary. Litho in USA. 0110-2 TM-1964 (Nov-86)/410B&C/510B8CPowered Wheels and Fastenings NOTE: See the John Deere Oft-The-Road Maintenance ‘Manual to mount the fire on the wheel 4, Make sure all parts are clean and free from rust or grease before assembly. 5. To prevent slipping of the wheel under load, the inside and outside of wheel (A) must be free of paint, rust, oil, grease, dirt or other foreign material before installation. 6. Install valve stem (8) in rim base and tighten valve core housing finger tight. CAUTION: Serious bodily injury can occur from explosion when mounting and inflating tires if safe procedures are not followed. 7. Before mounting tire on rim, add soap lubricant to beads of the tire (Cp. 8. Clear the area of all persona. 8, Tur tire so valve stem Is pointing down. Use a pressure regulating valve (A) with clip-on chuck and extension hose ong enough to allow you to stand to one side and NOT in front of tire while inflating, 10. Use only recommended air pressure. Pressure over this, limit ean cause an explosion. 44. Add aie until side flange of tre slides st against the rim RECOMMENDED TIRE OPERATING PRESSURE Ske Ply Rating Pressure 195/24 2 285 19 kPa (23 x: 0.4 bar) (4 + 2s) 10.4128 2 248 + 19 kPa (26 x 0.1 ban) (26 2 2p) 2iLies 10 170 + 19 kPa (18 + 0.1 ba) (26 £2 ps) wones a 44d a $9 kPa (24 04 Da) (uEWD) (G0 4 2s} NOTE: Adjust tire pressure to suit working conditions according to manufacturer's recommendations. Litho in USA, 0110-3 TM-1364 (Nov-86)/410B8C/510B8CPowered Wheels and Fastenings litho in USA. 0110-4 "TM-1964 (Nov-86)/410B8C/510B&CGroup 0120 NON-POWERED WHEELS AND FASTENINGS Name Floor Stand Heavy Duty Wheel Lift | SERVICE EQUIPMENT AND TOOLS | us NOTE: Order tools from your SERVICE-GARD™ Catalog. Some tools may be available trom a local supplier. To support unit while removing and installing wheels. To move and install wheels, | SPECIFICATIONS tem Front wheel assembly Without Fluid WL x16 12 Ph 12 x 16.5 8 PRS 145/75 —16.1 10 PR F3 NOTE: Approximately 1.6 kg (3. solid at —47°C (52°F), Front wheel to axle cap screws Without MFWD With MFWD . Front Wheel 41084106 TL 18 10 PR E3 41 Lx 10 12 PRO ‘ R rn 12 Lx 16.5 8 PR F. 1251x158 PR It 145/75—16.1 10 PR FS 51088100 11 Lx 16 21 PR FS 12x 16.58 PRES. Litho in USA, With Flug (Weighs are for tres 75 14.5/75—16.1 10 PR FS 2 Measurement Weight percent full of fluid) bacty a Weight Water Cac: Weigit Waler CaCig Weight Specification A1 kg (90 Ib) 87 (15 gah 24 kg (62 Ib) 70 kg (155 Ib) 49 (13 gal) 20 kag (45 Ib) 70 kg (134 Ib {oo Be gah 44 kg (97 Ib) 82 kg (180 Ib) Ib) CaC1g per gallon of water will stay lush free 0 ~24°C (12°F) and will treeze Torque Torque Tire operating pressure Tite operating pressure - operating pressure operating pressure - Tire operating pressure - Tire operating pressure - Tire operating pressure Tire operating pressure 0120-1 138 + 20 — 27 N'm (100 +15 — 20 theft) 300 + 110 — 40 Nm (221+ Of — 28 Ibtt) 859 kPa (3.6 bar) (52 psi) 441 kPa (4.4 bar) (64 pa) 414 kPa (4:1 bar) (60 psi) 379 wea 28 bas (40 pat 3fe kPa (28 bat 444 kPa (4 bar) (64 psi) 444 kPa (4 bar) (60 psi) 276 kPa (3 bar) (40 Psi) TM-1364 (Mar-86)‘Non-Powered Wheels and Fastenings REMOVE AND INSTALL FRONT WHEEL ASSEMBLY CAUTION: Front whost weighs approximately BA eg 015) witnout fut, 82 kg (80 1) with thu 1. Use a wheel lift (A) to alin removing andinstalling wheel 2. Remove cap screws (B) to remove wheel. 3. Thoroughly clean the cap screws, washers, and the tapped holes in the flanged axle. Use compressed air to dry all parts and tapped holes. 4, Install wheel and cap screws. IMPORTANT: If a power wrench is used, be sure that the cap screws are engaged to prevent stripping. Operate the wrench slowly to prevent thread damag 5. Cross tighten cap screws, without MFWD, to 136 + 20 = 27 Nem (100 + 15 — 20 Ib-ft). Gross tighten cap screws, with MEWD, to 300 + 110 — 40 Nem (221 + 81 — 29 Ibett), 0120-2 T1364 (Mar-86)Non-Powered Wheels and Fastenings REMOVE AND INSTALL TIRE 4. The tire can be removed without removing the wheel from the machine. See the John Deore Off-The-Road Tiro Maintenance Manual to remove the tire from the wheel. CAUTION: Failure to follow proper procedures when demounting or mounting a tire from a wheel or rim can produce an explosion which may result in serious bodily injury. DO NO attempt to demount or mount a tire unless you have the proper equipment and experience to Perform the job safely. Have it done by a ‘qualified tire repair service. 2. Always completely deflate the tre by removing the valve core (A) from valve before attempting any demounting eration. Check the valve stem by running a probe through to make sure the valve stem is not plugged. Remove valve nut (8). CAUTION: explosion when mounting and Inflating th safe procedures are not followed. jerlous bodily Injury can occur from it NOTE: See the John Deere Ort-The-Road Tire Mainte- nance Manual fo mount the tire on the wheel. 4, Make sure al parts are clean and free from rust or grease before assembly, 5. To prevent slipping of the wheel under load, the inside and outside of wheel (A) must be free of paint, rust, oll, {grease, dirt or other foreign materia! before installation 6. Ista valve stern (B) in rin basse and tighten valve core housing finger tight. A CAUTION: Serious bodily injury can occur from | explosion when mounting and inflating tires if safe procedures are not followed. | 7. Before mounting tre on rim, add soap lubricant to beads | of the tire (C) Litho in U.S.A. 0120-3 "TM-1364 (Nov-86)/410B&C/510B8CNon-Powered Wheels and Fastenings Tithe in USA. 0120-4 "TM-1364 (Mar-66)Section 02 AXLES AND SUSPENSION SYSTEMS CONTENTS GROUP 0230—NON-POWERED WHEEL AXLES APL 745 Axio Service Equipment and Toole. = 0230-4 Dicaasemblo Knucklo Housing and Wheel Other Material : + 0230-4 Hubb With Planctary Drive... 0240-48 Specifications «.... 9250 2 Disaooomblo Alo Shaft and Axle, Hub, and Knuckle Assembiy Constant Velocity Joint 0240-52 Grose Section =... 0290 8 ——_Azcomble Axle Shaft and Constant Hub Assembly Velocity Joint “ 0240.58 ROMOvO vos oceseeeses sos 0204 Remove Differential SS oaaose | Install. 0280-8 Differential Exploded View - 0240.56 | ‘djuot Whos! Hub Bearinge ....--... 023040 —_Diaeaomblo Diflerentil 22 oaao.s0 Spine and Knuckle Assembiy ‘Assemble Differential... o2so-ss | Romavo . 0200. 5 —_inetll iforential I) oaso.7s: Install 2 Solis, 0280-7 Assemble and Adjust Knuckle Housing | Tie Rod and Whee! Hub With Planetary Drive». 0240-77 Remove... cesceesses 028041 Adjust Toon 0240-84 inatll 0290-12 Adjust Steering Stop Sevews Non-Powered Front Axle APL 1552 Axlo -... 0240.85 Remove «= -.-+ cesses OB0049 APL TAB Arle oss 0240-05 {Instat 2. 0230-16 Toe-In Adjustment (Gee Group 0240) GROUP 0250—AXLE SHAFT, BEARINGS, AND | Axe Bushings REDUCTION GEARS iemove and Instl ++ 0200-14 Service Cauipment and Tools += 0250-1 | Other Materials «2.0... 0250. 1 nour 0240—POWERED WHEEL Specifications... 0250: 1 AXLE (MFWD) Axle 4108 ( 704001) Cssential Tools. sees 0240-1 Disassemble .. o2s0-2 | Service Equipment and Tools ............ 0240+ 2 Planet Pinion Carior | Other Material... SS. 0240-8 Disassemble and Assemble += 0250-2 | Specifications .... SLI! 02d 4 Axle Shaft | Drive Shaft Disassemble and Inspect ....-.se-.s+ 0250" 8 | Remove and Disassemble .. +. 0240-6 Ale Shaft Assemble LT 0280: 9 | Assemble and Install... 0240-7 © Assumible ...... 22) 0280: 8 Powered Front Axle ‘Avlo—4108 (704002), 5108, 4100, 6100 Remove ceceteettessesess 0240.8 Disable 0260-18 Install 0240- 10 Planet Pinion Carrier | APL 1852 Axio Disassemble ard Asse ++ 0250-18 Disassemble Knuckle Housing Axle Shaft Disassemble | anu Wire Hub with Planetary o2so12 and Inspect 0250-22 Remove Differential . 0240-19 Axle Shaft Assemble . +, 0250-23 | Disassemble Diflorentia oo... 0240-20 ASBEMBIE vo enssenes on SI 280-24 Assemble Differential siccss 0240-25 Axle Shatt | install... 020038 Grease 250-29 | Assemble and Adjust Knuckle Housing | ana Whee! Hub with Planetary 0240.36 | L ee seen _] Litho in U.S.A. 02-1 TM.1469 (Doo-88)Page GROUP 92s0-—Hydrauie System | Other Material. 0260-1 Specifications ....... 0260-1 Steering Cylinder Cross Section | APL 745 Axle - 0260-2 Steering Cylinder Disassemble ........cecsesceseeseees 0260-8 Assemble ...... : + 0260-3 Adjust Tracking Angie To Zero 0260-7 | | Litho in USA. 02-2 TM-1489 (Dec-88)Non-Powered Wheel Axles | SERVICE EQUIPMENT AND TOOLS Name 39 and 44 mm disks 39 and 49 mm disks J0G265 Wiper Seal Installer 79 and 106 mm disks 34 and 25 mmm disks 444 and 49 mm disks «.. 44 and 64 mm disks NOTE: Order tools from your SERVICE-GARD™ Catalog. Some tools may be available from a local supplier. Use To remove spindle bushings. To install spindle bushings, To install bearing cup in hub. To install bearing cups Into hub. To install bushings and seals to lie rod. To install axle pivot bushings, To install axlo bushings. Group 0230 OTHER MATERIAL Number 749515 Litho in USA. John Deere Retaining Compound "0280-1 Use To rotain axlo epindlo buchinge and axle pivot bushings: Tiw-1469 (Dec-¥8)| nonomered Het Ae ‘SPECIFICATIONS Item Measurement Specification Front tires cectcreeeee TOGHN Go eeeeeeseeeetssseesss Measurement between front mark | On tires must be 12 + 6 mm (0.47 = 0.24 in) less than | ear measurement. | King pin cap serew .. cece Torque... 47 Nom (35 Ibett) Wheel hub-to-spindle slotted nut .. Torque . 47 Nem (35 ib-f) | Axle-to-support ... cece Gap cece 0.0—1.0 mm (0.0—0.4 in.) Tie rod clamp cap screw ......... Torque 60 Nim (44 Ib-) ‘Axle pivot pin cap screw ......... Torque cecseses 121 Nem (89 b-f) Litho in USA. 0230-20 0°=¢«¢~—~N TM-1469 (Dec-88)Non-Powered Whee! Axles CROSS SECTION OF AXLE, HUB, AND KNUCKLE ASSEMBLYNon-Powered Wheel Axles REMOVE HUB ASSEMBLY bly , Group 0120.) 2. Remove cap. 1. Remove front wheel. (See Remove Front Wheel Assem- 8. Remove cotter key to remove nut. 4. Remove washer (8), bearing (A) and hub (C). 5. Remove bearing cone and seal (A). Litho in U.S.A, ‘TM-1469 (Dec-88)‘Non-Powered Wheel Axles 6. Remove seal cup. 7. Inspect bearing cup (A). Remove cups only if replace- ‘ment is necessary. 8. Remove bearing cups using a soft steel rod. REMOVE SPINDLE AND KNUCKLE ASSEMBLY 1, Flemove hub. (See Remove Hub Assembly in this group.) 0230-5 TW-1469 (Dec-68) Litho in USA.Non-Powered Whee! Axles 8, Remove cap screw. 4, Remove king pin using a soft steel rod. 5, Remove knuckle (C) with thrust washer (B) and stop i” thrust washer (A) 66. Inspect thrust washer (A) and spring pin (B) for wear or damage. Remove spring pin only if replacement is necessary. 7. Inspect all parts for wear or damage including axle bushings. Litho in U.S.A. 0230-6 ‘TM-1469 (Dec-88)Non-Powered Wheel Axles 8. Remove upper and lower seals. i ; ‘9. Remove upper and lower bushings (A) using 89 mm and 44 mm disks from Bushing, Bearing and Seal Driver Set. INSTALL SPINDLE AND KNUCKLE ASSEMBLY 1. Apply retaining compound to outside surface of new bushings. Install new bushings using 39 and 49 mm disks. Install bushings flush to 0.3 mm (0.01 in.) recessed from spindle side (A) of bores. | tgsias Tune Taree 09 ste Litho in U.S.A. 0230-7 ‘TM-1469 (Deo-88)Non-Powered Wheel Axles 2, Install new seals using 38 mm and 49 mm disk. Install seals fight against bushings. 3. Install new knuckle spring pin, it removed. 4, Install stop thrust washer (A), thrust washer (B), and knuckle (C). 5. Install king pin. 6. Install and tighten cap screw to 47 N'm (85 Ib-t). Litho in US.A. 0230-8 TW-1468 (Dec-88)Non-Powered Wheel Axles 7. Align tie rod to install pin (A) and cotter pin. 8. Install hub, (See Install Hub Assembly in this group.) INSTALL HUB ASSEMBLY 1. Install new bearing cup using a préss and 73 mm disk. | Install cup tight against its shoulder. 2, Install bearing cup using a press and 68 mm and 106 mm disk. Install cup tight against its shoulder. 8, Put multi-purpose grease on the inner and outer bearing cups, ~ 4 Install seal cup using a pres and 108 mm ever i | Litho in USA. 0230-9 TM-1489 (De0-68)Non-Powered Whee! Axles 5. Install seal (A) using a piece of pipe with a 8.975 in. LD. 3.785 in, 0.0 x 6 in, ony rournd mectranical tubing, Install seal tight against its shoulder with flat side of seal against river. 6. Apply multi-purpose grease on lips (B) of seal 7. Install inner bearing cone. 8. Apply multi-purpose grease in space between bearing ‘cone and eeal (A) until space is ful 9. Install hub (©), bearing cone (A), and washer (B). ADJUST WHEEL HUB BEARINGS 4. Install and tighten slotted nut to 47 Nem (35 lb-ft. 2. Tum hub several times and tighten nut again to 47 Nem (35 Ib-fh. 3, Loosen nut just enough to install cotter pin. If hole in knuckle is aligned with slot in nut when nut is tightened to 47 Nim (85 Ibst), loosen nut one slot and install cotter pin. Litho in U.S.A, 0230-10 ‘TM-1469 (Dec-88)CONTINUE TO INSTALL HUB ASS! 1, Remove set screw and install a grease fi bbagins to come through cuter bearing cone. 4. Install cap. 2. Apply multi-purpose grease into hub until the grease 8. Remove graase fiting and install set scraw, EMBLY iting. REMOVE TIE ROD 1. Remove cotter pin. 2. Remove pin (A). 3. Flemove seal. Litho in USA. 0230-11 ‘TM-1469 (Deo-88)Non-Powered Wheel Axles 4, Remove bushing (A) using 28 and 25 mm disk. INSTALL TIE ROD 41. Install new bushing using 34 and 25 mm disks. 2, Install new seal using 34 and 25 mm disks. 3. Install pin (A) and cotter pin. Litho in U.S.A, 0230-12 ‘TM-1469 (Deo-88)| Non-Powered Whoo! Axleo REMOVE NON-POWERED FRONT AXLE 1. Raise loader and install boom lock bar. 2, Remove counterweights it equipped. - 3. Remove both front wheels. (See Remove Front Whee! ‘Assembly in Group 0120.) 4, Install two floor stands with wooden blocks under main frame. CAUTION: Escaping fluid under pressure can penetrate the skin causing serious injury. Re- lleve pressure betore disconnecting nydraulic or other lines. Tighten all connections before aS applying pressure. Keep hands and body away under high pressure. Use a piece of cardboard ‘or paper to search for leaks. Do not use your hand. HANY fui 1cted into the skin, it must be surgically removed within a few hours by a doctor familiar with this type injury or gangrene may result. 5. Operate all hydraulic control valves to release pressure in hydraulic system, | 6. Disconnect ines (A), Cap and plug all openings to prevent | dirt from entering the hydraulic system. 7. Placa a scissors or service jack under axle. 8. Remove nut and cap sorew (A). 9. Remove grease fittings from rear of pin (B). Remove pin to remove axle. AAGTEDOSAD 7470290 C7 259085 Litho in USA, 0230-13 TM-1469 (Dec-88)Non-Powered Wheel Axles REMOVE AND INSTALL AXLE BUSHINGS 1, Remove both seals. 2. Remove top plug from hole (A). 3, Remove pivot bushings by diving outward through hole (A) oF with chieel. 4. Clean bushing bores and new bushings. Surfaces must be free of grease, oil, dirt or paint. 5. Apply retaining compound to outside surface of new bushings. Install new bushings using 44 mm and 54 mm disks, Install new bushings flush to 0.8 mm (0.03 in) racessad from edge of seal shaulder (A). Litho in U.S.A. 0230-14 ‘TW-1469 (Dec-88)Non-Powered Wheel Axles I 6. Install new seals using 44 mm and 54 mm disks. install now scale tight against bushings with sealing lips facing driver. 7. Install plug in top of axle, INSTALL NON-POWERED FRONT AXLE 1. Position front axle. install as many shims as will fit between axle and support. 2. Install pin and cap screw. Tighten cap screw. 8. Measure the amount of play between axie and support ‘Add or subtract shims to get 0.00 to 1.50 mim (0.00 to 0.06 in) end play. 4, Tighten cap screw to 121 Non (89 Ib-f). 5. Install and tighten grease fitings (A). Apply recom- mended grease to fitings (6108). Install and tighten grease fitings (A). Connect lines. Apply recommended grease (610C). Litho in USA 0230-15 ‘TM-1469 (Deo-86)6. Connect two hydraulic hoses (A). 7. Install front wheels. (See Install Front Wheel Assembly oo eS in Group 0120) ee : ®, Install counterweight if equipped. 8, Raise unit and romove floor ctande. Litho in USA. 0230-16 ‘TM-1469 (Dec-88)Group 0240 Powered Wheel Axle (MFWD) | ESSENTIAL TOOLS Number JDG-73 JDG59S (APL 745 Axle) KML-10008 JT30014 (APL 745 Axle) JOG-74 KML-10012 (APL 1552 Axle), . . KML-10013 (APL 1552 Axle). Name Differential Bearing Puller Set Measuring Ring Ring Nut Socket. Ring Nut Socket . Ring Nut Socket Special Forcing Screws. Cone Point Adjusting Set... NOTE: Order tools from your SERVICE-GARD™ Catalog. Some tools may be available from a local supplier. Use Remove differential bearing cones . Determine spacer thickness. Remove and install adjusting nuts in differential, on nub. Remove and install ing year nul on hub. Remove planet pinion cartier Adjust cone point of MFWD Remove and install ring gear nut differential Litho in USA 0240-1 TM-1469 (Dec-88)Powered Wheel Axle (MFWD)/Service Equipment and Tools tL Litho in U.S.A. SERVICE EQUIPMENT AND TOOLS NOTE: Order tools from your SERVICE-GARD™ Catalog. Some tools may be available from a local supplier. Low Lift Transmission Jack Wheel and Axle Lift Disk Drivers—APL 1552 Axle Only 20-Ton Stand 29mm 40 mm 33mm 41 mm 34mm 43mm 36 mm — 45 mm 37mm 50 mm 39mm 54 mm Disk Drivers—APL 745 Axle Only 29 mm 45 mm 49 mm 67 mm 74mm 87 mm 60 mm 89 mm 93 mm 108 mm, 112 mm 82 mm 104 mm Drivers—APL 1552 Axle Only © DFI004 * DFi005, Drivers—APL 745 Axle Only 17—1/2 and 30 Ton Puller Set Metric Dial Caliper * DF1002—Rolling Drag Torque Bar Use Remove and install steer axle. Remove and install wheels, To support unit when removing front axle To remove and install bearings, bushings and oil seals. To remove and install bearings, bushings and oil seals. To instal! bearing cone on pinion shaft. To install oil seal in differential. To install ring gear lock plate. To remove and install planet pinion shafts Measure differential cone point. To measure rolling drag torque of hub and housing. * Fabricated tools, dealer made. (See Section 99 for instructions to make tools.) TM-1469 (Dec-86)OTHER MATERIAL Number Name yag514 . Plastic Gasket, 749612... Thread Lock and Scaler (medium strength) a Pipe sealant with Tetlon®... Teast Retaining Compound PTseo . John Deere NEVER-SEEZ® | Lubricate To lubricate king pins | TEFLON is a trademark of the Du Pont Company. NEVER SEEZ is a trademark of the Emhart Chemical Group, Litho in USA. 0240-3 { Powered Wheel Axle (MFWD)/Other Material screws . Transfer housing. Drain cap screw Use Carrier housing to axle mating surface, Planot pinion carrier to hub cap for MEWD APL 745. MEWD Bushings IL TW-1468 (Dec-88)SPECIFICATIONS tem Pivot Casting Cap Screws (APL. 1552 Axle Oniy) Steer Axle Pivot Pin Cap Screw Drive Shaft to Axle Cap Screw Differertia—APL 1852 Axle Gears: | Goar Cap Screws. | Ring Gear Carrier !ousing Cap Screws. Pinion ‘Yoke Nut Bearings Differontial— APL 745 Axle Plate Pack . Ring Gear Cap Screws. Ring Goar Carrier Housing Cap Screws Pinion Yoke Nut New Bearings: Used Bearings . . Bottom Cover Cap Screws (API 1559 Axle Only) Steering Arm Cap Screws (APL. 1552 Axle Only) King PinsAPL 745 Axle Cap Screws New Bearings Used Bearings. Hub Carrier Cap Screws tno in USA. Measurement lorque End Play Torque . Torque Backlash Torque * Backlash - Torque - Torque + Rolling Drag Torque End Play Torque Backlach Torque Torque Rolling Drag Torque - Rolling Drag Torque Torque Torque Rolling Drag Torque Torque Rolling Drag Torque Rolling Drag Torque Torque 0240-4 Specitication 5y0 + BS Nm (991 + 69 lb-ft) 4.5 mm (0.06 in.) maximum 185 Nem (63 lb-ft) 47 4.Nm (5 = 3 by 0,180.25 mm (0.006—0.01 in.) 69 Nim (61 Ib-tt) 0,150.25 mm (0.006-0.01 in) = 70 Nem (52 Ib-tt) + 250 Nem (184 lb-ft) 23 Nem (14-22 Ibn) 0.10.2 mm (0.004—0.008 in.) 69 Nem (51 lb-ft) 1 0.490.418 mm (0.005—0,007 in) = 230 Nim (170 lb-ft) 250 Nem (184 ltt) D8 Nem (186 Ibn) 45-2 Nem (1318 Ib-in) 195 Nem (100 Ib-f) = 121 Nem (89 Ib-tt) 14—15 Nm (9-11 Ib-ft) = 120 Nm (85 lb-ft) 10—12 Nm (7—8 Ibett) + 5-6 Nm (94 Ib-ft) 190 Nim (140 Ib-f) TM-1469 (Dec-86)Powered Wheel Axle (MFWD)/Specitications SPECIFICATIONS tem Measurement Specitcation Wheel Hub—APL 1862 Axle Inner Nut to Axle Shaft. Rolling Nrag Torque AB Nem (2297 Ibeft) Outer Nut to Axle Shaft... ... Torque : ~ - 300. Nm (221 Ib-ft) Rolling Drag Torque... -.. +... . 5.8 Nm (3.76.9 lb-ft) Wheel Hub—APL 745 Axle Slotted Nut. : Torque Limit... 0... = + 480 Nim (354 Ib-ft) New Bearings = Rolling Drag Torque... 2. 16-20 Nim (12—15 Ib-ft) Used Bearings. Rolling Drag Torque 1114 Nem (@—10 Ib) ‘Axle Shatt ‘APL 1552 Axle End Play : 1.21.4 mm (0.047—0.055 In) APL TAS Axle... ee End Py. eee - . 0.3—0.6 mm’ (0.012—0.024 in) Planot Pinion Carricr Cap Screws APL 1852 Axlo Torque . 25 Nem (18 Ibett) APL 745 Axle... . ++ + Torque - 49. Nim (36 Ib-ft) Tie Rod Nut (APL 1852 Axle Only)... 2.6... Torque. eee eee. 100-120 Nim (7488 Ib-tt) Steering Cylinder to Steering Arm Nut APL 1552 Axle... we TOC. eee 280-300 Nm (208-221 Ib-tt) APL 745 Axle : Torque ce eee es « 200-220 Nem (147—162 Ib-tt) Front Tires Toe In 12 4 6 mm (0.50 + .25 in) TM-1469 (Dec-88) Lith in USA.Powered Wheel Axle (MFWD)/Drive Shatt REMOVE AND DISASSEMBLE DRIVE SHAFT 1. lemove four cap screws at each end to remove drive shaft. 2, Remove grease fiting (8). 8. Remove snap rings (A). ustoersa tana 36 uc. 4, Put shaft in a vice 5. Move shaft down, using a soft steel rod, until bearing assembly (A) is about halfway out. ©. Remove bearing assembly (A) using a piles, ora vise wilh soft-faced jaws if assembly is to be reused. 7. Repeat procedure to remove other bearing assembly. 8. Remove U-joint (B). 9. Inspect all parts for wear or damage. Replace as necessary. Litho in U.S.A. 0240-6 IIM-1469 (De0-88)Powered Whee! Axle (MFWD)/Drive Shaft ASSEMBLE AND INSTALL DRIVE SHAFT 1. Check that rollers (A) and seal (B) are installed correctly. If necessary, apply multi-purpose grease to rollers to hold them in place. 2. Install U-joint (C). 8. Carefully push bearing assemblies into yoke just far ‘enough to install snap ring using push adapter from 17-1/2 and 30-ton puller set, and 26 mm disk. 4, Install snap rings (A). 5. Install grease fitting (8). 6. Install drive shaft. Install and tighten cap screws at each end to 47 = 4 Nm (85 3 Ib-t), Litho in USA 0240-7 M1489 (Dec-88)Powered Wheel Axle (MIWD)/Powered Front Axle-APL 1552 | REMOVE POWERED FRONT AXLE | NOTE: Axle type APL 1552 is shown throughout unless otherwise noted. Removal of later model APL 745 | axle is similar. ~ | 1. Raise loader and install boom lock bar. | 2. Remove counterweights. 3, Install two floor stands such as 20-ton floor stand with | ‘wooden blocks under main frame. 4, Remove the front wheels (see Group 0110). CAUTION: Escaping fluid under pressure can penetrate the skin causing serious injury. Re- lieve pressure before disconnecting hydraulic oF other lines. Tighten all connections before applying pressure. Keep hands and body away | from pinholes and nozzles which eject fluids under high pressure. Use a plece of cardboard or paper to search for leaks. DO NOT use your hand. If ANY fluid is injected into the skin, it must be eurgically romoved within a fow houre by a doctor familiar with this type injury or gangrene may result. 5. Operate all hydraulic control valves to release pressure in hydraulic system. Disconnect ines (A). Close all openings with caps and plugs. | 6. Remove cap screws to disconnect drive shatt ‘TM-1469 (Dec-88) Litho in U.S.A.Powered Wheel Axle (MFWD)/Powered Front Axle-APL 1552 NOTE: Axle shown removed for clanty of photograph. 7. Install low lift transmission jack under center of front axle. Remove one differential cap screw and install adjusta-grip arm (A), Install and tighten all cap screws. Install chain and feyebalt assembly (2). 8. Remove cap screw (A). 9. Remove grease fittings from pin (B). 10. Remove pin to remove axle assembly. 11, Remove seal, NOTE: Pivot assambly not removable on APL 745 axle. 12. Inspect bushing for wear or damage. Remove only if replacement is necessary. 18, Remove cap screws (A) to remove pivot. pene = OUATOATS Tague 27018 Lithe in USA 0240-9 TM-1469 (Dec-86)Powered Whee! Axle (MFWD)/Powered Front Axle-APL 1552 INSTALL POWERED FRONT AXLE NOTE: Axle type APL 1552 is shown throughout unless otherwioe notod. Pivot assembly is not removable on APL 745 axle. 41. Install tightan can screws to 530 + AB Nim (291 4 6a lb-ft). 2. Apply retaining compound to new bushings and install bishing using 45 mm and &4 mm disks from bushing, bearing and seal driver set. 3. Install new seal against bushing with sealing lip opposite bushing using 43 mm and 64 mm disks from bushing, bearing, and seal driver set. ‘4, Move axle under frame assembly. Install as many shims (A) as will fit between front axle pivot (C) and frame (B) so there 1.5 rn (0.060 in.) end play. Litho in U.S.A. 0240-10 TW-1469 (Dec-88)Powered Wheel Axte (MFWD)/Powered Front Axle-APL 1552 5, Raise axle into position. Apply multi-purpose grease on pin. Install pin into bore, rotating it to help seal stietch over it Install grease fittings (A) in pin. Connect grease lines to fittings (410C and 510C). 6, Tighten cap screw and nut to 85 Nm (63 lb-ft). 7. Install drive shaft. Install and tighten the cap screws to 47 Nem (35 Ib). Litho in USA 0240-11 ‘TM-1469 (Dec-88)Powered Wheel Axle (MFWD)/Powered Front Axle-APL 1552 8. Connect lines (A). 9. Install the front wheels (see Group 0110). 10. Remove shop stands. 11, Install counterweights. 12. Remove boom lock bar and lower loader. soil peo oss DISASSEMBLE KNUCKLE HOUSING AND WHEEL HUB WITH PLANETARY DRIVE— APL 1552 AXLE 1. Raise unit to install two 20-ton shop stands. 2. Tur planetary carrier so drain plug (B) is on the bottom. Ba SALTON: Whee! welane approximately 186 ka (414 Ib) with fluid. 3, Remove nuts (A) to remove wheel using wheel and axle | ite 4, Remove drain plug to drain oil, Oil capacity is approxi- mately 1 L (0.3 gal) TM-1469 (Dec-86) Litho in USA.Powered Wheel Axle (MIWD)/Powered Iront Axle-APL 1562 5, Remove cap screws. Remove planet pinion carrier using KML-10013 Special Forcing Screws. 8. Remove the snap rings (A). 7. Remove shafts using pushing adapter from 17-1/2 and 30-ton puller set and a press, 8 Remove the pinions, washers, thrust washers, and needle bearings. 9. Remove snap ring to remove sun gear (A). 410. Straighten locking washer (A) Litho in U.S.A. 0240-13 TM-1489 (Dee-AA)Powered Wheel Axle (MFWD)/Powsred Front Axie-APL 1552 14. Remove nut, locking plate, and second nut using KML-10012 Ring Nut Sockel, 42. Remove ring gear (A). 18. Remove snap ting to remove backing plate (A). 14, Inspect backing plate and ring gear teeth for cracks, chips or damage; raplace if necessary. Litho in USA. 0240-14 TM-1469 (Dec-88)Powered Wheel Axle (MFWO)}/Powered Front Axle-APL 1552 415, Attach hub to a hoist using lifting strap. 16. Remove bearing cone (A). 17. Carefully remove hub (8). on 18. Remove bearing cup, bearing cone, washer, and seal using a soft steel rod. 19. Remove cap seraws to remove hub carrier Litho in USA. 0240-15 ‘TM-1469 (Dec-88)Powered Wheel Axle (MFWD)/Powsred Front Axle-APL 1552 20, Remove seal (A), ring (B), and plate (0). 21. Inspect bushing for wear or damage. Remove bushing if roplacoment io necossary. 22, Remove axle shaft. 23. Remove cotter pins and nuts (A) to disconnect steering covlinder and tie rod. 24. Remove cap screws (B) to remove steering arm (C). ouroang Tare 37-108 Litho in U.S.A, 0240-16 ‘TM-1469 (Dec-88)Powered Wheel Axle (MI'WD)/Powered Front Axle-APL 1552 25. Remove grease fiting (A) from top and bottom king pins. 26. Remove four cap screws to remove cover (C). Remove hime (B). 27. Remove two king pins (B) and O-ring (A) using the 17-112 and 30-ton puller set. 28, Remove knuckle housing (E). A-o-Ring D-Slide Hammer 8 King Pin (2 wood) E—Knuokle Housing (C—Adapter 28, Remove race (A) and bearing cone (8). ‘TM-1469 (Deo-88) Litho in US.A. 2aPowered Wheel Axle (MEWD)/Pomered Front AxieAPL 1652 30. Remove two seals and seal retainer using attachments ‘rom biind nole puller set. 81. Remove bushing using attachments from blind hole puller set. 32. Clean and inspect all parts for wear or damage, replace if necessary. 33, Remove plugs (A). euaronte terone 6 view Litno in USA. 0240-18 Tw-1469 (Dev-68)Powered Wheel Axle (MIWD)/Powered Front Axie-APL 1952 84. Remove bearing cups using 17-1/2 and 30-ton puller set. REMOVE DIFFERENTIAL—APL 1552 NOTE: APL 1552 axle is shown. If only the differential is to be removed. see Remove and Disassemble Knuckle Housing and Whee! Hub with Planetary Drive to remove the following components from each side: whee!, planet pinion carrier, sun gear, ring gear, hub, hhub carrier, axle shaft, and tie rod. 1. Remove drain plug (A) to drain oil. Differential oil capacity is approximately 6.5 L (1.7 gal). 2, Puta mark (A) on carrier housing and axle housing to aid in installation. 8, Remove cap screws (B) to disconnect drive shaft. 4, Remove cap sorews (C) to remove housing, Litho in USA. 0240-19 TW-1469 (Dec-88)Powered Wheel Axis (MFWD)/Powered Front Axle-APL 1552 DISASSEMBLE DIFFERENTIAL—APL 1552 AXLE IMPORTANT: For correct operation, ring gear must be installed so it is on the right side of unit when carrier housing Is installed. 1, Put a mark (A) on ring goar cide of houcing to aid in installation 2. Remove roll pin from each side, 3. Remove adjusting nut from each side using KML-10008 Ring Nut Socket. Litho in U.S.A, 0240-20 TM-1469 (Dec-88)Powered Whoel Axle (MFWD)/Powered Front Axle-APL 1552 4, Remove bearing cup from each side. 5, Remove bearing cone from each side using forcing ‘screw, puller adapter (8), disc, and pilot (A) from JOG-73 Differential Bearing Puller Set. Slide puller down between rollers and turn it to pull on end of rollers. Put a mark (C) on the pinion housings to aid in installation. NOTE: Differential housing and ring gaar cannot ba ra- moved from carrier housing as an assembly. 6. Pull out ring gear just far enough to remove cap screws, nase Toronto 72 nies Litho in U.S.A, 0240-21 TM.1489 (ee-88)Powered Wheel Axle (MFWD)/Powered Front AxleAPL 1552 1 See teaig oumnannts tnt TRS A-Housings (c—Thrust Washer (4 used) ‘B-Pinion Shan (2 uses) —_D—Gear (4 used) 8, Remove the housings (A), side gears (C), disks, and plates (8). Litho in USA. 0240-22 TM-1469 (Dec-88)Powered Whee! Axle (MFWD)/Powered Front Axle-APL 1862 8. Inspect side gears (A), thrust washers (B), plates (C), and disks (D) for wear or damage. Inspect teeth of disks. Replace parts if necessary. ‘A—Side Gear (2 used) c—Piate (10 used) B—Thrust Washer D~Disk (@ used) (2s required) 10, Remove the retainer. Litho in USA 0240-23 ‘TM-1469 (Deo-88)Powered Wheel Axle (MFWD)/Powered Front Axie-APL 1552 11, Remove nut (@) and washer (F) to remove yoke (D) with dust cover (E), and pinion stat (A). Remove sleeve (8) from pinion shaft. ‘A-Pinion Shatt Dust Cover BoSleeve FoWasher ‘c—Housing Nut Yoke 12. Inspect bearing cone for wear or damage. If replace- mant is necessary, remove cone using a 17-1/2 and 30.ton puller set. 18. Remove seal (A) and bearing cone (8). Litho in U.S.A. 0240-24 ‘TM-1469 (Dec-88)Powered Wheel Axle (MFWO)/Powered Front Axle-APL 1552 414, Remove bearing cup using a soft steel rod. 15. Remove bearing cup using a 17-1/2 and 30-Ton Puller Set. ASSEMBLE DIFFERENTIAL—APL 1552 IMPORTANT: Cone point adjustment must be done if replacement of pinion and ring gear set or carrier housing is necessary. ‘The measurement given on the end of Pinion shaft is metric, All measurements used to determine cone point adjustment are metric. Probe of caliper must be perpendicular to bottom of bore for an accurate measurement. 1. Install disks (B) and shaft (A) ftom JOG-74 Cone Point ‘Adjusting Set. Install probe of metric dial caliper through hole in shatt to measure distance trom top of shaft to bottom of bore. Repeat this measurement three times. (If customary callper Is used, multiply measurement by 25.4 to convert (o metric.) Make @ record of average measurement. Litho in USA. 0240-25 TM-1489 (Dec-88)Powered Wheel Axle (MFWD)/Powsred Front Axle-APL 1552 2. Measure the diameter of shaft. Divide measurement by two. Make & record of this measurement, record of measurement. 8. Put bearing cone in bearing cup and turn several tums to seat bearing Measure the width af assembly. Make a Litho in USA. 0240-26 ‘TM-1469 (Dec-88)Powered Wheel Axle (MIWD)/Powered Front Axle-APL 1552 IMPORTANT: The dimension etched on end of pinion shaft is metric. 4, Use the following example to determine shim pack for cone point adjustment using measurements taken in Steps 1—3 and dimension etched on end of pinion shaft. Example: 153.7 mm—Top of shaft to bottom of bore (Step 1) — 149 mm—t/2 diameter of shatt (Step 2) =188.8 mm — 30.3 mm—Width of bearing assembly (Step 3) (08.5 mm —107.9 mm—Dimension etched on pinion shaft = 0.6 mm-—Shim pack for cone point adjustment 5. Install the shim pack. 6. Install bearing cup tight against shoulder in housing using 93 mm disk. 7. Push bearing cup to the bottom of bore using 71 mm disk. me Taam 07 21008 Litho in U.S.A, 0240-27 “TM-1469 (Dec-88)Powered Whee! Axle (MEWD)/Powered Front Axle-APL 1982 8. Install new bearing cone, if removed, using a press and, ‘a piece of round mechanical tubing with 1./5 in. LU. 2.125 In, O.D. and 6 in. long. NOTE: A collapsible sleeve is used between the pinion bearings instead of shims for setting rolling drag torque. The sleeve can be used only once. 9. Install new sleeve on bevel pinion shatt. B SAUTION: D0 NOT heat oil over 182°C (360°). ‘Oil fumes or oll can ignite above 193°C (380°F). Use a thermometer. Do not allow a flame or heating element to come in direct contact with the oil. Heat the oil in a well-ventilated area Plan a safe handling procedure to avoid burns. 10. Install assembled pinion shaft (A). 11. Heat bearing cone to 160°C (300'F) and install on shaft against cup. Litno in USA. 0240-28 “Tw-1409 (Dec-68)Powered Wheel Axle (MIWD)/Powered Front Axle-APL 1552 12, Install new oil seal using a press and a 2.76 in. LD. x 8.00 in, 0.0. round mechanical tubing 152 mm (6 in.) long. Install seal with lip (spring side) toward inside of housing. 49. Install yoke (C) with dust shield (0), washer (B) and nut (2). Tighten nuit (A) to 250 Nem (184 Ibe) ACNut c—Yoke BoWasher (D—Dust Shiota 14, Measure rolling drag torque using an inch-pound torque wrench. Rolling torque must be 2—3 Nim (14—-22 Ibn). 45. If rolling drag torque is less than specified, tighten nut more. If torque is more than specified, loosen nut and adjust with a lower torque. ATMErD W030 12 0065 Litho in U.S.A. 0240-29 M1489 (Deo-B8)Powered Wheel Axle (MIWD)/Powered Front Axle-APL 1552 16, Install retainer and bend locking tabs. IMPORTANT: DO NOT apply oilto differential parts until backlash adjustment is checked. 17. Starting with a plate (B), alternately install ive plates and four disks (C).. 48. Install thrust washer (A) with ground surface toward side gear. Thrust washers come in different thicknesses and are Used in adjusting backlash between side gear and bevel Pinions. 19. Install side geer. Splines of gear must engage teeth of disks. Litho in U.S.A. 0240-30 TM-1469 (De0-88)Powered Wheel Axie (MFWO)/Powered Front Axle-APL 1552 20. Starting with a plate (8), alternately install five plates and four disks (©). 21. Install thrust washer (A) with ground eurfaoe toward sido gear. 22. Install side gear. Splines of gear must engage teeth of disks. 23, Install shafts (C), bevel pinions (A), and thrust washers (®) into housing cover. 24, Measure the backlash between bevel pinions and side ‘gear using dial indicator. Move assembly to other half of housing and measure the backlash BACKLASH SPECIFICATION Backlash . ceo 0150.25 mm (0.008—00010 in) | backlash does not meet specification, adjust by installing ‘a thrust washer of a different thicknass under sire gaar. 25. Before continuing assembly, apply clean hydraulic oil to the assembled parts, L ‘unT¥s) T7020 09 sss Litho in U.S.A 0240-31 TM.1489 (Dec-88)Powered Whee! Axle (MEWD)/Powered Front AxleAPL 1552 26. Install housing cover (A) into carrier housing. Hold side gear, plales, disks, anid thrust washer In cover using snap ring pliers as shown. Then install housing (E) and ring gear. 27. Turn housing (E) to align marks (F). 28. Install bevel pinions (B), shafts (C), and thrust washers (0). Be careful to koop tange on thrust wachors (D) located {as shown. AcHousing Cover D—Thrust Washer (¢ used) ‘sear (# used) Housing (Coshaft (2 used) FAlignment Marks 28, Install and tighten cap screws to 69 N-m (61 lb-ft) 0240-32 TM-1469 (Dec-88) Litho in USA.Powered Wheel Axle (MIWD)/Powered Front Axle-APL 1552 CAUTION: DO NOT heat oil over 182°C (360°F). Oil fumes or oil can ignite above 198°C (880°F). Use a thermometer. Do not allow a flame or heating element to come in direct contact with the oil. Heat the oil in a well-ventilated area, Plan a safe handling procedure to avoid burns. 0. Heat hearing conas to 150°C (20°F) and install ona on each side. 31. Install bearing cup in each side of carrier housing. +: To get tne correct bearing preload, there must be some backlash between ring gear and pinion shaft while making adjustment. 82, Using KMIL-10008 Ring Nut Socket, install and tighten {adjusting nuts so differential housing axial end play io zoro with some backlash between ring gear and pinion shatt. 33. Tighten the adjusting nut opposite ring gear two notches to get the hearing proload l Litho in USA. 0240-33, TM-1469 (Dec-8tPowered Wheel Axle (MFWD)/Powered Front Axie-APL 1552 IMPORTANT: When adjusting backlash, one adjusting nut must be tighten the same amount that other nut is loosen to keep the correct bearing preload. 84. Measure backlash at three equally spaced positions on ring gear using a dial indicator. BACKLASH SPECIFICATION Backlash coseseevess 0450.25 mm (0.006—0.010 in) Toincrease backlash, loosen adjusting nut on ring gear side then tighten nut on opposite side the same amount. ‘To decrease hacklash, loosen adjusting nut on side opposite ring gear then tighten nut on ring gear side the same amount. litho in USA. 0240-34 TM-1469 (Dec-88)Powered Wheel Axle (MFWD)/Powered Front Axio-APL 1552 IMPORTANT: Gear tooth contact pattern must be 95. Apply grease to several teeth of ring gear. With a load applied, turn pinion in both directions to determine gear- tooth contact pattem. If pattern is not correct, backlash distance must be increased or decreased checked on the const 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 nat engaged. ‘A~Ideal Tooth Contact Pattern ‘D-1deal Tooth Contact Pattern Backlash Must Bo Decreased E—Backlash Must Be Decreased ‘coBaexiasn Must Be Increased FoBacklash Must Be Increased Gear-Teath Contact Pattern ‘G—Coast Side (Concave) H—Drive Side (Convex) Litho in USA 0240-35 TM-1469 (Deo-88)Powered Wheel Axis (MFWD)/Powered Front AxleAPL 1552 36, Install roll pin (A) on each side of cartior housing to seuure aujusting nuts INSTALL DIFFERENTIAL—APL1552 AXLE 1. Apply plastic gasket on surface of carrier housing that ‘contacts axle. 2. Install differential with ring gear toward right side of unt. ‘Make sure marks (A) on housings are in alignment. 3, Tighten cap screws (C) to 70 Nem (62 Ib-t 4, Connect drive shaft. Install and tighten cap screws (8) 10.47 4 Nem (95 3 lb-ft). 5. Install drain plug (A) and remove fill plug (8). 6. Fill differential to bottom of fil hole with the recom- mended oil. (See Fuels and Lubricants, Section I, Group IV.) il capacity is approximately 6.5 L (1.7 gal. ASSEMBLE AND ADJUST KNUCKLE HOUSING AND WHEEL HUB WITH PLANE- TARY—APL 1552 AXLE 1. Install plug using 87 mm disk and 40 mm disk, Litho in U.S.A 0240-36 ‘TM-1469 (Dec-88)Powered Wheel Axle (MFWD)/Powered Front Axle-APL 1552 2, Install bearing cup using 41 mm and 57 mm disk. 3. Install bushing using 36 mm and 40 mm disks. 4, Install three piece seal using 36 mim anid 60 1 5. Install race (A) and bearing cone (B). Lithe in USA 0240-37 ‘TM-1469 (Dec-88)Powered Wheel Axie (MFWD)/Fowered Front Axle-APL 1592 6. Install king pin (A) and O-ring (8) in top and bottom of slverliy Knuckle. 7. Install an equal number of shims (A) on top and bottom of knucklo housing. a 8. Install bottom cover (8). 9. Install and tighten cap screws to 135 Nem (100 tb.) Titho in USA. 0240-38 TW-1469 (Dec-88)Powered Wheel Axle (MFWD)/Powered Front Axle-APL 1552 10. Install steering arm, rolling drag torque bar, and cap ‘sorewe hand tight. Install and tighten by hand only, two cap screws holding torque bar. Install remaining cap screws and tighten to specifications. NOTE: To install torque bar on lett hand steering knuckle, use two cap screws from right hand steering arm. 11. Install a torque wrench on the center cap sorew to measure the rolling drag torque. ROLLING DRAG TORQUE SPECIFICATION Fling Drag Torque 11-15 Nm ear To adjust rolling drag torque, add or remove shims between upper and lower king pin and cover. 12, Remove torque bar and tighten two cap screws to ‘specifications. Install grease fittings to upper and lower king pins. Apply recommended grease to fillings. (See Section |, Group IV.) 19, Install axle stall. 14, Install new bushing in hub carrier. it replacement is necessary, using 39 mm and 34 mm disks. ‘naToann 1470860 12108 lithe in USA, 0240-39 TM-1469 (Deo-88)Powered Whee! Axle (MIWD)/Powered Front Axle-APL 1552 15. Install new seal using 50 mm and 36 mm disks. 16. Install hub carrier. Install and tighten cap screws to 190 Nem (140 Ibs), 17, Install new bearing cup in hub using 108 mm disk, a spacer, and 93 mm disk. 18, Install bearing cone (A) and washer (8). Litho in U.S.A. 0240-40 ‘TM-1469 (Deo-88)Powered Wheel Axle (MFWD)/Rowered Tront Axle-APL 1552 19, Install new oil seal using 112 mm and 89 mm disks. 20. Install bearing cup using 79 mm disk, a spacer, and 93, mm disk 21, Attach hub (B) to & hoist using a lifting strap. Install nub on carrier and center it by installing bearing cone (A). Litho in USA, 0240-41 TM.1489 (Dee-88)Powered Wheel Axle (MFWD)/Powered Front Axle-APL 1552 22. Install ring gear on backing plate (A) and secure with ‘snap rings. 23. Install ring gear (A) 24. Install and tighten inner nut (A) using KML-10012 Ring ‘Nut Socket. Install rolling drag torque bar and an inch pound torque wrench to measure rolling drag torque. Adjust inner nut (A) torque to obtain correct rolling drag torque. ROLLING DRAG TORQUE SPECIFICATION Fling Drag Torque... ..... oe o-5Nm (26-44 tory Remove rolling drag torque bar. 26. Install tocking plate and outer nut. Tighten nut to 300 Nem (221 tb-f) using KML-10012 Ring Nut Socket and a torque wrench, Litho in U.S.A, 0240-42 ee 1M-1469 (De0-88)Powered Wheel Axle (M-WD)/Powered Front Axle-APL 1552 26. Install roling drag torque bar and an inch pound torque ‘wrench to measure rolling drag torque. Adjust outer nut (A) torque to obtain correct roliing drag torque. ROLLING DRAG TORQUE SPECIFICATION Fling Drag Torque ess... s8Nm (471 Bein) Remove rolling drag torque bar. 27. When correct rolling torque is reached, bend locking washer (A) to secure nuts. 20, Axle shatlmusl be fee lomeve axially andracaly when Le knuckle housings are turned, as during steering. If there is no racial play, the installed king pin shims must bo changod to move the knuckle housing up or down to got radial play. The total thickness of shim pack (top plus bottom) must remain the same, or roling drag torque of knuckle bearings will change. Example: If upper and lower shim each have a thickness of 3mm (0.118 in.) for a total thickness of 6 mm (0.236 in.) then install a 3.1 mm (0.122 in.) shim at the top and a 2.9 mm (0.114 in, shim at the bottom to move knuckle housing up. The total thickness of shim pack, 3.1 + 2.9 = 6 mm (0.122 + 0.114 = 0,236 in), is the same. enasoay Taneneo 38 0 Litho in USA 0240-43 TM-1469 (Dec-88)Powered Wheel Axle (MFWD)/Powered Front Axle-APL 1552 29. Apply petroleum jelly to parts (C-F). Install needle bearings (F) in pinion (E). IMPORTANT: Thrust washers must be isntalled with raised area (B) in notch (A) to keep washer from turning. 80. Assemble a washor (O) and thrust washor (C) on each ‘side of pinion. Install assembly into (G) with raise area (B) ‘of thrust washers in notches (A. Groove of Housing E-Pinion (3 used) 1B Raleed Area of Wacher ‘Boaring ‘CoThvust Washer 3 per pinion) (2 used per pinion) ‘G—Planetary Housing D—Washer (2 used per pinion) 81. Install shafts (B) using pushing adapter (A) and a press. 32. Install snap rings. Litho in U.S.A, 0240-44 ‘TM-1469 (Dec-88)Powered Wheel Axie (MFWO)/Powered Front Axle-APL 1552 93. Install sun gear (A) and snap ring. 34, Place a 203 mm (8.00 in.) length of 8.2 mm (125 in) diameter solder (A) in planetary housing as shown, ‘95. Install planetary nousing to planet pinion carrer. Install five cap screws (A) and tighten to 25 Nem (18 lb-ft). 36. Remove cap screws. Remove planet pinion carrier using KML-10019 Special Forcing Screws. Litho in U.S.A. 0240-45 ‘TM-1469 (Deo-88)Powered Whee! Axle (MFWD)/Powered Front Avle-APL 1552 97. Remove solder from cartier. Using metric dial caliper, ‘measure the thickness of the flattened areas. This measure- ment is the axle shaft end play. AXLE SHAFT END PLAY SPECIFICATION End Pay - 4201.40 mm (o.087—0.055 im) 38, Ifaxle shaft end play is not within specifications, remove plug (C), shims (B), and end stop (A) using a punch, Axle shaft end play is adjusted by adding or removing shims or using shims of diferent thicknesses. 39. Install proper shims in hole (0). Install plug (C) with ‘chamfered end down using a soft steel rod. 40. Turn carrier over and install end stop (A) flush with outside surface. ‘A-End Stop cpu Shims (as required) DHole NOTE: Line up arain plug note in carer with notch in nub. 41 Apply plastic gasket to flange of planet pinion camer. Install the carrier. 42. Apply thread lock and sealer (medium strength) on cap ‘screw threads. Install and tighten cap screws to 25 Nem (18 ‘bap. Litho in USA, 0240-46 ‘TM-1469 (Dec-88)Powered Wheel Axle (MFWO)/Knuckle Housing and Wheel Hub With Planetary Drive-APL 1552 43, Connect tie rod. Install and tighten aut to 100—120 Nm (7408 Ib-th. Install cotter pin 44, Connect steering cylinder. Install and tighten nut to 280300 N-m (208—221 lb-ft). Install cotter pin. ‘ nageers 7820" ws aro 45. Turn hub to locate drain hole (A) in 3 o-clock or 9 o-clock position. Fill planetary to drain hole with recommended oll Oil capacity is approximately 1 L (0.3 gal) for each planetary. (Gee Fuels and Lubricants, Section I, Group IV.) 46, Install wheel assembly. Install and tighten nuts (B) to 300 Nim (221 lb-th. 47. Remove shop stands and lower un Litho in USA 0240-47 Tive146y (D38c-88)Powered Wheel Axle (MFWD)/Knuckte Housing and Wheel Hub With Planetary Drive-APL 745 DISASSEMBLE KNUCKLE HOUSING AND WHEEL HUB WITH PLANETARY DRIVE— APL 745 AXLE 1, Raise unit to install two 20-ton shop stands. 2, Tum planetary carrier so drain plug (8) is on the bottom. A. CAUTION: Wheel weighs approximately 106 kg (414 Bb). 8. Remove nuts (A) to remove wheal using the wheal and axle lit, NOTE: Warmed hubs may have build up of pressure in oi! compartment. Use care when loosening drain plug. 4. Remove drain plug to drain ol Oil capacity is approx- mately 7 L (0.75 qi). 5, Remove socket head cap screws (A). Remove planet pinion carrier Litho in USA 0240-48 TM-1469 (Dec-88)Powered Wheel Axle (MFWD)/Knuckle Housing and Wheel !luo With Planetary DriverAPL 745 6. Remove snap rings (A). Using a puller, remove pinion gears (8) from carter. 7. With a oharp piok removo nap ring (E), rolioro (F) and ‘center hub (G) from pinion. 8, Remove center snap ring (C) and thrust washer (0). ‘A~Snap Ring Snap Ring B-Pinion Gear Faller cosnap Ring Go center Hub DoThrust Washer 8. Remove O-ring (A). 10. Remove two cap screws (0) to remove locking plate (E). 11. Using JT30014 Ring Nut Sockst, remove ring nut (8) and ring gear (C). A-O-Ring D—Cap Screw (2 used) Bing Nut Leek Plate (c—Aing Gear CAUTION: The approximate weight of carrier hub Is 28 kg (62 Ib). 12. Using a pullor from 17-1/2—80-ton puller set, remove carsier hub. Litho in U.S.A. 0240-49, usteomn sergnto sore orate ‘TM-1469 (De0-88)Powered Whee! Axle (MFWD)/Kouckle Housing and Whee! Hub With Plantary rive-APL 745 19, Remove outer bearing cone, 14, Drive outinner bearing cup to remove seal, bearing cone and cup. 1. Turn carrier hub over and remove outer bearing cup. NOTE: Pry on universal joint behind knuckle housing to push snap ring out of locking washer 16. Remove snap ting and two washers. Litho in USA, 0240-50 TM-1469 (Dec-88)Powered Wheel Axie (MFWD)/Knuckle Housing and Wheel Hub With Planetary DriveAPL 745 17. Remove cotter pin and nut (A). 18. Remove ball joint CAUTION: The approximate weight of knuckle housing is 29 kg (64 Ib). 19. Remove tinnar and lower king pins (A) 20. Remove steering knuckle housing 21. Remove O-rings from king pins. 22. Using a knife edge puller from 17-1/2—90-ton puller sel, remove bearing cones and sealing caps, 23. Remove oll seal and bushing trom Inside of steering knuckle housing, Litho in USA. 0240-51 IM-1469 (DeC-88)Powered Wheel Axle (MFWD)/Axle Shaft and Constant Velocity JointAPL 745 24, Remove axle shatt from axle housing 25, Remove oil seal (B) and bushing (C). 26. Remove bearing cups (A). DISASSEMBLE AXLE SHAFT AND CON- STANT VELOCITY JOINT—APL 745 AXLE 1. Squeeze snap ring tangs (A) and pull sun gear and axle shatt out of CV. joint. 2, Remove outer bearing cone. 8. Drive inner bearing cup out to remove scraper ring, seal, bearing cone and cup. Litho in US.A. 0240-52 TM-1469 (Dec-88)Powered Wheel Axle (MFWD)/Axle Shaft and Constant Velocity Joint APL 745: 4, Clamp joint in a vise, 5. Drive cross shaft down. 6. Tum joint over and drive yoke down. 7. Remove bearing assembly and cross shatt. 8. Repeat procedure for other bearings. ASSEMBLE AXLE SHAFT AND CONSTANT VELOCITY JOINT—APL 745 AXLE 1. Install cross shaft in yoke. 2. Using a 29 mm disk, drive in bearing assembly just far enough to install snap ring, Tuteoan ercomo 13 exes 3. Turn joint over and press the other bearing assembly in just far enough to install the snap ring. 4, Repeat the procedure for other bearings. NOTE: Do not install sun gear shart in C.V. joint at this time. This is done after installing knuckle housing to prevent damaging seal in housing. 5. Slide axle shaft in C.V. joint to lock in snap ring (A). 6. Apply rocommonded groace to fittinge. (Seo Section |, Group IV.) cours «vgn asa oncer_ | Litho in US.A, 0240-53 "TM-1469 (Deo-88)Powered Wheel Axle (MFWD)/DilferentiahAPL 745 REMOVE DIFFERENTIAL—APL 745 AXLE NOTE: If removing altferential ony, frst remove axle shafts. On each end of axle. remove wheels, uisconnect steering ball joint and remove knuckle housing assembly with axle shaft. (ee Disasaemble Knuckle Housing and Wheel Hub with Planetary Drive in this, group.) 4. Remove ol drain plug to drain ol. Diforential capacity is approximately 8.2L (2.1 gal. 2, Remove cap screws (A) to disconnect drive shaft. CAUTION: The approximate weight of the dif- ferential is 36 ka (80 Ib). 3, Remove cap screws (B) to remove differential Litho in USA. 0240-54 ‘TM-1469 (Dec-88)Powered Wheel Axle (MFWL)/LitterentaAPL /45 0240-55 ‘TM-1469 (Dec-88)Powered Wheel Axle (MFWD)/DitferentialAPL 745 | DIFFERENTIAL EXPLODED VIEW—APL 745 AXLE Litho in USA. "0240-56Powered Wheel Axle (MFWD)/DifferentialAPL 745 ACAajusting Nut E-Pinion Shaft Fin Bearing (Cup and Cone) F—Ring Gear ‘Measuring Ring/Spacer (CoDitferential Carrier G—Dowel Bearing (Cup and Cone) Shim H-Bearing (Cup and Cone) L—Oil Seal fing Gear Side M—Dust Cap Legend For Exploded View—APL 745 Axle ~ ~~ TM-1469 (Dec-88) Litho in USA, 0240-57Powered Whee! Axle (MEWD)/DillereriiaAPL 745 Litho in U.S.A 0240-58(10 Useay Powered Wheel Axle (MIWD)/DitferentiaAPL 745 ‘AAllen Cap Screw (2 Used) E—Internal Splined Washer GInternal Splined Disk tack Plate (4 Used) oo) (2 Usec) (C—Housing Differential Half FBevel Gear (2 Used) HTheust Washer (4 Used) ‘D-External Splined Disk Bevel Pinion (4 Used) ‘J-Bevel Pin Cross, k—Spring Pin ‘Roll Pin Housing Ditterentiat fing Gear Hat DISASSEMBLE DIFFERENTIAL—APL 745 IMPORTANT: For correct operation, ring gear must be stalled so it is on the right side of unit when carrier housing Is installed. 4. Put a mark (C) on ring gear side of housing to aid in Installation, 2. Remove roll pin (A) from each side. 3. Remove nuts using KML-10008 Ring Nut Socket (B). IMPORTANT: Note which side cup was removed from for proper assembly. 4, Remove bearing cups. Litho in USA. ~~ 0240-59 "TM-1469 (Dec-88)[ Powered Wheel Axle (MFWD)/DitferentialAPL 745 NOTE: Bearing puller will not work on the ring gear side bearing. 5. Fiemove bearing cone using forcing screw, puller adapter, disk, and pilot from JDG-73 Differential Bearing Puller Set. Place disk in center of bearing. Slide puller down | between rollers and turn it to catch on end of rollers. Turn forcing screw to pull bearing out. L nTeasee Tne 6. Mark pinion housing (A) to aid in installation. 7. Move pinion housing forward and rotate to remove cap screws and plates. Litho in US.A. 0240-60 “TM-1469 (Dec-88)Powered Wheel Axle (MFWD)/DitferentiakAPL 745 8, Install a screw driver under drive gear to hold gear, plates, | and diake up in pinion housing. 8. Hold pinion housing (A) up whilo moving bevel gear (B) off shaft through notch holes (C) in housing, 10. Remove remaining bevel gears and shaft. 11. Inspect bevel gears and shaft. Replace if necessary as a assembly. 12, Remove slide gear, plates, and disks trom pinion housing (A). 19, Remove siide gear, plates and disks from ring gear housing (8). TM.1489 (Dec-88) Litho in U.S.A, 0240-61Powered Wheel Axis (MFWD)/DilferentiabAPL. 745 414, Inspect side gears (A), thrust washers (B), plates (C), and disks (0) for wear or damage. Inspect teeth of disks Replace parts if necessary. Acide Gear (2 uso) Pate (10 used) sothvust wasner 01K (6 seat (es required) | 415. Drive ring gear bearing off using a punch through holes | Win pinion housing, Litho in USA 0240-62 TM-1469 (Dec-88)17. Remove pinion shaft nut retainer, nut, washer, yoke, dust shield and ail seal 18, Press pinion shaft from outer bearing cone and pinion housing. 119, Pull cone trom pinion shaft using bearing pulling attacn- ment from 17-1/2 and 30-ton puller set Litho in USA. 0240-63 TM-1469 (De0-88)Powered Wheel Axle (MFWO)/DitferentialAPL 745 men) 20. Remove outer pinion shaft bearing cone. 21, Remove outer pinion shaft cup (A) and inner cup (8). ASSEMBLE DIFFERENTIAL—APL 745 AXLE IMPORTANT: Cone point adjustment must be done If replacement of pinion and ring gear sot or cartier housing Is necessary. The measurement given on end of pinion shaft is metric. All measurements used to determine cone point adjustment are metric. Probe of caliper must be perpendicular to bottom of bore for accurate measurement. 4. Install disks and shaft from JDG-74 Cone Point Adjusting Set. Install probe of metric dial caliper through hole in shaft, to measure distance from top of shaft to bottom of bore. Repeat this measurement three times. (if customary caliper is used, multiply measurement by 25.4 to convert to metric.) Make a record of average measurement, 2. Measure the diameter of shatt. Divide measurement by two, Make @ record of this measurement, Litho in USA. 0240-64 UATOOTAK Tene aoz0. ossts TM-1469 (Dec-88)Powered Wheel Axle (MIWD)/DitterentiaicAPL 745 8. Put bearing cone in bearing cup and turn several turns to seat bearing. Measure the width of assembly. Make a record of this measurement. IMPORTANT: The dimension etched on end of pinion shaft is matrie. 4. Use the following example to determine shim pack for cone point adjustment using measurements taken in Steps 1—3 and dimension etched on end of pinion shatt. Example: From step 1: 130.18 mm (Top of shaft to bottom of bore) From step 2: — 16.0 mm (1/2 diameter of shatt) =115.18 mm From step 3: ~25.4 mm (Width of bearing assembly) = 89.78 mm 88.5 mm (Dimension etched on pinion shaft) =1.28 mm (Shim pack width) 6. Install the shim pack. 6. Install pinion inner bearing cup in housing using 82 mm and 104 mm disk from driver set. Litho in U.S.A. 0240-65 ‘TM-1469 (Dec-88)Powered Wheel Axle (MFWD)/DilferenilialAPL 745 7. Push pinion outer bearing cup to the bottom of bore using 2 67 ni disk from driver sel. CAUTION: DO NOT heat oil over 182°C (260° F), Oil fumes or oll can ignite above 193° C (380° F). Use a thermometer. DO NOT allow a flame or heating element to come in direct contact with the oil. Heat the oil in a well- ventilated area. 8. Heat pinion innar bearing cone to 95° © (203° F) and install on shaft. Seat cone atter it has cooled. Litho in USA. 0240-66 TM-1469 (Dec-88)Powered Wheel Axle (MFWO)/Diferential-APL 745 9. Extend pins of JDG593 Measuring Ring to outer most Position. Place measuring ring, with pins up, on dive pinion, ‘and insert pinion (A) into differential housing. CAUTION: DO NOT heat oil over 182°C (360° F). Oil fumes or oll can ignite above 193° C (380° F). Use a thermometer. DO NOT allow a flame or heating element to come in direct contact with the oil. Heat the oil in a well- ventilated area, Plan a safe handling procedure to avold burns. 10. Heat pinion bearing outer cone to 95° C (203" F) and install on shaft against cup. 11. Install yoke (C) with dust shield (D), washer (B) and nut A). ‘ACNut ‘B—Washer C—Yoke D—Dust ohiela Litho in U.S.A. 0240-67 ‘TM-1469 (Dec-88)Powered Wheel Axle (MFWD)/DitferentialAPL 745 12, Measure rolling drag torque. ROLLING DRAG TORQUE SPECIFICATIONS New bearings. 2-3 Nem (18-27 lin) ‘Old bearings 15-2.Nem (13-18 bin) 13. When rolling drag torque has been reached disassem- ble pinion ahaft and romove measuring ring. 14, Meaeuro JDG593 ring at all thros pine and determine average "X” dimension. Replace with spacer of the same thickness. 15, Insert pininn shaft with spacer into differential housing and reinstall outer bearing. Refer to Step 10. 16. Clean seal bore and O.D. with denatured alcohol and water miture. Leave seal O.D. wet for installation 47. Apply grease on sealing lip. Install oil saal. Top of seal should be flush with recess in housing, 18, Reinstall yoke, dust shield, washer and nut, Refer to Step 11 IMPORTANT: Nut retainer must be replaced after each repair. 19. Install nut retainer using 1-1/2 in. socket. Bend out locking tabs. Litho in U.S.A. 0240-68 TM-1469 (Dec-88)| Powered Wheel Axle (MFWD)/DiferentialAPL 745 IMPORTANT: DO NOT apply oil to differential parts until backlash adjustment is checked. 20, Starting witha plato (@), alternately inatll five plates and | four disks (C). 21. Install thrust washer (A) with ground surface toward side ‘gear. Thrust washers coma in differant thicknassas and ara used in adjusting backlash between side gear and bevel pinions. 22. Install side gear. Splines of gear must engage teeth of 4 disks i 23, Starting with a plate (8), alternately install five plates and four disks (C). 24. Install thrust washer (A) with ground surface toward side gear. UA TosDL Taro 147 010208 Litho in U.S.A. 0240-69 TM-1469 (Deo-88)Powered Wheel Axle (MFWD)/Ditferentia APL 745 25. Install side gear. Splines of gear must engage teeth of isk. 26. Install cross shafts (A), bevel pinions (B), and thrust washers (C) into housing cover. 27, Meaeuro the backlash botweon bevel pinione and sido gear using dial indicator. Move assembly to other half of housing and measure the backlash. BACKLASH SPECIFICATION Beckiash 016-0.25 mm (e.000—2070 in) IH backlash does not meat specification, adjust by installing a thrust washer of a different thickness under side gear. 28. Before continuing assembly, apply clean hydraulic oil to the assembled parts. Litho in U.S.A. 0240-70 TW-1469 (Dec-88)_Powered Whee! Axle (MFWD)/Dilterential APL 745: 29. Install a piace of wire (A) through center of cross shaft ‘assembly. Thread wire through center bore and cap screw hole in pinion housing. 20. install pinion housing (C) into carrier housing (B). Attach ware to a hoist. 31. Ralse pinion housing tight against carrier housing. Install ‘and titring gear assembly (E). Align holes (0) and move gear ‘assembly through relief slot (F) in carrier housing. 982, Rotate assemblies to align marks (A). Cut and remove 99. Install plates and cap screws. Tighten cap sorows to 69 Nem (51 Ib-t), Litho in USA. 0240-71 TM-1469 (Dec-88)Powered Whee! Axle (MFWD)/Dilferential-APL 745 CAUTION: DO NOT heat oil over 182°C (360'F). Oil fumes or oil can ignite above 193°C (380°F). Use a thermometer. Do not allow a flame or heating element to come in direct contact with the oil. Heat the oil in a well-ventilated area. Plan safe handling procedure to avoid burns. 84, Heat bearing cones to 150°C (300°F) and inetall one on each side. 35. Install bearing cup in each side of carrier housing. Litho in USA. 0240-72 TW-1469 (Dec-88)Powered Wheel Axle (MFWD)/Ditferential-APL 745 IMPORTANT: To get the correct bearing preload, there must be some backlash between ring gear and pinion shaft while making ‘adjustment. 36. Install adjusting nuts using JDG-73-8 disk in center bore and a steel ball, install dial indicator. Tighten adjusting nuts so differential housing axial end play is zera with some backlash between ring gear and pinion shaft. 37. Tighten the adjusting nut opposite ring gear two notches. | to get the bearing preload. IMPORTANT: When adjusting backlash, one adjusting nut must be tightened the same amount that other nut is loosened to keep the correct bearing preload. 38. Measure backlash at three equally spaced positions on ring gear using a dial indicator. BACKLASH SPECIFICATION Backiash 0.45~0.25 mm (0.005—0.010'n) To Increase backlash, loosen adjusting nut on ring gear side then tighten nut on opposite side the same amount. ‘To decrease backlash, loosen adjusting nuton side opposite ring gear then tighten nut on ring gear side the same amount. ouraneon eraun 157 010208 Litho in U.S.A. 0240-73 TM-1489 (Dec-88)Powered Whe! Axle (MFWD)/DifferentiahAPL 745 Sy ‘A-doa! Tooth Contact Pattorn Idea! Tooth Cor Gcoast cide (Concave) ‘BBacklash Must Be Decreased Backlash Must sed H-Drive Side (Convex) (0—Backlash Must Be Increased FBacklash Must Be Increased Gear-Tooth Contact Pattern IMPORTANT: Gear tooth contact pattern must be 39. Apply grease to several teeth of ring gear with a checked on the coast side and drive load applied. Turn pinion in both directions to determine side with a load applied. The pattern _gear-tooth contact pattern. if pattem is not correct, may be correct onthe drive side and backlash distance must be increased or decreased. incorrect on the coast side causing the differential to “whine” when iti not engaged. Litho in USA 0240-74 TMPowered Wheel Axle (MFWD)/Differential-APL 745 40. Install roll pin (A) on each side of differential housing to secure ring nut. INSTALL DIFFERENTIAL—APL 745 AXLE 1. Apply plastic gasket to surface of differential housing that contacts axle, IMPORTANT: Differential dowel pins must alian with bores in axle housing. If they do not, differential backlash is incorrect. Meas- ure distance between bores and readjust backlash to obtain correct dimension between dowel pins. 2, Install dtferential attaching cap screws (A), Tighten cap screws to 280 Nim (170 Ibs) 3. Install drive shaft. Install new cap screws (8) and tighten 0 47.5 Non (85 Ib), 4, Install drain plug. Remove fill plug (C). Fill differential to the bottom of fill hole with recommended oil. (See Section |, Group IV} Oil capacity is approximately 8.2 L (2.1 gal). Install fil plug. Titho in USA 0240-75 ‘TM-1469 (Dec-88)WeSnap Ring X-Sun Gear Shaft tosnap ino 2st Washer c= ansnap Rio o—o-Fing ‘A8—Snap Rina Ring Gear ‘he—Rotr Bearing S—Ring Nat ‘A5—Manctary Prion | Fook Pate ‘Ae—Plantary Carer | Urner Washer ‘AF Drain Pe V—Outer Washer | Litho in USA. "0240-76 T1468 (De0-88)| Powered Wheel Axle (MPWD)/Kauckle Housing and Whel Hub With Planetary Drive-APL 745 ASSEMBLE AND ADJUST KNUCKLE HOUS- ING AND WHEEL HUB WITH PLANETARY DRIVE—APL 745 AXLE 1. Install bearing cups (A) using 67 mm and 74 mm disk from driver eet. NOTE: Align bushing so vee formed by oll grooves is at bottom of bushing, pointing to center of axle. 2, Install axle bushing using a 45 mm and 49 mm disk from driver set . 3. Install axle seal using a 45 mm and 74 mm disk from driver set. 4, Install axle shaft. e vse 9 terse sas exer Litho in USA - ~ 0240-77 ~ TM-1469 (Dec-88)Powered Wheel Axle (MFWO)/Knuckie Housing and Whe! Hub With Planetary DriverAPL 745 5. Install ring (A) on king pins with lip side up. 6. Install bearing cones on king pins. 7. Install O-rings between ring (A) and king pin. NOTE: Align bushing so vee formed by oil grooves is at bottom of bushing, pointing to conter of axl when knuckle housing is installed. 8. Install axle bushing in steering knuckle housing using a 45 mm and 49 mm disk fram driver set 9. Install axle seal using a 45 mm and 74 mm disk from driver sel. Litho in USA. 0240-78 ‘TM-1469 (Dec-88)Powered Wheel Axle (MEWD)/Knuckle Housing and Whel Hub With Planetary Drive-AL 745 10, Install steering knuckle housing, 11, Apply NEVER-SEEZ lubricant to surface (A) on king pins. Install upper and lower king pins, with shims under ‘upper king pin only. 42. Install cap screws and tighten to 120 N:mm (88 lb-ft) 13, Install sun gear shaft (B), being careful not to damage seal in knuckle housing 5 © 14. Install rolling drag torque bar. (See Section 99 for instructions to make tool.) 415, Place a torque wrench on the center cap screw to measure the rolling drag torque. HOLLING DHAG TORQUE SPECIFICATION New Bearings 10—12 Nm (748.8 >t) Used Bearings 12: 16 Nm (G66 Ios) 16, To adjust bearing preload add or remove shims under upper king pin, 17. Apply recommended grease to fittings on upper and lower king pins. (See Section |, Group IV.) 18. Install washers and snap ring on suin gear. Seat snap ring in groove in larger washer. Litho in USA. 0240-79 ‘TM.1469 (Dee-88)Powered Wheel Axle (MFWD)/Knuckle Housing and Whe! Hub With Planetary Drive-APL 745 419. Install inner and outer bearing cups in carrier hub using bearing driver. (See Section 99 for inslructions lo make tool) I | 20. Install inner bearing cone (A) in carrier hub. 21. Apply plastic gasket to outer circumference of seal (B). Install eoal, rubber sido up, using eoal driver. (See Section | 89 for instructions to make tool) Coat sealing lips with grease. (0240-60 TW-1469 (Dec-88) Litho in USA.Powered Wheel Axle (MFWO)/Knuckle Housing and Whel Hub With Planetary Drive-APL 745 lat 22. Install corner hub. dh CAUTION: DO NOT heat oll over 182°C (360° F) 4 Oll fumes or oll can Ignite above 193°C (380°F). Use a thermometer. DO NOT allow a flame or - heating element to come in direct contact with % the oil. Heat the oil in a well-ventilated area. Heat outer bearing cone to 95°C (203° F) and install on ‘tooring knuckle housing. 24, Install ring gear and ring nut with chamforad edge out Tighten with JT30014 Ring Nut Socket. 25. Install rolling drag torque bar using two M10 x 140 cap screws. 26. Adjust ring nut torque to obtain correct rolling drag torque. ROLLING DRAG TORQUE SPECIFICATION New bearings. 16-20 Nim (12-15 ot) Used bearings 1114 Nam (610 [ost Litho in U.S.A 0240-81 ~_TM-1469 (Dec-88)Powered Wheel Axle (MFWD)/Knuckle Housing and Whel Huby Willt Planetary DriveAPL 746 27. Apply grease to O-ring (A) and install in groove in carrior housing. 26. Install locking plate (8) and two new cap screws (C). Do not reuse old cap screws. 29. Tighton cap screws to 43 Nem (32 Ib-t). 30. Install snap ring (E) in pinion (B) with flat side of ring toward conter of goar. 31. Apply petroleum jelly to center hub (G). Position rollers () on hub and slide into pinion. 32. Install snap ring (E) in pinion (B) with fet side of ring toward riers 39. Install assemblied pinion in planetary pinion carrier with large radius of center hub down. Install snap ring (A). 34. Apply petroleum jelly to thrust washer (D) and install in cartier. Be careful to align tabs on washerin recesses. Install snap ring (C). AcSnap Ring Snap Ring B-Pinion F-Rolier coSnap Ring G—Center Hub DoTheust Washer Litho in USA. 0240-82 TW-1469 (Dec-88)Powered Wheel Axle (MTWD)/Knuckle Housing and Whel Hub With Planetary Drive-APL 745 85. Place a 20 cm (8 in) length of 1.57 mm (.062 in) diameter solder in planet pinion carrier. 6. Install carrior on hub. Install socket head cap screws in holes (A) and tighten to 49 Nem (96 lb-ft) 97. Remove cap screws and carrier hub. 88, Remove solder and measure thickness to determine sun gear end play. Adjust to specification using appropriate thrust washer. ‘SUN GEAR END PLAY SPECIFICATION | ena play. (0,300.00 mm (0.012—0.024 in) | 29. Install cartier an hub. Install aap serews and tighten to 49. Nm (36 Ib-t), 40. Connect tie rod. Install and tighten nut to 200-220 Nem (147—162 lb-ft). Install cotter pin, 41. Turn hub to locate drain hole (A) in 3 o-clock or 9 o-clock position. Fill planetary to drain hole with recommended oil | Oilcapacity is approximatoly.7 L (0.75 at for each planetary. (See Fuels and Lubricants, Section |, Group IV.) | 42. Install whee! assembly. (See Group 0110). 43, Remove shop stands and lower unit. Titho in USA ~~ 0240-83 TM-1469 (Dec-88)Powered Wheel Axle (MFWD)/Check and Adjust Toe-In CHECK AND ADJUST TOE-IN 41. Measure distance from ground to hub center (A). At this height, mark front (6) and rear (C) in center of tread of each front tire. 2. Measure distance between front marks (8), and rear marke (C). Units Without (MFWD) Mechanical Front Wheel Drive: 8, Front marks must be 12 + 6 mm (0.50 +t 0.25 in) closer than rear marks To adjust toe-in, loosen bath tie rod clamps (E) and turn the rod tube (0). After adjustment, tip cap screws 45° down toward rear of machine. Tighten clamp cap screws to 95 = 14.N'm (70 = 10 Ib-f. Unit With (MFWD) Mechanical Front Wheel Drive: 4, Front marks must be 12 3: 6 mm (0.50 +: 0.25 in. closer than rear marks. 5. To adjust toe-in on APL 1852 Axle, loosen nuts (H), remove cotter pin (G) and nut (F). Remove tie rod end from steering arm. Turn end to get proper toe-in. Install nut (), tighten to 220 Nem (162 b-t) and install cotter pin. Tighten nuts (+. 6. On APL 745 axle, loosen nul (I) on each side of axle, Turn each tio rod (J) equally to adjust. Tighten nuts. NOTE: On APL 745 axle, steering cylinder tracking angle must be set to zero before tow-in adjustment is made, (See procedure, Group 0260.) ‘A~Center of Hub FoNut B-Front of Tire G—cotter Pin (C—Roar of Tie HoNut D—Tie Rod Tube nut Ee Rod Clamp soTle now Litho in USA 0240-84 TM-1469 (Dec-88)Powered Wheel Axle (MPWD)/Steering Stop Screws-APL 745 Axle With Intregal Steering Cylinder ADJUST STEERING STOP SCREWS—APL 1552 AXLE 4. Tum stecring wheel to the left until steoring stop sorow contacts front axle frame. 2, Measure distance from end of steering cylinder to center fut Maasuirement must be 954 mm (13.94 in) maximum 3. Tur steering wheel to the right until steering stop screw feantacts frant axle frame, 4, Measure distance from rod end of steering cylinder to center of tie rod nut. Measurement must be 97 mm (3.81 in.) maximum, 5. If either of distances measured are more than specified, adjust by adding washers behind the steering stop screw. ADJUST STEERING STOP SCREWS— APL 745 AXLE WITH INTREGAL STEERING CYLINDER NOTE: Perform the following steps for both wheels. 1. lum steering wheel unti steering stop sorew contacts, axle body. 2. Measure distance (A) on steering cylinder rod. Measure- ‘menit must be 200.6 in (7.80 in.) maximum, 3. If distance ia more then specified, adjust by adding washers behind steering stop screw. nasooas 6 Tastee see 180s Litho in U.S.A 0240-85 ‘TM-1469 (Dec-88)Powered Wheel Axle (MFWO)/Steering Stop Screws-APL 745 Axie With Intregal Steering Oylinder Litho in U.S.A. 0240-86 ‘TM-1469 (Deo-88)Group 0250 Axles, Bearings, and Reduction Gears SERVICE EQUIPMENT AND TOOLS NOTE: Order tools from your SERVICE-GARD™ Catalog. Some tools may be available from a local supplier. Name u WUT8B065 eee esceeeeteseeeeeeeeses To install axle shaft seal | *JT38059 : . To install axle shaft seal. “Rolling Drag Torque Bar To adjust axle bearings. 17-1/2 and 80-Ton Puller Set : To remove bearing cones, bearing cups and seals. 4108 (——_-704001) (66 mm and 92 mm disks ... 93 mm and 110 mm disk 114 mm and 135 mm disks. To install inner oll seal To Install Inner and outer bearing cups. To install outer oil seal 4408 (704002. ) 410 and 610C: | 70 mm and 94 mm disk ....eceseseeeeseses To install inner oil seals. 95 mm and 113 mm disks Sitestssesesesess To install inner and outer bearing cups. 115 mm and 186 mm disk fees To install outer oil seal. “Fabricated tools, dealer made. (See Section 99 for instructions to make tool.) OTHER MATERIAL Number Name Use ‘AR04076 Load Balls (Bag of 200) -To caloulate axle bearing proload shims. John Deere High Temperature Grease To grease axle bearing, SPECIFICATIONS Item Measurement Spectication | Air Pressure Test Axles Air Prossure 241 34 kPa (2.4 + 03 bar) | (85 + 5 psi) Axle Shaft Retaining Cap Screw..... TOmQUe....6..eceeeeeeeeee 245 + 80 ~ 0Nm | (180 + 6 0 lb-ft) 1116 Nem (96144 Ib-in) rolling drag torque ern 03 ames _| Litho in USA 0250-1 TM.1489 (Dee-RA)Aules, Bearings, anid Fleuuclion Gears DISASSEMBLE AXLE—410B ( 704001) 1. Remove axies from transaxle assembly. (See Remove ‘Transaxle in Group 0300.) 2. Remove shaft (A) and brake disk (8). SAGTOLO Tero a9 onze NOTE: It may be necessary to tighten or loosen cap screw to remove look plate. 8. Remove lock plate and cap screw. 4, Remove planet pinion cartior using tie band. DISASSEMBLE AND ASSEMBLE PLANET PINION CARRIER 4. Thoroughly clean the planet pinion carrier before disassembly. 2. Remove snap ring to remove planet pinions. Remove one planet pinion assembly at a time. Litho in U.S.A. 0250-2 TM-1469 (Deo-88)Axles, Bearings, and Reduction Gears 3, Remove shatt (A) to remove pinion (8) with bearings (©), jand thrust washers (0). 4, Thoroughly clean and inspect parts of the planet pinion carrier assembly for wear and damage. Replace parts as necessary. ‘APlanet Pinion Shaft (3 used) C—Bearing Roller (29 used per ‘B—Pianet Pinon (3 Used) pinion-69 total) D—Thrust Washer (2 used por nian) 5. Use petroleum jelly on bearing rollers before assembly. 6. Install 28 bearing rollers in each planet pinion. If any hearing raller is lost or damaged, replace bearing rollers ae a sot. ‘A~-Planet Pinion (2 used) (C—Thrust Washer (2 used per ‘B—Planet Pinion Shaft pinion) (used) ‘D-Bearing Rolier (29 used per pinon-=09 total) Litho in USA. 0250-3 TM-1469 (Dec-88)‘Antes, Bearings, and Reduction Gears 7. Put petroleum jelly on both sides of thrust washers (C). Install one washer on each side of planet pinion (B). 8, Install planet pinion assembly with bearing rollers (C). 2. Install the planet pinion shatt (A) with groove towara the snap ring. 10. install snap ring in each planet pinion shaft aroove and into the groove of the planet pinion carrier. Make sure each planet pinion assembly is properly assembled, DISASSEMBLE AXLE HOUSING 1. Remove shims (A) and thrust washer (8). Litho in U.S.A. 0250-4 “TW-1469 (Deo-88)‘Axles, Bearings, and Reduction Gears 2. Loosen axle housing using attachments from 17-1/2 and 80-ton puller set. 3, Remove inner bearing cone. 4, Throughly clean and inspect bearing cone for wear and damage; replace it necessary. agtsiuea Treaso 89 ose Litho in USA 0250-5 TM-1469 (Deo-88)AV srousing's 63 9 (17) hoist to remove housing. CAUTION: The approximate weight of axle 5. Attach lifting straps to housing and connect straps to @ ‘Axles, Bearings, and Reduction Gears ‘aero Tain 99 wanes 30-ton puller set. Litho in USA, 6, Hemove bearing cup using attachments from 17% and 0250-6 TM-1469 (Dec-88)Axles, Bearings, and Reduction Gears 7. Inspect grease dam surface for wear or damage. Replace housing if necessary. 8. Remove bearing cup using attachments from 17% and 80.10n puller set 9. Remove seal using attachments from the 17¥ and 30-ton puller set. 40. Thoroughly clean and inspect axle housing for wear or damage. Replace if necessary. 11. Hemove brake pressure plate (A) using a rolled tace prybar. sAGTi0e8 Tease wae 0266 Litho in U.S.A. 0250-7 ‘TM-1469 (Dec-88)Axles, Bearings, and Reduction Gears 42. Remove inner (A) and outer (B) packing from pressure plate. 19, Inspect brake pressure plate for wear or damage; replace if necessary. DISASSEMBLE AND INSPECT AXLE SHAFT 1. Remove bearing cone from lower bearing step using attachments from 17% and 30-ton pullor cot. 2, Remove oil seal from axle shaft. 3. Thoroughly clean and inspect axle shaft and bearing cones for wear or damage: replace parts if necessary. Litho in U.S.A, 0250-8 TM-1469 (Dec-88)Axles, earings, and Heauction Gears ASSEMBLE AXLE SHAFT 4. Install new seal (A) using a piece of round mechanical tubing, 3.188 in, I.D. x 3.75 in, O.D. x 22 in. long, with metal side facing away trom driver. Install seal even with axle shatt shoulder. CAUTION: DO NOT heat oll over (182°C) 360° ll fumes or oll can Ignite above (193°C) 380° Use a thermometer. Do not allow a flame or heating element to come in direct contact with the oil. Heat the oil in a well-ventilated area. Plan a safe handling procedure to avoid burns. | 2 Heat bearing cone not to exceed (140°C) 800°F for installation on axle shaft. 2. Install heated bearing cone before cone cools. The bboaring cone must be tight against the axle shoulder. A. Use multi-purpose grease to grease pack the hearing | cone. ASSEMBLE AXLE—410B ( -704001) 1. Install new inner (A) and outer (B) packings. 2, Put petroleum jelly on inner and outer packings. Litho in USA, 0250-9 TM-1469 (Dec-88)Axles, Bearings, and Reduction Gears piston housing, 3. Install pressure plate so holes engage dowel pinsin brake. 4. Install new inner oil seal with spring side facing driver. Install tight against avle shoulder using 68 mm and 92 mm. disks. Put clean hydraulic oil on the seal lips. Litho in US.A 5. Install bearing cup tight against axle shoulder using 93 ‘mm and 110 mm disks and a spacer of approximately 1/4 in. Put clean hydraulic olf on bearing cup surface. ‘TM-1469 (Dec-88)Antes, earings, and Reduction Gears 6. Install bearing cup tight against axle shoulder using 93 ‘and 110 mm disks and a spacer of approximately 1/4 in. Put ‘clean hydraulic oil on bearing cup surface. 7. Install new oil seal tight against the end of axle housing Using 114 and 125 mm disk. Put mulipurpase grease an inside of bearing cup surface. 8, Install the axle shaft assembly in axle housing. Turn axle housing approximately three revolutions to seat outer bear- ing cone. Litho in USA. 0250-11 ‘TM-1469 (Dec-88)Axles, Bearings, and Reduction Gears CAUTION: DO NOT heat oil over (182°C) 360 Ad Gittumes or cit ean ignite above (189°C) 380°F. ‘a thermometer. Do not allow a flame or heating element to come in direct contact with ‘the oll. Heat the oil in a well-ventilated area, Plan ‘a safe handling procedure to avoid burns. NOTE: If damage to outer bearing grease dam was noticed during disassembly. apply grease fo axle housing. (See Grease Quler Axle Bearing in this group.) 9. Heat inner bearing cone not to exceed (149°C) 300°F. 10. Install heated bearing cone on axle tight against bearing ccup before it cools. Put clean hydraulic oil around bearing, 14. Install thrust washer. Litho in USA 0250-12 “TM-1469 (Dec-88)Axtes, Bearings, and eduction Gears 12, Install planet pinion carrier assembly and retainer cap 18. Tighton rotainor cap ccrowo to 76 4. 7 Nim (65 4. 6 lb ft). ‘Turn axle housing several revolutions to make sure bearing ‘cups and cones are seated. 14. Loosen cap serew. 15. Lift housing and tap axle shaft with a lead hammer to make sure there is no preload on bearings. 16. Install roling drag torque tool. (See Fabricated Tools in Section 99) 17. Rotate the housing atleast three times. check and make, a record of rolling drag torque. NOTE: Rolling drag torque is checked with a ibn, torque wrench with used seals because rolling drag torque is low enough that a lb-ft torque wrench may be ‘inaccurate, if rolling drag torque is above the specitication the inner beanng may not have moved when tapped witn a hammer and is providing some preload on the earings. it may be necessary fo press the axle shaft from the housing should the inner bearing be tight on the axle shat. 10. Remove cap screw and carrer. 19. Place three 8—10 mm (0.3—0.4 In.) diameter lead balls ‘on the end of axle shaft 120° apart. Use grease to hold lead balls in position. Litho in USA. 0250-13, iTesee2 eno2s0

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