John Deere

770G, 770GP, 772G, and
772GP
Motor Grader
Repair Manual
TECHNICAL MANUAL
770G, 770GP, 772G, and 772GP
Motor Grader Repair Manual
TM11207 11MAY09 (ENGLISH)
For complete service information also see:

770G, 770GP, 772G and 772GP Operation
and Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TM11206
770G, 770GP, 772G and 772GP Operator’s
Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OMT251544
POWERTECH9.0L Diesel Engine—Base
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CTM400
PowerTech Plus9.0L Diesel Engine—Level
14 Electronic Fuel System with Denso
HPCR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CTM385
DF180 Series Powershift Transmission
Repair Manual . . . . . . . . . . . . . . . . . . . . . . . . CTM308
TeamMateII 1200, 1400, and 1600 Series
Inboard Planetary Axles . . . . . . . . . . . . . . . . CTM43
120 Series Hydraulic Cylinders . . . . . . . . . . TM-H120A
JDLink and ZXLink Machine Monitoring
System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CTM10006
Worldwide Construction
And Forestry Division
LITHO in USA
Introduction
Foreword
This manual is written for an experienced technician. Information is organized in groups for the various
Essential tools required in performing certain service components requiring service instruction. At the
work are identified in this manual and are beginning of each group are summary listings of all
recommended for use. applicable essential tools, service equipment and tools,
other materials needed to do the job, service parts kits,
Live with safety: Read the safety messages in the specifications, wear tolerances, and torque values.
introduction of this manual and the cautions presented
throughout the text of the manual. Technical Manuals are concise guides for specific
machines. They are on-the-job guides containing only
the vital information needed for diagnosis, analysis,
This is the safety-alert symbol. When you see this
testing, and repair.
symbol on the machine or in this manual, be alert to
the potential for personal injury.
Fundamental service information is available from
other sources covering basic theory of operation,
Technical manuals are divided in two parts: repair and
fundamentals of troubleshooting, general maintenance,
operation and tests. Repair sections tell how to repair
and basic type of failures and their causes.
the components. Operation and tests sections help you
identify the majority of routine failures quickly.
,0004E4A –19–08SEP08–1/1
TM11207 (11MAY09) 770G, 770GP, 772G, and 772GP Motor Grader Repair Manual
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Contents
SECTION 18—Operator’s Station
SECTION —General Information Group 1800—Removal and Installation
Group 001—Safety Group 1810—Operator Enclosure
Group 0003—Torque Values Group 1815—Pedal Assembly
Group 1816—Steering Tilt Console
01
SECTION 01—Wheels Group 1821—Seat and Seat Belt
Group 0110—Powered Wheels and Fasteners Group 1830—Heating and Air Conditioning
SECTION 02—Axles and Suspension Systems SECTION 19—Sheet Metal and Styling
Group 0225—Input Drive Shafts and U-Joints Group 1921—Grille and Grille Housing
Group 0230—Non-Powered Wheel Axles 02
Group 0240—Powered Wheel Axles SECTION 21—Main Hydraulic System
Group 0250—Axle Shafts, Bearings, and Reduction Group 2160—Hydraulic System
Gears
Group 0260—Hydraulic System SECTION 34—Grading Device
Group 3415—Controls Linkage
03
Group 3440—Frames
SECTION 03—Transmission
Group 3450—Circle Gearbox
Group 0300—Removal and Installation
Group 3460—Hydraulic System
SECTION 42—Ground Conditioning Tool
SECTION 04—Engine Group 4240—Frames 04
SECTION 99—Dealer Fabricated Tools
SECTION 05—Engine Auxiliary System Group 9900—Dealer Fabricated Tools
Group 0510—Cooling System
Group 0560—External Fuel Supply Systems
05
SECTION 07—Torsional Isolator

Group 0752—Elements
SECTION 09—Steering System

Group 0920—Power Steering 07
SECTION 10—Service Brakes

Group 1011—Active Elements
Group 1060—Hydraulic System 09
SECTION 11—Park Brake

SECTION 17—Frame, Chassis or Supporting 10

Structure
Group 1740—Frame Installation
All information, illustrations and specifications in this manual are based on
the latest information available at the time of publication. The right is
reserved to make changes at any time without notice. 11
COPYRIGHT  2009
DEERE & COMPANY
Moline, Illinois
All rights reserved
A John Deere ILLUSTRUCTION Manual
TM11207 (11MAY09) i 770GP, 772G, and 772GP Motor Grader Repair Manual
770G,
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Contents
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02
03
04
05
07
09
10
11
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18
19
21
34
42
99
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Contents
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18
19
21
34
42
99
INDX
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Section
General Information
Contents
Page
Group 001—Safety . . . . . . . . . . . . . . . . . . . . . . 001-1
Group 0003—Torque Values

Torque Value
Metric Bolt and Cap Screw . . . . . . . . . . . . . . 0003-1
Additional Metric Cap Screw Torque Values . . . 0003-2
Torque Value
Unified Inch Bolt and Cap Screw . . . . . . . . . . 0003-4
Service Recommendations for 37° Flare
and 30° Cone Seat Connectors . . . . . . . . . . . 0003-5
Service Recommendations for O-Ring
Boss Fittings . . . . . . . . . . . . . . . . . . . . . . . . . 0003-6
Service Recommendations For Flared
Connections—Straight or Tapered
Threads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0003-8
Service Recommendations For Flat Face
O-Ring Seal Fittings. . . . . . . . . . . . . . . . . . . . 0003-9
Service Recommendation
O-Ring Face Seal Fittings with SAE
Inch Hex Nut and Stud End for High
Pressure. . . . . . . . . . . . . . . . . . . . . . . . . . 0003-11
O-Ring Face Seal Fittings with Metric
Hex Nut and Stud End for Standard
Pressure. . . . . . . . . . . . . . . . . . . . . . . . . . 0003-13
O-Ring Face Seal Fittings with Metric
Hex Nut and Stud End for High
Pressure. . . . . . . . . . . . . . . . . . . . . . . . . . 0003-15
Service Recommendations for Metric
Series Four Bolt Flange Fitting . . . . . . . . . . 0003-17
Service Recommendations For Inch
Series Four Bolt Flange Fittings. . . . . . . . . . 0003-18
Inch Series Four Bolt Flange Fitting For
High Pressure Service
Recommendations . . . . . . . . . . . . . . . . . . . . 0003-19
Service Recommendations For
Non-Restricted Banjo (Adjustable)
Fittings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0003-20
Service Recommendations For O-Ring
Boss Fittings With Shoulder . . . . . . . . . . . . . 0003-22
Service Recommendation
Metric 24 O-Ring Seal DIN 20078 . . . . . . . . 0003-25
TM11207 (11MAY09) 1 770GP, 772G, and 772GP Motor Grader Repair Manual
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TM11207 (11MAY09) 2 770GP, 772G, and 772GP Motor Grader Repair Manual
770G,
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Group 001
Safety
Recognize Safety Information 001
1
This is the safety alert symbol. When this symbol is
–UN–28AUG00
noticed on the machine or in this manual, be alert for
the potential of personal injury.
Follow the precautions and safe operating practices
T133555
highlighted by this symbol.
A signal word — DANGER, WARNING, or CAUTION — is

used with the safety alert symbol. DANGER identifies the
most serious hazards.
–19–28AUG00
On the machine, DANGER signs are red in color,
WARNING signs are orange, and CAUTION signs are
yellow. DANGER and WARNING signs are located near
specific hazards. General precautions are on CAUTION
T133588
labels.
TX03679,00016CC –19–03JAN07–1/1
Follow Safety Instructions
Read the safety messages in this manual and on the
–UN–24AUG00
machine. Follow these warnings and instructions carefully.
Review them frequently. Keep safety signs in good
condition. Replace missing or damaged safety signs. Be
sure new equipment components and repair parts include
T133556
the current safety signs. Replacement safety signs are
available from your John Deere dealer.
Be sure all operators of this machine understand every

safety message. Replace operator’s manual and safety
labels immediately if missing or damaged.
TX03679,00016F9 –19–11AUG03–1/1
TM11207 (11MAY09) 001-1

770G, 770GP, 772G, and 772GP Motor Grader Repair Manual
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Safety
001 Operate Only If Qualified

2
Do not operate this machine unless the operator’s machine functions with the machine in an open area
manual has been read carefully, and you have been before starting to work.
qualified by supervised training and instruction.
Know and observe all safety rules that may apply to
Operator should be familiar with the job site and every work situation and work site.
surroundings before operating. Try all controls and
TX03679,00016FA –19–03JAN07–1/1
Wear Protective Equipment
Guard against injury from flying pieces of metal or debris;

wear goggles or safety glasses.
Wear close fitting clothing and safety equipment

appropriate to the job.
–UN–23AUG88
Prolonged exposure to loud noise can cause impairment
or loss of hearing. Wear suitable hearing protection such
as earmuffs or earplugs to protect against objectionable or
TS206
uncomfortable loud noises.
TX03679,00016D0 –19–03JAN07–1/1
Avoid Unauthorized Machine Modifications
Modifications of this machine, or addition of Always contact an authorized dealer before making
unapproved products or attachments, may affect machine modifications that change the intended use,
machine stability or reliability, and may create a hazard weight or balance of the machine, or that alter
for the operator or others near the machine. The machine controls, performance or reliability.
installer of any modification which may affect the
electronic controls of this machine is responsible for
establishing that the modification does not adversely
affect the machine or its performance.
TX03679,00016B7 –19–11AUG03–1/1
TM11207 (11MAY09) 001-2

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Safety
Inspect Machine 001

3
Inspect machine carefully each day by walking around it

before starting.
Keep all guards and shields in good condition and
–UN–18OCT88
properly installed. Fix damage and replace worn or broken
parts immediately. Pay special attention to hydraulic
hoses and electrical wiring.
T6607AQ
TX03679,0001734 –19–03JAN07–1/1
Stay Clear of Moving Parts
–UN–12SEP01
Entanglements in moving parts can cause serious injury.
Stop engine before examining, adjusting or maintaining

any part of machine with moving parts.
T133592
Keep guards and shields in place. Replace any guard or
shield that has been removed for access as soon as
service or repair is complete.
TX03679,00016D2 –19–03JAN07–1/1
Avoid High-Pressure Oils
This machine uses a high-pressure hydraulic system.

Escaping oil under pressure can penetrate the skin
causing serious injury.
–UN–17MAR06
Never search for leaks with your hands. Protect hands.
Use a piece of cardboard to find location of escaping oil.
Stop engine and relieve pressure before disconnecting
lines or working on hydraulic system.
T133509
If hydraulic oil penetrates your skin, see a doctor
immediately. Injected oil must be removed surgically
within hours or gangrene may result. Contact a
knowledgeable medical source or the Deere & Company
Medical Department in Moline, Illinois, U.S.A.
–UN–20SEP00
T133840
TX03679,00016D3 –19–03NOV08–1/1
TM11207 (11MAY09) 001-3

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Safety
001 Beware of Exhaust Fumes

4
Prevent asphyxiation. Engine exhaust fumes can cause

sickness or death.
–UN–24AUG00
If you must operate in an enclosed space, provide
adequate ventilation. Use an exhaust pipe extension to
remove the exhaust fumes or open doors and windows to
T133546
bring outside air into the area.
TX03679,00016D4 –19–03NOV08–1/1
Prevent Fires
–UN–14SEP00
Handle Fuel Safely: Store flammable fluids away from
fire hazards. Never refuel machine while smoking or when
near sparks or flame.
T133552
Clean Machine Regularly: Keep trash, debris, grease
and oil from accumulating in engine compartment, around
fuel lines, hydraulic lines, exhaust components, and
electrical wiring. Never store oily rags or flammable
materials inside a machine compartment.
–UN–07SEP00
Maintain Hoses and Wiring: Replace hydraulic hoses
immediately if they begin to leak, and clean up any oil
T133553
spills. Examine electrical wiring and connectors frequently
for damage.
Keep A Fire Extinguisher Available: Always keep a

multipurpose fire extinguisher on or near the machine.
–UN–07SEP00
Know how to use extinguisher properly.
T133554
TX03679,00016F5 –19–03NOV08–1/1
Prevent Battery Explosions
Battery gas can explode. Keep sparks, lighted matches,

and open flame away from the top of battery.
Never check battery charge by placing a metal object

across the posts. Use a voltmeter or hydrometer.
–UN–23AUG88
Do not charge a frozen battery; it may explode. Warm

battery to 16°C (60°F).
TS204
TX03679,000174A –19–03NOV08–1/1
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Safety
Handle Chemical Products Safely 001

5
Exposure to hazardous chemicals can cause serious
–UN–25AUG00
injury. Under certain conditions, lubricants, coolants,
paints and adhesives used with this machine may be
hazardous.
T133580
If uncertain about safe handling or use of these chemical
products, contact your authorized dealer for a Material
Safety Data Sheet (MSDS) or go to
http://www.jdmsds.com. The MSDS describes physical
and health hazards, safe use procedures, and emergency
response techniques for chemical substances. Follow
MSDS recommendations to handle chemical products
safely.
TX03679,00016D7 –19–11AUG03–1/1
Dispose of Waste Properly
Improper disposal of waste can threaten the environment.
–UN–25AUG00
Fuel, oils, coolants, filters and batteries used with this
machine may be harmful if not disposed of properly.
Never pour waste onto the ground, down a drain, or into
T133567
any water source.
Air conditioning refrigerants can damage the atmosphere.

Government regulations may require using a certified
service center to recover and recycle used refrigerants.
If uncertain about the safe disposal of waste, contact your

local environmental or recycling center or your authorized
dealer for more information.
TX03679,0001733 –19–31JAN07–1/1
Prepare for Emergencies
Be prepared if an emergency occurs or a fire starts.
Keep a first aid kit and fire extinguisher handy.
Keep emergency numbers for doctors, ambulance service,

–UN–23AUG88
hospital, and fire department near your telephone.

TS291
TX03679,000174B –19–03NOV08–1/1
TM11207 (11MAY09) 001-5

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Safety
001 Use Steps and Handholds Correctly

6
Prevent falls by facing the machine when getting on and
–UN–30AUG00
off. Maintain 3-point contact with steps and handrails.
Never use machine controls as handholds.
Use extra care when mud, snow, or moisture present
T133468
slippery conditions. Keep steps clean and free of grease
or oil. Never jump when exiting machine. Never mount or
dismount a moving machine.
TX03679,00016F2 –19–15MAR07–1/1
Start Only From Operator’s Seat
–UN–07SEP00
Avoid unexpected machine movement. Start engine only
while sitting in operator’s seat. Ensure all controls and
working tools are in proper position for a parked machine.
T133715
Never attempt to start engine from the ground. Do not
attempt to start engine by shorting across the starter
solenoid terminals.
TX03679,0001799 –19–03JAN07–1/1
Use and Maintain Seat Belt
Use seat belt when operating machine. Remember to
–19–14SEP00
fasten seat belt when loading and unloading from trucks
and during other uses.
T133716
Examine seat belt frequently. Be sure webbing is not cut
or torn. Replace seat belt immediately if any part is
damaged or does not function properly.
The complete seat belt assembly should be replaced

every 3 years, regardless of appearance.
TX03679,00016DD –19–03NOV08–1/1
TM11207 (11MAY09) 001-6

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Safety
Prevent Unintended Machine Movement 001

7
Be careful not to accidentally actuate controls when

coworkers are present.
Lower all equipment to the ground during work
–UN–31OCT01
interruptions. Place transmission control and park brake
lever in park position P before allowing anyone to
approach the machine.
T147606
Follow these same precautions before standing up,
leaving the operator’s seat, or exiting the machine.
TX03679,00017C5 –19–20NOV08–1/1
Avoid Work Site Hazards
Avoid contact with gas lines, buried cables and water

lines. Call utility line location services to identify all
–UN–15JUN01
underground utilities before starting work.
Prepare work site properly. Avoid operating near

structures or objects that could fall onto the machine.
T141905
Clear away debris that could move unexpectedly if run
over.
Avoid contact with overhead obstacles or overhead

electrical lines. Never move machine closer than 3 m (10
ft) plus twice the line insulator length to overhead wires.
Keep bystanders clear at all times. Use barricades or a

signal person to keep vehicles and pedestrians away. Use
–UN–15MAY01
a signal person if moving machine in congested areas or
where visibility is restricted. Always keep signal person in
view. Coordinate hand signals before starting machine.
T141904
Operate only on solid footing with strength sufficient to

support machine. Be especially alert working near
embankments or excavations.
TX03679,00017A4 –19–14MAY01–1/1
TM11207 (11MAY09) 001-7

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Safety
001 Keep Riders Off Machine

8
Only allow operator on machine.
–UN–07MAY01
Riders are subject to injury. They may fall from machine,
be caught between machine parts, or be struck by foreign
objects.
T141744
Riders may obstruct operator’s view or impair his ability to
operate machine safely.
TX03679,00017A2 –19–20APR01–1/1
Avoid Backover Accidents
Before moving machine, be sure all persons or

vehicles are clear of machine path. Turn around and
–UN–04MAY01
look directly for best visibility. Use mirrors to assist in
checking all around machine. Keep windows and mirrors
clean, adjusted, and in good repair.
T141745
Be certain reverse warning alarm is working properly.
Use a signal person when backing if view is

obstructed or when in close quarters. Keep signal
person in view at all times. Use prearranged hand signals
to communicate.
TX03679,00017A3 –19–20APR01–1/1
TM11207 (11MAY09) 001-8

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Safety
Avoid Machine Tip Over 001

9
Use seat belt at all times.
–19–14SEP00
Do not jump if the machine tips. You will be unlikely to
jump clear and the machine may crush you.
T133716
Load and unload from trucks or trailers carefully. Be
sure truck is wide enough and on a firm level surface. Use
loading ramps and attach them properly to truck bed.
Be careful on slopes. Drive directly up or down steep

slopes whenever possible. Minimize articulation for best
–UN–22MAY01
machine stability when driving and turning across slopes.
Use extra care on wet, soft or frozen surfaces because
machine may slide more easily with these conditions.
T142271
Ensure solid footing. Do not operate close to banks or
open excavations that may cave in and cause machine to
top or fall. fall.
TX03679,00017A5 –19–02MAY01–1/1
Operating Or Traveling On Public Roads
Machines that work near vehicle traffic or travel slower

than normal highway speeds must have proper lighting
–UN–22MAY01
and markings to assure they are visible to other drivers.
Install additional lights, beacons, slow moving vehicle

(SMV) emblems, or other devices and use as required to
T141891
make the machine visible and identify it as a work
machine. Check state and local regulations to assure
compliance. Keep these devices clean and in working
condition.
TX03679,00017C8 –19–14JUN01–1/1
TM11207 (11MAY09) 001-9

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Safety
001 Inspect and Maintain ROPS

10
A damaged roll-over protective structure (ROPS) To maintain the ROPS:

should be replaced, not reused.
• Replace missing hardware using correct grade
The protection offered by ROPS will be impaired if hardware.
ROPS is subjected to structural damage, is involved in • Check hardware torque.
an overturn incident, or is in any way altered by • Check isolation mounts for damage, looseness or
welding, bending, drilling, or cutting. wear; replace them if necessary.
• Check ROPS for cracks or physical damage.
If ROPS was loosened or removed for any reason,
inspect it carefully before operating the machine again.
TX03679,000179F –19–20APR01–1/1
Add and Operate Attachments Safely
Always verify compatibility of attachments by that all connections are secure and attachment
contacting your authorized dealer. Adding unapproved responds properly to controls.
attachments may affect machine stability or reliability,
and may create a hazard for others near the machine. Carefully read attachment manual and follow all
instructions and warnings. In an area free of
Ensure that a qualified person is involved in bystanders and obstructions, carefully operate
attachment installation. Add guards to machine if attachment to learn its characteristics and range of
operator protection is required or recommended. Verify motion.
TX03679,00016F0 –19–24JAN07–1/1
TM11207 (11MAY09) 001-10

051809
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Safety
Park And Prepare For Service Safely 001

11
Warn others of service work. Always park and prepare

your machine for service or repair properly.
• Park machine on a level surface and lower equipment
–19–14DEC01
to the ground.
• Place transmission control and park brake lever in “P”
park position. Stop engine and remove key.
• Attach a “Do Not Operate” tag in an obvious place in
T133332
the operator’s station.
Securely support machine or attachment before working

under it.
• Do not support machine with any hydraulically actuated

equipment.
• Do not support machine with cinder blocks or wooden
pieces that may crumble or crush.
• Do not support machine with a single jack or other
–UN–23AUG88
devices that may slip out of place.
Understand service procedures before beginning repairs.

Keep service area clean and dry. Use two people
TS229
whenever the engine must be running for service work.
TX03679,00016E9 –19–02MAY01–1/1
Service Cooling System Safely
Explosive release of fluids from pressurized cooling

system can cause serious burns.
Shut off engine. Only remove filler cap when cool enough
to touch with bare hands. Slowly loosen cap to first stop
–UN–23AUG88
to relieve pressure before removing completely.

TS281
DX,RCAP –19–04JUN90–1/1
TM11207 (11MAY09) 001-11

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Safety
001 Remove Paint Before Welding or Heating

12
Hazardous fumes can be generated when paint is heated

by welding or using a torch. Dust from sanding or grinding
–UN–24AUG00
paint can also be hazardous.
Remove paint to at least 76 mm (3 in.) from area to be

heated. Wear an approved respirator when sanding or
T133546
grinding paint. If a solvent or paint stripper is used, wash
area with soap and water. Remove solvent or paint
stripper containers from work area, and allow fumes to
disperse at least 15 minutes before welding or heating.
Work outside or in a well-ventilated area. Dispose of

waste, paint, and solvents properly.
TX03679,0001732 –19–29AUG07–1/1
Make Welding Repairs Safely
IMPORTANT: Disable electrical power before welding.
–UN–31AUG00
Turn off main battery switch or
disconnect positive battery cable.
Separate harness connectors to engine
and vehicle microprocessors.
T133547
Avoid welding or heating near pressurized fluid lines.
Flammable spray may result and cause severe burns if
pressurized lines fail as a result of heating. Do not let heat
go beyond work area to nearby pressurized lines.
Remove paint properly. Do not inhale paint dust or fumes.

Use a qualified welding technician for structural repairs.
Make sure there is good ventilation. Wear eye protection
and protective equipment when welding.
TX03679,00016D5 –19–25APR08–1/1
TM11207 (11MAY09) 001-12

051809
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Safety
Drive Metal Pins Safely 001

13
–UN–14SEP00
Always wear protective goggles or safety glasses and
other protective equipment before striking hardened parts.
Hammering hardened metal parts such as pins and
bucket teeth may dislodge chips at high velocity.
T133738
Use a soft hammer or a brass bar between hammer and
object to prevent chipping.
TX03679,0001745 –19–03JAN07–1/1
TM11207 (11MAY09) 001-13

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Safety
001
14
TM11207 (11MAY09) 001-14

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Group 0003
Torque Values
Metric Bolt and Cap Screw Torque Values 0003
1
–UN–07SEP99
TORQ2
Top—Property Class and Head Markings; Bottom—Property Class and Nut Markings
METRIC BOLT AND CAP SCREW TORQUE VALUES—Tolerance is ±10% unless otherwise specified
Class 4.8 Class 8.8 or 9.8 Class 10.9 Class 12.9
Thread Lubricateda Dryb Lubricateda Dryb Lubricateda Dryb Lubricateda Dryb
Size N•m (lb-ft) N•m (lb-ft) N•m (lb-ft) N•m (lb-ft) N•m (lb-ft) N•m (lb-ft) N•m (lb-ft) N•m (lb-ft)
M6 4.7 (3.5) 6 (4.4) 9 (6.6) 11.5 (8.5) 13 (9.5) 16.5 (12.2) 15.5 (11.5) 19.5 (14.5)
M8 11.5 (8.5) 14.5 (10.7) 22 (16) 28 (20.5) 32 (23.5) 40 (29.5) 37 (27.5) 47 (35)
M10 23 (17) 29 (21) 43 (32) 55 (40) 63 (46) 80 (59) 75 (55) 95 (70)
M12 40 (29.5) 50 (37) 75 (55) 95 (70) 110 (80) 140 (105) 130 (95) 165 (120)
M14 63 (46) 80 (59) 120 (88) 150 (110) 175 (130) 220 (165) 205 (150) 260 (190)
M16 100 (74) 125 (92) 190 (140) 240 (175) 275 (200) 350 (255) 320 (235) 400 (300)
M18 135 (100) 170 (125) 265 (195) 330 (245) 375 (275) 475 (350) 440 (325) 560 (410)
M20 190 (140) 245 (180) 375 (275) 475 (350) 530 (390) 675 (500) 625 (460) 790 (580)
M22 265 (195) 330 (245) 510 (375) 650 (480) 725 (535) 920 (680) 850 (625) 1080 (800)
M24 330 (245) 425 (315) 650 (480) 820 (600) 920 (680) 1150 (850) 1080 (800) 1350 (1000)
M27 490 (360) 625 (460) 950 (700) 1200 (885) 1350 (1000) 1700 (1250) 1580 (1160) 2000 (1475)
M30 660 (490) 850 (625) 1290 (950) 1630 (1200) 1850 (1350) 2300 (1700) 2140 (1580) 2700 (2000)
M33 900 (665) 1150 (850) 1750 (1300) 2200 (1625) 2500 (1850) 3150 (2325) 2900 (2150) 3700 (2730)
M36 1150 (850) 1450 (1075) 2250 (1650) 2850 (2100) 3200 (2350) 4050 (3000) 3750 (2770) 4750 (3500)
a
"Lubricated" means coated with a lubricant such as engine oil, or fasteners with phosphate and oil coatings.
b
"Dry" means plain or zinc plated without any lubrication.
Fasteners should be replaced with the same or higher property class.

CAUTION: Use only metric tools on metric hardware. If higher property class fasteners are used, these should only be
Other tools may not fit properly. Tool may slip and tightened to the strength of the original.
cause injury.
Make sure fastener threads are clean and that you properly start
thread engagement. This will prevent them from failing when
DO NOT use these values if a different torque value or tightening tightening.
procedure is given for a specific application. Torque values listed are
for general use only. Check tightness of fasteners periodically. Tighten plastic insert or crimped steel-type lock nuts to approximately
50 percent of the dry torque shown in the chart, applied to the nut,
Shear bolts are designed to fail under predetermined loads. Always not to the bolt head. Tighten toothed or serrated-type lock nuts to the
replace shear bolts with identical property class. full torque value.
OUT3035,TORQUE2 –19–22MAR06–1/1
TM11207 (11MAY09) 0003-1

051809
PN=21
Torque Values
0003 Additional Metric Cap Screw Torque Values

2
–UN–18OCT88
CAUTION: Use only metric tools on metric
hardware. Other tools may not fit properly. They
may slip and cause injury.
T6873AA
Check tightness of cap screws periodically. Torque values
listed are for general use only. Do not use these values if
a different torque value or tightening procedure is listed
for a specific application.
–UN–18OCT88
Shear bolts are designed to fail under predetermined
loads. Always replace shear bolts with identical grade.
Fasteners should be replaced with the same or higher
T6873AB
grade. If higher grade fasteners are used, these should
only be tightened to the strength of the original.
Make sure fastener threads are clean and you properly

start thread engagement. This will prevent them from
failing when tightening.
–UN–18OCT88
Tighten cap screws having lock nuts to approximately 50
percent of amount shown in chart.
T6873AC
Continued on next page 04T,90,M170 –19–29SEP99–1/2
TM11207 (11MAY09) 0003-2

051809
PN=22
Torque Values
METRIC CAP SCREW TORQUE VALUESa 0003

3
T-Bolt H-Bolt M-Bolt
Nominal
Dia N•m lb-ft N•m lb-ft N•m lb-ft
8 29 21 20 15 10 7
10 63 46 45 33 20 15
12 108 80 88 65 34 25
14 176 130 137 101 54 40
16 265 195 206 152 78 58
18 392 289 294 217 118 87
20 539 398 392 289 167 125
22 735 542 539 398 216 159
24 931 687 686 506 274 202
27 1372 1012 1029 759 392 289
30 1911 1410 1421 1049 539 398
33 2548 1890 1911 1410 735 542
36 3136 2314 2401 1772 931 687
a
Torque tolerance is ±10%.
04T,90,M170 –19–29SEP99–2/2
TM11207 (11MAY09) 0003-3

051809
PN=23
Torque Values
0003 Unified Inch Bolt and Cap Screw Torque Values

4
–UN–27SEP99
TORQ1A
Top—SAE Grade and Head Markings; Bottom—SAE Grade and Nut Markings
UNIFIED INCH BOLT AND CAP SCREW TORQUE VALUES—Tolerance is ±10% unless otherwise specified
Grade 1 (No Mark) Grade 2a (No Mark) Grade 5, 5.1 or 5.2 Grade 8 or 8.2
b c
Thread Lubricated Dry Lubricatedb Dryc Lubricatedb Dryc Lubricatedb Dryc
Size N•m (lb-ft) N•m (lb-ft) N•m (lb-ft) N•m (lb-ft) N•m (lb-ft) N•m (lb-ft) N•m (lb-ft) N•m (lb-ft)
1/4 3.8 (2.8) 4.7 (3.5) 6 (4.4) 7.5 (5.5) 9.5 (7) 12 (9) 13.5 (10) 17 (12.5)
5/16 7.7 (5.7) 9.8 (7.2) 12 (9) 15.5 (11.5) 19.5 (14.5) 25 (18.5) 28 (20.5) 35 (26)
3/8 13.5 (10) 17.5 (13) 22 (16) 27.5 (20) 35 (26) 44 (32.5) 49 (36) 63 (46)
7/16 22 (16) 28 (20.5) 35 (26) 44 (32.5) 56 (41) 70 (52) 80 (59) 100 (74)
1/2 34 (25) 42 (31) 53 (39) 67 (49) 85 (63) 110 (80) 120 (88) 155 (115)
9/16 48 (35.5) 60 (45) 76 (56) 95 (70) 125 (92) 155 (115) 175 (130) 220 (165)
5/8 67 (49) 85 (63) 105 (77) 135 (100) 170 (125) 215 (160) 240 (175) 305 (225)
3/4 120 (88) 150 (110) 190 (140) 240 (175) 300 (220) 380 (280) 425 (315) 540 (400)
7/8 190 (140) 240 (175) 190 (140) 240 (175) 490 (360) 615 (455) 690 (510) 870 (640)
1 285 (210) 360 (265) 285 (210) 360 (265) 730 (540) 920 (680) 1030 (760) 1300 (960)
1-1/8 400 (300) 510 (375) 400 (300) 510 (375) 910 (670) 1150 (850) 1450 (1075) 1850 (1350)
1-1/4 570 (420) 725 (535) 570 (420) 725 (535) 1280 (945) 1630 (1200) 2050 (1500) 2600 (1920)
1-3/8 750 (550) 950 (700) 750 (550) 950 (700) 1700 (1250) 2140 (1580) 2700 (2000) 3400 (2500)
1-1/2 990 (730) 1250 (930) 990 (730) 1250 (930) 2250 (1650) 2850 (2100) 3600 (2650) 4550 (3350)
a
Grade 2 applies for hex cap screws (not hex bolts) up to 6 in. (152 mm) long. Grade 1 applies for hex cap screws over 6 in. (152 mm) long,
and for all other types of bolts and screws of any length.
b
"Lubricated" means coated with a lubricant such as engine oil, or fasteners with phosphate and oil coatings.
c
"Dry" means plain or zinc plated without any lubrication.
DO NOT use these values if a different torque value or tightening Make sure fastener threads are clean and that you properly start
procedure is given for a specific application. Torque values listed are thread engagement. This will prevent them from failing when
for general use only. Check tightness of fasteners periodically. tightening.
Shear bolts are designed to fail under predetermined loads. Always Tighten plastic insert or crimped steel-type lock nuts to approximately
replace shear bolts with identical grade. 50 percent of the dry torque shown in the chart, applied to the nut,
not to the bolt head. Tighten toothed or serrated-type lock nuts to the
Fasteners should be replaced with the same or higher grade. If full torque value.
higher grade fasteners are used, these should only be tightened to
the strength of the original.
OUT3035,TORQUE1 –19–14JAN04–1/1
TM11207 (11MAY09) 0003-4

051809
PN=24
Torque Values
Service Recommendations for 37° Flare and 0003

5
30° Cone Seat Connectors
1. Inspect flare and flare seat. They must be free of dirt

or obvious defects.
–UN–18OCT88
2. Defects in tube flare cannot be repaired.
Overtightening a defective flared fitting will not stop
leaks.
T6234AC
3. Align tube with fitting before attempting to start nut.
4. Lubricate male threads with hydraulic fluid or petroleum

jelly.
5. Index angle fittings and tighten by hand.
6. Tighten fitting or nut to torque value shown on torque

chart. Do not allow hoses to twist when tightening
fittings.
STRAIGHT FITTING OR SPECIAL NUT TORQUE CHART

Thread Size N•m lb-ft
3/8 - 24 UNF 8 6
7/16 - 20 UNF 12 9
1/2 - 20 UNF 16 12
9/16 - 18 UNF 24 18
3/4 - 16 UNF 46 34
7/8 - 14 UNF 62 46
1-1/16 - 12 UN 102 75
1-3/16 - 12 UN 122 90
1-5/16 - 12 UN 142 105
1-5/8 - 12 190 140
1-7/8 - 12 UN 217 160
NOTE: Torque tolerance is ± 10%.
T82,BHMA,EL –19–29SEP99–1/1
TM11207 (11MAY09) 0003-5

051809
PN=25
Torque Values
0003 Service Recommendations for O-Ring Boss

6
Fittings
Straight Fitting
1. Inspect O-ring boss seat for dirt or defects.
–UN–18OCT88
2. Lubricate O-ring with petroleum jelly. Place electrical
tape over threads to protect O-ring. Slide O-ring over
tape and into O-ring groove of fitting. Remove tape.
T6243AE
3. Tighten fitting to torque value shown on chart.
Continued on next page 04T,90,K66 –19–29SEP99–1/2
TM11207 (11MAY09) 0003-6

051809
PN=26
Torque Values
Angle Fitting 0003

7
1. Back-off lock nut (A) and back-up washer (B)

completely to head-end (C) of fitting.
2. Turn fitting into threaded boss until back-up washer
–UN–18OCT88
contacts face of boss.
3. Turn fitting head-end counterclockwise to proper index

(maximum of one turn).
T6520AB
NOTE: Do not allow hoses to twist when tightening
fittings.
4. Hold fitting head-end with a wrench and tighten locknut

and back-up washer to proper torque value.
STRAIGHT FITTING OR SPECIAL NUT TORQUE CHART

3/8-24 UNF 8 6
7/16-20 UNF 12 9
1/2-20 UNF 16 12
9/16-18 UNF 24 18
3/4-16 UNF 46 34
7/8-14 UNF 62 46
1-1/16-12 UN 102 75
1-3/16-12 UN 122 90
1-5/16-12 UN 142 105
1-5/8-12 UN 190 140
1-7/8-12 UN 217 160
NOTE: Torque tolerance is ± 10%.
04T,90,K66 –19–29SEP99–2/2
TM11207 (11MAY09) 0003-7

051809
PN=27
Torque Values
0003 Service Recommendations For Flared

8
Connections—Straight or Tapered Threads
1. Inspect flare and flare seat. They must be free of dirt

or obvious defects.
–UN–18OCT88
2. Defects in the tube flare cannot be repaired.
Overtightening a defective flared fitting will not stop
leaks.
T6873AE
3. Align the tube with the fitting before attempting to start
the nut.
Straight Thread
4. Lubricate the male threads with hydraulic fluid or
petroleum jelly.
5. Index angle fittings and tighten by hand.
6. Tighten fitting or nut to torque value shown on the

–UN–18OCT88
fittings.
a
TORQUE CHART
T6873AD
b
Straight Thread Tapered Thread
Thread
Size N•m lb-ft N•m lb-ft Tapered Thread
1/8 15 11
1/4 20 15 45 33
3/8 29 21 69 51
1/2 49 36 93 69
3/4 69 51 176 130
1 157 116 343 253
1-1/2 196 145 539 398
2 255 188 588 434
a
Torque tolerance is ±10%.
b
With seat face.
NOTE: If female thread is cast iron (control valves, brake

valves motors, etc.), torque must be reduced
approximately 10%.
04T,90,M171 –19–28JAN92–1/1
TM11207 (11MAY09) 0003-8

051809
PN=28
Torque Values
Service Recommendations For Flat Face 0003

9
O-Ring Seal Fittings
1. Inspect the fitting sealing surfaces and O-ring. They

must be free of dirt or defects.
2. Lubricate O-rings and install into grove using petroleum

jelly to hold in place.
3. Index angle fittings and tighten by hand pressing joint

together to insure O-ring remains in place.
4. Tighten fitting or nut to torque value shown on the

fittings, use backup wrench on straight hose couplings.
IMPORTANT: Tighten fittings to 150% of listed torque

value if indexing is necessary or if
fitting is attached to an actuating
devise.
Tighten fittings to 50% of listed torque

value if used in aluminum housing.
FLAT FACE O-RING SEAL FITTING TORQUE*

Nomial Tube O.D. Thread Size Swivel Nut Bulkhead Nut
mm in. in. N•m lb-ft N•m lb-ft
6.35 0.250 9/16-18 16 12 12 9
9.52 0.375 11/16-16 24 18 24 18
12.70 0.500 13/16-16 50 37 46 34
15.88 0.625 1-14 69 51 62 46
19.05 0.750 1 3/16-12 102 75 102 75
22.22 0.875 1 3/16-12 102 75 102 75
25.40 1.000 1 7/16-12 142 105 142 105
31.75 1.250 1 11/16-12 190 140 190 140
38.10 1.500 2-12 217 160 217 160
*Torque tolerance is +15 -20% unless otherwise specified.
Continued on next page OUO6092,00010A4 –19–02JAN08–1/2
TM11207 (11MAY09) 0003-9

051809
PN=29
Torque Values
0003 Stud End O-ring Seal Torque for Straight and Adjustable Fittings*
10
Thread Size Straight Hex Size Locknut Hex Size Straight Fitting or Locknut Toque
Inch Inch Inch N•m lb-ft
3/8-24 5/8 9/16 12 9
7/16-20 5/8 5/8 21 15
1/2-20 3/4 11/16 26 19
9/16-18 3/4 3/4 34 25
3/4-16 7/8 15/16 73 55
7/8-14 1 1/16 1 1/16 104 76
1 1/16-12 1 1/4 1 3/8 176 130
1 3/16-12 1 3/8 1 1/2 230 170
1 5/16-12 1 1/2 1 5/8 285 210
*Torque tolerance is +15 -20% unless otherwise specified.
OUO6092,00010A4 –19–02JAN08–2/2
TM11207 (11MAY09) 0003-10

051809
PN=30
Torque Values
O-Ring Face Seal Fittings With SAE Inch Hex Nut And Stud End For High Pressure 0003
11
Service Recommendations
A B
C D
–UN–12DEC01
E
H F
F
H70406
E
A—90° Swivel Elbow and Tube C—Stud Straight and Tube Nut E—Stud End G—Swivel Nut
Nut D—Bulkhead Union and Nut F—Tube Nut H—Hex Nut
B—90° Adjustable Stud Elbow
O-RING FACE SEAL FITTINGS WITH SAE INCH HEX NUT AND STUD END FOR HIGH PRESSURE, ABOVE 27 600 kPa (276 bar) (4000
psi), TORQUE VALUES—Tolerance is +15 -20% unless otherwise specified
Nominal Tube OD or Hose ID O-Ring Face Seal Hose or Tube Swivel Nut Bulkhead Nut
Metric Tube Inch Tube OD or Hose ID Thread Size Hex Size Torque Hex Size Torque
OD
mm Dash Size mm (in.) in. in. Nm (lb-ft) in. Nm (lb-ft)
5 -3 4.78 (0.188) — — — — —
6 -4 6.35 (0.250) 9/16-18 11/16 24 (18) 13/16 32 (24)
8 -5 7.92 (0.312) — — — — —
10 -6 9.53 (0.375) 11/16-16 13/16 37 (27) 1 42 (31)
12 -8 12.70 (0.500) 13/16-16 15/16 75 (55) 1-1/8 93 (69)
16 -10 15.88 (0.625) 1-14 1-1/8 103 (76) 1-5/16 118 (87)
20 -12 19.05 (0.750) 1-3/16-12 1-3/8 152 (112) 1-1/2 175 (129)
22 -14 22.23 (0.875) 1-3/16-12 — 152 (112) — 175 (129)
25 -16 25.40 (1.000) 1-7/16-12 1-5/8 214 (158) 1-3/4 247 (182)
32 -20 31.75 (1.250) 1-11/16-12 1-7/8 286 (211) 2 328 (242)
38 -24 38.10 (1.500) 2-12 2-1/4 326 (240) 2-3/8 374 (276)
Continued on next page OUT3035,0000420 –19–04MAY09–1/2
TM11207 (11MAY09) 0003-11

051809
PN=31
Torque Values
0003 O-RING STRAIGHT, ADJUSTABLE, AND EXTERNAL HEX PLUG WITH SAE INCH STUD END FOR HIGH PRESSURE, ABOVE 27 600
12 kPa (276 bar) (4000 psi), TORQUE VALUES—Tolerance is +15 -20% unless otherwise specified
Thread Size Straight Hex Sizea Adjustable Nut Hex Size Steel or Gray Iron Torque
in. in. in. Nm (lb-ft)
3/8-24 5/8 9/16 18 (13)
7/16-20 5/8 5/8 24 (18)
1/2-20 3/4 11/16 30 (22)
9/16-18 3/4 3/4 37 (27)
3/4-16 7/8 15/16 75 (55)
7/8-14 1-1/16 1-1/16 103 (76)
1-1/16-12 1-1/4 1-3/8 177 (131)
1-3/16-12 1-3/8 1-1/2 231 (170)
1-5/16-12 1-1/2 1-5/8 270 (199)
1-5/8-12 1-3/4 1-7/8 286 (211)
1-7/8-12 2-1/8 2-1/8 326 (240)
a
Straight hex size applies to fittings only and may not be the same as the corresponding plug of the same thread size.
1. Inspect fitting and connector sealing surfaces and To protect an O-ring from threads, wrap electrical
the O-rings. They must be free of dirt, scratches, tape over the threads. Slide O-ring over the tape
nicks, and burrs. O-ring must be free of dirt, cuts, into the turned down section. Remove the tape.
cracks, swelling or flatten condition.
4. Turn fitting into the boss by hand until face of nut or
2. Back the stud end hex nut off as far as possible. washer squeezes the O-ring into the seat and
Push backup washer towards the nut to fully contacts face of boss. Loosen adjustable fittings no
expose the turn down section. Washer must fit more than one turn for alignment.
turned down section and not be too loose
Hold connections together while tightening nut to
3. Lubricate O-rings using a thin film of clean hydraulic ensure O-ring remains in place.
oil or as needed, petroleum jelly to hold O-ring in
place. 5. Tighten fitting or nut to torque value shown. Use a
second wrench to hold the fitting in position or to
Install O-ring into groove making sure it is seated at keep hose from twisting while tightening nut.
the bottom. Excess petroleum jelly will prevent
seating of O-ring and cause it to pop out.
OUT3035,0000420 –19–04MAY09–2/2
TM11207 (11MAY09) 0003-12

051809
PN=32
Torque Values
O-Ring Face Seal Fittings With Metric Hex Nut And Stud End For Standard Pressure 0003
13
Service Recommendations
1 2 3 4
10
–UN–18NOV03
7 9
11 8 11
6 6 5
10 11
T196337
10
8 8
T196337
1—90° Swivel Elbow 4—Bulkhead Union and Nut 7—Swivel Nut 10—O-Ring
2—90° Adjustable Stud Elbow 5—External Hex Stud End Plug 8—Stud End 11—Identification Groove
3—Stud Straight 6—Tube Nut 9—Hex Nut
O-RING FACE SEAL AND FITTINGS WITH METRIC HEX NUT AND STUD END FOR STANDARD PRESSURE, BELOW 27 600 kPa
(275.8 bar) (4,000 psi), TORQUE VALUES—Tolerance is +15 -20% unless otherwise specified
OD
mm Dash Size mm (in.) in. mm Nm (lb-ft) mm Nm (lb-ft)
4 -2 3.18 (0.125) — — — — —
5 -3 4.78 (0.188) — — — — —
6 -4 6.35 (0.250) 9/16-18 17 16 (12) 22 32 (24)
8 -5 7.92 (0.312) — — — — —
10 -6 9.53 (0.375) 11/16-16 22 24 (18) 27 42 (31)
12 -8 12.70 (0.500) 13/16-16 24 50 (37) 30 93 (69)
16 -10 15.88 (0.625 1-14 30 69 (51) 36 118 (87)
20 -12 19.05 (0.750) 1-3/16-12 36 102 (75) 41 175 (129)
22 -14 22.23 (0.875) 1-3/16-12 36 102 (75) 41 175 (129)
25 -16 25.40 (1.000) 1-7/16-12 41 142 (105) 46 247 (182)
28 — — — — — — —
32 -20 31.75 (1.250) 1-11/16-12 50 190 (140) 50 328 (242)
38 -24 38.10 (1.500) 2-12 60 217 (160) 60 374 (276)
50 -32 50.80 (2.000) — — — — —
TM11207 (11MAY09) 0003-13

051809
PN=33
Torque Values
0003 O-RING STRAIGHT, ADJUSTABLE, AND EXTERNAL HEX PLUG WITH METRIC STUD END FOR STANDARD PRESSURE, BELOW 27
14 600 kPa (275.8 bar) (4,000 psi), TORQUE VALUES—Tolerance is +15 -20% unless otherwise specified
Thread Sizea Straight Hex Sizeb Adjustable Nut Hex Steel or Gray Iron Torque Aluminum or Brass
Size Torque
mm. mm mm Nm (lb-ft) Nm (lb-ft)
M8 x 1 12 12 8 (6) 5 (4)
M10 x 1 14 14 15 (11) 10 (7)
M12 x 1.5 17 17 25 (18) 17 (12)
M14 x 1.5 19 19 40 (30) 27 (20)
M16 x 1.5 22 22 45 (33) 30 (22)
M18 x 1.5 24 24 50 (37) 33 (25)
M22 x 1.5 27 27 69 (51) 46 (34)
M27 x 2 32 32 100 (74) 67 (49)
M30 x 2 36 36 130 (96) 87 (64)
M33 x 2 41 41 160 (118) 107 (79)
M38 x 2 46 46 176 (130) 117 (87)
M42 x 2 50 50 210 (155) 140 (103)
M48 x 2 55 55 260 (192) 173 (128)
M60 x 2 65 65 315 (232) 210 (155)
a
Stud end threads are identified as metric by an identification groove in the hex nut next to the O-ring.
b
OUT3035,0000366 –19–04MAY09–2/2
TM11207 (11MAY09) 0003-14

051809
PN=34
Torque Values
O-Ring Face Seal Fittings With Metric Hex Nut And Stud End For High Pressure Service 0003
15
Recommendations
1 2 3 4
10
–UN–18NOV03
7 9
11 8 11
6 6 5
10 11
T196337
10
8 8
T196337
1—90° Swivel Elbow 4—Bulkhead Union and Nut 7—Swivel Nut 10—O-Ring
2—90° Adjustable Stud Elbow 5—External Hex Stud End Plug 8—Stud End 11—Identification Groove
3—Stud Straight 6—Tube Nut 9—Hex Nut
O-RING FACE SEAL FITTINGS WITH METRIC HEX NUT AND STUD END FOR HIGH PRESSURE, ABOVE 27 600 kPa (275.8 bar) (4,000
psi), TORQUE VALUES—Tolerance is +15 -20% unless otherwise specified
OD
mm Dash Size mm (in.) in. mm Nm (lb-ft) mm Nm (lb-ft)
4 -2 3.18 (0.125) — — — — —
5 -3 4.78 (0.188) — — — — —
6 -4 6.35 (0.250) 9/16-18 17 24 (18) 22 32 (24)
8 -5 7.92 (0.312) — — — — —
10 -6 9.53 (0.375) 11/16-16 22 37 (27) 27 42 (31)
12 -8 12.70 (0.500) 13/16-16 24 75 (55) 30 93 (69)
16 -10 15.88 (0.625) 1-14 30 103 (76) 36 118 (87)
20 -12 19.05 (0.750) 1-3/16-12 36 152 (112) 41 175 (129)
22 -14 22.23 (0.875) 1-3/16-12 36 152 (112) 41 175 (129)
25 -16 25.40 (1.000) 1-7/16-12 41 214 (158) 46 247 (182)
28 — — — — — — —
32 -20 31.75 (1.250) 1-11/16-12 — 286 (211) 50 328 (242)
38 -24 38.10 (1.500) 2-12 — 326 (240) 60 374 (276)
TM11207 (11MAY09) 0003-15

051809
PN=35
Torque Values
0003 O-RING STRAIGHT, ADJUSTABLE, AND EXTERNAL HEX PLUG WITH METRIC STUD END FOR HIGH PRESSURE, ABOVE 27 600
16 KPA (275.8 BAR) (4,000 PSI), TORQUE VALUES—Tolerance is +15 -20% unless otherwise specified
Thread Sizea Straight Hex Sizeb Adjustable Nut Hex Size Steel or Gray Iron Torque
mm. mm mm Nm (lb-ft)
M8 x 1 12 12 8 (6)
M10 x 1 14 14 15 (11)
M12 x 1.5 17 17 35 (26)
M14 x 1.5 19 19 45 (33)
M16 x 1.5 22 22 55 (41)
M18 x 1.5 24 24 70 (52)
M22 x 1.5 27 27 100 (74)
M27 x 2 32 32 170 (125)
M30 x 2 36 36 215 159)
M33 x 2 41 41 260 (192)
M38 x 2 46 46 320 (236)
M42 x 2 50 50 360 (266)
M48 x 2 55 55 420 (310)
a
Stud end threads are identified as metric by an identification groove in the hex nut next to the O-ring.
b
OUT3035,0000421 –19–04MAY09–2/2
TM11207 (11MAY09) 0003-16

051809
PN=36
Torque Values
Service Recommendations for Metric Series Four Bolt Flange Fitting 0003
17
–UN–01MAR90
T6890BB
A—Sealing Surface B—Split Flange C—Pinched O-Ring D—Single Piece Flange
1. Clean sealing surfaces (A). Inspect. Scratches then tighten the diagonally opposite cap screw.
cause leaks. Roughness causes seal wear. Tighten two remaining cap screws. Tighten all cap
Out-of-flat causes seal extrusion. If defects cannot screws as specified in the chart below.
be polished out, replace component.
DO NOT use air wrenches. DO NOT tighten one
2. Install the correct O-ring (and backup washer if cap screw fully before tightening the others. DO
required) into groove using petroleum jelly to hold it NOT over tighten.
in place.
TORQUE CHARTa
3. Split flange: Loosely assemble split flange (B) Thread b
N•m lb-ft
halves. Make sure split is centrally located and M6 12 9
perpendicular to the port. Hand tighten cap screws M8 30 22
to hold parts in place. Do not pinch O-ring (C).
M10 57 42
4. Single piece flange (D): Place hydraulic line in M12 95 70

center of flange and install four cap screws. Flange M14 157 116
must be centrally located on port. Hand tighten cap M16 217 160
screws to hold flange in place. Do not pinch O-ring. M18 334 246
M20 421 318
5. After components are properly positioned and cap a
Tolerance ± 10%. The torques given are enough for the given
screws are hand tightened, tighten one cap screw, size connection with the recommended working pressure.
Increasing cap screw torque beyond these amounts will result in
flange and cap screw bending and connection failures.
b
Metric standard thread.
04T,90,K175 –19–29SEP99–1/1
TM11207 (11MAY09) 0003-17

051809
PN=37
Torque Values
0003 Service Recommendations For Inch Series Four Bolt Flange Fittings
18
–UN–01MAR90
T6890BB
1. Clean sealing surfaces (A). Inspect. Scratches TORQUE CHART

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

cap screw fully before tightening the others. DO
NOT over tighten.
04T,90,K174 –19–01AUG94–1/1
TM11207 (11MAY09) 0003-18

051809
PN=38
Torque Values
Inch Series Four Bolt Flange Fitting For High Pressure Service Recommendations 0003
19
–UN–01MAR90
T6890BB
1. Clean sealing surfaces (A). Inspect. Scratches, 4. Tighten one cap screw and then the diagonally
nicks, and burrs cause leaks. Roughness causes opposite cap screw. Tighten the two remaining cap
O-ring wear. Out-of-flat causes O-ring extrusion. If screws. Tighten cap screws within the specified
imperfection cannot be polished out, replace torque values.
component.
INCH SERIES FOUR BOLT FLANGE FITTING FOR 41 400 kPa
2. Install the O-ring (and backup ring, if used) into (414 bar) (6000 psi) PRESSURE SERIES TORQUE VALUES—
Tolerance is ± 10% unless otherwise specified
groove. Use petroleum jelly to hold it in place.
Nominal Cap Screw Sizea Min—Max Torque
Flange Size
IMPORTANT: DO NOT use air wrenches. DO NOT
tighten one cap screw fully before in. in. Nm (lb-ft)b
tightening the others. DO NOT over 1/2 5/16-18 UNC 20—31 (15—23)
tighten. 3/4 3/8-16 UNC 34—54 (25—40)
1 7/16-14 UNC 57—85 (42—63)
3. Split flange: Loosely assemble split flange (B) 1-1/4 1/2-13 UNC 85—131 (63—97)
halves. Make sure split is centrally located and
1-1/2 5/8-11 UNC 159—264 (117—195)
perpendicular to port. Hand tighten cap screws to
hold flange halves and line in place. Do not pinch 2 3/4-10 UNC 271—468 (200—345)
a
O-ring (C). JDM A17D, SAE Grade 5 or better cap screws with plated
hardware.
Lock washers are permissible but not recommended.
Single piece flange (D): Make sure flange is
b
centrally located on port and line is centered in Minimum torques given are enough for the given size connection
with the recommended working pressure. Torques can be
flange. Install the cap screws. Hand tighten cap increased to the maximum shown for each cap screw size if
screws to hold flange and line in place. Do not desired. Increasing cap screw torque beyond the maximum will
pinch O-ring. result in flange and cap screw bending and connection failures.
OUT3035,0000422 –19–05MAR09–1/1
TM11207 (11MAY09) 0003-19

051809
PN=39
Torque Values
0003 Service Recommendations For

20
Non-Restricted Banjo (Adjustable) Fittings
1. Inspect all fitting sealing surfaces. They must be free of

dirt and defects.
2. Inspect O-ring (A). It must be free of damage or

defects.
3. Inspect sealing ring (B) for damage or defects.
4. Hold body in desired position while tightening stud by

hand.
–UN–06MAR98
5. Tighten stud (C) to torque value shown on the chart.
Do not allow body to twist when tightening stud.
NOTE: The L in the Tube Fitting OD Size column
T113948
indicates “light” designed fitting and the S
indicates “heavy” designed fitting.
Torque Value
Tube Fitting Metric Thread N•m lb-ft
O.D. Size
6L M 10 x 1 30 22
8L M 12 x 1.5 40 30
10 L M 14 x 1.5 60 44
12 L M 16 x 1.5 100 74
15 L M 18 x 1.5 130 96
18 L M 22 x 1.5 160 118
22 L M 26 x 1.5 250 184
28 L M 33 x 2 400 295
35 L M 42 x 2 600 443
42 L M48 x 2 800 590
6S M 12 x 1.5 40 30
8S M 14 x 1.5 60 44
10 S M 16 x 1.5 100 74
12 S M 18 x 1.5 130 96
14 S M 20 x 1.5 160 118
16 S M 22 x 1.5 160 118
20 S M 27 x 2 250 184
25 S M 33 x 2 400 295
30 S M 42 x 2 600 443
38 S M 48 x 2 800 590
Continued on next page CED,OUO1002,562 –19–09MAR98–1/2
TM11207 (11MAY09) 0003-20

051809
PN=40
Torque Values
Torque Value 0003

21
Tube Fitting Inch Size N•m lb-ft
O.D. Size
6L 1/8 25 18
8L 1/4 50 37
10 L 1/4 50 37
12 L 3/8 90 66
15 L 1/2 130 96
18 L 1/2 150 111
22 L 3/4 250 184
28 L 1 400 295
35 L 1-1/4 600 443
42 L 1-1/2 800 590
6S 1/4 50 37
8S 1/4 50 37
10 S 3/8 90 66
12 S 3/8 100 74
14 S 1/2 130 96
16 S 1/2 150 111
20 S 3/4 250 184
25 S 1 400 295
30 S 1-1/4 600 443
38 S 1-1/2 800 590
CED,OUO1002,562 –19–09MAR98–2/2
TM11207 (11MAY09) 0003-21

051809
PN=41
Torque Values
0003 Service Recommendations For O-Ring Boss

22
Fittings With Shoulder
1. Inspect component seal boss seat for dirt or defects.
2. Inspect EOlastic seal (A) for damage. Replace seal or
–UN–06MAR98
fitting as necessary.
To replace seal, put electrical tape over threads to

protect seal. Slide seal over tape and into seal groove
T113957
of fitting. Remove tape.
3. Tighten fitting to torque value shown on chart.
IMPORTANT: Do not allow hoses to twist when

tightening fittings.
NOTE: The L in the Tube Fitting OD Size column

indicates “light” designed fitting and the S
indicates “heavy” designed fitting.
Torque Value
Tube Fitting Metric Thread N•m lb-ft
O.D. Size
6L M 10 x 1 20 15
8L M 12 x 1.5 30 22
10 L M 14 x 1.5 45 33
12 L M 16 x 1.5 60 44
15 L M 18 x 1.5 80 59
18 L M 22 x 1.5 130 96
22 L M 26 x 1.5 190 140
28 L M 33 x 2 300 221
35 L M 42 x 2 600 443
42 L M48 x 2 800 590
6S M 12 x 1.5 40 30
8S M 14 x 1.5 60 44
10 S M 16 x 1.5 80 59
12 S M 18 x 1.5 110 81
14 S M 20 x 1.5 140 103
16 S M 22 x 1.5 170 125
20 S M 27 x 2 250 184
25 S M 33 x 2 450 332
30 S M 42 x 2 600 443
38 S M 48 x 2 800 590
TM11207 (11MAY09) 0003-22

051809
PN=42
Torque Values
Torque Value 0003

23
Tube Fitting Inch Size N•m lb-ft
O.D. Size
6L 1/8 20 15
8L 1/4 40 30
10 L 1/4 40 30
12 L 3/8 80 59
15 L 1/2 140 103
18 L 1/2 100 74
22 L 3/4 180 133
28 L 1 300 221
35 L 1-1/4 600 443
42 L 1-1/2 800 590
6S 1/4 50 37
8S 1/4 50 37
10 S 3/8 90 66
12 S 3/8 90 66
14 S 1/2 160 118
16 S 1/2 140 103
20 S 3/4 250 184
25 S 1 400 295
30 S 1-1/4 650 479
38 S 1-1/2 800 590
TM11207 (11MAY09) 0003-23

051809
PN=43
Torque Values
0003 Hex Socket Head Plugs Only

24
Torque Value
M 10 x 1 13 10
M 12 x 1.5 30 22
M 14 x 1.5 40 30
M 16 x 1.5 60 44
M 18 x 1.5 70 52
M 20 x 1.5 90 66
M 22 x 1.5 100 74
M 26 x 1.5 120 89
M 27 x 2 150 111
M 33 x 2 250 184
M 42 x 2 400 295
M 48 x 2 500 369
1/8 15 11
1/4 33 24
3/8 70 52
1/2 90 66
3/4 150 111
1 220 162
1-1/4 600 443
1-1/2 800 590
CED,OUO1002,563 –19–09MAR98–3/3
TM11207 (11MAY09) 0003-24

051809
PN=44
Torque Values
Metric 24° O-Ring Seal DIN 20078 Service 0003

25
Recommendations
METRIC 24° O-RING SEAL DIN 20078 TORQUE VALUES
Fitting Heavy Fitting Light Fitting Torque
Tube OD Size Size
Size
mm mm mm Turns
6 — M12 x 1.5 Hand tighten so
O-ring contacts
seat plus an
additional 1/4—1/3
turn using a
wrench
8 M16 x 1.5 M14 x 1.5
10 M18 x 1.5 M16 x 1.5
12 M20 x 1.5 M18 x 1.5
14 M22 x 1.5 —
15 — M22 x 1.5
16 M24 x 1.5 —
18 — M26 x 1.5
20 M30 x 2 —
22 — M30 x 2
25 M36 x 2 —
28 — M36 x 2
30 M42 x 2 —
–UN–06MAR98
35 — M45 x 2
38 M52 x 2 —
NOTE: These fittings are also referred to as EO and
T113889
EO-2 Bite Type or Ermeto style fittings.
IMPORTANT: In this style of fittings, there are

“heavy” and “light” designs. Usually
“heavy” is used for pressure lines and
“light” for return lines.
Some “heavy” and “light” sizes can be

threaded together but do not seal
properly. Be sure not to mix “heavy”
and “light” fittings.
1. Inspect the fitting sealing surfaces. They must be free

of dirt scratches, nicks, and burrs.
Continued on next page CED,OUO1002,517 –19–14JAN04–1/2
TM11207 (11MAY09) 0003-25

051809
PN=45
Torque Values
0003 2. Inspect the O-ring. It must be free dirt, cuts, cracks,

26
swelling or flatten condition.
3. Lubricate O-rings using a thin film of clean hydraulic

oil.
4. Align an adjustable fitting with the tube.

ensure proper seal.
5. Tighten nut (A) hand tight so O-ring contacts seat and

then an additional 1/4—1/3 turn using a wrench.
CED,OUO1002,517 –19–14JAN04–2/2
TM11207 (11MAY09) 0003-26

051809
PN=46
Section 01
Wheels
Contents 01
Page
Group 0110—Powered Wheels and Fasteners

Wheel Remove and Install . . . . . . . . . . . . . .01-0110-1
Tire Remove and Install . . . . . . . . . . . . . . . .01-0110-2
TM11207 (11MAY09) 01-1 770GP, 772G, and 772GP Motor Grader Repair Manual
770G,
051809
PN=1
Contents
01
770G,
051809
PN=2
Group 0110
Powered Wheels and Fasteners
Wheel Remove and Install
CAUTION: Prevent crushing injury from heavy

component. Use appropriate lifting device when
lifting component. 01
0110
1
1. Raise machine and place appropriate shop stand
under axle. For machine weight see Machine
Specifications. (Operator’s Manual.)
2. Place wheel lift under wheel. Fasten safety chain

around upper part of tire.
MM16284,0000D40 –19–21JAN09–1/2
3. Remove cap screws and washers (1) to remove wheel.
4. Clean the threads of cap screws, the mating surfaces

on washers, rim, and axle flange. Apply a drop of oil to
cap screw threads after cleaning with solvent.
5. Clean mounting surface on wheel and axle flange.

Install wheel. Install cap screws. Cross tighten cap
screws to specifications.
Specification
Wheel Cap Screw—Torque.......................................................... 495 N•m
365 lb-ft
–UN–23JAN09
1—Cap Screw and Washer (14 used)
2—Valve Stem
TX1054816A
Wheel Remove and Install
MM16284,0000D40 –19–21JAN09–2/2
TM11207 (11MAY09) 01-0110-1

051809
PN=49
Tire Remove and Install

01 lifting component.
0110
2
1. Raise machine and place appropriate shop stand
under axle. For machine weight see Machine
Continued on next page JW00603,00000E6 –19–20JAN09–1/3
TM11207 (11MAY09) 01-0110-2

051809
PN=50
01
0110
–UN–21JUL97
3
T110424
Rim Assembly (Split and One-Piece Rims Shown)
1—Valve Stem 3—Washer 5—Wheel Ring 7—Split Ring

2—Wheel Rim 4—Cap Screw 6—O-Ring
Maintenance Manual to remove the tire from the

CAUTION: Explosive separation of a tire and
wheel.
rim parts can cause serious injury or death.
3. Always completely deflate the tire by removing the
Always maintain the correct tire pressure.
valve core from the valve stem (1) before
Do not inflate the tires above the
attempting any demounting operation. Check the
recommended pressure.
valve stem by running a probe through it to make
sure the valve stem is not plugged.
Inspect tires and wheels daily. DO NOT
operate with low pressure, cuts, bubbles,
4. Inspect all parts for damage; replace parts as
damaged rims, or missing lug bolts and
necessary.
nuts.
5. To prevent slipping of the rim under load, the inside
Never weld or heat a wheel and tire
and outside must be free of paint, rust, oil, grease,
assembly. The heat can cause an increase in
dirt or other foreign material before installation.
air pressure resulting in a tire explosion.
Welding can structurally weaken or deform
6. Install valve stem in rim base (2) and tighten valve
the wheel.
core housing finger tight.
When inflating tires, use a clip-on chuck and
extension hose long enough to allow you to CAUTION: Serious bodily injury can occur
stand to one side and NOT in front of or from explosion when mounting and inflating
over the tire assembly. Use a safety cage if tires if safe procedures are NOT followed.
available.
7. Apply soap lubricant to bead of tire, bead seat on
Do not attempt to mount a tire unless you rim and O-ring (6) (on split rim).
have the proper equipment and experience
to perform the job. Have it done by your 8. Before adding air to tire, make sure the back ring
authorized repair service. (5) fits tight against the base all around the
circumference.
2. The tire can be removed without removing the
wheel from the machine. See the Off-The-Road Tire 9. Clear area of all persons.
Continued on next page JW00603,00000E6 –19–20JAN09–2/3
TM11207 (11MAY09) 01-0110-3

051809
PN=51
IMPORTANT: Use a pressure regulating valve with 12. Adjust tire pressure to recommended pressure.
clip-on chuck and extension hose Use only recommended air pressure. Pressure
long enough to allow you to stand to over the limit can cause an explosion. For
one side and NOT in front of or over recommended pressure see Checking Tire
top of tire while inflating. Pressure. (Operator’s Manual.)
01
0110
4 10. Turn wheel so valve stem is pointing down.
11. Inflate tire to specified pressure to seat tire bead

on the rim.
Specification
Air Pressure to Seat Tire on
Rim—Pressure (Bias Ply) ....................................................... 379 kPa
55 psi
Pressure (Radial) .................................................................... 386 kPa
65 psi
JW00603,00000E6 –19–20JAN09–3/3
TM11207 (11MAY09) 01-0110-4

051809
PN=52
Section 02
Axles and Suspension Systems
Contents
Page Page
Tandem Wheel Axle Assembly Disassemble

Group 0225—Input Drive Shafts and U-Joints and Assemble . . . . . . . . . . . . . . . . . . . . .02-0250-12 02
Transmission-to-Rear Axle Drive Shaft Tandem Pivot Disassemble and
Remove and Install . . . . . . . . . . . . . . . . . .02-0225-1 Assemble. . . . . . . . . . . . . . . . . . . . . . . . .02-0250-18
Transmission-to-Rear Axle Drive Shaft Final Drive Axle Remove and Install . . . . . .02-0250-22
Disassemble and Assemble. . . . . . . . . . . .02-0225-2 Final Drive Axle Disassemble and
Assemble. . . . . . . . . . . . . . . . . . . . . . . . .02-0250-29
Group 0230—Non-Powered Wheel Axles Brake Component Remove and Install . . . .02-0250-33
Front Wheel Hub and Spindle Remove Planet Pinion Carrier Remove and
and Install—Non 6WD . . . . . . . . . . . . . . . .02-0230-1 Install. . . . . . . . . . . . . . . . . . . . . . . . . . . .02-0250-34
Front Wheel Hub and Spindle Tandem Drive Shaft Remove and Install . . .02-0250-36
Disassemble and Assemble—Non Drive Chain Remove and Install . . . . . . . . .02-0250-41
6WD . . . . . . . . . . . . . . . . . . . . . . . . . . . . .02-0230-4
Front Axle Remove and Install—Non Group 0260—Hydraulic System
6WD . . . . . . . . . . . . . . . . . . . . . . . . . . . . .02-0230-7 6WD Pump Remove and Install . . . . . . . . . .02-0260-1
6WD Pump Disassemble. . . . . . . . . . . . . . . .02-0260-4
6WD Pump Assemble . . . . . . . . . . . . . . . . .02-0260-22
Group 0240—Powered Wheel Axles 6WD Charge Pump Remove and Install . . .02-0260-42
Front Wheel Hub and Spindle Remove and 6WD Engagement Manifold Remove and
Install—6WD . . . . . . . . . . . . . . . . . . . . . . .02-0240-1 Install. . . . . . . . . . . . . . . . . . . . . . . . . . . .02-0260-42
Front Wheel Hub and Spindle Differential Lock Pump Remove and
Disassemble and Assemble—6WD . . . . . .02-0240-5 Install. . . . . . . . . . . . . . . . . . . . . . . . . . . .02-0260-45
Front Wheel Hub and Spindle 6WD Motor Remove and Install. . . . . . . . . .02-0260-46
Disassemble and Assemble with 6WD Motor Disassemble and Assemble . . .02-0260-48
Steering Angle Sensor—6WD . . . . . . . . .02-0240-11
6WD Drive Hub Disassemble and
Assemble. . . . . . . . . . . . . . . . . . . . . . . . .02-0240-18
Planetary Drive Disassemble and
Assemble. . . . . . . . . . . . . . . . . . . . . . . . .02-0240-20
Planetary Brake Disassemble and
Assemble. . . . . . . . . . . . . . . . . . . . . . . . .02-0240-24
6WD Bearings Remove and Install . . . . . . .02-0240-29
6WD O-Ring Metal Face Seal Remove
and Install . . . . . . . . . . . . . . . . . . . . . . . .02-0240-34
Front Axle Remove and Install—6WD . . . . .02-0240-42
Group 0250—Axle Shafts, Bearings, and Reduction

Gears
TEAMMATE II 1400 Series Inboard
Planetary Axle—Use CTM43 . . . . . . . . . . .02-0250-1
Rear Axle Remove and Install . . . . . . . . . . . .02-0250-1
Rear Axle Disassemble and Assemble . . . . .02-0250-6
Tandem and Wheel Axle Assembly Remove
and Install . . . . . . . . . . . . . . . . . . . . . . . . .02-0250-7
Tandem Wheel Axle Assembly Remove
and Install . . . . . . . . . . . . . . . . . . . . . . . .02-0250-10
770G,
051809
PN=1
Contents
02
770G,
051809
PN=2
Group 0225
Input Drive Shafts and U-Joints
Transmission-to-Rear Axle Drive Shaft Remove and Install
02
0225
1
–UN–01MAY09
TX1058978
Transmission-to-Rear Axle Drive Shaft
1—Cap Screw (4 used) 3—Drive Shaft Assembly 4—Transmission Yoke 5—Cap Screw (4 used)
2—Axle Yoke
NOTE: Universal joints are “Lube for Life” and are not
CAUTION: When drive shaft assembly is
serviceable or repairable. Replace if worn.
removed, park brake is inoperative. Chock
wheels to prevent unexpected machine
5. Clean and inspect parts. Replace parts as
movement.
necessary. See Transmission-to-Rear Axle Drive
Shaft Disassemble and Assemble. (Group 0225.)
1. Park machine on flat level surface and lower all
attachments to ground.
6. Install drive shaft and cap screws. Tighten cap
screws to specification.
2. Loosen cap screws (1 and 5). Do not remove.
Specification
3. Remove cap screws (1) and push transmission Transmission-to-Rear Axle
yoke (4) into transmission as far as possible. Drive Shaft Cap Screw—
Torque.................................................................................... 111 N•m
4. Remove cap screws (5) and remove drive shaft 82 lb-ft
assembly (3).
MM16284,0000DAF –19–11MAR09–1/1
TM11207 (11MAY09) 02-0225-1

051809
PN=55
Input Drive Shafts and U-Joints
Transmission-to-Rear Axle Drive Shaft

Disassemble and Assemble
1. Remove drive shaft. See Transmission-to-Rear Axle

Drive Shaft Remove and Install. (Group 0225.)
02
0225
2 JW00603,0000109 –19–21JAN09–1/2
2. Remove cap screws (1) and separate cross and

bearing assemblies (2) from coupling (3).
NOTE: Cross and bearing assemblies are “Lube for Life.”

They are not repairable and do not require
periodic service. Replace if worn or rough in
operation.
3. Clean and inspect parts. Replace parts as necessary.
–UN–30APR09
4. Position cross and bearing assemblies on coupling and
install cap screws. Tighten cap screws to specification.
Specification
TX1058979
Transmission-to-Rear Axle Drive
Shaft Cap Screw—Torque ........................................................... 111 N•m
82 lb-ft
Rear Axle Drive Shaft
5. Install drive shaft. See Transmission-to-Rear Axle Drive
Shaft Remove and Install. (Group 0225.) 1—Cap Screw (8 used)
2—Cross and Bearing Assembly (2 used)
3—Coupling
4—Drive Shaft Assembly
JW00603,0000109 –19–21JAN09–2/2
TM11207 (11MAY09) 02-0225-2

051809
PN=56
Group 0230
Non-Powered Wheel Axles
Front Wheel Hub and Spindle Remove and
Install—Non 6WD

CAUTION: Prevent possible crushing injury

from unexpected machine movement. Install
articulation lock pin when machine is raised or
when working in articulation joint area. 02
0230
2. Install articulation lock pin. See Locking Machine 1
Frame. (Operator’s Manual.)
3. Raise front of machine and install appropriate shop

stands. For machine weight see Machine
4. Remove front wheel. See Wheel Remove and Install.

(Group 0110.)
JW00603,00000F7 –19–05MAY09–1/5

from heavy component. Use appropriate lifting
device.
5. Support wheel hub, spindle, and yoke assembly.
Specification
Wheel Hub, Spindle, and Yoke—
Weight (approximate) ...................................................................... 125 kg
275 lb
29—Support Strap
30—Lean Angle Linkage Assembly
–UN–27MAR09
31—Front Wheel Hub, Spindle, and Yoke

TX1057507A
Support Wheel Hub, Spindle, and Yoke
Continued on next page JW00603,00000F7 –19–05MAY09–2/5
TM11207 (11MAY09) 02-0230-1

051809
PN=57
6. Remove cotter pin (27) and nut (28) from front axle
upper tie rod end (24) and steering cylinder tie rod end
(25).
7. Remove front axle upper tie rod end and steering

cylinder tie rod end. 24
3—Yoke
8—Wheel Hub
3
24—Upper Tie Rod End
02 25—Steering Cylinder Tie Rod End
27
0230 26—Steering Cylinder Rod
2 27—Cotter Pin (2 used) 8
28—Nut (2 used) 28
–UN–26MAR09
26 25
TX1057434
TX1057434
Front Tie Rod Ends
TM11207 (11MAY09) 02-0230-2

051809
PN=58
13
B37
11
14 12
10
15 16
17
02
18 0230
9
3
19
20
–UN–23MAR09
7
8
TX1057404
4
6 5
TX1057404
Wheel Hub, Spindle, and Yoke—Non 6WD (right side shown)
1—Yoke Pin Cap Screw 7—Spindle 12—Lean Bar Linkage Retainer 17—Seal
2—Yoke Pin 8—Wheel Hub 13—Steering Angle Sensor 18—Upper King Pin
3—Yoke 9—Upper King Pin Assembly Cap Screw (2 used) 19—Steering Angle Sensor
4—Lower King Pin Assembly with Steering Angle Sensor 14—Snap Ring Locating Pin
5—Lower King Pin Cap Screw 10—Lean Bar Linkage Cap 15—Spacer Plate Cap Screw (2 20—Bearing Assembly
(8 used) Screw (6 used) used) B37—Steering Angle Sensor
6—Threaded Hole (2 used) 11—Lean Bar Linkage Pin 16—Spacer Plate
8. Remove lower king pin cap screws (5). 11. Remove upper king pin (18) and bearing assembly
(20) using appropriate puller.
9. Insert cap screw into threaded hole (6) on opposite
sides of king pin assembly (4) to remove king pin. 12. Remove steering angle sensor locating pin (19).
10. Remove steering angle sensor (B37) (right side 13. Remove wheel hub (8) and spindle (7) assembly
only). See Steering Angle Sensor Remove and from yoke (3).
Install. (Group 9015-20.)
TM11207 (11MAY09) 02-0230-3

051809
PN=59
14. Clean, inspect and replace parts as necessary. 19. Install lower king pin assembly.
15. Install wheel hub and spindle assembly into yoke. 20. Install front wheel. See Wheel Remove and Install.
(Group 0110.)
16. Install steering angle sensor locating pin.
21. Remove shop stand and lower machine.
17. Install upper king pin and bearing assembly.
22. Remove articulation lock pin. See Locking
18. Install steering angle sensor. See Steering Angle Machine Frame. (Operator’s Manual.)
Sensor Remove and Install. (Group 9015-20.)
02
0230
4 JW00603,00000F7 –19–05MAY09–5/5
Front Wheel Hub and Spindle Disassemble

and Assemble—Non 6WD


when working in articulation joint area.
2. Install articulation lock pin. See Locking Machine



(Group 0110.)
Continued on next page JW00603,000010A –19–21JAN09–1/3
TM11207 (11MAY09) 02-0230-4

051809
PN=60
B37 27
26
25
24
23
22
02
0230
5
21
20
5
7
4
19
14
13
12 18
6 8 9 11
1 2 3 17
10
–UN–25MAR09
16
TX1057433
15
TX1057433
Wheel Hub and Spindle
1—Cap Screw (3 used) 9—Bearing Cup 16—Lower King Pin 23—Seal

2—Lock Washer (3 used) 10—Hub 17—Shim 24—Spacer
3—Cap 11—Bearing Cup 18—Bearing Assembly 25—Cap Screw (2 used)
4—Gasket 12—Bearing 19—Spindle 26—Snap Ring
5—Cotter Pin 13—Grease Seal 20—Bearing Assembly 27—Steering Angle Sensor
6—Nut 14—Oil Cup 21—Steering Angle Sensor Pin Cap Screw (2 used)
7—Washer 15—Lower King Pin Cap 22—Upper King Pin B37—Steering Angle Sensor
8—Bearing Screw (8 used)
5. Remove cap screws (1) and lock washers (2) to 7. Remove bearing (8).
remove cap (3) and gasket (4).
6. Remove cotter pin (5), nut (6), and washer (7).
TM11207 (11MAY09) 02-0230-5

051809
PN=61
17. Grease bearing (12) and install on spindle.

from heavy component. Use appropriate
lifting device. CAUTION: Prevent possible crushing injury
NOTE: Bearing cup (9 and 11) will stay in hub when lifting device.
bearing is removed.
18. Install hub on spindle.
8. Remove hub (10).
Specification
Specification Front Wheel Hub—Weight.......................................................... 54 kg
02 Front Wheel Hub—Weight.......................................................... 54 kg 117 lb
0230 117 lb
6
19. Grease bearing (8) and install.
9. Press bearing cups from hub.
20. Install washer and nut.
10. Remove bearing (12), grease seal (13), and oil
cup (14). 21. Rotate hub while tightening nut. Tighten nut to
specification.
11. Remove spindle (19). See Front Wheel Hub and
Spindle Remove and Install—Non 6WD to remove Specification
king pin assemblies. (Group 0230.) Hub Nut—Torque..................................................................... 95 N•m
70 lb-ft
12. Clean, inspect and replace parts as necessary.

22. Back off nut to install cotter pin.
13. Install spindle. See Front Wheel Hub and Spindle
23. Install gasket, cap, cap screws and lock washers.
Remove and Install—Non 6WD to install king pin
assemblies. (Group 0230.)
24. Install front wheel. See Wheel Remove and Install.
(Group 0110.)
14. Press bearing cups into spindle.
15. Install oil seal on spindle.
16. Fill lip of grease seal with PT507 Multi-Purpose

Grease and install on spindle.
JW00603,000010A –19–21JAN09–3/3
TM11207 (11MAY09) 02-0230-6

051809
PN=62
Front Axle Remove and Install—Non 6WD
1. If equipped, remove push block, scarifier or front

attachment. See Scarifier Remove and Install. (Group
4240.)

02
0230

4. Remove front wheels. See Wheel Remove and Install.

(Group 0110.)
CAUTION: To avoid injury from escaping fluid

under pressure, stop engine and relieve the
pressure in the system before disconnecting or
connecting hydraulic or other lines. Tighten all
connections before applying pressure.
5. To release pressure in the system, slowly loosen

fittings on hoses at cylinders.
Continued on next page JW00603,000010B –19–14MAY09–1/4
TM11207 (11MAY09) 02-0230-7

051809
PN=63
IMPORTANT: Hose routing is critical. To avoid

chaffing mark location and routing of
each hose.
6. Attach identification tags on hydraulic oil hoses.

1
7 2
7. Disconnect hoses (1—3 and 5—7). Cap and plug all
6 3
openings.

02
0230 from heavy component. Use appropriate lifting
8 device.
–UN–01APR09
8. Support axle with appropriate lifting device.
Specification
Front Axle Assembly—Weight 5
4
TX1057565
(approximate)................................................................................... 542 kg
1194 lb
Front Axle Hoses
1—Pressure Hose-to-Left Steering Cylinder

2—Left Steering Cylinder Head End-to-Right
Steering Cylinder Rod End Hose
3—Wheel Lean Cylinder Head End
4—Axle
5—Wheel Lean Cylinder Rod End
6—Right Steering Cylinder Head End-to-Left
7—Pressure Hose-to-Right Steering Cylinder
TM11207 (11MAY09) 02-0230-8

051809
PN=64
9. Disconnect steering angle sensor harness (W24) from

steering angle sensor (B37). Also remove cap screws
(8) and clamps (9).
B37
4—Axle
8—Cap Screw (4 used)
9—Clamp (4 used)
B37—Steering Angle Sensor
W24—Steering Angle Sensor Harness
W24
02
0230
9
–UN–30APR09
9 4
8
TX1057596
Steering Angle Sensor Wire Connector
TM11207 (11MAY09) 02-0230-9

051809
PN=65
10. Remove axle pin cap screw (10). Remove axle pin
(11) taking notice of location and quantity of washers.
11. Inspect, repair or replace parts as necessary.
12. Install axle pin and washers as needed. Axle must be

free to pivot in the main frame without binding.
13. Install axle pin cap screw.
02 14. Connect steering angle sensor harness to sensor.

0230 Install cap screws and clamps to secure wire. 10
10
–UN–01MAY09
IMPORTANT: Hose routing is critical. Route hoses as
noted earlier to prevent chaffing of
hose. 11 5
TX1057597
15. Connect hoses to steering cylinders and lean cylinder.
TX1057597
16. Install front wheels. See Wheel Remove and Install.
Axle Pin
(Group 0110.)
4—Axle
17. Remove shop stands and lower machine. 10—Axle Pin Cap Screw
11—Axle Pin
18. Remove articulation lock pin. See Locking Machine
19. If equipped, install push block, scarifier or front

attachment. See Scarifier Remove and Install. (Group
4240.)
20. Check hydraulic oil level. See Checking Hydraulic

Tank Oil Level. (Operator’s Manual.)
JW00603,000010B –19–14MAY09–4/4
TM11207 (11MAY09) 02-0230-10

051809
PN=66
Group 0240
Powered Wheel Axles
Front Wheel Hub and Spindle Remove and
Install—6WD


0240


(Group 0110.)
TM11207 (11MAY09) 02-0240-1

051809
PN=67
Powered Wheel Axles
CAUTION: Prevent possible injury from

crushing. Use appropriate lifting device.
NOTE: If servicing left side, wheel lean cylinder must be

disconnected from spindle. See Wheel Lean
Cylinder Remove and Install. (Group 0960.)
5. Support wheel hub, spindle, and yoke assembly (3).
Specification
02 Front Wheel Hub, Spindle and
0240 Yoke—Weight (approximate) .......................................................... 390 kg
2 860 lb
1—Support Strap
2—Lean Angle Linkage Assembly
3—Front Wheel Hub, Spindle, and Yoke
–UN–19MAR09
TX1057244A
Support Wheel Hub, Spindle, and Yoke Assembly
TM11207 (11MAY09) 02-0240-2

051809
PN=68
Powered Wheel Axles
6. Remove cap screws (7) and front hose guard (6) from
wheel assembly.
7. Remove cap screws (5) and hose guard (4) from axle.
4—Hose Guard
6—Hose Guard Wheel Assembly
02
0240
3
–UN–22APR09
TX1058601A
Hose Guards
JW00603,00000F8 –19–14MAY09–3/6
NOTE: Right side is shown, left side is the same unless

noted.
8. Attach identification tags and remove hoses (12—16).

Cap and plug all openings.
9. Remove tie rod end nuts (9), cotter pins (10), and tie
rod ends (8 and 11).
8—Wheel Lean Linkage Tie Rod End

9—Tie Rod End Nut
10—Cotter Pin
11—Steering Cylinder Tie Rod End
–UN–22APR09
12—Right Motor Drain Hose

13—Right Reverse Pressure Hose
14—Right Forward Pressure Hose
15—Flushing Valve Pressure Hose
16—Right Brake Hose
TX1058602A
Tie Rod Ends and 6WD Hoses (right side shown)
TM11207 (11MAY09) 02-0240-3

051809
PN=69
Powered Wheel Axles
10. Disconnect wheel speed sensor harness (W18) and

wheel lean solenoid (Y79).
11. Remove spindle yoke pin grease hoses (19).
12. Remove wire clip (20) and disconnect steering angle

sensor harness (W24) (right side only).
13. Remove wheel lean linkage retainers (21). Lift wheel

lean leakage up and support out of way.
–UN–22APR09
02
0240 14. Remove spindle yoke pin cap screw (18). Remove
4
spindle yoke pin (17).
TX1058603A
15. Remove wheel hub, spindle and yoke assembly.
16. Clean and inspect. Repair or replace parts as Wire Connectors and Spindle Yoke Pin
necessary. See Front Wheel Hub and Spindle
Disassemble and Assemble—6WD. (Group 0240.)
17. Position wheel hub, spindle , and yoke into axle.
18. Install spindle yoke pin cap screw. Tighten to

specification.
Specification
Spindle Yoke Pin Cap Screw—
Torque .......................................................................................... 140 N•m
130 lb.-ft.
19. Install wheel lean linkage and retainers. Tighten cap

–UN–22APR09
Specification
Wheel Lean Linkage Retainer
Cap Screw—Torque ..................................................................... 133 N•m
TX1058620A
98 lb.-ft.
20. Install yoke pin grease hoses.

Wheel Lean Linkage and Grease Hoses
21. Connect steering angle sensor wire harness and wire
clips. 17—Spindle Yoke Pin
18—Cap Screw
19—Spindle Yoke Pin Grease Hose (2 used)
22. Connect wheel speed sensor harness and wheel lean 20—Wire Clip (3 used)
sensor. 21—Wheel Lean Linkage Retainer (2 used)
W18—Wheel Speed Sensor Harness
23. Install 6WD motor hoses. W24—Steering Angle Sensor Harness
Y79—Wheel Lean Solenoid
TM11207 (11MAY09) 02-0240-4

051809
PN=70
Powered Wheel Axles
24. Install both tie rod ends. Tighten nut to specification.

If cotter pin hole does not line up, tighten nut to first
available hole.
Specification
Steering Cylinder and Wheel
Lean Linkage Tie Rod Nut—
Torque .......................................................................................... 170 N•m
125 lb.-ft.

(Group 0110.) 02
0240
5
26. Lower machine to ground and remove articulation pin.
27. Run machine to check for leaks.

JW00603,00000F8 –19–14MAY09–6/6

and Assemble—6WD
NOTE: The following procedure must be performed with

front wheel hub, spindle, and yoke removed from
machine and wheel hub face set flat on work
surface.
1. See Front Wheel Hub and Spindle Remove and

Install—6WD. (Group 0240.)
Continued on next page MM16284,0000DC4 –19–29APR09–1/8
TM11207 (11MAY09) 02-0240-5

051809
PN=71
Powered Wheel Axles
2
3
4
5
02 6
0240 7
6
8
9
10
27 12
26
25
19
11
16
24
23 17
18 13
22
14
15
21 17
20
–UN–29APR09
TX1058912
TX1058912
Front Hub and Spindle
1—Snap Ring 8—Cap Screw (4 used) 15—Bearing Assembly 22—Shim

2—Cap Screw 9—Cap Screw (2 used) 16—Wheel Hub 23—Bearing
3—Grease Zerk 10—Spindle 17—Nut 24—Yoke
4—Spacer 11—Cap Screw (3 used) 18—Hose Guard 25—Yoke Pin
5—Upper King Pin 12—Hose Guard 19—Cap Screw (4 used) 26—Yoke Pin Bushing (2 used)
6—Bearing 13—Bearing Assembly 20—Cap Screw (8 used) 27—Key
7—Lean Angle Linkage 14—Wheel Seal O-Ring 21—Lower King Pin
Retainer (2 used)
TM11207 (11MAY09) 02-0240-6

051809
PN=72
Powered Wheel Axles
Specification
CAUTION: Prevent possible injury from 6WD Front Wheel Hub,
crushing. Use appropriate lifting device. Spindle, and Yoke—Weight
(approximate) ............................................................................ 390 kg
2. Position yoke (24) vertically using appropriate lifting 860 lb
device.
02
0240
MM16284,0000DC4 –19–29APR09–3/8 7
NOTE: Note position of shims and quantity for

reassembly if bearing is not replaced.
3. Remove lower king pin cap screws (20). Use two cap
screws in threaded holes (28) to push lower king pin
(21) from yoke.
4. Remove cap screw (2) and grease zerk (3).
5. Remove spacer (4).
6. Remove snap ring (1).
–UN–29APR09
28—Threaded Hole
TX1058918A
Lower King Pin Remove
TM11207 (11MAY09) 02-0240-7

051809
PN=73
Powered Wheel Axles
IMPORTANT: Attach gear puller with longer cap

screws to allow for full thread
engagement.
7. Attach appropriate gear puller (29) to upper king pin

using cap screws (30). Remove king pin using slide
hammer.

02
0240
8 8. Lift yoke straight up to separate it from spindle and
hub.
–UN–29APR09
Specification
Front Yoke—Weight
(approximate)..................................................................................... 30 kg
TX1058922A
66 lb.
9. Inspect upper and lower king pin and bearing

assemblies (6 and 23). Replace parts as necessary. Puller Attached to Upper King Pin
5—Upper King Pin

10. Inspect bushings (26). Replace if necessary.
24—Yoke
29—Gear Puller
11. Position yoke on spindle and hub. 30—Cap Screw
12. Install upper king pin.
13. Install snap ring.
14. Install spacer and cap screw. Tighten to specification.
Specification
Upper King Pin Cap Screw—
Torque .......................................................................................... 138 N•m
102 lb.-ft.
NOTE: If bearings are not replaced, original shim pack

can be used.
15. Install lower king pin without shims using four cap
screws (21) evenly spaced. Tighten cap screws to
specification.
Specification
Lower King Pin Cap Screw
Bearing Adjustment—Torque ......................................................... 20 N•m
177 lb.-in.
TM11207 (11MAY09) 02-0240-8

051809
PN=74
Powered Wheel Axles
NOTE: Make sure that upper king pin is against snap

ring.
16. Rotate lean yoke back and fourth a minimum of five

times. Tighten cap screws again to specification.
Repeat this sequence until torque is maintained.
02
0240
MM16284,0000DC4 –19–29APR09–6/8 9
17. Measure gap between lower king pin and yoke in

three places.
18. Use shims as required to obtain the average

measured clearance.
–UN–29APR09
NOTE: If the exact shim thickness can not be obtained,
set clearance to the next thinnest size using
available shims.
TX1058926A
19. Remove lower king pin and install shims.
20. Install lower king pin using four evenly spaced cap Shim Adjustment
screws. Tighten to specification.
21—Lower King Pin
24—Yoke
Specification
Final—Torque ............................................................................... 138 N•m
102 lb.-ft.
21. Rotate yoke back and fourth a minimum of five times.
TM11207 (11MAY09) 02-0240-9

051809
PN=75
Powered Wheel Axles
22. Attach DFT1282 King Pin Torque Adapter (32) to king

pin as shown. See DFT1282—King Pin Torque
Adapter. (Group 9900.)
23. Position angle finder (33) as shown.
24. Measure rolling drag torque in both directions from

5-15° clockwise from vertical using torque wrench as
shown. Measurement must be within specification.
02 Specification
0240 Front Axle Lean Yoke—Rolling
10 Drag Torque ................................................ 15—25 N•m in each direction
with no more than 5 N•m
–UN–29APR09
difference
133—221 lb.-in. in each direction
with no more than 44 lb.-in.
difference
TX1058927A
25. If rolling drag torque is not within specification, adjust
shim thickness. Rotate yoke and repeat rolling torque
measurement. Rolling Torque Measurement
26. If rolling drag torque is within specification, install 21—Lower King Pin
24—Yoke
remaining four cap screws and tighten to final torque
31—M12x20 Flanged Cap Screw
specification. 32—DFT1282 King Pin Torque Adapter
33—Angle Finder
Specification
Final—Torque ............................................................................... 138 N•m
102 lb.-ft.

27. Install wheel hub spindle and yoke assembly. See

Front Wheel Hub and Spindle Remove and Install—
6WD. (Group 0240.)
Specification
6WD Front Wheel Hub, Spindle,
and Yoke—Weight (approximate) ................................................... 390 kg
860 lb.
28. Fill wheel hub assembly with appropriate oil. See

Replacing 6WD Hub Oil—If Equipped. (Operator’s
Manual.)
MM16284,0000DC4 –19–29APR09–8/8
TM11207 (11MAY09) 02-0240-10

051809
PN=76
Powered Wheel Axles

and Assemble with Steering Angle Sensor—
6WD

surface.
1. See Front Wheel Hub and Spindle Remove and

02
Install—6WD. (Group 0240.)
0240
11
TM11207 (11MAY09) 02-0240-11

051809
PN=77
Powered Wheel Axles
1
2
3
4
6
7
02
8
0240
12 9
10
11
12
13
30
29
28
24
15
23 14
25
16
27 17
22
26
18
21
19
20
–UN–29APR09
TX1058883
TX1058883
Front Hub and Spindle with Steering Angle Sensor
TM11207 (11MAY09) 02-0240-12

051809
PN=78
Powered Wheel Axles
1—Snap Ring 10—Dowel Pin 18—Lower King Pin 26—Hose Guard

2—Cap Screw (2 used) 11—Seal 19—Cap Screw (8 used) 27—Cap Screw (4 used)
3—Spacer 12—Steering Angle Sensor Pin 20—Bearing Assembly 28—Cap Screw (2 used)
4—Cap Screw (2 used) 13—Yoke 21—Wheel Seal O-Ring 29—Cap Screw (4 used)
6—Grease Zerk 14—Yoke Pin Retainer 22—Bearing Assembly 30—Lean Angle Linkage
7—Upper King Pin 15—Bushing (2 used) 23—Hose Guard Retainer (2 used)
8—Key 16—Bearing 24—Cap Screw (3 used) B37—Steering Angle Sensor
9—Bearing 17—Shim 25—Spindle
Specification
CAUTION: Prevent possible injury from 6WD Front Wheel Hub,
crushing. Use appropriate lifting device. Spindle, and Yoke—Weight
(approximate) ............................................................................ 390 kg 02
860 lb 0240
2. Position yoke (13) vertically using appropriate lifting
13
device.
MM16284,0000DC2 –19–29APR09–3/8
3. Remove lower king pin cap screws (19). Use two cap
screws in threaded holes (31) to push lower king pin
(20) from yoke.
4. Remove steering angle sensor (B37). See Steering

Angle Sensor Remove and Install. (Group 9015-20.)

31—Threaded Hole
–UN–29APR09
TX1058890A
Lower King Pin Remove
TM11207 (11MAY09) 02-0240-13

051809
PN=79
Powered Wheel Axles
IMPORTANT: Attach gear puller with longer cap

screws to allow for full thread
engagement.
6. Attach appropriate gear puller (31) to upper king pin

using cap screws (32). Remove king pin.
7. Drive dowel pin (10) from steering angle sensor pin

(12).
02 8. Remove steering angle sensor pin.

0240
14
–UN–29APR09
9. Lift yoke straight up to separate it from spindle and

hub.
TX1058895A
Specification
Front Yoke—Weight
(approximate)..................................................................................... 30 kg Puller Attached to Upper King Pin
66 lb.
7—Upper King Pin
13—Yoke
NOTE: Bearing, seal, and bearing cup are serviced as an 31—Gear Puller
assembly. 32—Cap Screw
10. Inspect upper and lower king pin, steering angle

sensor seal (11) and bearing assemblies (9 and 16).
Replace parts as necessary.
11. Inspect bushings (15). Replace if necessary.
12. Position yoke on spindle and hub.
13. Apply LOCTITE 271 Thread Lock and Sealer (high

strength) to dowel pin and install in bore.
14. Install steering angle sensor pin.
15. Install upper king pin.
16. Install snap ring.
LOCTITE is a trademark of Henkel Corp. Continued on next page MM16284,0000DC2 –19–29APR09–5/8
TM11207 (11MAY09) 02-0240-14

051809
PN=80
Powered Wheel Axles
NOTE: Steering angle sensor connector must face front

of machine.
17. Install steering angle sensor and tighten cap screws.

See Steering Angle Sensor Remove and Install.
(Group 9015-20.)
NOTE: If bearings are not replaced, original shim pack

can be used.
18. Install lower king pin without shims using four cap 02
screws evenly spaced. Tighten cap screws to 0240
15
specification.
Specification
Bearing Adjustment—Torque ......................................................... 20 N•m
177 lb.-in.
NOTE: Make sure that upper king pin is against snap

ring.

times. Tighten cap screws again to specification.
Repeat this sequence until torque is maintained.
TM11207 (11MAY09) 02-0240-15

051809
PN=81
Powered Wheel Axles
20. Measure gap between lower king pin and lean yoke in
three places.
21. Use shims as required to obtain the average

measured clearance.
–UN–29APR09
NOTE: If the exact shim thickness can not be obtained,
set clearance to the next thinnest size using
available shims.
TX1058896A
02 22. Remove lower king pin and install shims.
0240
16 Shim Measurement
23. Install lower king pin using four evenly spaced cap
screws. Tighten to specification.
13—Lean Yoke
18—Lower King Pin
Specification
Final—Torque ............................................................................... 138 N•m
102 lb.-ft.

times.
TM11207 (11MAY09) 02-0240-16

051809
PN=82
Powered Wheel Axles
25. Attach DFT1282 King Pin Torque Adapter (34) to king

pin as shown. See DFT1282—King Pin Torque
Adapter. (Group 9900.)
26. Position angle finder (35) as shown.
27. Measure rolling drag torque in both directions from

5-15° clockwise from vertical using torque wrench as
shown. Measurement must be within specification.
Specification 02
Front Axle Lean Yoke—Rolling 0240
Drag Torque ................................................ 15—25 N•m in each direction 17
with no more than 5 N•m
–UN–29APR09
difference
133—221 lb.-in. in each direction
with no more than 44 lb.-in.
difference
TX1058898A
28. If rolling drag torque is not within specification, adjust
shim thickness. Rotate yoke and repeat rolling torque
measurement. Rolling Torque Measurement
29. If rolling drag torque is within specification, install 13—Lean Yoke

19—Lower King Pin
remaining four cap screws and tighten to final torque
33—M12x20 Flanged Cap Screw
specification. 34—DFT1282 King Pin Torque Adapter
35—Angle Finder
Specification
Final—Torque ............................................................................... 138 N•m
102 lb.-ft.

30. Install wheel hub spindle and yoke assembly. See

6WD. (Group 0240.)
Specification
6WD Front Wheel Hub, Spindle,
and Yoke—Weight (approximate) ................................................... 390 kg
860 lb.
31. Fill wheel hub assembly with appropriate oil. See

Replacing 6WD Hub Oil—If Equipped. (Operator’s
Manual.)
MM16284,0000DC2 –19–29APR09–8/8
TM11207 (11MAY09) 02-0240-17

051809
PN=83
Powered Wheel Axles
6WD Drive Hub Disassemble and Assemble


02
0240 2. Install articulation lock pin. See Locking Machine
18 Frame. (Operator’s Manual.)


(Group 0110.)
5. Drain 6WD drive hub. See Replacing 6WD Hub Oil—If

Equipped. (Operator’s Manual.)
6. Remove 6WD drive hub. See Front Wheel Hub and

Spindle Remove and Install—6WD. (Group 0240.)
Continued on next page MM16284,0000DBB –19–05MAY09–1/2
TM11207 (11MAY09) 02-0240-18

051809
PN=84
Powered Wheel Axles
7. Remove cap screws (2) and cap screw plug (1).

Tighten cap screw in threaded hole for plug to
separate wheel drive hub.
8. Perform Planetary Drive Disassemble and Assemble or

perform Planetary Brake Disassemble and Assemble.
(Group 0240.)
9. Install planetary assembly into spindle assembly.

Tighten cap screws to specification.
02
Specification 0240
Drive Hub Cap Screws—Torque .................................................... 80 N•m 19
59 lb-ft
–UN–23APR09
10. Install 6WD drive hub. See Front Wheel Hub and
TX1058710A
11. Fill 6WD drive hub with oil. See Replacing 6WD Hub
Oil—If Equipped. (Operator’s Manual.)
6WD Drive Hub
12. Install front wheel. Remove front wheel. See Wheel
Remove and Install. (Group 0110.) 1—Cap Screw Plug (3 used)
13. Calibrate 6WD control unit. See 6WD Controller
Calibration. (Group 9015-20.)
MM16284,0000DBB –19–05MAY09–2/2
TM11207 (11MAY09) 02-0240-19

051809
PN=85
Powered Wheel Axles
Planetary Drive Disassemble and Assemble


02


(Group 0110.)
5. Remove drive hub. See 6WD Drive Hub Disassemble

and Assemble. (Group 0240.)
Continued on next page MM16284,0000DBF –19–23APR09–1/4
TM11207 (11MAY09) 02-0240-20

051809
PN=86
Powered Wheel Axles
36
19
7 39
37
11 35 18
34 12 38
35 17
29 02
16 33 0240
21
41
32
4 31
5
–UN–24APR09
30 15
TX1058735
TX1058735
Planetary Drive Exploded View
4—Second Stage Carrier Cap 16—Needle Bearing 31—First Stage Planet Gear 37—Second Stage Planet Gear
Screw (12 used) 17—Wheel Hub Shaft (3 used) Pin (3 used)
5—Cap Screw (3 used) 18—Dowel Pin (3 used) 32—Pin Retainer (3 used) 38—Pin Retainer (3 used)
7—Cap Screw (3 used) 19—Second Stage Planet Gear 33—First Stage Carrier 39—Second Stage Carrier
11—Snap Ring Roller Bearing (3 used) 34—Second Stage Sun Gear 41—Bearing Race (2 used)
12—Snap Ring 29—First Stage Drive Shaft 35—Thrust Washer (2 used)
15—First Stage Planet Gear 30—First Stage Planet Gear (3 36—Second Stage Planet Gear
Roller Bearing (3 used) used) (3 used)
6. Remove second stage carrier cap screws (4). 9. Remove second stage planet gears (36) and planet
Remove second stage carrier assembly (39) from bearings (19).
hub (17).
10. Repeat above steps for first stage planet gears.
7. Remove retaining cap screws (7) and pin retainers
(38).
8. Remove second stage planet gear pins (37) using a

press.
TM11207 (11MAY09) 02-0240-21

051809
PN=87
Powered Wheel Axles
12. Remove thrust washer (35).
13. Remove snap ring (12) from second stage sun gear
(34).
–UN–17DEC01
14. Remove drive shaft (29).
15. Remove second stage sun gear from carrier (33).
T148071B
02
0240 16. Remove thrust bearing (16) and bearing races (41)
22 First Stage Carrier, Second Stage Sun Gear, and Drive Shaft
from hub.
Assembly
17. Clean, inspect , repair or replace all parts as
necessary.
18. Apply oil to all parts before assembly.
19. Install second stage sun gear and snap ring in first
–UN–17DEC01
stage carrier.
20. Install one thrust washer on drive shaft.
T148072B
21. Install drive shaft into first stage carrier assembly.
Install second washer and snap ring.
Second Stage Sun Gear Snap Ring
22. Assemble first and second carrier assemblies. Use
press to install pins. 11—Snap Ring
12—Snap Ring
23. Install pin retainers, cap screws, and backing plates. 29—Drive Shaft
33—First Stage Carrier
34—Second Stage Sun Gear
Tighten cap screws to specification. 35—Thrust Washer
Specification
Planet Pin Retainer Cap
Screws—Torque ............................................................................. 50 N•m
204 lb.-in.
24. Install needle bearing with bearing races.
25. Install first stage carrier assembly into hub.
26. Install second stage carrier assembly.
TM11207 (11MAY09) 02-0240-22

051809
PN=88
Powered Wheel Axles
Tighten cap screws (7) to specification.
Specification
Second Stage Carrier Mounting
Cap Screws—Torque ................................................................... 340 N•m
251 lb.-ft.
27. Install drive hub. See 6WD Drive Hub Disassemble

02
0240
MM16284,0000DBF –19–23APR09–4/4 23
TM11207 (11MAY09) 02-0240-23

051809
PN=89
Powered Wheel Axles
Planetary Brake Disassemble and Assemble
21 13
58 47
42 42 43
43 42 44
26
2
02
0240
24
14 14
24 14
24 24
27
46 55
46 54 52
25
45
51
13 21 3 40
28
1 53
–UN–28APR09
6 8
TX1058803
TX1058803
Planetary Brake Assembly Exploded View
1—Cap Screw (12 used) 14—Friction Disk (3 used) 42—Shim 51—Cover

2—Cap Screw (12 used) 21—Bearing Cup 43—Shim 52—Piston
3—Cap Screw (30 used) 24—Wear Plate (3 used) 44—Shim 53—Brake Pressure Plate
6—Cap screw 26—Plate 45—Spindle 54—Back-Up Ring
8—Washer 27—Ring Gear 46—Seal 55—Back-Up Ring
9—Spring Pin 28—Snap Ring 47—Brake Piston Carrier 58—Wheel Seal O-Ring
13—Roller Bearing 40—Seal
TM11207 (11MAY09) 02-0240-24

051809
PN=90
Powered Wheel Axles
1. Place spindle assembly on blocks to level ring gear.
2. Remove caps crews (2), plate (26), and shims

(42—44).
MM16284,0000DC1 –19–28APR09–2/8
02
0240
25
–UN–28APR09
TX1058810A
Chain and Lifting Eyelets
27—Ring Gear 59—Mark Position 60—Lift Eyelet (3 used) 61—Hoist Lift Chain (3 used)
3. Install three lifting eyelets (60).

IMPORTANT: Damage to brake pressure tube will
occur if planetary brake is not lined
5. Lift planetary brake using hoist chains (61).
up appropriately.
4. Mark position (59) as shown to aid assembly.
TM11207 (11MAY09) 02-0240-25

051809
PN=91
Powered Wheel Axles
6. Remove brake pressure tube (48). Replace O-rings

(49).
48—Brake Pressure Tube

49—O-Ring (2 used)
–UN–28APR09
50—Back-Up Washer (2 used)
TX1058812A
02
0240
26 Brake Pressure Tube
MM16284,0000DC1 –19–28APR09–4/8
7. Install cap screws (63) removed when splitting

planetary housing from brake housing. Install cap
screws until flush with ring gear as shown.
8. Turn planetary brake housing over.
–UN–28APR09
IMPORTANT: Pressure plate retaining cap screws (1)
must be replaced with new cap screws
after disassembly.
TX1058813A
9. Remove caps crews (1) and pressure plate (53).
Discard cap screws.
Leveling Cap Screws
62—Strait Edge
63—Cap Screw for Leveling (3 used)
TM11207 (11MAY09) 02-0240-26

051809
PN=92
Powered Wheel Axles
NOTE: Springs (25) alternate every other three holes.
10. Remove springs.
–UN–28APR09
12. Remove friction disks (14) and wear plates (24).
13. Remove ring gear (27).
TX1058814A
14. Turn brake piston assembly over. 02
0240
Snap Ring, Friction Disk, and Springs 27
15. Remove piston (52) with rubber hammer.
14—Friction Disk
16. Remove backup rings (54 and 55) and brake piston 25—Spring (12 used)
seals (46). 28—Snap Ring
17. Inspect O-rings, friction disks, and wear plates.
18. Apply oil to O-ring and piston before assembly.
19. Install seals and backup rings on brake piston carrier

(47).
20. Flip brake housing so three cap screws are on level

surface.
21. Install brake piston on brake piston carrier using

rubber hammer.
22. Install ring gear with snap ring grove up.
NOTE: Holes for springs must line up when assembling

friction disks and brake plates.
23. Install one wear plate.
24. Install friction disk.
Install remaining wear plates and friction disks in this

order.
25. Install springs in sets of three alternating every other

three holes.
26. Install brake pressure plate with new cap screws.

TM11207 (11MAY09) 02-0240-27

051809
PN=93
Powered Wheel Axles
Specification
Planetary Brake Pressure Plate
Cap Screws—Torque ..................................................................... 20 N•m
168 lb-in.
Torque Turn .................................................................................... 1/6 turn
27. See 6WD Bearings Remove and Install to service

bearings. (Group 0240.)
28. Install brake pressure tube.
02 29. Install brake assembly to spindle.

0240
28
30. Install shims (42—44).
31. Install plate. Tighten cap screws to specification.
Specification
Carrier Brake Retaining Plate
102 lb-ft
TM11207 (11MAY09) 02-0240-28

051809
PN=94
Powered Wheel Axles
32. Install JT07192 Hydraulic Pump to brake port (65).
33. Pressurize brake to specification (1). Pressure must

hold for 60 seconds.
Specification
–UN–17DEC01
Brake Pressure Test (1)—
Pressure ..................................................................................... 2000 KPa
20 bar
290 psi
T149262B
34. Pressurize brake to specification (2). Pressure must 02
0240
Brake Pressure Port 29
Specification
65—Brake Pressure Port
Pressure .................................................................................. 10 000 KPa
100 bar
1450 psi
35. Pressurize brake to specification (3). Pressure must

Specification
Pressure .................................................................................. 40 000 KPa
400 bar
5800 psi
If pressure drop occurs, check brake seals and brake

pressure tube.
MM16284,0000DC1 –19–28APR09–8/8
6WD Bearings Remove and Install
1. Remove wheel. See Wheel Remove and Install.

(Group 0110.)
2. Remove 6WD drive hub. See Front Wheel Hub and

Continued on next page AS79221,000005F –19–29APR09–1/5
TM11207 (11MAY09) 02-0240-29

051809
PN=95
Powered Wheel Axles
02
0240
30
–UN–13NOV01
T147944
T147944
Hub Cover and Face Seals
44—Cover 48—Metal Face Seals (2 used) 50—Alignment Pin 52—Backup Ring

47—Roller Bearing 49—Wheel Spindle Assembly 51—O-ring 53—Brake Pressure Tube
3. Remove cover (44) from wheel spindle assembly 5. Adjust bearing preload:
(49).
a. Remove metal face seal from cover (44). Face
4. Inspect roller bearing (47) and bearing cups. seal in wheel spindle assembly can remain
Replace if necessary. installed during preload adjustment.
NOTE: If roller bearings are replaced, adjust bearing b. Install cover (44).
preload.
TM11207 (11MAY09) 02-0240-30

051809
PN=96
Powered Wheel Axles
c. Remove brake pressure tube (27).
d. Apply oil to spindle and install carrier brake

assembly.
–UN–17DEC01
27—Brake Pressure Tube
T147981B
02
0240
Brake Pressure Tube 31
TM11207 (11MAY09) 02-0240-31

051809
PN=97
Powered Wheel Axles
e. Install retaining plate (26).
f. Install four cap screws (25). Cross tighten to

specification.
Specification
–UN–17DEC01
Cap Screws to Adjust Bearing
Preload.—Torque ........................................................................... 20 N•m
177 lb-in.
T149252B
02
0240
32 Shim Measurement
g. Rotate cover (44) two revolutions in both directions.
25—Retaining Plate Cap Screws
h. Torque cap screws to above specification. 26—Retaining Plate
49—Spindle
i. Repeat above two steps until torque stays at
specification.
j. Measure distance between retaining plate (26) and

spindle (49) in four places using feeler gauge.
k. Build a shim pack with a thickness that is 0.12 mm

(0.005 in) less than average of four measurements.
Specification
Wheel Drive Shim Pack
Thickness—Thickness ........................... 0.12 mm less than measurement
between brake carrier face and
spindle face
0.005 in. less than measurement
between brake carrier face and
spindle face
l. Remove retaining plate.
m. Install shims and retaining plate with all cap

screws. Tighten cap screws to specification.
Specification
102 lb-ft
n. Rotate cover two revolutions in each direction.
TM11207 (11MAY09) 02-0240-32

051809
PN=98
Powered Wheel Axles
NOTE: Make sure DFT1225 tool is installed with center

nut (56) directly over motor shaft (57).
o. Install rolling torque measurement tool DFT1225

(55). Measure rolling torque using torque wrench on
center nut (56). Rolling torque must be within
–UN–17DEC01
specification.
Specification
6WD Bearing—Rolling Drag
T149254B
Torque ....................................................................................... 3—10 N•m
02
27—89 lb-in.
0240
Measure Rolling Torque 33
55—DFT1225 Rolling Torque Measurement Tool

If rolling torque is not within specification, adjust shim 56—Center Nut
pack thickness. 57—Motor Shaft
p. Remove retaining plate and brake carrier assembly.
q. Install metal face seal in cover. See 6WD O-Ring

Metal Face Seal Remove and Install. (Group 0240.)
6. Install cover, brake assembly and retaining plate.

Specification
102 lb-ft
7. Install wheel. See Wheel Remove and Install for lug

nut torque specification. (Group 0110.)
AS79221,000005F –19–29APR09–5/5
TM11207 (11MAY09) 02-0240-33

051809
PN=99
Powered Wheel Axles
6WD O-Ring Metal Face Seal Remove and

Install
1. Lean top of wheel hub approximately five degrees

inward towards machine frame.

(Group 0110.)
3. Drain 6WD drive hub. See Replacing 6WD Hub Oil—If

02 Equipped. (Operator’s Manual.)
0240
34
AS79221,0000060 –19–29APR09–1/14
4. Disconnect brake pressure supply line (1). Cap and

plug line.

–UN–19AUG03
Specification
Wheel End—Weight
(approximate)..................................................................................... 48 kg
105 lb
T194252A
5. Support wheel end using hoist and strap.
Brake Pressure Supply Line
1—Brake Pressure Supply Line
Continued on next page AS79221,0000060 –19–29APR09–2/14
TM11207 (11MAY09) 02-0240-34

051809
PN=100
Powered Wheel Axles
NOTE: 6WD hub assembly shown removed from machine

for clarity.
6. Remove cap screws (45) and plug (46). Use cap screw
(45) in threaded hole for plug (46) to separate wheel
drive hub.
–UN–08NOV01
45—Hub Mounting Cap Screws
46—Plug
T147937B
02
0240
Wheel End Cap Screws 35
AS79221,0000060 –19–29APR09–3/14

crushing. Support cover with floor jack.
7. Support cover (6) using floor jack (5).

8. Support brake clutch assembly (8) using hoist and

strap (7).
5—Floor Jack
6—Cover
–UN–18AUG03
7—Hoist Strap
8—Brake Clutch Assembly
T194174A
Brake Clutch Assembly
TM11207 (11MAY09) 02-0240-35

051809
PN=101
Powered Wheel Axles
IMPORTANT: Avoid damage to timing pin by marking

an index position on brake clutch
assembly.
9. Mark index position (9) on brake clutch assembly (8)

and hub (10) to aid in assembly.
–UN–19AUG03
NOTE: Keep brake clutch in hoist strap for ease of
assembly.
T194172B
02 10. Remove brake clutch assembly.
0240
36 Index Position
8—Brake Clutch Assembly
9—Index Position
10—Hub
AS79221,0000060 –19–29APR09–5/14

11. Remove cover (6).
12. Remove metal face seal by prying on edges to

remove from wheel axle and discard seal.
IMPORTANT: Use extreme care not to scratch metal

face seal surface throughout this
procedure.
13. Thoroughly clean O-ring pockets of both seals and
–UN–14AUG03
exposed surfaces using TY16041 Brake and Clutch
Cleaner.
5—Floor Jack
T194016A
6—Cover
Cover
TM11207 (11MAY09) 02-0240-36

051809
PN=102
Powered Wheel Axles
NOTE: Seal installing tool is shown expanded to show

proper installation.
14. Install JDG1824 Seal Installing Tool (7) to seal (9).

Check that lip (8) is fully inserted around entire seal.
–UN–18AUG03
IMPORTANT: Use only rubbing alcohol on seals.
Damage could occur to seals if other
lubricants are used.
T194164A
15. Spray rubbing alcohol on O-ring seal and pockets for 02
lubrication. 0240
Seal Installing Tool 37
7—JDG1824 Seal Installing Tool

8—JDG1824 Tool Lip
9—Seal
AS79221,0000060 –19–29APR09–7/14
16. Before alcohol evaporates, install seal (8) by pushing

evenly and firmly on tool (7) until tool bottoms out all
way around housing.
IMPORTANT: Damage will occur to O-ring seal if

unseated during tool removal. Use care
when removing tool from seal.
17. Remove seal installing tool.
18. Inspect O-ring to see that it is seated at same height

all the way around.
–UN–19AUG03
7—JDG1824 Seal Installing Tool
8—Seal
T194018B
Seal Installing Tool
TM11207 (11MAY09) 02-0240-37

051809
PN=103
Powered Wheel Axles
IMPORTANT: Failure to properly lubricate outer zone

of seals may result in seal failure.
19. Lubricate outer zone (13) of metal face on seal using

TY6354 HY-GARD oil.
–UN–20AUG03
20. Repeat procedure for remaining seal.
13—Outer Zone of Seal
T194304A
02
0240
38 Metal Face of Seal
HY-GARD is a trademark of Deere & Company AS79221,0000060 –19–29APR09–9/14

21. Raise cover (6) into position.
5—Floor Jack
6—Cover
–UN–14AUG03
T194023A
Cover and Floor Jack
TM11207 (11MAY09) 02-0240-38

051809
PN=104
Powered Wheel Axles
IMPORTANT: Damage will occur to seals if not

properly aligned. Seals must be aligned
top-to-bottom and left-to-right to avoid
damage.
22. Adjust floor jack height until seal halves (11) are at
–UN–18SEP03
same height and aligned left-to-right.
11—Seal Half (2 used)
T194175B
02
0240
Seal Alignment 39
TM11207 (11MAY09) 02-0240-39

051809
PN=105
Powered Wheel Axles
IMPORTANT: Timing pin must be in center of through

hole when installing brake clutch
assembly. Damage could occur to brake
supply line if timing pin is not in center
of through hole.
23. Install brake clutch assembly (8) using hoist strap (7).
24. Use indexing position to line up brake clutch

assembly and hub.
02
0240 25. With correct indexing and role pin in center of through
40
hole slide brake clutch assembly onto splines on
spindle. Install retainer plate and shims.
–UN–18AUG03
NOTE: Since seals are not fully compressed brake clutch
assembly may protrude as far as 19 mm (0.75 in)
from retainer plate bolt pattern on spindle.
T194174A
26. Using three evenly spaced cap screws carefully turn
each cap screw, one turn at a time until retainer plate Clutch Assembly
is 3 mm (0.125 in) from being fully seated.
5—Floor Jack
6—Cover
27. Remove floor jack and hoist strap on brake clutch 7—Hoist Strap
when brake clutch is within 3 mm (0.125 in.) of 8—Brake Clutch Assembly
retainer plate pattern on spindle.
28. Install remaining cap screws. Cross tighten cap

Specification
Cap Retainer Plate Cap Screw—
Torque .......................................................................................... 138 N•m
102 lb-ft
29. Rotate cover three revolutions in each direction to

check for binding.
TM11207 (11MAY09) 02-0240-40

051809
PN=106
Powered Wheel Axles
30. Push in on sun gear shaft (11) to make sure it is

seated and rotates freely.
31. Install wheel end and cap screws. Tighten cap screws
to specification.
Specification
Wheel End Cap Screw—Torque .................................................... 80 N•m
59 lb-ft
11—Sun Gear Shaft 02

0240
41
–UN–09SEP03
T194649A
Wheel End
AS79221,0000060 –19–29APR09–13/14
32. Connect brake pressure supply line (1).
33. Fill front wheel drive hub. See Replacing 6WD Hub
Oil—If Equipped. (Operator’s Manual.)
34. Install front wheel. See Wheel Remove and Install for
–UN–19AUG03
lug nut torque specification. (Group 0110.)
1—Brake Pressure Supply Line
T194252A
Brake Pressure Supply Line
AS79221,0000060 –19–29APR09–14/14
TM11207 (11MAY09) 02-0240-41

051809
PN=107
Powered Wheel Axles
Front Axle Remove and Install—6WD

2. If equipped, remove pushblock, scarifier, or front

attachments. See Midmount Scarifier Cylinder Remove
and Install or see Scarifier Remove and Install or see
Balderson Style Lift Group Remove and Install.
(Group 4240.)
02
0240
42 CAUTION: Prevent possible crushing injury

NOTE: Do not install shop stands under axle assembly.

5. Remove front wheels. See Wheel Remove and Install.

(Group 0110.)
JW00603,0000112 –19–14MAY09–1/7
6. Remove nut and cotter pin (4) and tie rod ends (3). 3
Remove tie rod assembly (2). 2 3
1—Axle
2—Tie Rod Assembly
–UN–12MAY09
3—Tie Rod End (2 used)

4—Nut and Cotter Pin (2 used)
4
4 1
TX1059268
Tie Rod Assembly
Continued on next page JW00603,0000112 –19–14MAY09–2/7
TM11207 (11MAY09) 02-0240-42

051809
PN=108
Powered Wheel Axles
7. Remove cap screws (5 and 7) and hose guards (6 and

8).

6—Hose Guard
8—Hose Guard
02
0240
43
–UN–13MAY09
TX1059319A
Hose Guards
TM11207 (11MAY09) 02-0240-43

051809
PN=109
Powered Wheel Axles
8. Remove clamps (9). Disconnect steering angle sensor

harness (W24).
9. Disconnect wheel speed sensor harness (W18) and

wheel lean solenoid (Y79).
9—Clamp (4 used)
W18—Wheel Speed Sensor Harness
W24—Steering Angle Sensor Harness
Y79—Wheel Lean Solenoid
02
0240
44
–UN–13MAY09
TX1059322A
Steering Angle Sensor
–UN–13MAY09
TX1059324A
Wheel Speed Sensor
TM11207 (11MAY09) 02-0240-44

051809
PN=110
Powered Wheel Axles

each hose.

Remove 6WD hoses (10—14). Cap and plug all
openings.

02
pressure in the system before disconnecting or 0240
connecting hydraulic or other lines. Tighten all 45
–UN–13MAY09
fittings on hoses at cylinders.
TX1059334A
10—Right Motor Drain Hose
11—Right Reverse Pressure Hose
12—Right Forward Pressure Hose 6WD Hoses (right side shown)
13—Flushing Valve Pressure Hose
14—Right Brake Hose
TM11207 (11MAY09) 02-0240-45

051809
PN=111
Powered Wheel Axles

each hose.

Remove front axle hoses (15—20). Cap and plug all 17
16 18
openings.
15 19

02
0240 device.
46
13. Support axle with appropriate lifting device.
–UN–12MAY09
Specification
Front Axle Assembly—Weight
(approximate)................................................................................. 1123 kg 20
2475 lb 1
TX1059335
1—Axle
15—Right Steering Cylinder Head End-to-Left Front Axle Hoses
16—Pressure Hose-to-Right Steering Cylinder
17—Pressure Hose-to-Left Steering Cylinder
18—Left Steering Cylinder Head End-to-Right
19—Wheel Lean Cylinder Head End
20—Wheel Lean Cylinder Rod End
TM11207 (11MAY09) 02-0240-46

051809
PN=112
Powered Wheel Axles
14. Remove axle pin cap screw (21). Remove axle pin
(22) taking notice of location and quantity of washers
and shims.
15. Inspect, repair, or replace parts as necessary.
16. Install axle pin with washers and shims as needed.

Axle must be free to pivot in the main frame without
binding.
17. Install axle pin cap screw. 02

0240
21
47
IMPORTANT: Hose routing is critical. Route hoses as
–UN–13MAY09
noted earlier to prevent chaffing of
hose.
22 1
18. Install front axle hoses.
TX1059342
19. Install 6WD hoses. TX1059342
20. Connect wheel speed sensor and wheel lean solenoid

1—Axle
on both sides of axle.
21—Axle Pin Cap Screw
22—Axle Pin
21. Connect steering angle sensor on right side of axle.
Install clamps to hold wiring in place.
22. Install hose guards and cap screws.
23. Install tie rod assembly.
24. Install front wheels. See Wheel Remove and Install.

(Group 0110.)
25. Lower machine.
26. Remove articulation lock pin. See Locking Machine

27. If equipped, install pushblock, scarifier, or front

attachments. See Midmount Scarifier Cylinder
Remove and Install or see Scarifier Remove and
Install or see Balderson Style Lift Group Remove
and Install. (Group 4240.)

JW00603,0000112 –19–14MAY09–7/7
TM11207 (11MAY09) 02-0240-47

051809
PN=113
Powered Wheel Axles
02
0240
48
TM11207 (11MAY09) 02-0240-48

051809
PN=114
Group 0250
Axle Shafts, Bearings, and Reduction Gears
TEAMMATE II 1400 Series Inboard
Planetary Axle—Use CTM43
For complete repair information, the component technical

manual (CTM) is also required.
Use the CTM in conjunction with this machine manual.
–UN–17JAN89
TS225
02
0250
Component Technical Manual (CTM) 1
JW00603,00000F9 –19–20JAN09–1/1
Rear Axle Remove and Install

2. Install articulation lock pin.
3. Turn battery disconnect switch to OFF position.
4. Remove ripper, if equipped. See Ripper Remove and

Install. (Group 4240.)
CAUTION: Avoid crushing injury. Use

appropriate lifting device.
5. Raise rear of machine and place appropriate

supporting device under engine frame. See Machine
Specifications for machine weights. (Operator’s
Manual.)
6. Drain axle housing oil. See Changing Axle Housing Oil.

(Operator’s Manual.)
7. Remove rear wheels. See Wheel Remove and Install.

(Group 0110.)
8. Remove left and right tandem and wheel axle

assemblies. See Tandem and Wheel Axle Assembly
Remove and Install. (Group 0250.)
TM11207 (11MAY09) 02-0250-1

051809
PN=115
9. Remove transmission-to-rear axle drive shaft (4). See

Transmission-to-Rear Axle Drive Shaft Remove and 3
10. Disconnect wire harness from differential lock

solenoid (Y6). See Rear Platform Harness (W26) 2
5
Component Location. (Group 9015-10.) 4
1
CAUTION: Escaping fluid under pressure can

penetrate the skin causing serious injury. Avoid
02
0250 the hazard by relieving pressure before
2 disconnecting hydraulic or other lines. Tighten
all connections before applying pressure. Y6
–UN–27APR09
Search for leaks with a piece of cardboard.
Protect hands and body from high pressure
fluids.
TX1058796
If an accident occurs, see a doctor immediately.
Any fluid injected into the skin must be
surgically removed within a few hours or Rear Axle (top view)
gangrene may result. Doctors unfamiliar with
this type of injury should reference a 1—Hydraulic Hose (7 used)
knowledgeable medical source. Such 2—Rear Axle
information is available from Deere & Company 3—Rear Axle-to-Engine Frame Cap Screws (8
used)
Medical Department in Moline, Illinois, U.S.A. 4—Transmission-to-Rear Axle Drive Shaft
5—Engine Frame
NOTE: It takes at least 60 cycles of the brake pedal to Y6—Differential Lock Solenoid
discharge brake accumulator.
11. Depress service brake pedal continuously until

service brake pedal offers no resistance to discharge
service brake accumulator.
12. Install vacuum pump to hydraulic oil tank. See

Vacuum Pump Installation. (Group 9025-25.)


fittings on hoses at differential lock valve and
differential.
TM11207 (11MAY09) 02-0250-2

051809
PN=116
14. Disconnect and tag hydraulic hoses (1) from

differential lock valve and differential. Cap and plug all
openings. See Power Train Component Location for
hydraulic hose locations. (Group 9020-15.)

15. Support rear axle (2) with appropriate lifting device.

02
Specification
0250
Rear Axle Assembly—Weight
3
(approximate)................................................................................. 1100 kg
2500 lb.
TM11207 (11MAY09) 02-0250-3

051809
PN=117
16. Remove rear axle-to-front support cap screws (6).
17. Remove rear axle-to-engine frame cap screws (3).
18. Lower rear axle (2) and remove from under machine.
19. Repair or replace components as needed. See Rear 5

Axle Disassemble and Assemble. (Group 0250.) 3

02
0250 appropriate lifting device.
4
20. Lift rear axle in place under machine using an
–UN–28APR09
Specification
Rear Axle Assembly—Weight
TX1058797
(approximate)................................................................................. 1100 kg
2500 lb. 6 2
21. Loosely install rear axle-to-front support cap screws Rear Axle Front Supports
(6).
2—Rear Axle
3—Rear Axle-to-Engine Frame Cap Screws (8
22. Loosely Install rear axle-to-engine frame cap screws used)
(3). 5—Engine Frame
6—Rear Axle-to-Front Support Cap Screws (6
23. With rear axle held against the engine frame at the used)
top mounts and front mount (no gaps), tighten cap
Specification
Front Support-to-Axle Cap
Screws—Torque ........................................................................... 620 N•m
460 lb.-ft.
Specification
Engine Frame-to-Axle Cap
Screws—Torque ......................................................................... 1070 N•m
790 lb.-ft.
24. Connect hydraulic hoses to differential lock valve and

differential. See Power Train Component Location for
hydraulic hose locations. (Group 9020-15.)
25. Remove vacuum pump from hydraulic oil tank. Check

for hydraulic oil leaks. See Vacuum Pump Installation.
(Group 9025-25.)
TM11207 (11MAY09) 02-0250-4

051809
PN=118
26. Connect wire harness to differential lock solenoid

(Y6). See Rear Platform Harness (W26) Component
Location. (Group 9015-10.)
27. Install transmission-to-rear axle drive shaft. See

Transmission-to-Rear Axle Drive Shaft Remove and
28. Install left and right tandem and wheel axle

assemblies. See Tandem and Wheel Axle Assembly
Remove and Install. (Group 0250.) 02
0250
5
29. Fill axle housing with oil. See Changing Axle Housing
Oil. (Operator’s Manual.)
30. Remove machine supports and lower rear of machine

to ground.
31. Install ripper, if equipped. See Ripper Remove and

32. Turn battery disconnect switch to ON position.
33. Remove articulation lock pin.

35. Return machine to service.
JW00603,0000114 –19–05MAY09–5/5
TM11207 (11MAY09) 02-0250-5

051809
PN=119
Rear Axle Disassemble and Assemble
1 2 3
4 1
02
0250
6
–UN–27APR09
7 5
TX1058806
TX1058806
Rear Axle
1—Tandem Pivot Housings 3—Differential 5—Right Final Drive Axle 7—Left Final Drive Axle
2—Left Final Drive Axle 4—Right Final Drive Axle 6—Rear Axle
Housing Housing
To disassemble and assemble rear axle, see the • Brake Component—See Remove and Install Brake
following procedures: Components from Differential Case. (CTM43.)
• Differential—See 1400 John Deere Grader
• Tandem Pivot—See Tandem Pivot Disassemble and Differential Housing Reference List. (CTM43.)
Assemble. (Group 0250.)
• Final Drive Axle—See Final Drive Axle Remove and
JW00603,0000115 –19–04MAY09–1/1
TM11207 (11MAY09) 02-0250-6

051809
PN=120
Tandem and Wheel Axle Assembly Remove

and Install
1. Park machine on hard level surface. Lower all

attachments.

unexpected machine movement. Install
0250
4. Drain tandem housing. See Changing Tandem Oil.


5. Raise rear of machine and install shop stands under

rear of engine frame. See Machine Specifications.
6. Remove wheels from tandem being removed. See

Wheel Remove and Install. (Group 0110.)
PG32926,0000071 –19–22APR09–1/5
7. Remove platform (5), top access panels (6) and side 5

access panels (7).
5—Platform
6—Top Access Panel (2 used)
–UN–29APR09
7—Side Access Panel (4 used)
6
TX1058920
Tandem Access Panels
Continued on next page PG32926,0000071 –19–22APR09–2/5
TM11207 (11MAY09) 02-0250-7

051809
PN=121
8. Remove drive sprocket retaining ring (2).

device.
9. Install appropriate lifting device.
Specification
Tandem and Wheel Axle
02 Assembly—Weight ......................................................................... 726 kg
0250 1600 lb
8
–UN–23APR09
1—Tandem Assembly
2—Retaining Ring
TX1058702A
Drive Sprocket Retaining Ring
TM11207 (11MAY09) 02-0250-8

051809
PN=122
10. Remove cap screws (3).
11. Pull tandem housing tandem drive sprocket and

chains straight off tandem drive shaft.
12. Repair or replace parts as necessary.
IMPORTANT: Carefully align tandem drive sprocket

with tandem drive shaft for ease of
installation.
02
13. Lubricate O-ring on tandem pivot housing pilot 0250
9
diameter and mating surface in tandem housing with
–UN–23APR09
petroleum jelly.
14. Install tandem housing onto tandem pivot housing.

Apply T43512 Thread Lock and Sealer (medium
TX1058703A
strength) to threads of cap screws and tighten.
Specification
Pivot Housing Retaining Ring Tandem Pivot
190 lb-ft 1—Tandem Assembly
15. Install drive sprocket retaining ring.
16. Install top access cover and side access cover on

tandem assembly. Apply T43512 Thread Lock and
Sealer (medium strength) to threads of cap screws
and tighten.
Specification
Tandem Housing Cover Cap
Screw—Torque ............................................................................... 47 N•m
35 lb-ft
17. Install platforms on tandem assembly.
18. Install wheels and tighten to specification. See Wheel

19. Lower machine to the ground.
20. Fill tandem housing flush to bottom of oil level check

plug. See Drain and Refill Capacities. (Operator’s
Manual.)
TM11207 (11MAY09) 02-0250-9

051809
PN=123
PG32926,0000071 –19–22APR09–5/5
Tandem Wheel Axle Assembly Remove and

Install
02
1. Park machine on level surface.
0250
10

PG32926,000006F –19–21APR09–1/3
4. Drain tandem assembly (1). See Changing Tandem


–UN–29APR09
5. Raise back of machine using appropriate lifting device.
6. Support each end of tandem housing using appropriate TX1058874A

supporting device.
7. Remove wheel. See Wheel Remove and Install. Tandem Wheel Assembly (front shown)
(Group 0110.)
1—Tandem Assembly
IMPORTANT: Excessive lifting force can split flange 2—O-Ring
3—Axle Assembly
on wheel axle assembly. 4—Oil Collection Cup
8. Install appropriate lifting device to wheel axle flange

and tire mounting flange.
Continued on next page PG32926,000006F –19–21APR09–2/3
TM11207 (11MAY09) 02-0250-10

051809
PN=124
9. Remove platform (5), top access panels (6) and side 5

access panels (7).
10. Remove drive chain from wheel axle sprocket. See

Drive Chain Remove and Install. (Group 0250.)
–UN–29APR09
crushing. Use appropriate lifting device. 6
TX1058920
Specification 7
Wheel Axle Assembly—Weight 02
(approximate) ................................................................................. 145 kg 0250
320 lb Tandem Access Panels 11
5—Platform
11. Remove cap screws and washers from wheel axle
6—Top Access Panel (2 used)
assembly flange and remove wheel axle assembly. 7—Side Access Panel (4 used)
13. Lubricate O-ring (2) and mating bore of tandem

housing with petroleum jelly.
14. Fill oil collection cup (4) in wheel axle assembly.
15. Position wheel axle assembly in tandem housing.
16. Apply T43512 Thread Lock and Sealer (medium

strength) to threads of cap screws. Install cap screws
and washer and tighten.
Specification
Wheel Axle Housing-to-Tandem
190 lb-ft
17. Install drive chain. See Drive Chain Remove and

18. Install wheel and tighten to specification. See Wheel

19. Fill tandem housing flush to bottom of oil level check

plug. See Drain and Refill Capacities. (Operator’s
Manual.)
PG32926,000006F –19–21APR09–3/3
TM11207 (11MAY09) 02-0250-11

051809
PN=125
Tandem Wheel Axle Assembly Disassemble and Assemble
02
0250
12
–UN–28APR09
TX1058838
Tandem Wheel Axle Assemblies

Continued on next page JW00603,0000119 –19–21JAN09–1/6
TM11207 (11MAY09) 02-0250-12

051809
PN=126
1—Cotter Pin 8—Outer Bearing Cup 14—Tandem Rear Wheel Alex 18—Oil Collection Cup (rear
2—Slotted Nut 9—Outer Bearing Cone Assembly axle)
3—Sprocket Retainer 10—Metal Face Oil Seal 17—Oil Collection Plate (front 19—Wheel Axle Housing
4—Wheel Axle Sprocket 11—Wheel Axle axle) 20—O-Ring
5—Thrust Washer 12—Cap Screw (2 used per 16—Clearance—Wheel Axle 23—Magnet
6—Inner Bearing Cone axle) Flange-to-Housing
7—Inner Bearing Cup 13—Tandem Front Wheel Alex
Assembly
02
0250
Continued on next page JW00603,0000119 –19–21JAN09–2/6 13
TM11207 (11MAY09) 02-0250-13

051809
PN=127

device.
1. Remove parts (1—5 and 12, 18 or 17, and 23).
Specification
Tandem Wheel Axle Assembly—
Weight ............................................................................................ 145 kg
320 lb
02
0250 2. Press wheel axle (11) through inner bearing cone (6)
14 and out of wheel axle housing (19).
NOTE: Metal face oil seal will be destroyed when

installing puller.
3. Pull outer bearing cone (9) off wheel axle using puller.
4. Remove metal face oil seal (10) from wheel axle and
discard seal.
–UN–18JUN97
5. Drive inner bearing cup (7) and outer bearing cup (8)
out of wheel axle housing.
T109864
6. Inspect and replace parts as necessary.
Bearing Cups Position
7. Position inner bearing cup and outer bearing cup in
wheel axle housing and press firmly against shoulders
in housing.
NOTE: Rubber lips on metal face oil seal, seal mounting

surface on wheel axle and wheel axle housing
must be dry and free of oil.
8. Remove plastic retainer band from outside diameter of

new metal face oil seal.
9. Clean metal face oil seal with denatured or isopropyl

alcohol using a lint free cloth.
10. Apply clean hydraulic oil to both faces of metal face

–UN–18JUN97
oil seal using a lint free cloth.
11. Clean wheel axle and wheel axle housing bores at

seal mounting surfaces using denatured or isopropyl
T109865
alcohol using a lint free cloth.

Wheel Axle Press
TM11207 (11MAY09) 02-0250-14

051809
PN=128
12. Install half of seal in wheel axle seal bore. Metal face
seal must be facing outward of seal bore.
13. Carefully place second half of face seal against first

half so oiled metal faces of seal end up touching each
other.
02
0250
Continued on next page JW00603,0000119 –19–21JAN09–4/6 15
TM11207 (11MAY09) 02-0250-15

051809
PN=129
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
oil. Heat oil in a well-ventilated area. Plan a safe
handling procedure to avoid burns.
–UN–23AUG88
IMPORTANT: Do not heat bearing for longer than 1
hour time period.
02
TS227
0250 14. Heat bearing cones (6 and 9) to specification.
16 Handle Fluids Safely—Avoid Fires
Specification
Bearing Cone—Temperature ........................................................... 118°C
250°F
15. Position and install outer bearing cone firmly against

shoulder on wheel axle.
16. Position wheel axle vertical, check metal face oil seal
to be sure it is properly seated and aligned. Slowly
lower housing onto wheel axle. Carefully guide wheel
axle housing over rubber lip on metal face oil seal.
17. Position and install inner bearing cone on wheel axle

and into wheel axle housing.
18. Install thrust washer (5).
NOTE: When assembling front tandem wheel axle

assembly, position sprocket (4) with teeth toward
wheel axle housing as shown.
When assembling rear tandem wheel axle

assembly, position sprocket with teeth away from
wheel axle housing as shown.
19. Install sprocket.
20. Install sprocket retainer (3) and slotted nut (2).
21. Position wheel axle assembly on a heavy table or

plate with wheel axle flange down. Secure wheel axle
flange to allow torque to be applied to slotted nut
without moving.
22. Rotate wheel axle housing in both directions to seat

bearings.
TM11207 (11MAY09) 02-0250-16

051809
PN=130
23. Partially tighten slotted nut and measure rolling torque

on wheel axle housing with end play on bearings.
NOTE: There is end play on bearings as long as

clearance (16) between wheel axle housing and
wheel axle flange changes when wheel axle
housing is pushed downward compressing rubber
lips on metal face oil seal.
24. Preload bearings by tightening slotted nut until rolling

torque increases more than rolling torque with end 02
play. After tightening turn to check for smooth rotation 0250
17
of assembly.
Specification
Slotted Nut—Torque ............................. 5—13 N•m more than rolling drag
torque with end play
44—115 lb-in. more than rolling
drag torque with end play
25. Apply TY6304 Flexible FORM-A-GASKET to oil

collector cup (17) and/or oil collector plate (18).
26. Install oil collector cup (rear wheel axle) or oil

collector plate (front wheel axle) with cap screws (12).
27. Lubricate bearings and flood oil seal cavity with John
Deere HY-GARD oil.
IMPORTANT: Proper break-in is required when

replacing metal face oil seal in axle
housing.
28. Operate machine in first gear, slow idle for ten

minuets to allow proper break-in of seal.
FORM-A-GASKET is a trademark of Loctite Corp.

HY-GARD is a trademark of Deere & Company. JW00603,0000119 –19–21JAN09–6/6
TM11207 (11MAY09) 02-0250-17

051809
PN=131
Tandem Pivot Disassemble and Assemble
1. Remove tandem and wheel axle assembly. See

Tandem Wheel Axle Assembly Disassemble and
3. Remove pivot retainer (1), shims (2) and outboard

thrust washer segments (3). Retain shims for
02 installation.
0250
18
–UN–28JAN09
device.
TX1055027A
4. Remove tandem pivot housing (5) by pulling straight off
final drive axle housing (9).
Specification Outboard Thrust Washer

Tandem Pivot Housing—Weight
(approximate)..................................................................................... 91 kg
200 lb
5. Remove inboard thrust washer segments (7) and

tandem pivot bushings (8).
7. Lubricate O-rings (6) on final drive axle housing and

mating surface on tandem pivot housing with grease.
8. Coat final drive axle housing with heavy grease and

install inboard thrust washer segments with chamfer
facing toward radius on final drive axle housing. Press
–UN–28JAN09
into position to secure.
9. Lubricate tandem pivot bushings with oil and install on

final drive axle housing. Stagger bushing openings
TX1055026A
180° apart.
10. Position tandem pivot housing with sloping flange to Inboard Thrust Washer
top and install halfway. Push in slowly, making sure
thrust washer segments remain in position. Continue 1—Pivot Retainer
installing until contact with O-rings is made and 2—Shim
3—Outboard Thrust Washer Segment (3 used)
tandem pivot housing becomes difficult to move by 4—Cap Screw (16 used)
hand. 5—Tandem Pivot Housing
6—O-Ring (2 used)
7—Inboard Thrust Washer Segment (3 used)
8—Tandem Pivot Bushing (2 used)
9—Final Drive Axle Housing
TM11207 (11MAY09) 02-0250-18

051809
PN=132
11. Lubricate outboard thrust washer segments with oil

and install with corner chamfer facing outward so it is
visible when installed.
12. Install pivot retainer without shims using four evenly

spaced cap screws and washers. Using hand wrench,
gradually tighten cap screws to pull tandem pivot
housing over O-rings.
02
0250
Continued on next page JW00603,000011A –19–21JAN09–2/4 19
TM11207 (11MAY09) 02-0250-19

051809
PN=133
5 6
3
02
0250
20 2 7
4
10
8
12
–UN–29JAN09
11 TX1055028
TX1055028
Tandem Pivot Component Identification
1—Pivot Retainer 4—Cap Screw (16 used) 8—Tandem Pivot Bushing (2 11—Clearance
2—Shim 5—Tandem Pivot Housing used) 12—End Play Clearance
3—Outboard Thrust Washer 6—O-Ring (2 used) 9—Final Drive Axle Housing
Segment (3 used) 7—Inboard Thrust Washer 10—Hardened Washers (16
Segment (3 used) used)
13. Using feeler gauge, check clearance (11) between mm (0.098 in.) when tandem pivot housing stops
tandem pivot housing (5) and final drive axle moving and torque on cap screws (4) begins to
housing (9). It should measure approximately 2.5 rise.
TM11207 (11MAY09) 02-0250-20

051809
PN=134
Specification 16. Using a feeler gauge, check end play clearance

Tandem Pivot Housing-to-Final (12) between pivot retainer and outboard tandem
Drive Axle Housing—Clearance
(approximate) ........................................................................... 2.5 mm
pivot segments (3). Move feeler gauge completely
0.098 in. around joint. Add or subtract shims to establish
correct end play.
If clearance (11) measures approximately 8.5 mm
Specification
(0.335 in.), inboard thrust washer segments (7) have
Pivot Retainer-to-Outboard
moved and must be repositioned. Tandem Pivot Segments—End
Play ......................................................................... 0.026—0.040 mm
Specification 0.010—0.015 in.
Inboard Thrust Washer 02
Segments—Clearance 0250
(approximate) ........................................................................... 8.5 mm 17. Remove eight cap screws and discard. Dip
21
0.335 in. threads of 16 new cap screws in oil and install
with hardened washers after allowing excess oil to
14. When clearance between tandem pivot housing drip off. Torque to specification. Go around bolt
and main drive axle housing measures circle twice with torque wrench.
approximately 2.5 mm (0.098 in.) install four more
cap screws (evenly spaced). Tighten all eight cap Specification
Wheel Axle Housing-to-Tandem
screws to specification to extrude excess grease Cap Screw—Torque .............................................................. 258 N•m
from surfaces of inboard thrust washer segments. 190 lb.-ft.
Specification
18. Install tandem and wheel axle assembly. See
Tandem Pivot Housing-to-Main
Drive Axle Housing—Clearance
Tandem Wheel Axle Assembly Disassemble and
(approximate) ........................................................................... 2.5 mm Assemble. (Group 0250.)
0.098 in.
Inboard Thrust Washer 19. Using grease fitting on front of tandem pivot
Segments—Torque ................................................................ 140 N•m housing, pump grease into cavity between O-rings
103 lb.-ft.
(6) until grease that is free of air is purged out of
hole in rear of tandem pivot housing. Clean up
15. Remove pivot retainer (1) and install with
excess grease.
previously removed shims (2) and eight evenly
spaced cap screws (4) and washers (10). Torque
to specification.
Specification
Pivot Housing Retaining Ring
Cap Screw—Torque .............................................................. 278 N•m
205 lb.-ft.
JW00603,000011A –19–21JAN09–4/4
TM11207 (11MAY09) 02-0250-21

051809
PN=135
Final Drive Axle Remove and Install

4. Remove ripper, if equipped. See Ripper Remove and

02 Install. (Group 4240.)
0250
22
the hazard by relieving pressure before
disconnecting hydraulic or other lines. Tighten
all connections before applying pressure.
fluids.

surgically removed within a few hours or
this type of injury should reference a
knowledgeable medical source. Such
information is available from Deere & Company
NOTE: It takes at least 60 cycles of the brake pedal to

5. Depress service brake pedal continuously until service

brake pedal offers no resistance to discharge service
brake accumulator.

6. Raise rear of machine and place appropriate

supporting device under engine frame. See Machine
Specifications for machine weights. (Operator’s
Manual.)
7. Drain axle housing oil. See Changing Axle Housing Oil.

Continued on next page JW00603,000011B –19–21JAN09–1/7
TM11207 (11MAY09) 02-0250-22

051809
PN=136
8. Place shop stands under both ends of tandem housing

opposite side of machine being serviced.
9. Remove tandem and wheel axle assembly for side of

machine being serviced. See Tandem and Wheel Axle
Assembly Remove and Install. (Group 0250.)
10. Disassemble tandem pivot housing for side of

machine being serviced. See Tandem Pivot
Disassemble and Assemble. (Group 0250.)
02
0250
Continued on next page JW00603,000011B –19–21JAN09–2/7 23
TM11207 (11MAY09) 02-0250-23

051809
PN=137
02
0250
24
6
5 16 9 7 10
15 13 8
14
4
11
3
12 2
19
17
23
21
–UN–29JAN09
24 22
20
TX1055054
18
TX1055054
Final Drive Axle Component Location
1—Differential Case 8—Brake Separator Plate (6 13—O-Ring 19—Inboard Bearing Cone

2—Final Drive Axle Housing used) 14—Cap Screw 20—Snap Ring
3—Final Drive Ring Gear 9—Brake Disk (5 used) 15—Lock Plate 21—Oil Seal
4—Brake Backing Plate 10—Brake Pack Retaining Pin 16—Planet Pinion Carrier 22—Outboard Bearing Cup
5—Dowel Pin (2 used) (2 used) Assembly 23—Inboard Bearing Cup
6—Sun Pinion Shaft 11—Dowel Pin (2 used) 17—Snap Ring 24—Outboard Bearing Cup
7—Brake Pack Retaining Snap 12—Dowel Pin (2 used) 18—Tandem Drive Shaft
Ring (2 used)
TM11207 (11MAY09) 02-0250-24

051809
PN=138
15. Position hydraulic jack under center of tandem

housing on opposite side and raise slightly.
16. Check for clearance between top mounts of final
11. Support rear axle with an appropriate lifting
drive axle and engine frame on side of machine
device.
being serviced.
Specification
Rear Axle Assembly—Weight Specification
(approximate) .......................................................................... 1100 kg Tandem Housing—Clearance ........................................ 0.5—1.0 mm
2500 lb. 0.020—0.040 in.
02
a. If clearance exists, securely block ends of 0250
CAUTION: Avoid crushing injury. Use tandem housing on either side of jack to 25
appropriate lifting device. prevent tandems from rotating.
12. Support final drive axle housing (2) at bottom of

front and rear mounting pads. CAUTION: Prevent injury from unexpected
machine movement. Do not apply so much
Specification load that the engine frame comes off other
Final Drive—Weight supports.
(approximate) ............................................................................ 140 kg
310 lb.
b. If clearance does not exist, apply just enough
pressure on tandem with the jack to create
13. Remove three cap screws and washers that attach specified clearance.
lower front mount of final drive axle housing to the
front engine frame support. c. Block ends of tandem housing on either side of
jack to prevent tandem from rotating.
14. Remove four cap screws and washers that attach
top mounts of final drive axle housing to engine
frame.
TM11207 (11MAY09) 02-0250-25

051809
PN=139
IMPORTANT: Cap screws removed from the final

2
drive axle housing-to-differential case 25
joint during disassembly have been
26
torqued to yield and must be replaced
with new cap screws for assembly.
17. Remove and discard final drive axle

housing-to-differential case cap screws and washers
(25 and 26).
02 18. Use two pry bars at notches between differential case

0250 (1) and brake backing plate (4) to break sealed joint
26
at this location.
–UN–28APR09
IMPORTANT: During removal of the final drive axle,
sealant holding brake backing plate,
final drive ring gear (3) and final drive
axle housing (2) may break. However,
TX1058842
do not allow these parts to separate
from each other.
Final Drive Housing
19. Pull final drive axle away from differential case as
shown. Differential case-to-brake backing plate dowel 25—Final Drive Axle Housing-to-Differential Case
pins (5) will stay with the differential case. Washer
26—Final Drive Axle Housing-to-Differential Case
IMPORTANT: The sun pinion shaft (6) is not retained Cap Screw
in the differential or the final drive. Do
not allow this shaft to fall when final
drive axle is moved away from
differential case.
20. Remove sun pinion shaft.
21. Clean and inspect parts. Repair or replace parts as

necessary. See Final Drive Axle Disassemble and
22. Apply PM38655 LOCTITE Gasket Maker onto the

mounting surface of the differential case. Check to be
sure the mounting surface of the differential case
contains two locating dowel pins (5).
23. Install final drive axle onto differential case.
24. Rotate differential input yoke to align splines on sun

pinion shaft with splines in differential side gears.
LOCTITE is a trademark of Henkel Corporation Continued on next page JW00603,000011B –19–21JAN09–5/7
TM11207 (11MAY09) 02-0250-26

051809
PN=140
IMPORTANT: Cap screws removed from the final

drive axle housing-to-differential case
joint during disassembly have been
torqued to yield and must be replaced
with new cap screws for assembly.
25. Loosely install final drive axle housing-to-differential

case cap screws and washers.
26. Tighten cap screws to specification in alternating

pattern shown. 02
0250
Specification 27
Final Drive Axle
Housing-to-Differential Case Cap
–19–21JUL97
Screws—Torque ........................................................................... 230 N•m
170 lb-ft
T109839
Final Drive Axle Housing to Differential Case Tightening Pattern
TM11207 (11MAY09) 02-0250-27

051809
PN=141
02
0250
28
–19–13AUG97
T110705
Cap Screw Heads and Final Drive Axle Housing
27. Mark cap screws as shown. Tighten each cap 32. Perform vacuum leak down test on brake piston
screw and additional 90° in same alternating packing rings. Perform Brake Piston Packings—
pattern. Vacuum Leakdown Test. (CTM43.)
28. Lower jack under opposite tandem housing. 33. Assemble tandem pivot housing. See Tandem
Pivot Disassemble and Assemble. (Group 0250.)
29. Loosely install three cap screws and washers that
attach the lower front mount of final drive axle 34. Fill rear axle assembly with oil. See Changing Axle
housing (2). Housing Oil. (Operator’s Manual.)
30. Loosely install four cap screws and washers that 35. If equipped, install ripper. See Ripper Remove and
attach the top mounts of the final drive axle Install. (Group 4240.)
housing to the engine frame.
31. With axle held against the engine frame at the two
top mounts and the front mount (no gaps), tighten 37. Remove articulation lock pin.
cap screws to specification.
Specification
Final Drive-to-Engine Frame
Cap Screw—Torque ............................................................ 1070 N•m
790 lb-ft
Final Drive-to-Front Support
Cap Screw—Torque .............................................................. 620 N•m
460 lb-ft
JW00603,000011B –19–21JAN09–7/7
TM11207 (11MAY09) 02-0250-28

051809
PN=142
Final Drive Axle Disassemble and Assemble
1
02
0250
29
6
5 16 9 7 10
15 13 8
14
4
11
3
12 2
19
17
23
21
24 22 –UN–29JAN09
20
TX1055054
18
TX1055054

6—Sun Pinion Shaft 11—Dowel Pins (2 used) 17—Snap Ring 24—Outboard Bearing Cup
7—Brake Pack Retaining Snap 12—Dowel Pins (2 used) 18—Tandem Drive Shaft
Ring (2 used)
Continued on next page JW00603,000011C –19–21JAN09–1/4
TM11207 (11MAY09) 02-0250-29

051809
PN=143
1. Remove brake components. See Brake Component 5. Remove tandem drive shaft oil seal (21).
NOTE: Dowel pins are tight in final drive housing and
2. Remove planet pinion carrier. See Planet Pinion cannot be reused.
Carrier Remove and Install. (Group 0250.)
6. Clean final drive axle housing. Dowel pins (12)
3. Remove tandem drive shaft. See Tandem Drive must be tight in axle housing. Inspect and replace
Shaft Remove and Install. (Group 0250.) as necessary.
4. Remove inboard bearing cup (23) and outboard

02 bearing cup (24) from final drive axle housing (2).
0250
30
TM11207 (11MAY09) 02-0250-30

051809
PN=144
3MM (.12IN.)
2
02
0250
31
21
25
–UN–29JAN09
TX1055055
TX1055055
Clearance Between Seal/Bottom Seal Bore
2—Final Drive Axle Housing 21—Oil Seal 25—Bearing Installer
7. If a new final drive axle housing is being 9. Coat seal bore in final drive axle housing with
assembled, install two new dowel pins in mounting TY16285 Cure Primer and cover outside diameter
surface that mates with final drive ring gear (3). of oil seal with plastic gasket.
8. Clean all parts to be assembled.
TM11207 (11MAY09) 02-0250-31

051809
PN=145
NOTE: Oil seal must be positioned as shown and 11. Chill inboard bearing cups and outboard bearing
either side of seal must not be more than 0.51 cups in dry ice or in a freezer and drive firmly
mm (0.020 in.) deeper than its opposite side against shoulders in each end of final drive axle
when installed. housing using DFT1153 Oil Seal Driver.
10. Install tandem drive shaft oil seal (21) into bore in 12. Install drive shaft. See Tandem Drive Shaft
final drive axle housing with spring side of oil seal Remove and Install. (Group 0250.)
facing DFT1153 Oil Seal Driver. Drive oil seal into
bore until driver seats against bearing shoulder 13. Install planet pinion carrier. See Planet Pinion
(25) to specification. Carrier Remove and Install. (Group 0250.)
02
0250 Specification 14. Install brake components. See Brake Component
32 Tandem Drive Shaft Oil Seal to Remove and Install. (Group 0250.)
Final Drive Axle Housing Bore
Bottom—Gap (approximate) .................................................... 3.0 mm
0.12 in.
Oil Seal—Depth ..................................................................... 0.51 mm
0.020 in.
JW00603,000011C –19–21JAN09–4/4
TM11207 (11MAY09) 02-0250-32

051809
PN=146
Brake Component Remove and Install
NOTE: The brake components are located on the left and

right side of the differential case. The tandem and
wheel axle assembly, tandem pivot, and final drive
axle must be removed from the left and right side
of the rear axle assembly to gain access to the
brake components.
1. Remove tandem and wheel axle assembly. See

Tandem and Wheel Axle Assembly Remove and 02
Install. (Group 0250.) 0250
33
2. Remove tandem pivot. See Tandem Pivot Disassemble

3. Remove final drive axle. See Final Drive Axle Remove

4. Remove brake component. See Remove and Install

Brake Components from Differential Case. (CTM43.)
5. Install final drive axle.
6. Install tandem pivot.
7. Install tandem and wheel axle assembly.
JW00603,000011D –19–21JAN09–1/1
TM11207 (11MAY09) 02-0250-33

051809
PN=147
Planet Pinion Carrier Remove and Install
1
02
0250
34
6
5 16 9 7 10
15 13 8
14
4
11
3
12 2
19
17
23
21
–UN–29JAN09
24 22
20
TX1055054
18
TX1055054

6—Sun Pinion Shaft 11—Dowel Pin (2 used) 17—Snap Ring 24—Outboard Bearing Cup
7—Brake Pack Retaining Snap 12—Dowel Pin (2 used) 18—Tandem Drive Shaft
Ring (2 used)
Continued on next page JW00603,000011E –19–21JAN09–1/2
TM11207 (11MAY09) 02-0250-34

051809
PN=148
1. Remove final drive axle. See Final Drive Axle 8. Install cap screw (14). Tighten to specification.
Specification
2. Remove brake components. See Brake Component Planet Pinion-to-Axle Shaft Cap
Screw—Torque ...................................................................... 908 N•m
Remove and Install. (Group 0250.) 670 lb-ft
3. Remove O-ring (13) from head of cap screw (14) 9. Install O-ring (13) to head of cap screw (14) and
and lock plate (15). lock plate (15).
4. Remove cap screw (14). 10. Install brake components. See Brake Component
02
5. Remove planet pinion carrier from axle shaft. See 0250
35
Disassemble Planet Pinion Carrier 1400 Series. 11. Install final drive axle. See Final Drive Axle
(CTM43.) Remove and Install. (Group 0250.)
6. Inspect planet pinion carrier components. See
Inspect Planet Pinion Components 1400 Series.
(CTM43.)
7. Install planet pinion carrier to axle shaft. See

Assemble Planet Pinion Carrier 1400 Series.
(CTM43.)
JW00603,000011E –19–21JAN09–2/2
TM11207 (11MAY09) 02-0250-35

051809
PN=149
Tandem Drive Shaft Remove and Install
02 1
0250
36
5 6 10
16 7
9 8
13
15 14 4
3
11
12
2
17 19
23
21
–UN–29JAN09
24
22
20
TX1055097
18
TX1055097

4—Brake Backing Plate 10—Brake Pack Retaining Pin 16—Planet Pinion Carrier 22—Outboard Bearing Cone
6—Sun Pinion Shaft 11—Dowel Pins (2 used) 17—Snap Ring 24—Outboard Bearing Cup
7—Brake Pack Retaining Snap 12—Dowel Pins (2 used) 18—Tandem Drive Shaft
Ring (2 used)
Continued on next page JW00603,000011F –19–21JAN09–1/6
TM11207 (11MAY09) 02-0250-36

051809
PN=150
1. Remove final drive axle. See Final Drive Axle

lifting device.
2. Remove brake components. See Brake Component
5. Hoist final drive axle housing (2) to an upright
position (bolting flange up).
3. Remove planet pinion carrier. See Planet Pinion
Carrier Remove and Install. (Group 0250.) Specification
Final Drive Axle Housing with
IMPORTANT: Protect all exposed machined Tandem Drive Shaft—Weight
surfaces on final drive axle housing (approximate) ............................................................................ 203 kg 02
450 lb 0250
(2) from damage.
Tandem Drive Shaft—Weight 37
(approximate) .............................................................................. 27 kg
4. Remove inboard (carrier end) bearing retaining 60 lb
snap ring (17).
JW00603,000011F –19–21JAN09–2/6
6. Attach axle DF1057 Axle Adjusting Tool (26) to final

drive axle housing.
7. Attach chain hoist to DF1057 Axle Adjusting Tool.
NOTE: While working with tandem drive shaft, protect

sealing surface with a single wrap of electrical
tape.
8. Put disks between hydraulic jack and tandem drive

shaft (18).
9. Push tandem drive shaft through inboard bearing cone
–UN–29JAN09
(19).
10. Remove outboard bearing cone retaining snap ring

(20) and pull outboard bearing cone (22) off tandem
TX1055096A
drive shaft.
NOTE: Tandem axle shaft bearings must be replaced

with reassembly. Attach Axle Adjusting Tool and Chain Hoist

11. Inspect and replace as necessary. 26—Axle Adjusting Tool
TM11207 (11MAY09) 02-0250-37

051809
PN=151

–UN–23AUG88
12. Heat outboard bearing cone and install on outboard
(sprocket) end of tandem drive shaft just far enough
past groove in tandem drive shaft to allow installation
02
TS227
0250 of bearing retaining snap ring.
38 Handle Fluids Safely—Avoid Fires
Specification
Bearing Cone—Temperature .................................................. 116—127°C
240—260°F
13. Install bearing retaining snap ring in groove next to

outboard bearing cone. Be sure bearing retaining
snap ring is firmly seated in groove.
NOTE: If bearing cone did not properly seat against snap

ring, install a 1.0 in. UNC cap screw with a
washer through hole in inboard bearing driver and
into tapped hole in tandem drive shaft. Use
tandem drive sprocket as a holding tool and
tighten cap screw to push bearing cone firmly
against snap ring. Be careful not to damage
threads in tandem drive shaft.
14. Seat outboard bearing cone firmly against bearing

cone retaining snap ring using DFT1151 Outboard
Bearing Driver and DFT1152 Inboard Bearing Driver.
15. Install beveled end of DFT1151 Outboard Bearing

Driver against bearing cone and DFT1152 Inboard
Bearing Driver against outboard bearing driver and
rap inboard bearing driver with a lead hammer.
16. Remove electrical tape from oil seal surface on

tandem drive shaft and wipe clean.
17. Protect seal (21) from damage by wrapping inboard

(carrier) end shaft splines and groove edges with
electrical tape. Install tandem drive shaft with
outboard bearing cup into outboard (sprocket) end of
final drive axle housing.
TM11207 (11MAY09) 02-0250-38

051809
PN=152
18. Position final drive axle housing with mounting flange

up. Support tandem drive shaft using a steel ball in
center to allow bearing cone to be seated in bearing
cup (24) while rotating tandem drive shaft.
19. Remove electrical tape from shaft.
02
0250
Continued on next page JW00603,000011F –19–21JAN09–5/6 39
TM11207 (11MAY09) 02-0250-39

051809
PN=153

–UN–23AUG88
NOTE: If bearing cone did not install onto shaft far
enough to permit installation of snap ring , place a
1.0 in. UNC cap screw with washer through hole
02
TS227
0250 in inboard bearing driver and into tapped hole in
40 tandem drive shaft. Use tandem drive sprocket as Handle Fluids Safely—Avoid Fires
a holding tool and alternately tighten cap screw
and turn shaft to push bearing cone past groove
in shaft just enough to allow snap ring to be
installed in groove. Be careful not to damage
threads in shaft.
20. Heat inboard (carrier) end bearing cone (19) and

install over inboard (carrier) end of tandem drive
shaft. Quickly seat bearing cone firmly into inboard
bearing cup (23) using inboard bearing driver and a
lead hammer while rotating tandem drive shaft.
Specification
Bearing Cone—Temperature .................................................. 116—127°C
240—260°F
21. Install bearing cone retaining snap ring in groove next

to inboard bearing cone. Be sure snap ring is firmly
seated in groove.
22. Install planet pinion carrier. See Planet Pinion Carrier

23. Install brake components. See Brake Component

24. Install final drive axle. See Final Drive Axle Remove
JW00603,000011F –19–21JAN09–6/6
TM11207 (11MAY09) 02-0250-40

051809
PN=154
Drive Chain Remove and Install
NOTE: Right side is shown. Left side is similar.


02
appropriate lifting device. 0250
41
3. Raise tandem housing and support with appropriate
lifting device. See Machine Specifications for machine
weights. (Operator’s Manual.)
4. Remove wheels from tandem. See Wheel Remove and

5. Drain tandem assembly. See Changing Tandem Oil.

JW00603,0000120 –19–21JAN09–1/5
6. Remove cap screws (1) and platforms (2) from tandem 1 1

2 3
assembly (3).

2—Platform (2 used)
–UN–29APR09
3—Tandem Assembly
TX1058899
Tandem Assembly Platforms
TM11207 (11MAY09) 02-0250-41

051809
PN=155
7. Remove cap screws (4) and access covers (5).

4 5
CAUTION: Avoid injury from unexpected 5

machine movement. Ensure that differential
lock switch is in OFF position so the tandem
–UN–29APR09
assemblies are able to rotate independently
from each other.
8. Turn differential lock switch to OFF position.
TX1058900
02
0250 4—Cap Screw (28 used)
42 5—Access Cover (6 used) Tandem Assembly Access Covers
TM11207 (11MAY09) 02-0250-42

051809
PN=156
CAUTION: Avoid injury from unexpected

machine movement. Ensure that area is clear of
bystanders before operating the machine.
9. Start machine and slowly rotate wheels to position
–UN–29APR09
chain connecting link (6) in a top cover opening.
10. Turn machine off.
TX1058901
11. Remove cotter pins (8) and end plate (7) from
02
connecting link through side cover. 0250
Drive Chain Connecting Link 43
12. Remove connecting link from drive chain.
6—Connecting Link
13. Remove drive chain from tandem housing. 7—End Plate
8—Cotter Pin (2 used)

necessary.
15. Position chain on drive sprocket and turn opposing

wheel to feed chain to wheel axle sprocket. Position
ends of chain in top cover opening.
16. Pull chain ends together.
17. Install connecting link so pins are directed away from

center of tandem housing. Cotter pins will be close to
sides of tandem housing.
18. Install end plate and cotter pins.
19. Install access covers. Apply PM37418 LOCTITE

Thread Lock and Sealer (medium strength) to threads
of cap screws and tighten to specification.
Specification
Planetary Housing-to-Wheel Hub
Cap Screw—Torque ....................................................................... 47 N•m
35 lb-ft
20. Install platforms on tandem assembly.
21. Install wheels to tandem assembly. See Wheel

22. Fill tandem assembly with oil. See Changing Tandem

LOCTITE is a trademark of Henkel Corporation Continued on next page JW00603,0000120 –19–21JAN09–4/5
TM11207 (11MAY09) 02-0250-43

051809
PN=157
JW00603,0000120 –19–21JAN09–5/5
02
0250
44
TM11207 (11MAY09) 02-0250-44

051809
PN=158
Group 0260
Hydraulic System
6WD Pump Remove and Install

2. Turn battery disconnect switch to OFF position or

disconnect negative battery cable.
3. To access 6WD pumps, remove right rear access

panel and access door panel.
02
0260
JW00603,00000FA –19–14MAY09–1/4 1
4. Attach identification tags on hydraulic oil lines. Remove

hydraulic oil lines (1, 3, and 4). Cap and plug all
opening.
5. Support filter bank panel (6) up.
6. Remove filter bank support (5).
7. Disconnect rear platform harness-to-transmission

harness connector (2).
8. Remove cap screws to tip hydraulic oil cooler down.

For cap screw location, see Hydraulic and Differential
–UN–25FEB09
Oil Cooler Remove and Install. (Group 0510.)
1—Hydraulic Oil Return to Hydraulic Tank from 6WD

Pumps
TX1055626A
2—Rear Platform Harness-to-Transmission Harness
Connector
3—From Differential Cooler to Differential Filter
4—From Hydraulic Oil Cooler to Hydraulic Oil Tank 6WD Hydraulic Pumps
5—Filter Bank Support
6—Filter Bank Panel
7—Transmission Filter Base
Continued on next page JW00603,00000FA –19–14MAY09–2/4
TM11207 (11MAY09) 02-0260-1

051809
PN=159
Hydraulic System

Disconnect forward and reverse hoses (8, 10, 11, and 17
12) from right side of 6WD pump. Cap and plug all 13
openings.
10. Disconnect operating charge pressure hose (9). Cap 15

12 19
and plug all openings.
11. Remove transmission filter base (7) from filter bank

panel. Support filter off to the side of filter bank panel.
02
0260 12. Attach identification tags on hydraulic oil hoses.
2
Disconnect hoses (13, 14, 15, 17, and 19) from left 11
side of 6WD pump. Also disconnect 6WD pump
–UN–26FEB09
crossover return (18). Cap and plug all openings. 1
8
CAUTION: Prevent possible crushing injury 10 9
TX1055658
device.
6WD Pump Right Side View
13. Support 6WD pump.
Specification
6WD Pumps (both pumps)—
313 lb.
14. Remove 6WD pump support bracket cap screws (16).

13
15. Remove 6WD pump-to-transmission cap screws (20). 18
1—Hydraulic Oil Return-to-Hydraulic Tank from 6WD

Pumps
8—6WD Right Reverse
9—Operating Charge Pressure Drain
10—6WD Left Reverse
11—6WD Left Forward
–UN–26FEB09
12—6WD Right Forward
13—6WD Motor Flushing Relief Valve
14—Flushing Valve Pressure 20 19 17 16
15—Oil Cooler Bypass Valve
16—6WD Pump Support Bracket Cap Screw (4 used)
TX1055659
17—Neutral Charge Pressure Valve 15 14

18—6WD Pump Crossover Return (operating charge
pressure)
19—From Hydraulic Oil Filter 6WD Pump Left Side View
20—6WD Pump-to-Transmission Cap Screws (4 used)
Continued on next page JW00603,00000FA –19–14MAY09–3/4
TM11207 (11MAY09) 02-0260-2

051809
PN=160
Hydraulic System
16. Inspect, repair or replace parts as necessary. See

6WD Pump Disassemble and Assemble. (Group
0260.)
17. Install 6WD pump to transmission.
18. Install 6WD pump-to-transmission cap screws.
19. Install 6WD pump support bracket cap screws.
20. Connect 6WD pump crossover return tube. 02

0260
3
21. Connect all hydraulic hose to proper location on right
side of pumps.
22. Connect all hydraulic hoses to proper location on left

side of pumps.
23. Install transmission filter base on filter bank panel.
24. Connect rear platform harness-to-transmission

harness connector.
25. Install filter bank support.
26. Tip hydraulic oil cooler back into location and install
cap screws.
27. Install access panel and door.

29. Run 6WD pump start up procedure. See 6WD

Start-Up Procedure. (Group 9016-20.)
JW00603,00000FA –19–14MAY09–4/4
TM11207 (11MAY09) 02-0260-3

051809
PN=161
Hydraulic System
6WD Pump Disassemble
02
0260
4
–UN–07MAY09
TX1058951
6WD Pump Housing Assembly
TM11207 (11MAY09) 02-0260-4

051809
PN=162
Hydraulic System
1—Control Valve-to-Pump 9—Feedback Link 16—O-Ring (2 used) 26—Spring

Housing Cap Screw (5 10—Plug (5 used) 17—Orifice (2 used) 27—Spool
used) 11—O-Ring (5 used) 18—6WD Pump Housing 28—O-Ring
2—Solenoid Coil (2 used) 12—Control Piston 19—Pump Housing Seal 29—Plug
3—Solenoid Tube (2 used) Cover-to-Pump Housing 20—Seal 30—O-Ring
4—O-Ring (2 used) Cap Screw (8 used) 21—Snap Ring 31—Control Piston Cover
5—Solenoid Cap (2 used) 13—Control Piston Cover 22—O-Ring 32—Bearing Cup
6—Control Valve (adjustment side) 23—Lower Clocking Link 33—Bearing
7—Control Valve-to-Pump 14—Piston Cover O-Ring (2 Retaining Plug 34—Snap Ring
Housing Gasket used) 24—Pressure Relief Valve 35—Drive Shaft
8—Upper Clocking Link 15—Backup Ring (2 used) 25—Shim (as required)
Retaining Plug
02
0260
Continued on next page JW00603,0000122 –19–14MAY09–2/29 5
TM11207 (11MAY09) 02-0260-5

051809
PN=163
Hydraulic System
36
37
40
02
38 44A
0260
6
39
41
42
43
44B
45
47 49
46 50
64
52
48 51
65 53
54
64
55
53
56
57
46
63
62
61
60
63
66 54 59
68
–UN–12MAY09
47
70 67
69 48
71
72 58
TX1058952
TX1058952
6WD Pump End Cap Assembly
TM11207 (11MAY09) 02-0260-6

051809
PN=164
Hydraulic System
36—6WD Motor Flushing 44A—Gerotor (star) 53—Fitting (2 used) 63—Dowel Pin (3 used)
Pump Cover-to-End Cap 44B—Gerotor (outer ring) 54—Dowel (2 used) 64—O-Ring (2 used)
Cap Screw (4 used) 45—Valve Plate 55—Plug 65—Plug (2 used)
37—Washer (4 used) 46—End Cap-to-Pump Housing 56—Ring (2 used) 66—O-Ring (2 used)
38—6WD Motor Flushing Cap Screw (8 used) 57—Ring (2 used) 67—Spool (2 used)
Pump Cover 47—Circuit Relief and Make-Up 58—End Cap-to-Pump Housing 68—Washer (2 used)
39—O-Ring Valve (2 used) Gasket 69—Spring (2 used)
40—Pin 48—O-Ring (2 used) 59—Valve Plate 70—Shim (as required)
41—6WD Motor Flushing 49—Plug (2 used) 60—Bearing 71—Pressure Override Valve
Pump Coupling 50—O-Ring (2 used) 61—Bearing Cup (2 used)
42—Snap Ring 51—End Cap 62—Shim (as required) 72—Cap (2 used)
43—Eccentric Ring 52—Seal (4 used)
02
0260
Continued on next page JW00603,0000122 –19–14MAY09–4/29 7
TM11207 (11MAY09) 02-0260-7

051809
PN=165
Hydraulic System
76
78
73 74 79 81
80
75 82
02
0260
76 83
8
77
75
85 86
87
89
90
84
91
86 93 92
87
–UN–07MAY09
88 92
93 91
TX1058954
TX1058954
6WD Pump Rotate Group
TM11207 (11MAY09) 02-0260-8

051809
PN=166
Hydraulic System
73—Bearing Plate 79—Cap Screw (4 used) 84—Piston (9 used) 89—Control Piston

74—Snap Ring 80—Washer (4 used) 85—Plate 90—Slide Block
75—Thrust Washer (2 used) 81—Plate (2 used) 86—Spring (2 used) 91—Clocking Link (2 used)
76—Dowel Pin (2 used) 82—Spacer (4 used) 87—Washer (2 used) 92—Locating Pin (2 used)
77—Spring 83—Piston Spacer 88—Swash Plate 93—Bearing (2 used)
78—Piston Housing
NOTE: 6WD pump assembly includes two similar 2. Remove left 6WD pump from right 6WD pump.
pumps mounted in-line with a 6WD motor
flushing pump mounted at the end of the 3. Remove pressure override valves (71).
assembly. Disassemble procedure for one
6WD pump is explained. Procedure for both 4. Repair or replace pressure override valve 02
pumps is similar. components as needed. 0260
9
1. Remove 6WD pump assembly from machine. See

6WD Pump Remove and Install. (Group 0260.)
JW00603,0000122 –19–14MAY09–6/29
5. Remove and inspect circuit relief and make-up valves

(47).
6. Repair or replace circuit relief and make-up valves as

necessary.
–UN–06MAY09
7. Remove control valve-to-pump housing cap screws (1).
47—Circuit Relief and Make-Up Valve (2 used)
TX1058974A
Circuit Relief and Makeup Valves
TM11207 (11MAY09) 02-0260-9

051809
PN=167
Hydraulic System
8. Remove control valve (6).
9. Remove solenoid caps (5).
10. Remove O-rings (4) and solenoid coils (2).
–UN–06MAY09
11. Remove solenoid tubes (3).
12. Repair or replace parts as required.
TX1058965A
02 13. Install solenoid tubes. Tighten to specification.
0260
10 Specification Control Valve Assembly
Solenoid Tube—Torque ................................................................. 27 N•m
240 lb.-in. 2—Solenoid Coil (2 used)
3—Solenoid Tube (2 used)
14. Install solenoid coil and O-ring. 4—O-Ring (2 used)
5—Solenoid Cap (2 used)
6—Control Valve
15. Install solenoid cap. Tighten to specification.
Specification
Solenoid Cap—Torque ..................................................................... 3 N•m
27 lb.-in.
16. Set control valve assembly aside for 6WD pump

assembly.
JW00603,0000122 –19–14MAY09–8/29
17. Remove feedback link (9).
18. Disassemble 6WD motor flushing pump located on

the end of left 6WD pump.
–UN–06MAY09
IMPORTANT: Prevent damage to pump due to

misaligned flushing pump. Mark
orientation of 6WD flushing pump cover
before disassembly.
TX1058970A
a. Remove 6WD motor flushing pump cover-to-end

cap cap screw (36).
Feedback Link and Upper Clocking Link Retaining Plug
b. Remove 6WD motor flushing pump cover (38).
8—Upper Clocking Link Retaining Plug
9—Feedback Link
TM11207 (11MAY09) 02-0260-10

051809
PN=168
Hydraulic System
c. Remove 6WD motor flushing pump coupling (41)

and gerotor star (44A) as an assembly.
40—Shear Key
41—6WD Motor Flushing Pump Coupling
–UN–06MAY09
42—Snap Ring
44A—Gerotor (star)
TX1059118A
02
0260
6WD Motor Flushing Pump Coupling 11
–UN–06MAY09
TX1059119A
6WD Motor Flushing Pump Coupling and Gerotor Star
JW00603,0000122 –19–14MAY09–10/29
d. Remove gerotor outer ring (44B).
44B—Gerotor (outer ring)
–UN–06MAY09
TX1059121A
Gerotor Outer Ring
TM11207 (11MAY09) 02-0260-11

051809
PN=169
Hydraulic System

misaligned eccentric ring. Mark
orientation of eccentric ring before
disassembly.
–UN–06MAY09
e. Remove eccentric ring (43).
43—Eccentric Ring
TX1059122A
02
0260
12 Eccentric Ring
JW00603,0000122 –19–14MAY09–12/29

misaligned valve plate. Mark orientation
of valve plate before disassembly.
f. Remove valve plate (45).
–UN–06MAY09
45—Valve Plate
TX1059126A
Valve Plate
TM11207 (11MAY09) 02-0260-12

051809
PN=170
Hydraulic System

escaping parts under preload. Evenly loosen
cap screws in a criss-cross pattern to ensure
safe removal of end cap.
–UN–06MAY09
19. Slowly remove cap screws (46).
IMPORTANT: Internal parts are not secure. Internal
TX1059130A
parts may fall out of pump housing
when end cap is removed, secure
02
internal parts while removing end cap. 0260
End Cap 13
20. Remove end cap (51).
46—End Cap-to-Pump Housing Cap Screw (8
used)
51—End Cap
JW00603,0000122 –19–14MAY09–14/29
21. Remove valve plate (59).
59—Valve Plate
63—Dowel Pin
–UN–06MAY09
TX1059133A
Valve Plate
TM11207 (11MAY09) 02-0260-13

051809
PN=171
Hydraulic System
22. Remove bearing cup (61).
61—Bearing Cup
–UN–06MAY09
TX1059135A
02
0260
14 Bearing Cup
JW00603,0000122 –19–14MAY09–16/29
NOTE: Note number and position of shims for ease of

assembly.
23. Remove shims (62).
–UN–06MAY09
62—Shim (as required)
TX1059138A
Shims
TM11207 (11MAY09) 02-0260-14

051809
PN=172
Hydraulic System
24. Remove bearing plate (73).
25. Remove springs (86) and washers (87).
73—Bearing Plate
–UN–06MAY09
86—Spring (2 used)
87—Washer (2 used)
TX1059142A
02
0260
Bearing Plate 15
JW00603,0000122 –19–14MAY09–18/29
NOTE: Snap ring is located on the right 6WD pump only.
26. Remove snap ring (21) from right 6WD pump.
27. Remove rotating group from 6WD pump housing (18).
–UN–06MAY09
21—Snap Ring
TX1058973A
Right 6WD Pump Snap Ring
TM11207 (11MAY09) 02-0260-15

051809
PN=173
Hydraulic System
28. Remove slide block (90) from swash plate (88).
88—Swash Plate
90—Slide Block
–UN–07MAY09
TX1059192A
02
0260
16 Slide Block
JW00603,0000122 –19–14MAY09–20/29
29. Remove bearing (60) from drive shaft (35).
NOTE: Rotate group and swash plate are serviced as

one assembly.
–UN–07MAY09
30. Remove rotate group and swash plate (100) from
drive shaft.
35—Drive Shaft
TX1059194A
60—Bearing
100—Rotate Group and Swash Plate
Rotate Group and Bearing
TM11207 (11MAY09) 02-0260-16

051809
PN=174
Hydraulic System
31. Remove upper clocking link retaining plug (8).

9—Feedback Link
–UN–06MAY09
TX1058970A
02
0260
Control Feedback Link and Upper Clocking link Retaining Plug 17
JW00603,0000122 –19–14MAY09–22/29
32. Remove lower clocking link retaining plug (23) from

6WD pump housing (18).
18—6WD Pump Housing

23—Lower Clocking Link Retaining Plug
–UN–07MAY09
TX1059196A
Lower Clocking Link Retaining Plug
TM11207 (11MAY09) 02-0260-17

051809
PN=175
Hydraulic System
33. Remove bearings (93A), bearing races (93B), and

clocking links (91).
91—Clocking Link (2 used)

93A—Bearing (2 used)
–UN–07MAY09
93B—Bearing Race (2 used)
TX1059223A
02
0260
18 Bearings, Clocking Links, and Bearing Races
JW00603,0000122 –19–14MAY09–24/29
34. Remove pump housing seal (19) from 6WD pump

housing (18).
35. Remove bearing cup (32) from 6WD pump housing.
–UN–08MAY09
19—Pump Housing Seal
32—Bearing Cup
TX1059226A
6WD Pump Housing Seal
TM11207 (11MAY09) 02-0260-18

051809
PN=176
Hydraulic System
36. Remove control piston cover-to-pump housing cap

screws (12) and control piston cover (31).
12—Control Piston Cover-to-Pump Housing Cap

Screw (4 used)
–UN–08MAY09
31—Control Piston Cover
TX1059230A
02
0260
Control Piston Cover 19
JW00603,0000122 –19–14MAY09–26/29
37. Remove control piston adjustment screw (101) from

control piston cover (13).
38. Remove control piston cover-to-pump housing cap

screws (12) and control piston cover.
–UN–08MAY09
Screw (4 used)
13—Control Piston Cover (adjustment side)
TX1059231A
101—Control Piston Adjustment Screw
Control Piston Cover (adjustment side)
TM11207 (11MAY09) 02-0260-19

051809
PN=177
Hydraulic System
39. Remove control piston cover O-rings (14) from control

piston covers (13 and 31).
40. Remove control piston from 6WD pump housing.
–UN–08MAY09
14—Control Piston Cover O-Ring (2 used)
TX1059237A
02
0260
20 Control Piston Cover O-Rings
JW00603,0000122 –19–14MAY09–28/29
IMPORTANT: Prevent damage to pump. Do not

scratch piston bore when removing
O-rings and backup rings.
41. Remove backup rings (15) and O-rings (16) from
–UN–08MAY09
control piston bore (102).
15— Backup Ring (2 used)
TX1059240A
102—Control Piston Bore
Control Piston Bore
–UN–08MAY09
TX1059241A
Control Piston O-Rings and Backup Rings
JW00603,0000122 –19–14MAY09–29/29
TM11207 (11MAY09) 02-0260-20

051809
PN=178
Hydraulic System
02
0260
21
TM11207 (11MAY09) 02-0260-21

051809
PN=179
Hydraulic System
6WD Pump Assemble
02
0260
22
–UN–07MAY09
TX1058951
6WD Pump Housing Assembly
Continued on next page BR70016,000006A –19–14MAY09–1/37
TM11207 (11MAY09) 02-0260-22

051809
PN=180
Hydraulic System
1—Control Valve-to-Pump 9—Feedback Link 16—O-Ring (2 used) 26—Spring

Housing Cap Screw (5 10—Plug (5 used) 17—Orifice (2 used) 27—Spool
used) 11—O-Ring (5 used) 18—6WD Pump Housing 28—O-Ring
2—Solenoid Coil (2 used) 12—Control Piston 19—Pump Housing Seal 29—Plug
3—Solenoid Tube (2 used) Cover-to-Pump Housing 20—Seal 30—O-Ring
4—O-Ring (2 used) Cap Screw (8 used) 21—Snap Ring 31—Control Piston Cover
5—Solenoid Cap (2 used) 13—Control Piston Cover 22—O-Ring 32—Bearing Cup
6—Control Valve (adjustment side) 23—Lower Clocking Link 33—Bearing
7—Control Valve-to-Pump 14—Piston Cover O-Ring (2 Retaining Plug 34—Snap Ring
Housing Gasket used) 24—Pressure Relief Valve 35—Drive Shaft
8—Upper Clocking Link 15—Backup Ring (2 used) 25—Shim (as required)
Retaining Plug
02
0260
Continued on next page BR70016,000006A –19–14MAY09–2/37 23
TM11207 (11MAY09) 02-0260-23

051809
PN=181
Hydraulic System
36
37
40
02
38 44A
0260
24
39
41
42
43
44B
45
47 49
46 50
64
52
48 51
65 53
54
64
55
53
56
57
46
63
62
61
60
63
66 54 59
68
–UN–12MAY09
47
70 67
69 48
71
72 58
TX1058952
TX1058952
6WD Pump End Cap Assembly
TM11207 (11MAY09) 02-0260-24

051809
PN=182
Hydraulic System
36—6WD Motor Flushing 44A—Gerotor (star) 53—Fitting (2 used) 63—Dowel Pin (3 used)
Pump Cover-to-End Cap 44B—Gerotor (outer ring) 54—Dowel (2 used) 64—O-Ring (2 used)
Cap Screw (4 used) 45—Valve Plate 55—Plug 65—Plug (2 used)
37—Washer (4 used) 46—End Cap-to-Pump Housing 56—Ring (2 used) 66—O-Ring (2 used)
38—6WD Motor Flushing Cap Screw (8 used) 57—Ring (2 used) 67—Spool (2 used)
Pump Cover 47—Circuit Relief and Make-Up 58—End Cap-to-Pump Housing 68—Washer (2 used)
39—O-Ring Valve (2 used) Gasket 69—Spring (2 used)
40—Pin 48—O-Ring (2 used) 59—Valve Plate 70—Shim (as required)
41—6WD Motor Flushing 49—Plug (2 used) 60—Bearing 71—Pressure Override Valve
Pump Coupling 50—O-Ring (2 used) 61—Bearing Cup (2 used)
42—Snap Ring 51—End Cap 62—Shim (as required) 72—Cap (2 used)
43—Eccentric Ring 52—Seal (4 used)
02
0260
Continued on next page BR70016,000006A –19–14MAY09–4/37 25
TM11207 (11MAY09) 02-0260-25

051809
PN=183
Hydraulic System
76
78
73 74 79 81
80
75 82
02
0260
76 83
26
77
75
85 86
87
89
90
84
91
86 93 92
87
–UN–07MAY09
88 92
93 91
TX1058954
TX1058954
6WD Pump Rotate Group
TM11207 (11MAY09) 02-0260-26

051809
PN=184
Hydraulic System
73—Bearing Plate 79—Cap Screw (4 used) 84—Piston (9 used) 89—Control Piston

74—Snap Ring 80—Washer (4 used) 85—Plate 90—Slide Block
75—Thrust Washer (2 used) 81—Plate (2 used) 86—Spring (2 used) 91—Clocking Link (2 used)
76—Dowel Pin (2 used) 82—Spacer (4 used) 87—Washer (2 used) 92—Locating Pin (2 used)
77—Spring 83—Piston Spacer 88—Swash Plate Assembly 93—Bearing (2 used)
78—Piston Housing
IMPORTANT: Prevent catastrophic pump damage. flushing pump mounted at the end of the
Apply clean hydraulic oil to all assembly. Assembly procedure for one 6WD
bearings and finished surfaces. pump is explained. Procedure for both pumps
is similar.
IMPORTANT: Prevent damage to pump seals and 02
O-rings. Lubricate all seals and 1. Inspect and replace damaged parts and 0260
27
O-rings with petroleum jelly during assemblies.
assembly.
2. Clean all parts and assemblies before assembly.
NOTE: 6WD pump assembly includes two similar
pumps mounted in-line with a 6WD motor
BR70016,000006A –19–14MAY09–6/37
IMPORTANT: Prevent damage to pump seals and

O-rings. Lubricate all seals and O-rings
with petroleum jelly during assembly.
3. Lubricate and install two new O-rings (16) and backup
–UN–08MAY09
rings (15) into control piston bore (102).
15— Backup Ring (2 used)
TX1059240A
102—Control Piston Bore
Control Piston Bore

–UN–08MAY09
TX1059241A
Control Piston O-Rings and Backup Rings
TM11207 (11MAY09) 02-0260-27

051809
PN=185
Hydraulic System
4. Lubricate and install new control piston cover O-rings

(14) on control piston covers (13 and 31).

14—Control Piston Cover O-Ring (2 used)
–UN–08MAY09
TX1059237A
02
0260
28 Control Piston Cover O-Rings
BR70016,000006A –19–14MAY09–8/37
5. Install control piston cover (13) to the approximate

middle of the control piston adjustment screw (101)
threads.
IMPORTANT: Prevent a possible leak, the beveled
–UN–11MAY09
side of the beveled washer must face
the threaded seal washer.
6. Install a new threaded seal washer (105), beveled
TX1059277A
washer (104), and adjustment screw lock nut (103) on
the adjustment screw. Do not tighten adjustment screw
lock nut at this time.
Control Piston Adjustment Screw
7. Lubricate and install control piston assembly into 6WD
pump housing.

103—Adjustment Screw Lock Nut
104—Beveled Washer
105—Threaded Seal Washer
TM11207 (11MAY09) 02-0260-28

051809
PN=186
Hydraulic System
8. Install control piston covers (13 and 31) and control

piston cover-to-pump housing cap screws (12). Tighten
cap screws to specification.
Specification
–UN–08MAY09
Control Piston Cover-to-Pump
Housing Cap Screw—Torque......................................................... 23 N•m
204 lb.-in.
TX1059230A
Screw (8 used)
02
0260
31—Control Piston Cover Control Piston Cover 29
–UN–08MAY09
TX1059231A
Control Piston Cover (adjustment end)
BR70016,000006A –19–14MAY09–10/37
9. Use a square (106) to set the flat side of the control

piston (89) perpendicular to the 6WD pump housing
(18) face as shown.
–UN–11MAY09
89—Control Piston
106—Square
TX1059310A
Control Piston
TM11207 (11MAY09) 02-0260-29

051809
PN=187
Hydraulic System
10. Install bearing cup (32) to 6WD pump housing (18).
11. Install pump housing seal (19) to 6WD pump housing.
–UN–08MAY09
19—Pump Housing Seal
32—Bearing Cup
TX1059226A
02
0260
30 6WD Pump Housing Seal
BR70016,000006A –19–14MAY09–12/37
12. Lubricate and install bearing races (93B) on their

locating pins (92) with the groove side of the races
toward the center of the 6WD pump housing.
13. Apply petroleum jelly on pin pivots and install clocking
–UN–07MAY09
links (91) into the 6WD pump housing.
14. Lubricate and install bearings (93A) into 6WD pump

housing.
TX1059223A
15. Lubricate and install bearing (33) and snap ring (34)
on drive shaft (35).
Bearings, Clocking Links, and Bearing Races
91—Clocking Link (2 used)

93A—Bearing (2 used)
93B—Bearing Race (2 used)
TM11207 (11MAY09) 02-0260-30

051809
PN=188
Hydraulic System
16. Lubricate and install drive shaft (35) into rotate group
(100) and swash plate assembly (88).
35—Drive Shaft
88—Swash Plate Assembly
–UN–11MAY09
100—Rotate Group
TX1059316A
02
0260
Rotate Group and Drive Shaft 31
BR70016,000006A –19–14MAY09–14/37
17. Lubricate and install bearing (60) onto drive shaft

(35).
35—Drive Shaft
60—Bearing
–UN–11MAY09
100—Rotate Group
TX1059321A
Rotate Group and Bearing
TM11207 (11MAY09) 02-0260-31

051809
PN=189
Hydraulic System
18. Install two identical rubber bands (107) across both

arms of the swash plate assembly (88) to hold the
swash plate assembly and rotate group (100)
approximately centered during assembly.
–UN–13MAY09
100—Rotate Group
107—Rubber Band (2 used)
TX1059325A
02
0260
32 Rubber Bands
BR70016,000006A –19–14MAY09–16/37
19. Lubricate and install slide block (90) onto swash plate
assembly (88).
20. Install rotate group, swash plate, drive shaft assembly

into 6WD pump housing.
–UN–13MAY09
90—Slide Block
TX1059326A
Slide Block
TM11207 (11MAY09) 02-0260-32

051809
PN=190
Hydraulic System
21. Install upper and lower clocking link retaining plugs (8

and 23). Tighten to specification.
Specification
Clocking Link Retaining Plug—
Torque .......................................................................................... 169 N•m
–UN–06MAY09
125 lb.-ft.
22. Remove rubber bands from both arms of the swash

plate assembly.
TX1058970A
02
23. Adjust control piston to zero position.
0260
Feedback Link and Upper Clocking Link Retaining Plug 33
9—Feedback Link
23—Lower Clocking Link Retaining Plug
–UN–07MAY09
TX1059196A
Lower Clocking Link Retaining Plug
BR70016,000006A –19–14MAY09–18/37
a. Place parallel bar (108) across face of 6WD pump

housing (18).
b. Record swash plate face (110) depth.
–UN–11MAY09
108—Parallel Bar
109—Depth Micrometer
110—Swash Plate Face
TX1059329A
Swash Plate Face Measurement Location One
TM11207 (11MAY09) 02-0260-33

051809
PN=191
Hydraulic System
c. Move parallel bar (108) to the opposite swash

plate face (110).
d. Record swash plate face depth at second location.
–UN–11MAY09
108—Parallel Bar
109—Depth Micrometer
110—Swash Plate Face
TX1059330A
02
0260
34 BR70016,000006A –19–14MAY09–20/37
e. Turn control piston adjustment screw (101) until

swash plate face depth is equal at both
measurement locations.
f. Hold control piston adjustment screw (101) at zero
–UN–13MAY09
position and tighten adjustment screw lock nut to
specification.
Specification
TX1059331A
Adjustment Screw Lock Nut—
Torque ............................................................................................ 61 N•m
45 lb.-ft.
Control Piston Adjustment
103—Adjustment Screw Lock Nut
BR70016,000006A –19–14MAY09–21/37
24. Install dowels (54), washers (87), springs (86), and

gasket (58) as shown.
54—Dowel (2 used)
58—End Cap-to-Pump Housing Gasket
–UN–12MAY09
86—Spring (2 used)
TX1059337A
Dowels, Washers, Springs, and Gasket
TM11207 (11MAY09) 02-0260-34

051809
PN=192
Hydraulic System
25. Lubricate and install shims (62) and bearing cup (61)
into end cap (51).
51—End Cap
61—Bearing Cup
–UN–11MAY09
TX1059343A
02
0260
End Cap 35
BR70016,000006A –19–14MAY09–23/37
26. Install end cap (51) on 6WD pump housing (18).
27. Use a machinist rule (111) to align swash plate hold

down ears and springs with recesses in end cap.
–UN–12MAY09
51—End Cap
111—Machinist Rule
TX1059345A
Swash Plate Alignment
TM11207 (11MAY09) 02-0260-35

051809
PN=193
Hydraulic System
28. Install four cap screws (46) and tighten.
46—End Cap-to-Pump Housing Cap Screw (8 used)
–UN–13MAY09
TX1059347A
02
0260
36 End Cap Cap Screws
BR70016,000006A –19–14MAY09–25/37
29. Seat drive shaft (35) to end cap by gently tapping

with a hammer (112) on the input side of the drive
shaft.
35—Drive Shaft
–UN–12MAY09
112—Hammer
TX1059348A
Seat Drive Shaft
TM11207 (11MAY09) 02-0260-36

051809
PN=194
Hydraulic System
NOTE: Snap ring is located on the right 6WD pump only.
30. Install snap ring (21) to right 6WD pump.
–UN–06MAY09
21—Snap Ring
TX1058973A
02
0260
Right 6WD Pump Snap Ring 37
BR70016,000006A –19–14MAY09–27/37
31. Measure drive shaft (35) end play with dial indicator
(113) while prying drive shaft up with pliers (114).
32. Compare measurements to specification.
–UN–12MAY09
Specification
Drive Shaft—End Play .............................................. 0.0508—0.1778 mm
0.002—0.007 in.
33. Add or remove shims (62) in end cap (51) to set end
TX1059352A
play to specification.
34. Remove end cap. Drive Shaft End Play Measurement
35—Drive Shaft
113—Dial Indicator
114—Pliers
TM11207 (11MAY09) 02-0260-37

051809
PN=195
Hydraulic System
35. Lubricate and install bearing plate (73).
73—Bearing Plate
–UN–13MAY09
TX1059353A
02
0260
38 Bearing Plate
BR70016,000006A –19–14MAY09–29/37
36. Apply petroleum jelly to the end cap (51) side of valve
plate (59).
37. Install valve plate into end cap.
–UN–13MAY09
38. Install end cap and cap screws (46). Tighten to
specification.
Specification
TX1059356A
End Cap-to-Pump Housing Cap
Screw—Torque ............................................................................... 88 N•m
65 lb.-ft.
Valve Plate
39. Assemble 6WD motor flushing pump to the end cap
of left 6WD pump. 51—End Cap
59—Valve Plate
TM11207 (11MAY09) 02-0260-38

051809
PN=196
Hydraulic System

misaligned valve plate. Align valve plate
with alignment mark during assembly.
a. Lubricate and install valve plate (45) in end cap
–UN–13MAY09
(51). Align narrow side of oil passage (116) with
alignment mark (115) on end cap.
TX1059360A
45—Valve Plate
51—End Cap
115—Alignment Mark 02
116—Oil Passage 0260
6WD Motor Flushing Pump Valve Plate 39
BR70016,000006A –19–14MAY09–31/37

misaligned eccentric ring. Align
eccentric ring with marks made during
disassembly.
–UN–06MAY09
b. Lubricate and install eccentric ring (43).
43—Eccentric Ring
TX1059122A
Eccentric Ring
TM11207 (11MAY09) 02-0260-39

051809
PN=197
Hydraulic System
c. Lubricate and install gerotor outer ring (44B).
44B—Gerotor (outer ring)
–UN–06MAY09
TX1059121A
02
0260
40 Gerotor Outer Ring
BR70016,000006A –19–14MAY09–33/37
d. Lubricate and install 6WD motor flushing pump

coupling (41) and gerotor star (44A).
40—Shear Key
41—6WD Motor Flushing Pump Coupling
–UN–06MAY09
42—Snap Ring
44A—Gerotor (star)
TX1059118A
6WD Motor Flushing Pump Coupling
–UN–06MAY09
TX1059119A
6WD Motor Flushing Pump Coupling and Gerotor Star
TM11207 (11MAY09) 02-0260-40

051809
PN=198
Hydraulic System

misaligned flushing pump. Align notch
on flushing pump cover with flushing
pump inlet during assembly.
–UN–13MAY09
e. Install 6WD motor flushing pump cover (38) with
notch (117) facing 6WD motor flushing pump inlet.
f. Install cap screws (36) and tighten to specification.
TX1059371A
Specification 02
6WD Motor Flushing Pump 0260
Cover-to-End Cap Cap Screw— 6WD Motor Flushing Pump Cover Notch 41
Torque ............................................................................................ 30 N•m
22 lb.-ft.
36—6WD Motor Flushing Pump Cover-to-End Cap

Cap Screw (4 used)
38—6WD Motor Flushing Pump Cover
–UN–13MAY09
51—End Cap
117—Notch
118—6WD Motor Flushing Pump Inlet
TX1059372A
6WD Motor Flushing Pump Cover
BR70016,000006A –19–14MAY09–35/37
40. Lubricate and install feedback link (9).
41. Install control valve gasket (7) and control valve

assembly (6) onto 6WD pump housing (18).
–UN–06MAY09
42. Install control valve-to-6WD pump housing cap
screws (1). Tighten to specification.
Specification
TX1058970A
Control Valve-to-6WD Pump
Housing Cap Screws—Torque ....................................................... 30 N•m
22 lb.-ft.
Feedback Link
9—Feedback Link
TM11207 (11MAY09) 02-0260-41

051809
PN=199
Hydraulic System
43. Repair or replace circuit relief and make-up valves

(47) as needed.
44. Install circuit relief and make-up valves. Tighten to

specification.
–UN–06MAY09
Specification
6WD Circuit Relief and Make-Up
Valve—Torque .............................................................................. 176 N•m
130 lb.-ft.
TX1058974A
02
45. Repair or replace pressure override valve (71)
0260
42 components as needed.
Circuit Relief and Makeup Valves
46. Install pressure override valves. Tighten to 47—Circuit Relief and Make-Up Valve (2 used)
specification.
Specification
Pressure Override Valve—Torque ............................................... 136 N•m
100 lb.-ft..
47. Connect left 6WD pump to right 6WD pump.
48. Install 6WD pump assembly to machine. See 6WD

Pump Remove and Install. (Group 0260.)
BR70016,000006A –19–14MAY09–37/37
6WD Charge Pump Remove and Install
See Hydraulic Fan Pump Remove and Install. (Group

2160.)
JW00603,0000123 –19–21JAN09–1/1
6WD Engagement Manifold Remove and

Install
1. Park machine on a hard level surface and lower all

attachments.
Continued on next page PG32926,000006C –19–20APR09–1/4
TM11207 (11MAY09) 02-0260-42

051809
PN=200
Hydraulic System
3. Remove cap screw (2) and side access panel (1).
1—Side Access Panel (2 used)

2—Cap Screw (2 Used)
–UN–28APR09
TX1058840A
02
0260
Side Access Panel 43
PG32926,000006C –19–20APR09–2/4
4. Remove cap screws (4) and top access panel (3).
5. Install vacuum pump on hydraulic oil tank. See

Vacuum Pump Installation. (Group 2160.)
–UN–21APR09
3—Top Access Panel
TX1058530A
Top Access Panel
Continued on next page PG32926,000006C –19–20APR09–3/4
TM11207 (11MAY09) 02-0260-43

051809
PN=201
Hydraulic System
6. Install identification tags on hydraulic lines (5-18).

15 14 13
7. Disconnect hydraulic lines. Close all openings using
caps and plugs.

8. Remove cap screws and 6WD engagement manifold.
02
Specification
0260 17 16
44
6WD Engagement Manifold 18
(approximate)—Weight ...................................................................... 33 kg
73 lb 10 5
–UN–21APR09
6
9. Clean and inspect parts. Repair or replace parts as 11
necessary. 7
TX1058479
9 8
10. Install 6WD engagement manifold and cap screws.
11. Connect hydraulic lines. 6WD Engagement Manifold
12. Remove vacuum pump and check for leaks. 5—Drain Line Engagement Valve Hydraulic Line
6—Right Forward Hydraulic Line
7—Left Forward Hydraulic Line
13. Check hydraulic tank oil level. See Checking 8—Left Motor Drain Line
Hydraulic Tank Oil Level. (Operator’s Manual.) 9—Right Reverse Hydraulic Line
10—Right Motor Drain Line Hydraulic Line
14. Install top access panel and cap screws. 11—Left Reverse Hydraulic Line
12—Right Brake Hydraulic Line
13—Left Brake Hydraulic Line
15. Install side access panel and cap screw. 14—Left Forward Hydraulic Line
15—Right Forward Hydraulic Line
16—Right Reverse Hydraulic Line
17—Return Oil Line Engagement Manifold
Hydraulic Line
18—Left Reverse Hydraulic Line
PG32926,000006C –19–20APR09–4/4
TM11207 (11MAY09) 02-0260-44

051809
PN=202
Hydraulic System
Differential Lock Pump Remove and Install


02
Frame. (Operator’s Manual.) 45
MM16284,0000DC7 –19–14MAY09–1/2
3. Attach identification tags and remove hoses (1 and 4).

4. Remove cap screws (2) and remove differential pump.

1 2
5. Remove O-ring.
6. Replace parts as necessary. 3
IMPORTANT: Fill pump case with proper oil before

startup.
7. Install O-ring and shaft coupler. 4
–UN–29APR09
8. Position pump input shaft into coupling and push into
place.
9. Install cap screws and tighten to specification.

TX1058956
Specification
Differential Lock Pump Cap Differential Lock Pump
Screw-to-Transmission—Torque .................................................... 61 N•m
45 lb.-ft. 1—Differential Oil Filter Hose
10. Install hydraulic hoses. 3—Differential Lock Pump
4—Differential Housing Hose
11. Start machine and check for leaks.

MM16284,0000DC7 –19–14MAY09–2/2
TM11207 (11MAY09) 02-0260-45

051809
PN=203
Hydraulic System
6WD Motor Remove and Install


02


(Group 0110.)

surface.
5. Remove front hub, spindle, and yoke assembly. See

6WD. (Group 0240.)
6. Remove yoke from spindle and hub. See Front Wheel

Hub and Spindle Disassemble and Assemble with
Steering Angle Sensor—6WD or see Front Wheel Hub
and Spindle Disassemble and Assemble—6WD.
(Group 0240.)
Continued on next page MM16284,0000DC5 –19–14MAY09–1/2
TM11207 (11MAY09) 02-0260-46

051809
PN=204
Hydraulic System
7. Remove cap screw (2).

–UN–29APR09
8. Support 6WD motor.
Specification
6WD Motor—Weight.......................................................................... 29 kg
TX1058972A
64 lb.
02
9. Remove motor. 0260
6WD Motor 47
10. Inspect and repair or replace parts as necessary. See 1—6WD Motor
6WD Motor Disassemble and Assemble. (Group 2—Cap Screw (2 used)
0260.)
11. Install motor. Tighten cap screws to specifications.
Specification
6WD Motor-to-Housing Cap
Screw—Torque ............................................................................. 495 N•m
365 lb.-ft.
12. Install yoke to spindle and hub assembly. See Front

Wheel Hub and Spindle Disassemble and Assemble
with Steering Angle Sensor—6WD or see Front
Wheel Hub and Spindle Disassemble and
Assemble—6WD. (Group 0240.)
13. Install front hub, spindle, and yoke assembly. See

6WD. (Group 0240.)

(Group 0110.)

MM16284,0000DC5 –19–14MAY09–2/2
TM11207 (11MAY09) 02-0260-47

051809
PN=205
Hydraulic System
6WD Motor Disassemble and Assemble
4
24 15
5 18
23 15
16
22 16
02
0260 15
48 16 20
16
5
9 4
9
15
8
2
1
5 10
6
17
13
4
5
14
11
17
13
12
5
–UN–29APR09
11 4 6
4
12 5
TX1058913
5
TX1058913 7
6WD Motor
TM11207 (11MAY09) 02-0260-48

051809
PN=206
Hydraulic System
1—Ring 7—Cap Screw (8 used) 13—Spring (2 used) 18—Cap Screw (4 used)

2—O-Ring 8—O-Ring 14—Spool 20—End Cap
3—Piston 9—O-Ring (5 used) 15—Plug (4 used) 22—Solenoid Valve Spool
4—Plug (4 used) 10—Gasket 16—O-Ring (4 used) 23—Solenoid Valve Coil
5—O-Ring (6 used) 11—Plug (2 used) 17—Spring Seat (2 used) 24—Nut
6—6WD Motor Shuttle Valve 12—O-Ring (2 used)
Plug (2 used)
02
0260
Continued on next page MM16284,0000DC8 –19–29APR09–2/4 49
TM11207 (11MAY09) 02-0260-49

051809
PN=207
Hydraulic System
40
38
40
35
43
02 39
0260
50
36
41
42
45
33
34
32
48 46
32
47
34
33
44
–UN–29APR09
37
31
TX1058924
TX1058924
6WD Motor
TM11207 (11MAY09) 02-0260-50

051809
PN=208
Hydraulic System
31—Valve 36—Cap Screw (8 used) 41—Retaining Ring 45—Piston Ring (9 used)

32—Dowel Pin (2 used) 37—Valve Plate 42—Gasket 46—Front Motor Speed Sensor
33—Plug (2 used) 38—Seal 43—Seal 47—O-Ring
34—O-Ring (2 used) 39—O-Ring 44—Shaft 48—Cap Screw
35—O-Ring 40—Retaining Ring (2 used)
1. Disassemble parts as shown. End Cap Cap Screw (18)—

Torque.................................................................................... 110 N•m
81 lb.-ft.
2. Clean and inspect parts. Repair or replace parts as Plug (4)—Torque ..................................................................... 20 N•m
necessary. 177 lb-in.
End Cap Plug (15)—Torque ...................................................... 9 N•m
3. Assemble parts. Tighten to specifications. 80 lb-in. 02
Housing Cap Screw (7)— 0260
Torque...................................................................................... 66 N•m 51
6WD Motor—Specification
6WD Motor Shuttle Valve Plug 49 lb.-ft.
(6)—Torque.............................................................................. 37 N•m Plug (11)—Torque ............................................................ 32—44 N•m
27 lb.-ft. 24—33 lb.-ft.
6WD High/Low Speed Solenoid
Valve Nut (24)—Torque........................................................ 5—7 N•m
44—62 lb-in.
MM16284,0000DC8 –19–29APR09–4/4
TM11207 (11MAY09) 02-0260-51

051809
PN=209
Hydraulic System
02
0260
52
TM11207 (11MAY09) 02-0260-52

051809
PN=210
Section 03
Transmission
Contents
Page

DF180 Transmission . . . . . . . . . . . . . . . . . . .03-0300-1
Transmission Remove and Install . . . . . . . . .03-0300-3

Transmission Charge Pump Remove and
03
Install. . . . . . . . . . . . . . . . . . . . . . . . . . . . .03-0360-1
770G,
051809
PN=1
Contents
03
770G,
051809
PN=2
Group 0300
Removal and Installation
DF180 Transmission
For additional information on DF180 transmission and

components, see the following Component Technical
Manuals.
• See Transmission Identifications and General

Procedures List. (CTM308.)
Continued on next page JW00603,00000E8 –19–05MAY09–1/2
03
0300
1
TM11207 (11MAY09) 03-0300-1

051809
PN=213
–UN–25JAN05
03
0300
2
YZ5394
Control Valve Components (DF180)
A—Direction Clutch 2 D—Speed Clutch C (3rd or 4th F—Pressure Regulating Valve H—Speed Clutch B (5th or 6th
(High-Forward) Gear) (System Pressure) Gear)
B—Direction Clutch 4 E—Speed Clutch D (7th or 8th G—Speed Clutch A (1st or 2nd I—Direction Clutch 1
(High-Reverse) Gear) Gear) (Low-Forward)
C—Direction Clutch 3
(Low-Reverse)
FORWARD
Gear Range Directional Clutch Speed Clutch
1st 1 (Low) A (1st)
2nd 2 (High) A (1st)
3rd 1 (Low) C (2nd)
4th 2 (High) C (2nd)
5th 1 (Low) B (3rd)
6th 2 (High) B (3rd)
7th 1 (Low) D (4th)
8th 2 (High) D (4th)
REVERSE
Gear Range Directional Clutch Speed Clutch
1st 3 (Low) A (1st)
2nd 4 (High) A (1st)
3rd 3 (Low) C (2nd)
4th 4 (High) C (2nd)
5th 3 (Low) B (3rd)
6th 4 (High) B (3rd)
7th 3 (Low) D (4th)
8th 4 (High) D (4th)
JW00603,00000E8 –19–05MAY09–2/2
TM11207 (11MAY09) 03-0300-2

051809
PN=214
Transmission Remove and Install


CAUTION: Park brake will not operate when

transmission is removed. Chock front wheels
before starting this procedure.

03
3
3. Install chocks at front wheels. Install articulation lock
pin. See Locking Machine Frame. (Operator’s Manual.)
4. Remove ripper if equipped. See Ripper Remove and

5. Remove fuel tank. See Fuel Tank Remove and Install.

(Group 0560.)
6. Drain transmission oil. See Changing Transmission Oil

and Cleaning Transmission Pump Inlet Screen.

device.
7. Remove rear access panels and doors on both right

and left side of machine.
Specification
Access Door (right and left)—
Weight (approximate) ........................................................................ 29 kg
64 lb.
8. Remove 6WD pumps. See 6WD Pump Remove and

9. Remove differential lock pump. See Differential Lock

Continued on next page JW00603,000012A –19–14MAY09–1/5
TM11207 (11MAY09) 03-0300-3

051809
PN=215
10. Remove hydraulic pump. See Hydraulic Pump

11. Remove transmission-to-rear axle drive shaft. See

12. Raise rear of machine and install appropriate shop

stands under tandems. For machine weight see
Machine Specifications. (Operator’s Manual.)

device.
03 13. Support transmission with appropriate lifting device.

0300
4 Specification
Transmission—Weight
(approximate)................................................................................... 600 kg
1323 lb.
TM11207 (11MAY09) 03-0300-4

051809
PN=216
14. Disconnect rear platform harness-to-transmission

harness connector (X22) and cylinder shaft speed
sensor (B23).
15. Attach identification tags on hydraulic oil hoses. X22 B23

Remove hydraulic hoses (3—7) on rear of
transmission. Cap and plug all openings.
3—Park Brake Manual Release Hose 7

4—Transmission Cooler-to-Transmission Hose
5—Transmission Filter-to-Transmission Hose (pump) 6
6—Transmission-to-Transmission Cooler Hose
7—Transmission Filter-to-Transmission Hose (lube)
5
B23—Cylinder Shaft Speed Sensor
X22—Rear Platform Harness-to-Transmission Harness
Connector
4 03
3 0300
5
–UN–15MAY09
TX1059510
TX1059510
Rear Transmission Wire Connector and Hose Location
TM11207 (11MAY09) 03-0300-5

051809
PN=217
16. Disconnect flywheel housing drain hose (9) on front of 8

transmission. Cap and plug openings.
17. Remove transmission fill tube (10) from transmission.

Cap and plug openings.
18. Remove transmission sampling port hose (11). Cap

and plug opening. 12
19. Remove flywheel housing cap screws (8).
20. Move transmission rearward until drive hub spline

(12) is disengaged from torsional isolator on engine
flywheel.
9
21. Inspect, repair or replace parts as necessary. For
03
0300 disassembly and assembly of transmission See
6 Repair Procedures and Repair Stand List. (CTM308.)
22. Clean mating surfaces on flywheel housing and
–UN–26MAR09
transmission housing. 10
23. Apply TY6304 Flexible Form-In-Place Gasket to

flywheel housing and transmission housing.
TX1056737
11
TX1056737
from heavy component. Use appropriate lifting Front of Transmission
device.
8—Flywheel Housing Cap Screw (12 used)
9—Flywheel Housing Drain Hose
NOTE: Use JDG820 Flywheel Turning Tool to engage 10—Transmission Fill Tube
spline on transmission drive hub with the mating 11—Transmission Sampling Port Hose
spline in torsional isolator. 12—Drive Hub Spline
24. Lift transmission into place. To balance properly use

DFT1250, DFT1311, and appropriate lifting eyebolt
installed in front threaded hole on top of transmission.
Install cap screws to flywheel housing.
Specification
Transmission to Flywheel
Housing Cap Screw—Torque......................................................... 73 N•m
51 lb-ft
25. Install transmission sampling port hose.
26. Install transmission fill tube. Replace O-rings as

necessary.
TM11207 (11MAY09) 03-0300-6

051809
PN=218
27. Connect flywheel housing drain hose.
28. Install transmission-to-rear axle drive shaft. See

29. Install all hoses on rear of transmission.
30. Connect wire connectors.
31. Install hydraulic pump. See Hydraulic Pump Remove

32. Install differential lock pump. See Differential Lock

03
33. Install 6WD pumps. See 6WD Pump Remove and 0300
34. Fill transmission oil to proper level. See Changing

Transmission Oil and Cleaning Transmission Pump
Inlet Screen and see Drain and Refill Capacities.
35. Install fuel tank. See Fuel Tank Remove and Install.
(Group 0560.)
36. Install ripper if equipped. See Ripper Remove and


38. Turn battery disconnect to ON position.
39. Calibrate Transmission. See Transmission Control

Unit (TCU) Calibration. (Group 9015-20.)
JW00603,000012A –19–14MAY09–5/5
TM11207 (11MAY09) 03-0300-7

051809
PN=219
03
0300
8
TM11207 (11MAY09) 03-0300-8

051809
PN=220
Group 0360
Hydraulic System
Transmission Charge Pump Remove and
Install



03
0360
1
Continued on next page JW00603,00000FC –19–05MAY09–1/2
TM11207 (11MAY09) 03-0360-1

051809
PN=221
Hydraulic System
4. Remove cap screw (5) from suction tube (4) on lower

front of transmission. Remove suction tube from
bottom of transmission charge pump (3). Cap and plug
all openings.
5. Remove hydraulic pump. See Hydraulic Pump Remove 1

2
6. Remove transmission charge pump-to-transmission 3
filter hose (1). Cap and plug all openings.
7. Remove transmission charge pump-to-transmission

housing cap screws (2).
–UN–09MAR09
8. Remove transmission charge pump (3).
03
0360 9. Inspect, repair or replace parts as necessary. For
disassembly and assembly of charge pump, see
TX1056856
2
Repair Procedures and Repair Stand List. (CTM308.)
10. Install transmission charge pump. Transmission Charge Pump
11. Install transmission charge pump-to-transmission

housing cap screws.
Specification
Transmission Charge 3
Pump-to-Transmission Housing
74 lb-ft
12. Install hydraulic pump. See Hydraulic Pump Remove

13. Install transmission charge pump-to-transmission filter

hose.
–UN–31MAR09
14. Install new O-ring on suction tube. Install suction tube
to transmission charge pump and lower front of 4
transmission.
TX1057657
Specification 5
Suction tube Cap Screw—Torque.................................................. 25 N•m
221 lb-in Transmission Suction Tube
15. Fill transmission oil to proper level. See Changing 1—Transmission Charge Pump-to-Transmission
Filter Hose
Transmission Oil and Cleaning Transmission Pump 2—Transmission Charge Pump-to-Transmission
Inlet Screen and see Drain and Refill Capacities. Housing Cap Screw
(Operator’s Manual.) 3—Transmission Charge Pump
4—Suction Tube
5—Suction Tube Cap Screw (2 used)
JW00603,00000FC –19–05MAY09–2/2
TM11207 (11MAY09) 03-0360-2

051809
PN=222
Section 04
Engine
Contents
Page

PowerTech Plus 9.0L (6090) John
Deere Engine—9.0L Tier 3/Stage IIIA . . . .04-0400-1
PowerTech Plus 9.0L (6090) John
Deere Engine—9.0L Stage II . . . . . . . . . . .04-0400-1
Engine Remove and Install—9.0L Tier
3/Stage IIIA . . . . . . . . . . . . . . . . . . . . . . . .04-0400-2
Engine Remove and Install—9.0L Stage
II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .04-0400-11
04
770G,
051809
PN=1
Contents
04
770G,
051809
PN=2
Group 0400
PowerTech Plus 9.0L (6090) John Deere
Engine—9.0L Tier 3/Stage IIIA
For more information on John Deere engines and

Manuals.
• PowerTech Plus 9.0L Diesel Engines—Base Engine.

(CTM 400.)
• PowerTech Plus 9.0L Diesel Engines—Level 14
Electronic Fuel System with Denso HPCR. (CTM 385.)
JW00603,00000E9 –19–20JAN09–1/1
04
PowerTech Plus 9.0L (6090) John Deere 0400
Engine—9.0L Stage II 1
For more information on John Deere engines and

Manuals.
• PowerTech Plus 9.0L Diesel Engines—Base Engine.

(CTM 400.)
• PowerTech Plus 9.0L Diesel Engines—Level 14
Electronic Fuel System with Denso HPCR. (CTM 385.)
MM16284,0000DB3 –19–26MAR09–1/1
TM11207 (11MAY09) 04-0400-1

051809
PN=225
Engine Remove and Install—9.0L Tier

3/Stage IIIA
1. Park machine on flat level surface. Lower all

2. Install articulation lock. See Locking Machine Frame.

4. Drain engine coolant. See Drain, Flush, and Refill

Cooling System. (Operator’s Manual.)

6. Disconnect all cables from batteries.
7. Open and remove all engine compartment panels and

04 doors.
0400
2
8. Remove muffler.
Continued on next page AS79221,000005E –19–05MAY09–1/15
TM11207 (11MAY09) 04-0400-2

051809
PN=226
9. Disconnect air filter restriction switch (B6) and

compressor inlet temperature sensor (B14) from
harness.
10. Loosen intake hose clamp to remove engine inlet

hose (1) from engine intake.
11. Loosen turbocharger inlet hose clamp (2) and remove

hose from turbocharger. Cap and plug turbocharger
inlet and hose.
1—Engine Inlet Hose

2—Turbocharger Inlet Hose Clamp
–UN–24APR09
B6—Air Filter Restriction Switch
B14—Compressor Inlet Temperature Sensor
TX1058763A
Turbocharger Inlet
04
0400
3
AS79221,000005E –19–05MAY09–2/15
CAUTION: Starting fluid is highly flammable.

Prevent possible injury from exploding
container. Keep container away from heat,
sparks, and open flame. Contents are
pressurized. DO NOT puncture or incinerate
–UN–27APR09
container. Remove container from machine if
engine does not need starting fluid.
12. Remove starting fluid cylinder (5). See Replace
TX1058782A
Starting Fluid Cylinder—If Equipped. (Operator’s
Manual.)
13. Remove starting fluid bracket cap screws (4) from 4—Cap Screw (2 used)
engine cover, if equipped, and secure to engine. 5—Starting Fluid Cylinder
TM11207 (11MAY09) 04-0400-3

051809
PN=227

lifting component. 6
14. Remove engine cover with air cleaner (7) attached.
Specification
Engine Cover With Air Cleaner—
Weight................................................................................................ 89 kg 7
195 lb

lifting component.
15. Remove cap screws (8) from front engine shield

assembly (9) and remove.
8
–UN–13APR09
Specification
Front Engine Shield Assembly—
Weight................................................................................................ 28 kg
04 60 lb
9
TX1058105
0400
4 16. Remove engine accessory belt.
Engine
6—Muffler
7—Engine Cover With Air Cleaner
9—Front Engine Shield Assembly
TM11207 (11MAY09) 04-0400-4

051809
PN=228
17. Loosen upper engine coolant hose clamp (11) and

remove hose from engine. Cap and plug hose.
18. Loosen surge tank hose clamp and remove surge

tank hose (12) from engine. Cap and plug hose.
19. Remove heater hot water hose (13) from engine. Cap
and plug hose. 11 12
11—Upper Engine Coolant Hose Clamp

12—Surge Tank Hose
13—Heater Hot Water Hose
13
–UN–24APR09
TX1058764
Coolant Hoses
04
0400
5
AS79221,000005E –19–05MAY09–5/15
20. Loosen turbocharger outlet hose clamps (15) and

remove hose from turbocharger. Cap and plug
turbocharger and hose.
15—Turbocharger Outlet Hose Clamp
–UN–24APR09
TX1058765A
Turbocharger
TM11207 (11MAY09) 04-0400-5

051809
PN=229
21. Remove fuel lines (17 and 18). Cap and plug lines.
22. Remove engine coolant heater and set aside (if

equipped).
17—Fuel Supply Line

18—Fuel Return Line
–UN–27APR09
TX1058767A
Fuel Lines
04
0400
6
AS79221,000005E –19–05MAY09–7/15
23. Remove lower engine coolant hose (20) at water

pump.
24. Remove heater hot water hose (21).
25. Disconnect harness from air conditioner compressor

clutch solenoid. See Engine Interface Harness (W9)
Component Location-9.0L. (Group 9015-10.)
26. Remove air conditioner compressor, receiver-dryer,

and accumulator from engine and set aside.
20—Lower Engine Coolant Hose

–UN–27APR09
21—Heater Hot Water Hose

TX1058768A
Coolant Hoses
TM11207 (11MAY09) 04-0400-6

051809
PN=230
27. Remove harnesses from starter (M1) and starter

harness (W63). See Engine Interface Harness (W9)
28. Disconnect engine interface harness

connector-to-starter harness connector (X99)
29. Remove transmission fill tube clamp cap screw (23)

from engine mount.
–UN–24APR09
30. Remove engine oil drain tube clamp.
23—Cap Screw
M1—Starter 9.0L
TX1058769A
W63—Starter Harness
X99—Engine Interface Harness Connector-to-Starter
Harness Connector
Starter
04
0400
7
AS79221,000005E –19–05MAY09–9/15
31. Disconnect connectors at ECU (X11 and X13), engine

harness connector (X8), starter (M1) and engine Y1
X11 A2
frame ground (W2). See Engine Harness (W29)
Component Location—9.0L Tier 3/Stage IIIA or See
Engine Harness (W30) Component Location—9.0L X8
Tier 2/Stage II. (Group 9015-10.)
32. Remove transmission harness connector. See

Transmission Harness (W35) Component Location. X13
(Group 9015-10.)
A2—Engine Control Unit (ECU)

M1—Starter 9.0L W29,W30
–UN–28APR09
W2—Engine Frame Ground

W29—Engine Harness—9.0L Tier 3/Stage IIIA W2
W30—Engine Harness—9.0L Tier 2/Stage II
X8—Engine Harness Connector M1
X11—Engine Control Unit (ECU) Connector (black)
TX1058770
X13—Engine Control Unit (ECU) Connector (blue)

Y1—Ether Start Aid Solenoid
Engine Harness Component Location—9.0L
TM11207 (11MAY09) 04-0400-7

051809
PN=231
33. Disconnect flywheel housing drain hose (27) on front 23

of transmission. Cap and plug openings.
24
34. Remove transmission fill tube (25) from transmission.
Cap and plug openings.
35. Remove transmission sampling port hose (26). Cap

and plug opening. 25
23—Flywheel Housing Cap Screw (12 used)

24—Drive Hub Spline
25—Transmission Fill Tube
26—Transmission Sampling Port Hose 26
27—Flywheel Housing Drain Hose
27
–UN–15APR09
04
0400
TX1058123
8
Transmission
AS79221,000005E –19–05MAY09–11/15
36. Install DFT1308 Transmission Support Bracket (30) to

transmission (29). See DFT1308 Transmission
Support Bracket. (Group 9900.)
29—Transmission
30—DFT1308 Transmission Support Bracket (2 used)
–UN–14APR09
TX1057951A
DFT1308 Transmission Support Bracket
TM11207 (11MAY09) 04-0400-8

051809
PN=232
37. Install lifting brackets (32 and 33) to engine with cap 32
screws (31).

lifting component.
38. Attach an appropriate lifting device to engine lifting

brackets.
–UN–28APR09
Specification
Engine—Weight ............................................................................... 998 kg
2200 lb
31
TX1058816
39. Remove engine flywheel housing-to-transmission cap
screws.
Front Lifting Bracket
40. Remove all engine mounting cap screws from
isolators.
41. Move engine forward until drive hub spline is

disengaged from torsional isolator on engine flywheel. 04
0400
9
42. Remove engine.
33
44. Clean mating surfaces on flywheel housing and

transmission housing.
–UN–27APR09
31
45. Align engine with transmission but do not install.
46. Position harness on engine so harness will reach all
TX1058817
components when installed.
47. Apply TY16021 High Flex Form-In-Place Gasket to Rear Lifting Bracket
flywheel housing and transmission housing.
32—Front Lifting Bracket
48. Install engine to transmission and tighten cap screws. 33—Rear Lifting Bracket
49. Install engine mounting cap screws.
Specification
Front Engine Isolator-To-Frame
Cap Screw—Torque ............................................................ 310—381 N•m
230—281 lb.-ft.
TM11207 (11MAY09) 04-0400-9

051809
PN=233
Specification
Rear Engine Isolator-To-Frame
Cap Screw—Torque ............................................................ 610—746 N•m
450—550 lb.-ft.
50. Remove engine lifting brackets.
51. Install drain line to flywheel housing.
52. Install transmission sampling port hose, and fill tube.
53. Remove DFT1308 Transmission Support Bracket

from transmission.
54. Connect transmission harness connector. See

Transmission Harness (W35) Component Location.
(Group 9015-10.)
55. Connect connectors at ECU (X11 and X13), engine

harness connector (X8), starter (M1) and engine
frame ground (W2). See Engine Harness (W29)
Component Location—9.0L Tier 3/Stage IIIA or see
04
Engine Harness (W30) Component Location—9.0L
0400
10 Tier 2/Stage II. (Group 9015-10.)
56. Connect harnesses to starter. See Engine Interface

Harness (W9) Component Location-9.0L. (Group
19015-10.)
57. Install lower coolant line at water pump and heater

hot water lines.
58. Install engine coolant heater to frame (if equipped).
59. Connect fuel feed line to filter housing.
60. Install upper charge air cooler hose to intake

manifold.
61. Install engine oil drain tube clamp.
62. Install air conditioner compressor, receiver-dryer, and

accumulator to engine.
63. Connect harness to air conditioner compressor clutch

solenoid. See Engine Interface Harness (W9)
64. Install engine accessory belt.
TM11207 (11MAY09) 04-0400-10

051809
PN=234
65. Install transmission fill tube clamp to engine mount.
66. Install fuel return line to injection pump and clamp

hose to engine.
67. Install surge tank hose to engine with hose clamp.
68. Install front engine shield assembly to frame.
69. Install engine cover with air cleaner attached.
70. Install engine coolant upper hose to engine with hose

clamp.
71. Install both hoses to turbocharger with hose clamps.
72. Connect air filter restriction switch.
73. Install muffler.
74. Connect all cables to batteries.

04
75. Fill transmission oil. See Changing Transmission Oil 0400
11
76. Fill engine coolant. See Drain, Flush, and Refill

77. Bleed fuel system. See Bleeding the Fuel System.

78. Check engine oil level. See Checking Engine Oil

Level. (Operator’s Manual.)
79. Install all engine compartment panels and doors.
80. Operate machine and verify functions. See

Operational Checkout. (Group 9005-10.)
AS79221,000005E –19–05MAY09–15/15
Engine Remove and Install—9.0L Stage II
For Engine Remove and Install—9.0L Stage II See Engine

Remove and Install—9.0L Tier 3/Stage IIIA. (Group 0400.)
JW00603,0000130 –19–21JAN09–1/1
TM11207 (11MAY09) 04-0400-11

051809
PN=235
04
0400
12
TM11207 (11MAY09) 04-0400-12

051809
PN=236
Section 05
Engine Auxiliary System
Contents
Page
Group 0510—Cooling System

Fan Blade Remove and Install . . . . . . . . . . .05-0510-1
Radiator Remove and Install . . . . . . . . . . . . .05-0510-3
Hydraulic and Differential Oil Cooler Remove
and Install . . . . . . . . . . . . . . . . . . . . . . . . .05-0510-8
Transmission Oil Cooler Remove and
Install. . . . . . . . . . . . . . . . . . . . . . . . . . . .05-0510-10
Fuel Cooler Remove and Install—9.0L . . . .05-0510-13
Charge Air Cooler Remove and Install . . . .05-0510-14
Group 0560—External Fuel Supply Systems

Fuel Tank Remove and Install. . . . . . . . . . . .05-0560-1
Fast Fill Fuel System Disassemble and
Assemble—If Equipped . . . . . . . . . . . . . . .05-0560-6
05
770G,
051809
PN=1
Contents
05
770G,
051809
PN=2
Group 0510
Cooling System
Fan Blade Remove and Install

JW00603,00000EA –19–20JAN09–1/5
3. Remove cap screws (6) on rear fan door to access fan

blade guard.
–UN–09APR09
05
0510
TX1057853A
1
Fan Door Cap Screws
Continued on next page JW00603,00000EA –19–20JAN09–2/5
TM11207 (11MAY09) 05-0510-1

051809
PN=239
Cooling System
Remove cap screws (2).
1—Fan Blade Guard

–UN–09APR09
TX1054983A
Fan Blade Guard
JW00603,00000EA –19–20JAN09–3/5
05
0510
2
4. Remove fan blade hub retaining nut (3).
5. Remove two cap screws (4) opposite each other from

back side of fan blade.
3—Fan Blade Hub Retaining Nut

4—Fan Blade Cap Screw (6 used)
–UN–28JAN09
TX1054995A
Fan Blade Nut and Cap Screws
Continued on next page JW00603,00000EA –19–20JAN09–4/5
TM11207 (11MAY09) 05-0510-2

051809
PN=240
Cooling System
6. Remove fan blade using appropriate puller (5).
7. Inspect and replace fan blade as necessary.
8. Install two cap screws on back side of fan blade.
9. Install fan blade and hub retaining nut.
Specification
Fan Blade Hub Retaining Nut—
Torque ............................................................................................ 81 N•m
60 lb-ft
10. Install fan blade guard and cap screws.
–UN–09APR09
11. Install cap screws to secure rear fan door.
TX1054996A
5—Puller
JW00603,00000EA –19–20JAN09–5/5
05
0510
3
Radiator Remove and Install

3. Drain cooling system. See Drain, Flush, and Refill

4. Remove charge air cooler. See Charge Air Cooler

TM11207 (11MAY09) 05-0510-3

051809
PN=241
Cooling System

device.
5. Remove rear compartment hood (1).
Specification
Rear Compartment Hood—
Weight................................................................................................ 41 kg
90 lb.
1—Rear Compartment Hood

–UN–19FEB09
TX1055287A
Rear Compartment Hood

05
0510
4
TM11207 (11MAY09) 05-0510-4

051809
PN=242
Cooling System
6. Disconnect upper and lower radiator hoses (3 and 6)

and surge tank hose (5) from radiator (4).
3—Upper Radiator Hose

4—Radiator
5—Radiator-to-Surge Tank Hose
6—Lower Radiator Hose
–UN–19FEB09
TX1055288A
Upper Radiator Hose
05
0510
5
–UN–19FEB09
TX1055289A
Lower Radiator Hose
TM11207 (11MAY09) 05-0510-5

051809
PN=243
Cooling System
7. Remove radiator mounting cap screws (8).
4—Radiator
–UN–09APR09
TX1058128A
Top Rear of Radiator
05
0510
6
TM11207 (11MAY09) 05-0510-6

051809
PN=244
Cooling System
8. Remove radiator mounting nuts (7).

device.
–UN–09APR09
9. Support radiator.
Specification
TX1058124A
Radiator—Weight .............................................................................. 41 kg
90 lb.
IMPORTANT: Take care while lifting radiator, damage Lower Rear Side of Radiator
to radiator cores will require
4—Radiator
replacement of radiator. 7—Nut (4 used)
10. Lift radiator out top of machine.
IMPORTANT: Take care while lowering radiator,

damage to radiator cores will require
replacement of radiator.

device. 05
0510
7
12. Lower radiator to machine and install cap screws and
nuts.
Specification
Radiator—Weight .............................................................................. 41 kg
90 lb.
13. Connect upper and lower radiator and surge tank

hoses.
14. Install charge air cooler. See Charge Air Cooler

15. Fill cooling system. See Drain, Flush, and Refill

16. Operate machine.
17. Check coolant level. See Checking Engine Coolant

Surge Tank Level. (Operator’s Manual.)
JW00603,0000132 –19–21JAN09–5/5
TM11207 (11MAY09) 05-0510-7

051809
PN=245
Cooling System
Hydraulic and Differential Oil Cooler Remove

and Install

attachments to the ground.
3. Install vacuum pump to hydraulic tank. See Vacuum

Pump Installation. (Group 2160.)
JW00603,0000133 –19–21JAN09–1/5
4. Open right rear access door (8).
5—Right Engine Access Door

6—Right Lower Engine Access Panel
7—Right Rear Access Panel
8—Right Rear Access Door
–UN–08APR09
05
0510
8
TX1054873A
Right Side of Machine
JW00603,0000133 –19–21JAN09–2/5
5. Remove cap screws (9) to fold down hydraulic and

differential oil cooler (10).

10—Hydraulic and Differential Oil Cooler
–UN–09APR09
TX1054879A
Hydraulic and Differential Oil Cooler
TM11207 (11MAY09) 05-0510-8

051809
PN=246
Cooling System
6. Remove cap screws (11) and set air conditioning

condenser (12) aside.
7. Attach Identification tags and disconnect hydraulic oil

lines (13—16) from differential and hydraulic oil cooler
(10). Close all openings using caps and plugs.
IMPORTANT: Take care when supporting cooler to

prevent damage to cooler fins.
–UN–24APR09
device.
TX1054880A
8. Support hydraulic and differential oil cooler.
Specification Front Side of Hydraulic and Differential Oil Cooler

Hydraulic and Differential Oil
Cooler—Weight .............................................................................. 29.5 kg
65 lb.
9. Remove nut (18) and cap screw (17).
10. Remove hydraulic and differential oil cooler.
–UN–09APR09
05
TX1054881A
CAUTION: Prevent possible crushing injury 0510
from heavy component. Use appropriate lifting 9
device.
Left Side of Hydraulic and Differential Oil Cooler
12. Install hydraulic and differential oil cooler. Install cap
screw and nut. 11—Cap Screw (4 used)
12—Air Conditioning Condenser
13. Connect hydraulic oil lines to hydraulic and differential 13—Differential Oil Cooler-to-Differential Oil Filter
oil cooler. Line
14—Hydraulic Oil Cooler-to-Hydraulic Oil Tank
Line
14. Install air conditioning condenser to hydraulic and 15—Differential-to-Differential Oil Cooler Line
differential oil cooler. 16—Hydraulic Oil Cooler Bypass
Valve-to-Hydraulic Oil Cooler Line
17—Cap Screw
18—Nut
TM11207 (11MAY09) 05-0510-9

051809
PN=247
Cooling System
15. Fold hydraulic and differential oil cooler (10) up and

install cap screws (9).

–UN–09APR09
17. Check differential oil level. See Checking Axle
Housing Oil Level. (Operator’s Manual.)
TX1054879A
JW00603,0000133 –19–21JAN09–5/5
Transmission Oil Cooler Remove and Install
1. Park machine on a flat level surface and lower all

05 2. Turn battery disconnect switch to OFF position.

0510
10
TM11207 (11MAY09) 05-0510-10

051809
PN=248
Cooling System
3. Open left rear access door (2).
1—Left Engine Access Door

2—Left Rear Access Door
3—Left Rear Access Panel
4—Left Lower Engine Access Panel
–UN–04FEB09
TX1054872A
Left Side of Machine
JW00603,0000134 –19–21JAN09–2/5
05
0510
11
4. Remove cap screws (5) to fold down transmission oil
cooler (6).

6—Transmission Oil Cooler
–UN–09APR09
TX1054882A
Transmission Oil Cooler
TM11207 (11MAY09) 05-0510-11

051809
PN=249
Cooling System
5. Attach identification tags and disconnect transmission

oil cooler-to-transmission oil filter line (7) and
transmission-to-transmission oil cooler line (8) from
transmission oil cooler. Close all openings using caps
and plugs.
6. Support transmission oil cooler.
7. Remove nut, cap screw and transmission oil cooler (6).
–UN–09APR09
9. Install transmission oil cooler. Install cap screw and

nut.
TX1054905A
10. Connect transmission oil cooler lines.
Transmission Oil Cooler Lines
7—Transmission Oil Cooler-to-Transmission Oil Filter
Line
8—Transmission-to-Transmission Oil Cooler Line
JW00603,0000134 –19–21JAN09–4/5
05
0510
12
11. Fold transmission oil cooler (6) up and install cap
screws (5).
12. Check transmission oil level. See Checking

Transmission Oil Level. (Operator’s Manual.)
–UN–09APR09
TX1054882A
JW00603,0000134 –19–21JAN09–5/5
TM11207 (11MAY09) 05-0510-12

051809
PN=250
Cooling System
Fuel Cooler Remove and Install—9.0L

JW00603,0000135 –19–21JAN09–1/3
3. Open left rear access door (2).
4. to fuel lines.
1—Left Engine Access Door

2—Left Rear Access Door
3—Left Rear Access Panel
4—Left Lower Engine Access Panel
05
–UN–04FEB09
0510
13
TX1054872A
Left Side of Machine
TM11207 (11MAY09) 05-0510-13

051809
PN=251
Cooling System
5. Attach identification tags and disconnect fuel

return-to-fuel cooler hose (6) and fuel cooler-to-fuel
tank hose (7) from fuel cooler (5). Close all openings
using caps and plugs.
–UN–09APR09
6. Remove cap screws (8) and fuel cooler.
TX1054909A
8. Install fuel cooler and cap screws.
NOTE: It is not necessary to bleed fuel return lines. Fuel

return lines will self bleed. Fuel Cooler
5—Fuel Cooler
9. Connect fuel lines to fuel cooler. 6—Fuel Return-to-Fuel Cooler Hose
7—Fuel Cooler-to-Fuel Tank Hose
10. Operate machine and check for fuel leaks. 8—Cap Screw (2 used)
JW00603,0000135 –19–21JAN09–3/3
Charge Air Cooler Remove and Install

05 2. Turn battery disconnect switch to OFF position.

0510
14
3. Open right and left rear access doors.
JW00603,0000136 –19–21JAN09–1/5
4. Remove cap screws (5) holding transmission oil cooler

(6) and fold down.

–UN–09APR09
TX1054882A
TM11207 (11MAY09) 05-0510-14

051809
PN=252
Cooling System
5. Remove cap screws (9) holding hydraulic and

differential oil cooler (10) and fold down.
6. Remove fuel cooler if equipped. See Fuel Cooler

Remove and Install—9.0L. (Group 0510.)
–UN–09APR09
TX1054879A
JW00603,0000136 –19–21JAN09–3/5
7. Loosen clamps (12).
8. Remove cap screws (15) from charged air cooler

support.
–UN–09APR09
9. Slide charge air pipes (13 and 14) back off charge air 05
cooler (11). Close all openings using caps and plugs. 0510
15
TX1054908A
device.
Top of Charge Air Cooler
10. Support charge air cooler.
Specification
Charge Air Cooler—Weight ............................................................ 29.5 kg
65 lb.
–UN–15APR09
11—Charge Air Cooler
12—Clamp (4 used)
13—Upper Charge Air Pipe
14—Lower Charge Air Pipe
TX1055010A
16—Nut (4 used)
Bottom of Charge Air Cooler
TM11207 (11MAY09) 05-0510-15

051809
PN=253
Cooling System
IMPORTANT: When sliding charge air cooler ensure

that it does not contact hydraulic
pumps. Damage to charge air cooler
will result.
–UN–15APR09
11. Remove nuts (16) and slide charge air cooler out.
TX1055011A
device. Side of Charge Air Cooler
13. Install charge air cooler and nuts. 11—Charge Air Cooler
16—Nut (4 used)
Specification
Charge Air Cooler—Weight ............................................................ 29.5 kg
65 lb.
14. Install upper and lower charge air pipes and clamps
to charged air cooler.
15. Install cap screws to charge air cooler support.
16. Install fuel cooler if equipped. See Fuel Cooler

Remove and Install—9.0L. (Group 0510.)
05
0510 17. Fold transmission, hydraulic, and differential oil
16 coolers up and install cap screws.
18. Close access doors.
JW00603,0000136 –19–21JAN09–5/5
TM11207 (11MAY09) 05-0510-16

051809
PN=254
Group 0560
External Fuel Supply Systems
Fuel Tank Remove and Install

3. Drain fuel from tank. See Draining Fuel Tank Sump.

4. Remove ripper if equipped. See Ripper Remove and

05
0560
1
TM11207 (11MAY09) 05-0560-1

051809
PN=255
5. Disconnect fuel return (3) and fuel supply (1) hoses

from fuel tank. Close all openings using caps and
plugs.
1—Fuel Tank-to-Primary Fuel Filter Supply Hose

2—Fuel Tank
3—Engine-to-Fuel Tank Return Hose
4—Fuel Level Sending Unit
–UN–17APR09
TX1055296A
Fuel Return Hose and Fuel Level Sending Unit
05
0560
2
–UN–17APR09
TX1055316A
Fuel Supply Hose
TM11207 (11MAY09) 05-0560-2

051809
PN=256
6. Disconnect fast fill vent hose (6) from fast fill vent
fitting (5) if equipped.
5 6
7. Disconnect wire from fuel level sending unit (4).
5—Fast Fill Vent Fitting

6—Fast Fill Vent Hose
7—Engine Oil Drain Hose
8—Engine Oil Drain Hose Clamp
9—Coolant Drain Hose
10—Coolant Drain Hose Clamp
11—Fuel Tank Strap (2 used) 9 2 11
12—Fuel Tank Strap Cap Screw
12 8
–UN–16APR09
10 7
TX1058345
Fast Fill Vent Fitting

05
0560
3
TM11207 (11MAY09) 05-0560-3

051809
PN=257

device.
NOTE: Fuel tank is mounted inside of fuel tank guard.
–UN–17APR09
8. Support fuel tank and fuel tank guard.
Specification
TX1055294A
Fuel Tank and Guard—Weight ....................................................... 200 kg
441 lb.
9. Remove cap screws (14). Left Side of Fuel Tank Guard
13—Fuel Tank Guard

IMPORTANT: Take care when lowering fuel tank 14—Cap Screw (10 used)
guard and tank to prevent damage to
filler neck of fuel tank.
10. Lower fuel tank (2) and fuel tank guard (13) to access
coolant drain hose and engine oil drain hose (7 and
9) inside fuel tank guard.
11. Remove clamps (8 and 10) holding engine oil drain

and coolant drain hoses.
12. Lower fuel tank and remove from under machine.

05
0560 13. Remove fuel tank strap (11) holding fuel tank to fuel
4 tank guard.

device.
14. Support fuel tank and remove from fuel tank guard.
Specification
Fuel Tank—Weight (approximate) .................................................... 41 kg
90 lb.
TM11207 (11MAY09) 05-0560-4

051809
PN=258

device.
16. Install fuel tank to fuel tank guard.
Specification
Fuel Tank—Weight (approximate) .................................................... 41 kg
90 lb.
17. Install straps holding fuel tank to fuel tank guard.
18. Install clamps holding coolant drain and engine oil

drain inside fuel tank guard.

device.
IMPORTANT: Take care when installing fuel tank and

fuel tank guard to prevent damage to
filler neck of tank.
19. Install fuel tank , fuel tank guard and cap screws.
Specification
Fuel Tank and Guard—Weight ....................................................... 200 kg 05
441 lb. 0560
5
20. Connect wire to fuel level sending unit.
21. Connect supply and return fuel hoses.
22. Connect fast fill vent if equipped.
23. Fill fuel tank.
24. Bleed fuel system. See Bleeding the Fuel System.

25. Operate machine and check for leaks.
JW00603,0000137 –19–21JAN09–5/5
TM11207 (11MAY09) 05-0560-5

051809
PN=259
Fast Fill Fuel System Disassemble and Assemble—If Equipped
30 2
22 32
11 12
25
15
8 28
6
5 7
9
1 4
26 17 14
29
27 13
8 9
13
33 10
31
23
24
05
0560
6
28
16
32
19 18 –UN–13MAY09
3
21 20
34
TX1059382
TX1059382
Fast Fill Fuel System
Continued on next page JW00603,000018F –19–12MAY09–1/3
TM11207 (11MAY09) 05-0560-6

051809
PN=260
1—Flange Nut 10—Elbow Fitting 19—Receiver Valve 27—P Clamp

2—Lock Nut 11—Adapter Fitting 20—Cap 28—Gasket (2 used)
3—Cap Screw (3 used) 12—O-Ring 21—Guard 29—Hose Fitting
4—Cap Screw 13—Clamp 22—Breather Adapter 30—Breather
5—Cap Screw (2 used) 14—Inlet Valve 23—Fast Fill Shutoff Float 31—Hose
6—Flat Washer (2 used) 15—Plate 24—O-Ring 32—Cap Screw (21 used)
7—Adapter Fitting 16—Adapter Tube 25—Vent Line 33—Support Bracket
8—O-Ring (2 used) 17—Signal Line 26—Spacer 34—Cap Screw (4 used)
9—O-Ring (2 used) 18—Guard
NOTE: Fast fill breather assembly can remain on 9. Install gasket (28) to fast fill shutoff float and plate
machine or be removed from machine to assembly.
remove fuel tank.
10. Install O-ring (9) to adapter fitting (7) and connect
1. Remove cap screws (4 and 5) to remove breather signal line (17).
(30) assembly from machine.
NOTE: Take care to prevent kinking signal line when
2. Remove clamp (13) from hose fitting (29) to remove inserting into tank.
hose (31).
11. Route signal line toward hole in the left side of fuel
3. Remove breather assembly from machine. tank while inserting fast fill shutoff float into top
hole of fuel tank.
4. Remove fuel tank. See Fuel Tank Remove and
Install. (Group 0560.) 12. Align fast fill shutoff float assembly with hole in
fuel tank.
NOTE: Record positioning of the adapter tube (16) in
fuel tank. Also note the position of guard (21). 13. Install cap screws and tighten to specification.
5. Disassemble fast fill as shown. Specification 05

Fast Fill Assembly-to-Fuel 0560
Tank—Torque .......................................................................... 34 N•m 7
6. Inspect and replace parts as necessary. Gaskets 25 lb.-ft.
(28) must be replaced.
14. Install gasket (28) to adapter tube (16).
7. Apply PM38613 Pipe Sealant to shutoff float (23)
and install O-ring (24), plate (15) and torque to NOTE: It is necessary to orientate elbow fitting
specification. pointing to the center of fuel tank to prevent
kinking signal line.
Specification
Plate-to-Fast Fill Shutoff
Float—Torque .......................................................................... 30 N•m 15. Install inlet valve (14) assembly to adapter tube
22 lb.-ft. and torque to specification.
8. Install O-ring (8), adapter fitting (7) to fast fill shutoff Specification
float and torque adapter fitting to specification. Adapter Tube-to-Inlet Valve—
Torque...................................................................................... 30 N•m
22 lb.-ft.
Specification
Adapter Fitting-to-Fast Fill
Shutoff Float—Torque ............................................................ 3.4 N•m 16. Install O-ring (8), elbow fitting (10) to inlet valve
30 lb.-ft. (14) and torque to specification.
Continued on next page JW00603,000018F –19–12MAY09–2/3
TM11207 (11MAY09) 05-0560-7

051809
PN=261
Specification 21. Apply PM38613 Pipe Sealant to hose fitting (29)

Elbow Fitting-to-Inlet Valve— and install to fast fill shutoff float.
Torque..................................................................................... 3.4 N•m
30 lb.-ft.
22. Apply PM38613 Pipe Sealant to receiver valve
IMPORTANT: When connecting signal line take (19) and install. Tighten to specification.
care to prevent kinking. Fast fill fuel
Specification
system will not function properly. Receiver Valve—Torque.......................................................... 45 N•m
33 lb.-ft.
17. Connect signal line (17) to inlet valve.
23. Install fuel tank. See Fuel Tank Remove and
18. Align adapter tube (16) with hole in fuel tank. Install. (Group 0560.)
Position adapter as noted on removal.
24. Install guard (18) and cap screws (34).
19. Install nine cap screws (32) and tighten to
specification. 25. Install hose (31) and vent line (25) and install
clamps (13).
Specification
Adapter Tube-to-Fuel Tank—
Torque...................................................................................... 34 N•m
26. Install breather assembly with cap screws to
25 lb.-ft. support bracket (33) and bottom tab of battery
platform.
20. Install guard (21) and three cap screws (3) and
tighten to specification.
Specification
Adapter Tube-to-Fuel Tank—
Torque...................................................................................... 34 N•m
25 lb.-ft.
05
0560
8
JW00603,000018F –19–12MAY09–3/3
TM11207 (11MAY09) 05-0560-8

051809
PN=262
Section 07
Torsional Isolator
Contents
Page
Group 0752—Elements
Torsional Isolator Remove and Install . . . . . .07-0752-1
07
770G,
051809
PN=1
Contents
07
770G,
051809
PN=2
Group 0752
Elements
Torsional Isolator Remove and Install
1. Remove transmission. See Transmission Remove and

JW00603,00000EB –19–20JAN09–1/2
2. Remove cap screws and washers (4).
3. Remove torsional isolator (1) from flywheel (2) and

housing (3).
4. Replace parts as necessary.
5. Position torsional isolator on flywheel.
NOTE: New cap screws are required for torsional isolator.
6. Lubricate threads of new cap screws with engine oil,

install, and tighten to specification.
–UN–21APR09
Specification
Torsional Isolator-to-Flywheel
Cap Screw—Torque ................................................................ 45—55 N•m
33—41 lb.-ft.
TX1058555A
7. Install transmission. See Transmission Remove and
Torsional Isolator
1—Torsional Isolator
2—Flywheel
3—Flywheel Housing
07
0752
JW00603,00000EB –19–20JAN09–2/2
1
TM11207 (11MAY09) 07-0752-1

051809
PN=265
Elements
07
0752
2
TM11207 (11MAY09) 07-0752-2

051809
PN=266
Section 09
Steering System
Contents
Page
Group 0920—Power Steering

Toe-In Check and Adjustment . . . . . . . . . . . .09-0920-1

Steering Wheel, Column, and Valve
Remove and Install—Standard Controls . .09-0960-1
Steering Wheel, Column, and Valve
Remove and Install—EH Controls . . . . . . .09-0960-4
EH Controls Steering Canceling Valve
Remove and Install . . . . . . . . . . . . . . . . . .09-0960-6
Steering Cylinder Remove and Install . . . . . .09-0960-8
Hydraulic Cylinder Disassemble and
Assemble. . . . . . . . . . . . . . . . . . . . . . . . .09-0960-11
Wheel Lean Cylinder Remove and
Install. . . . . . . . . . . . . . . . . . . . . . . . . . . .09-0960-12
Secondary Steering Accumulator Remove
and Install—If Equipped. . . . . . . . . . . . . .09-0960-17
09
770G,
051809
PN=1
Contents
09
770G,
051809
PN=2
Group 0920
Power Steering
Toe-In Check and Adjustment
–UN–06NOV01
T147843
Toe-In Check Adjustment Measurements
1—Left Cylinder Length 4—Left Wheel Axle Center 6—Axle Center Line 9—Tie Rod Cap Screws
2—Right Cylinder Length Measurement 7—Tire Center Line 10—Cylinder Ends
3—Right Wheel Axle Center 5—Floor 8—Toe-in Measurement
Measurement
1. Position grader on a level surface. Check and Adjust Toe-In—Specification

Cylinder Overall Length
(compare left to right)—
2. Raise front of machine and place appropriate Distance ................................................................................. 0—3 mm
supporting device under front axle. See Machine 0.0—0.12 in. 09
Specifications machine weight. (Operator’s Manual.) 0920
4. Measure distance (3 and 4) from the floor (5) to the 1
NOTE: Cylinder overall length is measured to align center of axle.
front wheels in center position for starting point
for adjustment. Steering cylinders are not 5. Draw a horizontal (axle center) line (6) on the back
adjustable, tie rod ends (10) are locked in side of each tire. Draw a vertical center line (7) on
place and torqued to specification. See the back side of each tire.
Steering Cylinder Remove and Install. (Group
0960.) 6. Measure distance between center lines (7) to
record rear toe-in measurement (8).
3. Straighten wheels. Steering cylinder rod length (1
and 2) must be within specification of each other.
Continued on next page JW00603,00000EC –19–20JAN09–1/2
TM11207 (11MAY09) 09-0920-1

051809
PN=269
Power Steering
7. Rotate both tires 180° so marks are at the front. as required. Place container under cylinder to
catch oil.
8. Measure distance between center lines (7) to
record front toe-in measurement. b. Loosen tie rod cap screws (9). Rotate tie rod to
adjust length.
Front toe-in measurement must be less than rear
toe-in measurement. c. Check measurements. Adjust until within toe-in
specification.
Check and Adjust Toe-In—Specification
Toe-In (front less than rear )— d. Tighten tie rod cap screws (9).
Distance .............................................................................. 3—13 mm
0.12—0.50 in.
e. Tighten steering cylinder hoses. Properly
If measurement is not to specification: dispose of waste oil.
a. Loosen cylinder hose to both ends of one

cylinder so cylinder rod is free to move in or out
JW00603,00000EC –19–20JAN09–2/2
09
0920
2
TM11207 (11MAY09) 09-0920-2

051809
PN=270
Group 0960
Hydraulic System
Steering Wheel, Column, and Valve Remove and Install—Standard Controls
4 10
4
9
1 2
5
5 4 7 8
6
3
11
12
12
09
13
–UN–10MAR09
0960
1
TX1056833
TX1056833
Standard Controls Steering
1—Steering Wheel Cover 4—Cap Screw (4 used) 8—Steering Column 12—Cap Screw (6 used)
2—Steering Wheel Retaining 5—Cap Screw (4 used) 9—Mounting Bracket 13—Tilt Console Side Cover (2
Nut 6—Tilt Console Face Plate 10—Tilt Console Top Cover used)
3—Steering Wheel 7—Cap Screw (4 used) 11—Steering Valve
1. Park machine on flat level surface and lower all 2. Install articulation lock pin.
Continued on next page JW00603,00000FE –19–05MAY09–1/3
TM11207 (11MAY09) 09-0960-1

051809
PN=271
Hydraulic System
3. Turn battery disconnect switch to OFF position. hours or gangrene may result. Doctors
unfamiliar with this type of injury should
4. Remove steering wheel cover (1). reference a knowledgeable medical source.
Such information is available from Deere &
5. Remove steering wheel retaining nut (2). Company Medical Department in Moline,
Illinois, U.S.A.
IMPORTANT: Prevent possible damage to steering
wheel. Use shop rag around puller to 15. Stop engine and relieve hydraulic pressure in
prevent damaging steering wheel. steering cylinders by moving steering wheel back
and forth until front wheels stop steering.
6. Use bearing pulling attachment D01243AA from
17-1/2 ton capacity puller set D01048AA to remove 16. Install vacuum pump to hydraulic oil tank to
steering wheel (3). minimize hydraulic oil loss during repair. See
17. Disconnect and tag hydraulic hoses from steering
8. Remove tilt console top cover (10) from tilt console. valve (11). Cap and plug all hydraulic openings.
See Hydraulic System Component Location.
9. Disconnect wire harness from tilt console top cover. (Group 9025-15.)
See Tilt Console Harness (W36) Component
Location—Standard Controls. (Group 9015-10.) 18. Remove cap screws (7).
10. Remove cap screws (5). 19. Remove steering column (8) from mounting
bracket (9) and steering valve.
11. Remove tilt console face plate (6).
20. Repair or replace parts as needed.
12. Disconnect wire harness from tilt console face
plate. See Tilt Console Harness (W36) Component 21. Apply NEVER-SEEZ to splined joint between
Location—Standard Controls. (Group 9015-10.) steering valve and steering column.
13. Remove cap screws (12). 22. Install steering column to mounting bracket and
steering valve.
14. Remove side covers (13) from tilt console.
23. Connect hydraulic hoses to steering valve. See
Hydraulic System Component Location. (Group
CAUTION: Escaping fluid under pressure
9025-15.)
can penetrate the skin causing serious
injury. Avoid the hazard by relieving
24. Remove vacuum pump from hydraulic oil tank and
09 pressure before disconnecting hydraulic or
0960 check for hydraulic oil leaks. See Vacuum Pump
other lines. Tighten all connections before
2 Installation. (Group 2160.)
applying pressure. Search for leaks with a
piece of cardboard. Protect hands and body
25. Connect wire harness to tilt console face plate.
from high pressure fluids.
Location—Standard Controls. (Group 9015-10.)
If an accident occurs, see a doctor
immediately. Any fluid injected into the skin
26. Install tilt console face plate.
must be surgically removed within a few
NEVER-SEEZ is a trademark of Bostik Findley, Inc. Continued on next page JW00603,00000FE –19–05MAY09–2/3
TM11207 (11MAY09) 09-0960-2

051809
PN=272
Hydraulic System
27. Connect wire harness to tilt console top cover. 32. Install steering wheel cover.
Location—Standard Controls. (Group 9015-10.) 33. Turn battery disconnect switch to ON position.
28. Install tilt console top cover. 34. Remove articulation lock pin.
29. Install tilt console side covers. 35. Check hydraulic oil level. See Checking Hydraulic
30. Install steering wheel.
31. Tighten steering wheel retaining nut to
specification.
Specification
Steering Wheel Retaining Nut—
Torque............................................................................... 39—48 N•m
29—35 lb-ft
JW00603,00000FE –19–05MAY09–3/3
09
0960
3
TM11207 (11MAY09) 09-0960-3

051809
PN=273
Hydraulic System
Steering Wheel, Column, and Valve Remove and Install—EH Controls
1
2
16 3
15
14
4
13 4
9
10
5
8
6
12
11 7
–UN–10MAR09
09
0960
4
TX1056834
TX1056834
EH Controls Steering
1—Cap Screw (3 used) 5—Steering Valve 9—Steering Column 14—Steering Wheel Retaining
2—Advanced Display Unit 6—Tilt Console Side Cover (2 10—Cap Screw (4 used) Nut
(ADU) used) 11—Tilt Console Face Plate 15—O-Ring
3—Tilt Console Top Cover 7—Cap Screw (6 used) 12—Cap Screw (4 used) 16—Steering Wheel Cover
4—Cap Screw (6 used) 8—Mounting Bracket 13—Steering Wheel
1. Park machine on flat level surface and lower all 2. Install articulation lock pin.
TM11207 (11MAY09) 09-0960-4

051809
PN=274
Hydraulic System
3. Turn battery disconnect switch to OFF position. other lines. Tighten all connections before
4. Remove steering wheel cover (16) and O-ring (15). piece of cardboard. Protect hands and body
5. Remove steering wheel retaining nut (14).
IMPORTANT: Prevent possible damage to steering immediately. Any fluid injected into the skin
wheel. Use shop rag around puller to must be surgically removed within a few
prevent damaging steering wheel. hours or gangrene may result. Doctors
6. Use bearing pulling attachment D01243AA from reference a knowledgeable medical source.
17-1/2 ton capacity puller set D01048AA to remove Such information is available from Deere &
steering wheel (13). Company Medical Department in Moline,
Illinois, U.S.A.
17. Stop engine and relieve hydraulic pressure in
8. Remove tilt console face plate (11). steering cylinders by moving steering wheel back
9. Disconnect wire harness from advanced display unit
(ADU) (2). See Cab Interior Harness (W15) 18. Install vacuum pump to hydraulic oil tank to
Component Location—6WD or see Cab Interior minimize hydraulic oil loss during repair. See
Harness (W16) Component Location—Non 6WD. Vacuum Pump Installation. (Group 2160.)
(Group 9015-10.)
19. Disconnect and tag hydraulic hoses from steering
10. Remove cap screws (1). valve (5). Cap and plug all hydraulic openings.
See Hydraulic System Component Location—EH
11. Remove ADU from tilt console top cover (3). Controls. (Group 9025-15.)
12. Remove cap screws (4). 20. Remove cap screws (10).
13. Remove tilt console top cover from tilt console. 21. Remove steering column (9) from mounting
bracket (8) and steering valve.
14. Disconnect wire harness from tilt console top
cover. See Tilt Console Harness (W37) 22. Repair or replace parts as needed.
Component Location—EH Controls. (Group
9015-10.) 23. Apply NEVER-SEEZ to splined joint between
steering valve and steering column.
09
24. Install steering column to mounting bracket and 0960
16. Remove side covers (6) from tilt console. steering valve. 5
25. Connect hydraulic hoses. See Hydraulic System

9025-15.)
pressure before disconnecting hydraulic or
NEVER-SEEZ is a trademark of Bostik Findley, Inc. Continued on next page JW00603,000013B –19–05MAY09–2/3
TM11207 (11MAY09) 09-0960-5

051809
PN=275
Hydraulic System
26. Remove vacuum pump from hydraulic oil tank and 33. Install steering wheel.
check for hydraulic oil leaks. See Vacuum Pump
Installation. (Group 2160.) 34. Tighten steering wheel retaining nut to
specification.
27. Connect wire harness to tilt console top cover.
See Tilt Console Harness (W37) Component Specification
Location—EH Controls. (Group 9015-10.) Steering Wheel Retaining Nut—
Torque............................................................................... 39—48 N•m
29—35 lb-ft
28. Install tilt console top cover.
35. Install steering wheel cover and O-ring.
29. Install ADU to tilt console top cover (3).
30. Connect wire harness to advanced display unit
(ADU) (2). See Cab Interior Harness (W15) 37. Remove articulation lock pin.
Component Location—6WD or see Cab Interior
Harness (W16) Component Location—Non 6WD. 38. Check hydraulic oil level. See Checking Hydraulic
(Group 9015-10.) Tank Oil Level. (Operator’s Manual.)
31. Install tilt console face plate. 39. Return machine to service.
32. Install tilt console side covers.
JW00603,000013B –19–05MAY09–3/3

Remove and Install
1. Lower all attachments to the ground.

09
0960 CAUTION: To avoid injury from escaping fluid
6 under pressure, stop engine and relieve the
4. Relieve pressure in the steering circuit by operating the

steering wheel until front wheels stop steering.
5. Install vacuum pump to hydraulic oil tank to minimize

hydraulic oil loss during repair. See Vacuum Pump
Installation. (Group 2160.)
TM11207 (11MAY09) 09-0960-6

051809
PN=276
Hydraulic System
6. Remove cap screws (2) and nuts (1).
7. Remove cover (3) from main frame (4).
8. Disconnect and tag hydraulic hoses (5) from EH
–UN–09APR09
controls steering canceling valve (6). Cap and plug all
openings.
TX1058169A
10. Repair or replace components as needed.
11. Install cap screws (7). Main Frame Cover
12. Connect hydraulic hoses (5) to EH controls steering

canceling valve (6).

–UN–09APR09
(Group 2160.)
TX1058170A

1—Nut (2 used)
17. Return machine to service. 2—Cap Screw (4 used)
3—Cover
4—Main Frame
5—Hydraulic Hose (9 used)
6—EH Controls Steering Canceling Valve
09
0960
7
JW00603,000013C –19–21JAN09–2/2
TM11207 (11MAY09) 09-0960-7

051809
PN=277
Hydraulic System
Steering Cylinder Remove and Install
NOTE: Steering cylinders are not adjustable, tie rod ends

are locked in place with tread lock/sealer and
torqued to a specification.
NOTE: Left steering cylinder shown. Remove and install

procedure for right steering cylinder is similar.

fluids.

4. Stop engine and relieve hydraulic pressure in steering

cylinders by moving steering wheel back and forth until
front wheels stop steering.
09 5. Install vacuum pump to hydraulic oil tank to minimize

0960 hydraulic oil loss during repair. See Vacuum Pump
8
Continued on next page JW00603,000013D –19–04MAY09–1/4
TM11207 (11MAY09) 09-0960-8

051809
PN=278
Hydraulic System
6. Disconnect and tag hydraulic hoses (6). Cap and plug

all openings.
7. Remove tie rod cotter pin (1) and remove tie rod nut
(2).
–UN–15APR09
8. Use OEM9806 Slide Sledge 11/16" Tie Rod/Ball Joint
Separator Fork to remove tie rod (4) from wheel lean
assembly yoke (3).
TX1058178A
9. Remove head end pin retaining cap screw (7) and nut
(9).
Left Steering Cylinder
10. Remove head end pin (8). 1—Tie Rod Cotter Pin
2—Tie Rod Nut
11. Remove steering cylinder (5) from machine. 3—Wheel Lean Assembly Yoke
4—Tie Rod
5—Steering Cylinder
7—Head End Pin Retaining Cap Screw
8—Head End Pin
9—Nut
09
0960
9
TM11207 (11MAY09) 09-0960-9

051809
PN=279
Hydraulic System
12. Remove snap rings (13), spacers (11), and bushings

(12) as shown.
11
10
13. Inspect steering cylinder head end bore, spacers, 12
bushings, and pins for excessive wear or damage.
–UN–15APR09
Specification
Steering Cylinder Head End Bore
(10)—Diameter ......................................................................... 30—31 mm 13
1.181—1.220 in.
8
TX1058314
Spacer (11)—Inside Diameter ....................................... 29.95—30.20 mm 7
1.179—1.189
Spacer—Outside Diameter............................................ 33.75—34.25 mm 9
1.329—1.348 in. Steering Cylinder Head End
Bushing (12)—Inside Diameter ....................................................... 30 mm
1.181 in. 7—Head End Pin Retaining Cap Screw
Bushing—Outside Diameter ...................................... 47.007—46.982 mm 8—Head End Pin
1.851—1.850 in. 9—Nut
Head End Pin (8)—Diameter .................................... 29.893—29.939 mm 10—Steering Cylinder Head End Bore
1.177—1.179 in. 11—Spacer (2 used)
12—Bushing
14. Make cylinder repairs as required. See 120 Series 13—Snap Ring (2 used)
Hydraulic Cylinders. (TM-H120A.)
IMPORTANT: If new cylinder is installed and tie rod

end replaced, tie rod must be secured
with LOCTITE Threadlocker 271 (high
strength) thread lock/sealer on cylinder
rod and torqued to specification.
15. If new cylinder is installed, put LOCTITE

Threadlocker 271 (high strength) thread lock/sealer to
rod threads and tighten tie rod end to specifications.
Specification
Tie Rod End to Cylinder Rod—
Torque .......................................................................................... 270 N•m
200 lb-ft
16. Install cylinder.

09
0960 17. Install head end pin retaining cap screw and nut.
10 Tighten to specification.
Specification
Head End Pin Retaining Cap
Screw—Torque .................................................................... 154—187 N•m
113—138 lb-ft
LOCTITE is a trademark of Loctite Corp. Continued on next page JW00603,000013D –19–04MAY09–3/4
TM11207 (11MAY09) 09-0960-10

051809
PN=280
Hydraulic System
18. Install tie rod nut. Tighten to specification.
Specification
Tie Rod Nut—Torque .......................................................... 154—187 N•m
113—138 lb-ft
19. Install cotter pin.
20. Connect hydraulic hoses.

(Group 2160.)

JW00603,000013D –19–04MAY09–4/4
Hydraulic Cylinder Disassemble and

Assemble
For repair information on hydraulic cylinders, see 120

Series Hydraulic Cylinders. (TM-H120A.)
IMPORTANT: If new cylinder is installed and tie rod

end replaced, tie rod must be secured
with LOCTITE Threadlocker 271 (high
09
strength) thread lock/sealer on cylinder
0960
rod and torqued to specification. 11
1. Apply LOCTITE Threadlocker 271 (high strength)

thread lock/sealer to thread of steering cylinder rod.
2. Install tie rod end onto cylinder rod. Tighten to

specification.
Specification
Front Steering Cylinder—Torque ................................................. 271 N•m
200 lb-ft
LOCTITE is a trademark of Loctite Corp. JW00603,0000140 –19–21JAN09–1/1
TM11207 (11MAY09) 09-0960-11

051809
PN=281
Hydraulic System
Wheel Lean Cylinder Remove and Install

device.
4. Support front of machine main frame with an

appropriate lifting device. See Machine Specifications
for machine weights. (Operator’s Manual.)
5. Remove left front wheel. See Wheel Remove and


device.
6. Support left wheel lean yoke assembly using

Specification
Left Wheel Lean Yoke Assembly
(non 6WD)—Weight
(approximate)................................................................................... 125 kg
275 lb.
Left Wheel Lean Yoke Assembly
(6WD)—Weight (approximate) ........................................................ 390 kg
860 lb.
09
0960
12
TM11207 (11MAY09) 09-0960-12

051809
PN=282
Hydraulic System
7. Remove wheel lean bar pin cap screws (2).
8. Remove wheel lean bar pin (1) and disconnect wheel

lean bar from wheel lean yoke assembly.
9. Remove cotter pin and nut (3 and 6) from steering

cylinder (5) and tie rod (4).
10. Use OEM9806 Slide Sledge 11/16" Tie Rod/Ball Joint

Separator Fork to remove tie rod (4) from wheel lean
assembly yoke (7).
1—Wheel Lean Bar Pin
–UN–21APR09
2—Wheel Lean Bar Pin Cap Screw (6 used)
3—Tie Rod Cotter Pin and Nut
4—Tie Rod
5—Steering Cylinder
TX1058568A
6—Steering Cylinder Cotter Pin and Nut
7—Wheel Lean Assembly Yoke
Wheel Lean Bar and Yoke Assembly
09
0960
13
TM11207 (11MAY09) 09-0960-13

051809
PN=283
Hydraulic System
11. Disconnect lubrication lines (9).

device.
–UN–16APR09
12. Support wheel lean cylinder using appropriate lifting
device.
TX1058347A
Specification
Wheel Lean Cylinder—Weight
(approximate)..................................................................................... 25 kg
55 lb Wheel Lean Cylinder
13. Remove wheel lean cylinder rod end pin (8) from 8—Wheel Lean Cylinder Rod End Pin
9—Lubrication Line (2 used)
wheel lean cylinder (10). See NeverGrease Pin 10—Wheel Lean Cylinder
Joints. (Group 3440.) 11—Hydraulic Hose (2 used)
12—Wheel Lean Cylinder Head End Pin
14. Pivot wheel lean yoke assembly down and support.

15. To relieve pressure in the system, slowly loosen

fittings on hydraulic hoses (11) at wheel lean cylinder.

17. Disconnect and tag hydraulic hoses from wheel lean

cylinder.
18. Remove wheel lean cylinder head end pin (12). See
09 NeverGrease Pin Joints. (Group 3440.)
0960
14 19. Remove wheel lean cylinder from machine.
20. Inspect wheel lean cylinder bushings, and pins for

excessive wear or damage.
Specification
Wheel Lean Cylinder Bushing—
Inside Diameter ............................................................. 39.66—39.74 mm
1.561—1.564 in.
TM11207 (11MAY09) 09-0960-14

051809
PN=284
Hydraulic System
Specification
Wheel Lean Cylinder Bushing—
Outside Diameter........................................................... 50.06—50.11 mm
1.971—7.973 in.
Wheel Lean Cylinder Pin—
Diameter ........................................................................ 39.45—39.50 mm
1.55—1.56 in.
21. Repair or replace components as needed. See 120

22. Install wheel lean cylinder and wheel lean cylinder

head end pin. See NeverGrease Pin Joints. (Group
3440.)
23. Connect hydraulic lines to wheel lean cylinder.
24. Raise wheel lean yoke assembly into position.
25. Install wheel lean cylinder rod end pin to connect

wheel lean yoke assembly. See NeverGrease Pin
Joints. (Group 3440.)
26. Connect lubrication lines.
27. Install steering cylinder and tie rod. Tighten nut to

specification. Install cotter pin.
Wheel Lean Yoke—Specification

Steering Cylinder Nut—Torque ........................................... 153—186 N•m
112.5—137.5 lb-ft
Tie Rod Nut—Torque .......................................................... 153—186 N•m
112.5—137.5 lb-ft
28. Install wheel lean bar and pin. Tighten wheel lean bar
pin cap screw to specification.
Specification
Wheel Lean Bar Pin Cap
Screw—Torque .................................................................... 119—146 N•m
88—108 lb-ft 09
0960
29. Install left front wheel. See Wheel Remove and 15
30. Lower machine to the ground
TM11207 (11MAY09) 09-0960-15

051809
PN=285
Hydraulic System


JW00603,0000141 –19–21JAN09–5/5
09
0960
16
TM11207 (11MAY09) 09-0960-16

051809
PN=286
Hydraulic System
Secondary Steering Accumulator Remove and Install—If Equipped
3
4 4
3
1 2
1
–UN–17APR09
TX1058374
5 5
TX1058374
Secondary Steering Accumulator
1—Hydraulic Hose 3—Mounting Strap (2 used) 4—Cap Screw (2 used) 5—Nut (2 used)
2—Secondary Steering
Accumulator
1. Lower all attachments to the ground. unfamiliar with this type of injury should
reference a knowledgeable medical source.
2. Install articulation lock pin. Such information is available from Deere &
Company Medical Department in Moline,
3. Turn battery disconnect switch to OFF position. Illinois, U.S.A.
09
4. Stop engine and relieve hydraulic pressure in 0960
steering cylinders by moving steering wheel back 17
5. Install vacuum pump to hydraulic oil tank to
minimize hydraulic oil loss during repair. See
piece of cardboard. Protect hands and body
6. Disconnect hydraulic hose (1) from secondary
steering accumulator (2).
7. Remove cap screws (4) and nuts (5).
must be surgically removed within a few
hours or gangrene may result. Doctors
Continued on next page BR70016,0000057 –19–17FEB09–1/2
TM11207 (11MAY09) 09-0960-17

051809
PN=287
Hydraulic System
8. Remove mounting straps (3). 13. Install mounting straps.
14. Install cap screws and nuts.

15. Connect hydraulic hose to secondary steering
lifting device.
accumulator.
9. Lift secondary steering accumulator using
16. Remove vacuum pump from hydraulic oil tank.
Check for hydraulic oil leaks. See Vacuum Pump
Specification Installation. (Group 2160.)
Secondary Steering
Accumulator—Weight ................................................................. 31 kg 17. Turn battery disconnect switch to ON position.
69 lb.
10. Remove secondary steering accumulator from
machine. 19. Check hydraulic oil level. See Checking Hydraulic
12. Install secondary steering accumulator to machine.
BR70016,0000057 –19–17FEB09–2/2
09
0960
18
TM11207 (11MAY09) 09-0960-18

051809
PN=288
Section 10
Service Brakes
Contents
Page

Service Brake Repair . . . . . . . . . . . . . . . . . .10-1011-1

Service Brake Valve Remove and Install. . . .10-1060-1
Service Brake Bleeding . . . . . . . . . . . . . . . . .10-1060-3
Brake Accumulator Remove and Install. . . . .10-1060-4
10
770G,
051809
PN=1
Contents
10
770G,
051809
PN=2
Group 1011
Active Elements
Service Brake Repair
For repair information on service brake components, See

1400 Multiple Disk Brakes Reference List. (CTM43.)
JW00603,00000ED –19–04MAY09–1/1
10
1011
1
TM11207 (11MAY09) 10-1011-1

051809
PN=291
Active Elements
10
1011
2
TM11207 (11MAY09) 10-1011-2

051809
PN=292
Group 1060
Hydraulic System
Service Brake Valve Remove and Install

–UN–08DEC08
fluids.
X9811
knowledgeable source. Such information is
available from Deere & Company Medical
Department in Moline, Illinois, U.S.A.


2. Apply brake pedal and observe feedback. Pedal is

spring loaded away from brake valve actuator tube.
Reach under pedal to feel feedback on actuator tube.
When feedback is no longer observed (approximately
20 applications with a full accumulator), accumulator is
discharged.
Continued on next page JW00603,0000192 –19–09FEB09–1/3
10
1060
1
TM11207 (11MAY09) 10-1060-1

051809
PN=293
Hydraulic System
8
3
7
4
–UN–07DEC04
5
T204868
1 2
T204868
Brake Valve and Pedal
1—Electrical Connectors (2 2—Brake Valve 4—Spring 7—U-Bolt

used) 3—Cap Screw (3 used) 5—Pivot 8—Brake Pedal Assembly
3. Remove lines and seal openings from inner two 11. Remove hex nuts from U-bolt (7) at the brake
grader control valves at the right control valve valve pivot and remove U-bolt.
assembly to gain access to brake valve. Mark lines
for ease of assembly. 12. Remove cap screw (3) holding brake pedal
assembly (8) to the floor and lift pedal assembly
4. Disconnect electrical connectors (1) from the brake from machine.
valve.
13. Remove brake valve (2) from the machine.
5. Attach identification tags on hydraulic lines.
IMPORTANT: Brake valve is not serviceable.
6. Disconnect hydraulic lines from the brake valve (2).
Close all openings using caps and plugs. 14. Repair or replace parts as necessary.
10
1060
7. Remove screws holding floor mat in place. 15. Install brake pedal assembly (8) and tighten cap
2 screws (3).
8. Remove floor mat from around the brake valve.
16. Align brake valve with pedal tube and install U-bolt
9. Remove spring (4) from pivot (5). and install and tighten hex nuts and washers.
10. Remove lower link pin from the brake valve pivot. 17. Install all lines to the brake valve.
TM11207 (11MAY09) 10-1060-2

051809
PN=294
Hydraulic System
18. Install electrical connectors. 21. Remove articulation lock pin.
19. Install link pin from pedal to brake valve pivot with 22. Bleed service brakes. See Service Brake
hardware. Bleeding. (Group 1060.)
20. Install floor mat.
JW00603,0000192 –19–09FEB09–3/3
Service Brake Bleeding
NOTE: Service brakes are bled at bleed screws on the

brake housing when ever components are
replaced or repaired.
Bleed service brakes when ever main system components

have been repaired or replaced. Bleed screw (2) is
located on left and right top side of the brake housing. It
can be accessed by opening the left and right engine
access doors.
1. Place a clear plastic tube on bleed screw to route
–UN–10FEB09
hydraulic oil into a suitable container.
2. Apply hydraulic pressure to the brake system with

brake pedal until hydraulic oil starts to flow. Close
TX1055633A
brake bleed screw when hydraulic fluid in clear tube is
free of air bubbles.
3. Check hydraulic oil level. See Checking Hydraulic Tank Service Brake Bleed Screw (Right Side Shown)
Oil Level. (Operator’s Manual.)
1—Engine Oil Pan
2—Service Brake Bleed Screw
3—Service Brake Housing
JW00603,0000143 –19–21JAN09–1/1
10
1060
3
TM11207 (11MAY09) 10-1060-3

051809
PN=295
Hydraulic System
Brake Accumulator Remove and Install

–UN–08DEC08
fluids.
X9811


2. Apply brake pedal and observe feedback. Pedal is

spring loaded away from brake valve actuator tube.
Reach under pedal to feel feedback on actuator tube.
When feedback is no longer observed (approximately
20 applications with a full accumulator), accumulator is
discharged.
3. Attach identification tags to hydraulic lines.
10
1060
4
TM11207 (11MAY09) 10-1060-4

051809
PN=296
Hydraulic System
4. Slowly disconnect hydraulic lines (2) from accumulator

(1). Close all openings using caps and plugs.
5. Remove cap screws (3) and clamps (4). Remove brake

accumulator.
–UN–20NOV04
NOTE: Accumulator is not rechargeable or repairable.

Replace as necessary.
T204871A
7. Position accumulator in place and install clamps and
cap screws. Brake Accumulator
1—Brake Accumulator
8. Connect hydraulic lines. 2—Hydraulic Line (2 used)
9. Remove articulation lock pin. See Locking Machine 4—Clamp (2 used)
10. Bleed service brakes. See Service Brake Bleeding.

(Group 1060.)

JW00603,0000194 –19–09FEB09–2/2
10
1060
5
TM11207 (11MAY09) 10-1060-5

051809
PN=297
Hydraulic System
10
1060
6
TM11207 (11MAY09) 10-1060-6

051809
PN=298
Section 11
Park Brake
Contents
Page

Park Brake Repair. . . . . . . . . . . . . . . . . . . . .11-1111-1
11
770G,
051809
PN=1
Contents
11
770G,
051809
PN=2
Group 1111
Active Elements
Park Brake Repair
For additional information on DF180 transmission and

park brake components, see the following Component
Technical Manuals.
• See Park Brake List. (CTM308.)
JW00603,00000EE –19–04MAY09–1/1
11
1111
1
TM11207 (11MAY09) 11-1111-1

051809
PN=301
Active Elements
11
1111
2
TM11207 (11MAY09) 11-1111-2

051809
PN=302
Section 17
Frame, Chassis or Supporting Structure 17
Contents
Page
Group 1740—Frame Installation

Welding On Machine . . . . . . . . . . . . . . . . . . .17-1740-1
Welding Repair of Major Structure. . . . . . . . .17-1740-2
Separate Frames at Articulation Joint . . . . . .17-1740-3
Articulation Bearing Replacement . . . . . . . .17-1740-10
770G,
051809
PN=1
Contents
17
770G,
051809
PN=2
Group 1740
Frame Installation
Welding On Machine
IMPORTANT: Disconnect battery ground strap or WELD METAL SPECIFICATIONS 17

1740
turn battery disconnect switch to 1
OFF (if applicable). Item Specification
Tensile Strength 482.6 mPa (70 000 psi)
Disconnect both negative and
Yield Strength 413.7 mPa (60 000 psi)
positive battery cables and
microprocessor unit (if applicable). Elongation 22%
IMPORTANT: Have only a qualified welder do this Use one of the following weld processes:
job. Connect welder ground clamp
close to each weld area so electrical • AWS-E-7018 covered electrode with shielded metal
current does not pass through any arc welding (SMAW) process.
bearings. • AWS-ER-70S-3f wire electrode with gas metal arc
welding (GMAW) process.
Remove or protect all parts that can • AWS-E70T-1 or E71T-1 wire electrode with flux core
be damaged by heat or weld splatter. arc welding (FCAW) process.
TX,WELD,II –19–11APR95–1/1
TM11207 (11MAY09) 17-1740-1

051809
PN=305
Frame Installation
Welding Repair of Major Structure

17 • AWS-ER-70S-3 wire electrode with gas metal arc
1740 CAUTION: Avoid potentially toxic fumes and
welding (GMAW) process.
2 dust. Hazardous fumes can be generated
• AWS-E70T-1 or E71T-1 wire electrode with flux
when paint is heated by welding, soldering,
core arc welding (FCAW) process.
or using a torch. Do all work outside or in a
well ventilated area. Dispose of paint and Welding Repair of Major Structure—Specification
solvent properly. Weld Metal—Tensile Strength ............................................ 482.6 mPa
70,000 psi
If you sand or grind paint, avoid breathing Yield Strength ..................................................................... 413.7 mPa
the dust. Wear an approved respirator. If you 60,000 psi
Elongation ..................................................................................... 22%
use solvent or paint stripper, remove
stripper with soap and water before welding.
Remove solvent or paint stripper containers
and other flammable material from area.
Allow fumes to disperse at least 15 minutes
IMPORTANT: Area to be repaired must be
before welding or heating.
preheated to allow better weld
penetration.
1. Remove paint before welding or heating.
3. To repair weld metal failure, remove failed weld
IMPORTANT: Electrical current traveling from the
metal using arc or grinding equipment. Thoroughly
welder through the machine
clean area to be welded. Preheat structural
electrical system may damage the
assemblies to a minimum of 38°C (100°F). Preheat
machine electrical system, including
ground engaging tools (cutting edges, skid shoes,
battery, machine information center,
and teeth shanks) to 177°C (350°F).
and pump and valve controller.
Disconnect battery ground cable,
To repair base metal failure remove enough
machine information center, and
material to allow weld to penetrate to the bottom of
pump and valve controller electrical
crack. Preheat structural assemblies to a minimum
connectors before welding on the
of 38°C (100°F). Preheat ground engaging tools
machine.
(cutting edges, skid shoes, and teeth shanks) to
177°C (350°F).
Have only a qualified welder do this
job. Connect welder ground clamp Welding Repair of Major Structure—Specification
close to each weld area so electrical Structural Assemblies—Preheat
current does not pass through any Temperature ................................................................................ 38°C
bearings. Remove or protect all parts 100°F
that can be damaged by heat or weld Ground Engaging Tools—
Preheat Temperature................................................................. 177°C
splatter. 350°F
2. Use one of the following weld processes:
• AWS-E-7018 covered electrode with shielded

metal arc welding (SMAW) process.
LD30992,0000008 –19–17FEB03–1/1
TM11207 (11MAY09) 17-1740-2

051809
PN=306
Frame Installation
Separate Frames at Articulation Joint
1. Park machine on smooth level surface and align 17

1740
frames. 3
2. Lower all attachments except ripper, if equipped.
3. If equipped, support ripper in the up position to allow

for separation of the engine frame from the main
frame.
4. Stop engine.
NOTE: It takes at least 60 cycles of the brake pedal to

5. Depress service brake pedal continuously until service

brake pedal offers no resistance to discharge service
brake accumulator.
6. Relieve hydraulic pressure in steering cylinders by

moving steering wheel back and forth until front wheels
stop steering.

9. Recover air conditioner refrigerant. See R134a

Refrigerant Recovery/Recycling and Charging Station
Installation Procedure. (Group 1830.)
Continued on next page PG32926,000008D –19–14MAY09–1/7
TM11207 (11MAY09) 17-1740-3

051809
PN=307
Frame Installation
CAUTION: Avoid possible crushing injury or

17 death from heavy component. Use appropriate
1740 supporting device.
4
10. Install appropriate supporting devices under front cab
–UN–28APR09
mounting gussets.
28—Shop Stand (2 used)
TX1058809A
Main Frame Support
PG32926,000008D –19–14MAY09–2/7
CAUTION: Avoid possible crushing injury from

unexpected movement, support rear of engine
frame to keep engine frame from tipping to the
rear when articulation pins are pulled.
–UN–29APR09
11. Attach appropriate lifting device to lift points (31) on
rear of engine frame.
TX1058936A
31—Lift Point (2 used)
Lift Point on Rear on Engine Frame
TM11207 (11MAY09) 17-1740-4

051809
PN=308
Frame Installation
12. Remove wire harness cover (29) on rear of cab.
13. Disconnect wire harness clamps (30). 17

1740
5
14. Disconnect wire harness connectors from rear of cab.
–UN–29APR09
See Cab Interior Harness (W15) Component
Location—6WD, or see Cab Interior Harness (W16)
Component Location—Non 6WD. (Group 9015-10.)
TX1058925A
pressure in the system before disconnecting or Cab Wire Harness
connections before applying pressure. 29—Wire Harness Cover
30—Wire Harness Clamp (2 used)
fittings on hydraulic lines to be removed.
16. Install vacuum pump. See Vacuum Pump Installation.

(Group 2160.)
17. Remove and tag all hydraulic hoses from bulkhead at

main frame. Cap and plug all openings.
18. Disconnect 6WD system lines (if equipped) from

bulkhead in main frame. See 6WD System
Component Location. (Group 9016-15.)
19. Disconnect park brake lines from bulkhead in main

frame. See Power Train Component Location. (Group
9020-15.)
20. Disconnect service brake lines from bulkhead in main

frame. See Hydraulic System Component Location
(Group 9025-15) or see Hydraulic System Component
Location—EH Controls. (Group 9025-15.)
21. Disconnect hydraulic lines from bulkhead in main

frame. See Hydraulic System Component Location
(Group 9025-15) or see Hydraulic System Component
22. Disconnect air conditioner and heater lines. See Air

Conditioner and Heater Component Location. (Group
9031-15.)
TM11207 (11MAY09) 17-1740-5

051809
PN=309
Frame Installation
23. Remove articulation cylinder rod end pins to

disconnect articulation cylinders. See Articulation
17 Cylinders Remove and Install. (Group 3460.)
1740
6
TM11207 (11MAY09) 17-1740-6

051809
PN=310
Frame Installation
17
1740
7
TM11207 (11MAY09) 17-1740-7

051809
PN=311
Frame Installation
17
1740 1
8
2
3
6
10
4
11 9
5
10
16
17
18 12
27
19
13
20
21
14
22
22 15
23
24
–UN–01MAY09
25
26
TX1058327
TX1058327
Engine and Equipment Frames
TM11207 (11MAY09) 17-1740-8

051809
PN=312
Frame Installation
1—Cap Screw 10—Seal (2 used) 17—Seal 22—Shim

2—Washer 11—Bushing 18—Tapered Bearing 23—Locking Collar
3—Upper Pin 12—Bushing Assembly 24—Plate 17
4—Bushing (2 used) 13—Plate 19—Seal 25—Washer (10 used) 1740
5—Equipment Frame 14—Cap Screw (4 used) 20—Shim 26—Cap Screw (10 used) 9
6—Nut (4 used) 15—Cap Screw (6 used) 21—Shim 27—Engine Frame
9—Lower Pin 16—Spacer
24. Remove nuts (6) and cap screws (14). 35. Install cap screws (14) and nuts (6).
25. Remove cap screw (15), plate (13), and lower pin 36. Install plate (13) and cap screws (15).
(9).
37. Connect all hydraulic hoses, electrical harnesses,
26. Remove cap screw (1) and upper pin (3) and linkages.
27. Manually release park brake. See Towing 38. Remove vacuum pump and check for leaks.
Procedure. (Operators Manual.)
39. Connect heater and air conditioner lines.
28. Roll engine frame back from equipment frame.
40. Refill engine coolant. See Drain, Flush, and Refill
29. Repair and replace parts as necessary. Cooling System. (Operator’s Manual.)
30. Replace tapered bearing assembly (18), if needed. 41. Charge air conditioning. See R134a System
See Articulation Bearing Replacement. (Group Charge. (Group 1830.)
1740.)
42. Connect articulation cylinders. See Articulation
31. Assemble engine frame to equipment frame by Cylinders Remove and Install. (Group 3460.)
aligning bushing holes in each frame member.
43. Bleed service brakes. See Service Brake
32. Install upper pin through bushing (4) in equipment Bleeding. (Group 1060.)
frame (5) and through upper bushing (11) in
engine frame (27). 44. Check hydraulic oil level. See Hydraulic Tank Oil.
33. Install lower pin (9) through lower bushing in
equipment frame, tapered bearing assembly (18), 45. Turn battery disconnect switch to ON position.
and shims (20—22) in engine frame.
34. Install cap screw (1), an washer (2).
PG32926,000008D –19–14MAY09–7/7
TM11207 (11MAY09) 17-1740-9

051809
PN=313
Frame Installation
Articulation Bearing Replacement

17 1. Park machine on smooth level surface and lower all
1740
10
attachments.
2. Separate machine frames at articulation joint. See

Separate Frames at Articulation Joint. (Group 1740.)
Continued on next page PG32926,000008E –19–14MAY09–1/5
TM11207 (11MAY09) 17-1740-10

051809
PN=314
Frame Installation
17
1740
11
TM11207 (11MAY09) 17-1740-11

051809
PN=315
Frame Installation
17
1740
12
1
6
8
10
11
12
12
13
–UN–06MAY09
14
15
TX1059162
16
TX1059162
Articulation Bearing
TM11207 (11MAY09) 17-1740-12

051809
PN=316
Frame Installation
1—Engine Frame 5—Spacer 9—Seal 13—Locking Collar

2—Seal Spacer 6—Tapered Bearing (2 used) 10—Shim 14—Bearing Plate
3—Seal 7—Lower Bearing Cup 11—Shim 15—Washers (10 used) 17
4—Top Bearing Cup 8—Tapered Bearing Assembly 12—Shim 16—Cap Screw (10 used) 1740
13
3. Remove cap screws (16) and washers (15). 6. Repair or replace parts as necessary.
4. Remove bearing plate (14), locking collar (13), and 7. Apply a light coat of grease to the outside of the
shims (10—12) rollers or each half of the tapered bearing (6).
5. Remove bearing assembly using a 97mm (3.819 in)

puller disk under seal spacer (2).
PG32926,000008E –19–14MAY09–3/5
8. Install seal (3) into seal spacer with lip facing out. 3
Press seal to seal spacer shoulder (17).
9. Install seal spacer in top of bore.
–UN–07MAY09
IMPORTANT: To prevent bearing damage, do not
apply load to new bearing when
pressing in top bearing cup.
2
TX1059222
10. Press top bearing cup (4) to top of bore using
JDG1152 driver disk. 17
IMPORTANT: To prevent bearing damage, use the Seal Spacer and Seal
same spacer which was removed from
2—Seal Spacer
the bearing set. Spacers are not 3—Seal
interchangeable with other bearings. 17—Seal Spacer Shoulder
11. Install taper bearings (6), spacer (5) and lower

bearing cup (7).
12. Install seal (9) into bearing plate (14) with lip facing
out. Press seal to bearing plate shoulder.
TM11207 (11MAY09) 17-1740-13

051809
PN=317
Frame Installation
13. Hold bearing plate in place using four cap screws

spaced equally apart. Lightly tighten cap screws but
17 do not tighten to torque specification. Bearing plate
1740
14
must be in contact with bearing. Measure gap
between bearing cover and frame in three places.
–UN–13MAY09
Calculate the average of the three readings to 1
determine the shim pack required. 18
14. Subtract bearing preload thickness from averaged 14
TX1059414
measured distance to determine shim pack thickness.
Specification
Articulation Bearing—Preload ........................................... 0.03—0.13 mm Measure Shim Pack
0.001—0.005 in.
1—Engine Frame
15. Apply grease to top of bearing. Fill cavity above 14—Bearing Plate
18—Distance Between Bearing Plate and Engine
bearing to machined surface to prevent moisture from
Frame
entering bearing through shim pack.
16. Install cap screws and washers. Torque cap screws

to specification. Rotate inner bearing race after
tightening.
Specification
103 lb-ft
17. Assemble machine frames. See Separate Frames at

Articulation Joint. (Group 1740.)
PG32926,000008E –19–14MAY09–5/5
TM11207 (11MAY09) 17-1740-14

051809
PN=318
Section 18
Operator’s Station
Contents
Page Page 18
R134a Refrigerant Recovery/Recycling

Group 1800—Removal and Installation and Charging Station Installation
Cab Remove and Install . . . . . . . . . . . . . . . .18-1800-1 Procedure . . . . . . . . . . . . . . . . . . . . . . . .18-1830-10
Cab Remove and Install—GP Machine R134a System Recover . . . . . . . . . . . . . . .18-1830-11
Only. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18-1800-9 R134a System Evacuate . . . . . . . . . . . . . . .18-1830-12
R134a System Charge . . . . . . . . . . . . . . . .18-1830-14
Group 1810—Operator Enclosure Expansion Valve Remove and Install . . . . .18-1830-15
Windowpanes Remove and Install . . . . . . . .18-1810-1 Freeze Control Switch Remove and
Install. . . . . . . . . . . . . . . . . . . . . . . . . . . .18-1830-17
Cab Door Handle Remove and Install . . . . . .18-1810-2
Air Conditioning High-Low Pressure
Cab Door Latch Remove and Install . . . . . . .18-1810-3
Switch Remove and Install. . . . . . . . . . . .18-1830-19
Rivet Nut Installation . . . . . . . . . . . . . . . . . . .18-1810-5
Heater Control Valve Remove and
Install. . . . . . . . . . . . . . . . . . . . . . . . . . . .18-1830-20
Group 1815—Pedal Assembly Heater Control Valve Leak Check . . . . . . . .18-1830-21
Inching Pedal Remove and Install . . . . . . . . .18-1815-1 Blower Motor Assembly Remove and
Install. . . . . . . . . . . . . . . . . . . . . . . . . . . .18-1830-21
Group 1816—Steering Tilt Console Compressor Remove and Install—6.8L . . . .18-1830-22
Steering Support Console Remove and Compressor Remove and Install—9.0L . . . .18-1830-24
Install—Standard Controls . . . . . . . . . . . . .18-1816-2 Condenser Remove and Install . . . . . . . . . .18-1830-26
Steering Support Console Remove and Heater and Air Conditioner Remove and
Install—EH Controls. . . . . . . . . . . . . . . . . .18-1816-4 Install. . . . . . . . . . . . . . . . . . . . . . . . . . . .18-1830-28
Console Tilt Remove and Install . . . . . . . . . .18-1816-6 Receiver-Dryer Remove and Install . . . . . . .18-1830-33
Steering Tilt Assembly Remove and Accumulator Remove and Install . . . . . . . . .18-1830-34
Install. . . . . . . . . . . . . . . . . . . . . . . . . . . . .18-1816-8 Compressor Clutch Disassemble and
Assemble. . . . . . . . . . . . . . . . . . . . . . . . .18-1830-35
Compressor Manifold Inspect . . . . . . . . . . .18-1830-36
Group 1821—Seat and Seat Belt
Compressor Relief Valve Remove and
Seat Remove and Install . . . . . . . . . . . . . . . .18-1821-1
Install. . . . . . . . . . . . . . . . . . . . . . . . . . . .18-1830-37
Seat Belt Remove and Install . . . . . . . . . . . .18-1821-3
Armrest Remove and Install . . . . . . . . . . . . .18-1821-5
Armrest Remove and Install—EH
Controls . . . . . . . . . . . . . . . . . . . . . . . . . . .18-1821-6
Armrest Disassemble and Assemble—EH
Controls . . . . . . . . . . . . . . . . . . . . . . . . . . .18-1821-8
Standard Seat Disassemble and
Assemble. . . . . . . . . . . . . . . . . . . . . . . . .18-1821-10
Deluxe Seat Disassemble and
Assemble. . . . . . . . . . . . . . . . . . . . . . . . .18-1821-12
Air Suspension Disassemble and
Assemble. . . . . . . . . . . . . . . . . . . . . . . . .18-1821-14
Group 1830—Heating and Air Conditioning

Refrigerant Cautions and Proper
Handling . . . . . . . . . . . . . . . . . . . . . . . . . .18-1830-1
Flush and Purge Air Conditioner System. . . .18-1830-3
R134a Refrigerant Oil Information . . . . . . . . .18-1830-8
770G,
051809
PN=1
Contents
18
770G,
051809
PN=2
Group 1800
Cab Remove and Install


18
3. Turn battery disconnect switch to OFF position. 1800
1
5. Recover air conditioning system refrigerant. See R134a

System Recover. (Group 1830.)
6. Remove harness connectors and ground from back of

cab. See Cab Interior Harness (W15) Component
7. Remove harness connectors, ground strap, and

harness clamps from under right side of cab.
8. Remove cover over frame in front of cab.
9. Remove hydraulic steering lines from front of cab. Note

location of lines. Cap and plug all lines.
10. Disconnect harness from front lower wiper, front lower

window switches and remove harness clamp from
cab, if equipped.
Continued on next page AS79221,000005B –19–29APR09–1/9
TM11207 (11MAY09) 18-1800-1

051809
PN=321
11. Disconnect cab air conditioner outlet/inlet lines (1 and

2) from under left side of cab.
12. Remove nuts (8) to remove bracket (7) from cab.
13. Loosen hose clamps (5 and 6) to disconnect heater

hot water lines from under left side of cab after
18 engine cooling system has drained.
1800
2 14. Remove hose clamp (3) from cab drain hose and
remove cap screw (4).
15. Remove cab floor mat.
–UN–27FEB09
16. Remove grader control valve. See Grader Control
Valve Remove and Install. (Group 3460.)
TX1056380A
1—Cab Air Conditioner Outlet Line
2—Cab Air Conditioner Inlet Line
3—Hose Clamp
4—Cap Screw Air Conditioner and Heater Lines
5—Hose Clamp
6—Hose Clamp
7—Bracket
8—Nut (2 used)
TM11207 (11MAY09) 18-1800-2

051809
PN=322
17. Remove pin (10) from service brake valve.
18. Remove nuts from U-bolt (11) lower and support

service brake valve.
19. Disconnect roof harness from cab harness connector.

See Cab Roof Harness (W14) Component Location.
(Group 9015-10.) 18
1800
20. Disconnect heated mirrors (if equipped) from roof 11 3
harness.

–UN–03MAR09
cab, if equipped. See Front Platform Harness (W25)
10
22. Remove cap screws holding roof to cab. Note location
TX1056401
of spacers and washers.
23. Attach lifting straps to cab roof. Service Brake Valve
10—Pin
CAUTION: Avoid crushing injury. Use 11—U-Bolt
appropriate lifting device when removing cab
roof.
24. Using an appropriate lifting device, attach lifting straps

to DFT1101 Cab and ROPS Lifting Bracket and
remove cab roof.
Specification
Cab Roof—Weight............................................................................. 55 kg
121 lb
TM11207 (11MAY09) 18-1800-3

051809
PN=323
IMPORTANT: Route chains to prevent chains from

making contact with rear and side
window.
25. Attach lifting straps (15) to front cab hand rail (16)
and attach chains (20) to rear lifting bracket (19).
18 26. Attach lifting straps and chains to DFT1101 Cab and

1800 ROPS Lifting Bracket (21).
4
27. Remove cab isolator cap screws.
–UN–03DEC04
appropriate lifting device when removing cab.
T205812A
28. Using an appropriate lifting device, remove cab with
DFT1101 Cab and ROPS Lifting Bracket. Front Cab Lifting Point
Specification
Cab—Weight ................................................................................. 1035 kg
2280 lb
30. Install cab to frame.
Cab Isolators—Specification
Front Isolator—Torque ........................................................ 500—748 N•m
368—552 lb-ft
Rear Isolator—Torque ....................................................... 857—1285 N•m
–UN–03DEC04
632—948 lb-ft
15—Lifting Strap
16—Front Cab Hand Rail
T205811A
17—DFT1101 Cab and ROPS Lifting Bracket
19—Rear Lifting Bracket
20—Chain Rear Cab Lifting Point
TM11207 (11MAY09) 18-1800-4

051809
PN=324
IMPORTANT: Cab roof is an integral part to heater

and air conditioner external air intake.
Cab roof must seal correctly to prevent
contaminants from entering the system.
31. Inspect seal (23) around left rear cab corner post.
Replace if necessary.
18
32. Align left rear cab corner post with opening in cab 1800
roof. 5
–UN–03DEC04
23—Foam Seal
24—Cab Fresh Air Duct
T205810A
Cab Fresh Air Duct Seal
AS79221,000005B –19–29APR09–5/9
IMPORTANT: Spacers must be installed with cap

screws and washers to prevent
crushing roof when cap screws are
tightened.
33. Install spacers (29), washers (28), and cap screws
–UN–03DEC04
(27) to cab roof.
34. Connect heated mirrors (if equipped) and cab roof

harness connector. See Cab Roof Harness (W14)
T205809A
Cab Roof Cap Screws and Spacers

27—Cap Screw
28—Washer
29—Spacer
TM11207 (11MAY09) 18-1800-5

051809
PN=325
35. Install service brake valve with U-bolt (11) and secure
with nuts.
36. Install pin (10) to service brake valve.
37. Install grader control valve. See Grader Control Valve

18
1800 38. Install cab floor mat.
6 11
10—Pin
11—U-Bolt
–UN–03MAR09
10
TX1056401
Service Brake Valve
TM11207 (11MAY09) 18-1800-6

051809
PN=326
39. Install drain hose with hose clamp (3) and cap screw
(4) to cab drain tubes.
40. Connect heater hot water lines with hose clamps (5

and 6) under left side of cab.
41. Install bracket (7) with nuts (8) under cab.

18
42. Connect cab air conditioner outlet/inlet lines (1 and 2) 1800
under left side of cab. 7
Specification
Cab Air Conditioner Outlet Line
(1)—Torque ............................................................................... 41-47 N•m
–UN–27FEB09
30-35 lb.-ft.
Specification
Cab Air Conditioner Inlet Line
TX1056380A
(2)—Torque ............................................................................... 14-20 N•m
124-177 lb.-in.
43. Connect harnesses from front lower wiper, front lower Air Conditioner and Heater Lines
window switches and install harness clamp to cab, if
equipped. See Front Platform Harness (W25) 1—Cab Air Conditioner Outlet Line
Component Location. (Group 9015-10.) 2—Cab Air Conditioner Inlet Line
3—Hose Clamp
4—Cap Screw
44. Install hydraulic steering lines to front of cab. 5—Hose Clamp
6—Hose Clamp
45. Install cover over frame in front of cab. 7—Bracket
8—Nut (2 used)
46. Install harness connectors, harness clamps, and
ground strap under right side of cab.
47. Connect harness connectors and ground to back of

Location—6WD, or See Cab Interior Harness (W16)
48. Purge the system. See Flush and Purge Air

Conditioner System. (Group 1830.)
49. Evacuate the system. See R134a System Evacuate.

(Group 1830.)
50. Charge the system. See R134a System Charge.

(Group 1830.)
51. Fill cooling system with coolant. See Drain, Flush,

and Refill Cooling System. (Operator’s Manual.)
TM11207 (11MAY09) 18-1800-7

051809
PN=327
53. Remove articulation lock.

18
1800
8
AS79221,000005B –19–29APR09–9/9
TM11207 (11MAY09) 18-1800-8

051809
PN=328
Cab Remove and Install—GP Machine Only


18
9
5. Recover air conditioning system refrigerant. See R134a

6. Remove harness connectors and ground from back of

Location—6WD, or See Cab Interior Harness (W16)
7. Remove harness connectors, ground strap, and

harness clamps from under right side of cab.
8. Remove cover over frame in front of cab.
9. Remove hydraulic steering lines from EH control

steering canceling valve. Note location of lines. Cap
and plug all lines. See Hydraulic System Component
10. Remove steering supply hose from hydraulic system

manifold. See Hydraulic System Component

cab, if equipped. See Front Platform Harness (W25)
Continued on next page AS79221,000004D –19–16FEB09–1/9
TM11207 (11MAY09) 18-1800-9

051809
PN=329
12. Disconnect cab air conditioner outlet/inlet lines (1 and

2) from under left side of cab.
13. Remove nuts (8) to remove bracket (7) from cab.
14. Release hose clamps (5 and 6) to disconnect heater

hot water lines from under left side of cab after
18 engine cooling system has drained.
1800
10 15. Remove hose clamp (3) from cab drain hose and
remove cap screw (4).
16. Remove cab floor mat.
–UN–27FEB09
3—Hose Clamp
TX1056380A
4—Cap Screw
5—Hose Clamp
6—Hose Clamp
7—Bracket
8—Nut (2 used) Air Conditioner and Heater Lines
TM11207 (11MAY09) 18-1800-10

051809
PN=330
17. Remove pin (10) from service brake valve.
18. Remove nuts from U-bolt (11) lower and support

service brake valve.
19. Disconnect roof harness from cab harness connector.

See Cab Roof Harness (W14) Component Location.
(Group 9015-10.) 18
1800
20. Disconnect heated mirrors (if equipped) from roof 11 11
harness. See Cab Roof Harness (W14) Component
21. Remove cap screws holding roof to cab. Note location
–UN–03MAR09
of spacers and washers.
22. Attach lifting straps to cab roof.

10
TX1056401
appropriate lifting device when removing cab
Service Brake Valve
roof.
10—Pin
23. Using an appropriate lifting device, attach lifting straps 11—U-Bolt
to DFT1101 Cab and ROPS Lifting Bracket and
remove cab roof.
Specification
Cab Roof—Weight............................................................................. 55 kg
121 lb
TM11207 (11MAY09) 18-1800-11

051809
PN=331
IMPORTANT: Route chains to prevent chains from

making contact with rear and side
window.
24. Attach lifting straps (15) to front cab hand rail (16)
and attach chains (20) to rear lifting bracket (19).
18 25. Attach lifting straps and chains to DFT1101 Cab and

1800 ROPS Lifting Bracket (21).
12
26. Remove cab isolator cap screws.
–UN–03DEC04
appropriate lifting device when removing cab.
T205812A
27. Using an appropriate lifting device, remove cab with
DFT1101 Cab and ROPS Lifting Bracket. Front Cab Lifting Point
Specification
Cab—Weight ................................................................................. 1035 kg
2280 lb
29. Install cab to frame.
Cab Isolators—Specification
Front Isolator—Torque ........................................................ 500—748 N•m
368—552 lb-ft
Rear Isolator—Torque ....................................................... 857—1285 N•m
–UN–03DEC04
632—948 lb-ft
15—Lifting Strap
16—Front Cab Hand Rail
T205811A
19—Rear Lifting Bracket
20—Chain Rear Cab Lifting Point
TM11207 (11MAY09) 18-1800-12

051809
PN=332
IMPORTANT: Cab roof is an integral part to heater

and air conditioner external air intake.
Cab roof must seal correctly to prevent
contaminants from entering the system.
30. Inspect seal (23) around left rear cab corner post.
Replace if necessary.
18
31. Align left rear cab corner post with opening in cab 1800
roof. 13
–UN–03DEC04
23—Foam Seal
24—Cab Fresh Air Duct
T205810A
Cab Fresh Air Duct Seal
AS79221,000004D –19–16FEB09–5/9
IMPORTANT: Spacers must be installed with cap

screws and washers to prevent
crushing roof when cap screws are
tightened.
32. Install spacers (29), washers (28), and cap screws
–UN–03DEC04
(27) to cab roof.
33. Connect heated mirrors (if equipped) and cab roof

harness connector.
T205809A
27—Cap Screw
28—Washer Cab Roof Cap Screws and Spacers
29—Spacer
TM11207 (11MAY09) 18-1800-13

051809
PN=333
34. Install service brake valve with U-bolt (11) and secure
with nuts.
35. Install pin (10) to service brake valve.
36. Install cab floor mat.
18 10—Pin
1800 11—U-Bolt
14 11
–UN–03MAR09
10
TX1056401
Service Brake Valve
TM11207 (11MAY09) 18-1800-14

051809
PN=334
37. Install drain hose with hose clamp (3) and cap screw
(4) to cab drain tubes.
38. Connect heater hot water lines with hose clamps (5

and 6) under left side of cab.
39. Install bracket (7) with nuts (8) under cab.

18
40. Connect cab air conditioner outlet/inlet lines (1 and 2) 1800
from under left side of cab. 15
41. Connect harnesses from front lower wiper, front lower

window switches and install harness clamp to cab, if
–UN–27FEB09
equipped.
42. Install hydraulic steering lines to steering valve. See

Steering Wheel, Column, and Valve Remove and
TX1056380A
Install—EH Controls. (Group 0960.)
43. Install the one line to hydraulic system manifold. See

Hydraulic System Manifold Disassemble and Air Conditioner and Heater Lines
44. Install cover over frame in front of cab. 3—Hose Clamp
4—Cap Screw
45. Install harness connectors, harness clamps, and 5—Hose Clamp
ground strap under right side of cab. 6—Hose Clamp
7—Bracket
8—Nut (2 used)
46. Connect harness connectors and ground to back of


(Group 1830.)

(Group 1830.)

TM11207 (11MAY09) 18-1800-15

051809
PN=335

AS79221,000004D –19–16FEB09–9/9
18
1800
16
TM11207 (11MAY09) 18-1800-16

051809
PN=336
Group 1810
Operator Enclosure
Windowpanes Remove and Install
The adhesive used to hold the windowpanes in place is a

urethane adhesive that is used on most automobile
windshields. Urethane adhesive manufactured by
LOCTITE or equivalent is recommended. Do not use any
other type of adhesive. It is also recommended that an
auto glass dealer install the windowpanes. 18
1810
IMPORTANT: Windowpanes must have an ultra-violet 1
barrier around the edge of the glass
since ultra-violet rays will deteriorate
the adhesive. Windowpanes ordered
through John Deere Parts have the
ultra-violet barrier. If the windowpane is
purchased through a glass dealer, the
dealer must put an ultra-violet barrier
on the glass. Do not apply paint to the
border of the glass.
If an auto glass dealer is not installing the windowpanes,

use the following procedure:
1. Purchase urethane adhesive from your local auto glass

dealer.
2. If window frame is removable, remove frame from cab.
3. Scrape broken glass off existing adhesive. Do not

remove adhesive from window frame or cab.
IMPORTANT: Adhesive will not stick to bare metal.
4. If existing adhesive is removed from frame and paint is

scraped off window frame, paint window frame. Paint
must be fully cured before installing windowpane.
5. Trim existing adhesive so it has a smooth surface.
6. Follow the manufacturer’s instructions for using the

adhesive.
7. Apply a 6 mm (1/4 in.) bead of adhesive on top of the

existing adhesive.
LOCTITE is a trademark of Henkel Corporation Continued on next page JW00603,0000100 –19–20JAN09–1/2
TM11207 (11MAY09) 18-1810-1

051809
PN=337
Operator Enclosure
8. Put a new windowpane into position. Use hand

pressure to force windowpane down around the edges
until even with metal frame.
9. If windowpane is installed directly on cab, use duct

tape to hold it in place while adhesive cures.
18 10. Allow adhesive to cure for 24 hours before operating

1810 machine.
2
JW00603,0000100 –19–20JAN09–2/2
Cab Door Handle Remove and Install
1. Remove clip (2) and pin (3) from clevis (5).
2. Remove clevis from door handle.
3. Remove cap screws (4) and door handle.
–UN–03DEC04
1—Bracket
2—Clip
3—Pin
5—Clevis
T205821A
Cab Door Handle Inside
TM11207 (11MAY09) 18-1810-2

051809
PN=338
Operator Enclosure
5. Install handle (6), gasket (7) and spacer (8).
IMPORTANT: Do not over torque cap screws. Over

torquing cap screws may break cab
door glass.
–UN–03DEC04
6. Apply T43512 Thread Lock and Sealer (medium
strength) to cap screws and install through bracket into 18
handle. 1810
3
T205820A
Specification
Door Handle Cap Screw—Torque ........................................ 5.6—6.7 N•m
49—59 lb-in. Door Handle Parts
7. Install clevis to door handle. 4—Cap Screw (3 used)

5—Clevis
8. Install pin and clip to clevis. 6—Handle
7—Gasket
8—Spacer
JW00603,0000148 –19–21JAN09–2/2
Cab Door Latch Remove and Install
1. Remove cap screws (1) and cover plate (2).

2—Cover Plate
3—Door Latch
–UN–26JAN09
TX1054842A
Door Latch and Cover Assembly
TM11207 (11MAY09) 18-1810-3

051809
PN=339
Operator Enclosure
18
1810
4
–UN–26JAN09
TX1054843A
Door Latch Components
3—Door Latch 5—Bushing (4 used) 7—Latch Lever 9—Nut (2 used)

4—Cap Screw (2 used) 6—Spacer (2 used) 8—Washer (2 used)
NOTE: Cap screw (1) is threaded into door latch (3). 7. Use a wrench to hold cap screw from turning and
Lock nut (9) is also threaded on cap screw. install nuts.
2. Remove nut (9) from cap screw (4) and remove Specification
washers (8), bushings (5), spacers (6), and latch Cab Door Latch Nut—Torque............................................... 10.4 N•m
92 lb-in.
lever (7).
NOTE: Cap screw may loosen when installing nut.
3. Remove cap screws and remove door latch.
8. Verify torque on cap screws.
Specification
5. Install latch and cap screws to door. Cab Door Latch Cap Screw—
Torque................................................................................... 15.3 N•m
Specification 135 lb-in.
Cab Door Latch Cap Screw—
Torque................................................................................... 15.3 N•m 9. Install cover plate and cap screws.
135 lb-in.
6. Install washers, bushings, spacers, and latch lever

to door latch.
JW00603,0000149 –19–21JAN09–2/2
TM11207 (11MAY09) 18-1810-4

051809
PN=340
Operator Enclosure
Rivet Nut Installation
Remove Rivet Nut
Remove flange of rivet nut using a hammer and chisel.

Use care not to damage equipment’s surface under the
–UN–19JUL94
flange or the hexagonal hole.
18
Use a punch to remove threaded portion of fastener. 1810
5
T8287AJ
Install Rivet Nut
NOTE: It is not necessary to drill and broach when

replacing a rivet nut.
1. Locate and mark position for new fastener.
IMPORTANT: DO NOT use drill bit larger than

specified. Fastener will not hold
securely. A smaller drill bit may be
substituted, but will increase broaching
effort.
2. Use appropriate drill bit for fastener size being installed

and drill hole.
Rivet Nut Size Drill Bit Size

M6 8 mm
M6 21/64 in.
M8 10 mm
M8 27/64 in.
M10 13 mm
M10 33/64 in.
IMPORTANT: Do not let broach pop out of hole while

driving in broach. Broach will not create
a clean hexagonal hole if it pops out.
3. Broach rivet nut hole using appropriate broach for

fastener size being installed.
Rivet Nut Size Rivet Nut Broach

M6 JDG1829
M8 JDG1832
M10 JDG936
TM11207 (11MAY09) 18-1810-5

051809
PN=341
Operator Enclosure
NOTE: Hardware fastened to rivet nut fastener must have

full thread engagement to rivet nut when
installation is complete.
4. Select appropriate rivet nut fastener for thickness of

material being installed to. Fasteners are color-coded
as well as stamped on the flange surface. (Coding
18 indicates the nominal plate thickness for which the
1810 fastener can be used.)
6
Material Thickness Flange Color Code
Stamp
M6 RIVET NUT LENGTH SELECTION
2.50—5.00 mm (0.098—0.197 in.) 4.5 Silver
5.00—7.00 mm (0.197—0.276 in.) 6.0 Yellow
2.50—5.00 mm (0.098—0.197 in.) 4.5 Silver
5.00—7.00 mm (0.197—0.276 in.) 6.0 Yellow
2.50—4.50 mm (0.098—0.177 in.) 4 Yellow
5.74—7.09 mm (0.226—0.279 in.) 6 Yellow
7.75—9.09 mm (0.305—0.358 in.) 8 Red
9.75—11.10 mm (0.384—0.437 in.) 10 Black
11.73—13.08 mm (0.462—0.515 in.) 12 Olive Drab
JW00603,000014A –19–21JAN09–2/5
IMPORTANT: DO NOT force or drive fastener into

hole. Fastener can be damaged and
may not hold securely.
5. Make sure fastener fits easily into hexagon hole (A). If

necessary, use a small file to clean edges of hole.
–UN–17OCT94
A—Hexagon Hole
T8287AK
TM11207 (11MAY09) 18-1810-6

051809
PN=342
Operator Enclosure
IMPORTANT: Use only specified installation tool for

rivet nut. Use of other materials to
install rivet nut may result in fastener
failure.
6. Lubricate large threads (A) of the appropriate
–UN–19JUL94
installation tool for the fastener size being installed.
18
Rivet Nut Size Rivet Nut Installation Tool 1810
M6 JDG1830 7
T8287AL
M8 JDG1295
M10 JDG894
A—Large Threads
7. Install rivet nut fastener (C) on tool: B—Tool Shoulder
C—Rivet Nut Fastener
• Small threads (D) of installation tool must extend D—Small Threads
past fastener.
• Flange of fastener must contact tool shoulder (B).
TM11207 (11MAY09) 18-1810-7

051809
PN=343
Operator Enclosure
8. Install fastener with installation tool in hexagon hole.

Make sure flange (C) is flat against mounting surface.
IMPORTANT: NEVER turn or tighten installation tool

socket head screw. Damage to threads
of fastener can occur.
18 9. While holding socket head screw (A) stationary, tighten

1810 large nut (B) to specifications using a crowsfoot
8 wrench.
Specification
Rivet Nut Fastener
—Torque—M6 ......................................................................... 20—27 N•m
180—240 lb-in.
–UN–17OCT94
Torque—M8 ............................................................................. 39—46 N•m
29—34 lb-ft
Torque—M10 ........................................................................... 68—74 N•m
50—55 lb-ft
T8287AM
10. Loosen large nut to remove tool.
A—Socket Head Screw

B—Nut
C—Flange
Rivet Nut Size Drill Bit Size Broach Tool Installation Tool
M6 8 mm JDG1829 JDG1830
M6 21/64 in. JDG1829 JDG1830
M8 10 mm JDG1832 JDG1295
M8 27/64 in. JDG1832 JDG1295
M10 13 mm JDG936 JDG894
M10 33/64 in. JDG936 JDG894
JW00603,000014A –19–21JAN09–5/5
TM11207 (11MAY09) 18-1810-8

051809
PN=344
Group 1815
Pedal Assembly
Inching Pedal Remove and Install
18
1 1815
1
2
S7
–UN–31MAR09
4
TX1057644
TX1057644
Inching Pedal Module
1—Cap Screw 3—Cap Screw (3 used) 4—Inching Pedal Module S7—Inching Pedal Module
2—Cover Assembly
1. Park machine on flat level surface. Lower all 7. Install inching pedal module assembly with cap
attachments to ground. screws.
2. Turn battery disconnect switch to OFF position. 8. Connect harness to inching pedal module.
3. Remove cap screw (1) and cover (2). 9. Install cover with cap screw.
4. Disconnect harness from inching pedal module 10. Turn battery disconnect switch to ON position.
(S7).
11. Run machine to verify proper operation. See
5. Remove cap screws (3) and remove inching pedal Operational Checkout. (Group 9005-10.)
module assembly (4).
6. Replace parts as necessary.
AS79221,0000059 –19–26MAR09–1/1
TM11207 (11MAY09) 18-1815-1

051809
PN=345
Pedal Assembly
18
1815
2
TM11207 (11MAY09) 18-1815-2

051809
PN=346
Group 1816
Steering Tilt Console
18
1816
1
TM11207 (11MAY09) 18-1816-1

051809
PN=347
Steering Support Console Remove and Install—Standard Controls
18
1816
2
–UN–26MAR09
TX1057629
Steering Support Console—Standard Controls

Continued on next page AS79221,0000053 –19–04MAY09–1/2
TM11207 (11MAY09) 18-1816-2

051809
PN=348
1—Cap Screw (4 used) 13—Spring Pin 21—Bracket 37—Bracket

2—Cap Screw (4 used) 14—Bracket 22—Bushing (8 used) 38—Cap Screw (4 used)
3—Cap Screw (4 used) 16—Tilt Console Support 24—Front Console Support 39—Nut (4 used)
4—Cap Screw (6 used) Bracket 29—Washer (20 used) 40—Side Cover
7—Flange Nut (9 used) 17—Tilt Console Support 31—Spacer 41—Top Console Cover
9—Cap Screw (4 used) Bracket 32—Rear Console Support 42—Plate (2 used)
10—Cap Screw (8 used) 19—Bottom Console Support 35—Nut (4 used) 43—Side Cover
11—Cap Screw 20—Bushing 36—Nut (4 used) 44—Plate
18
Specification 1816
1. Park machine on flat level surface. Lower all 3
attachments to ground. Steering Support Console—
Weight ......................................................................................... 32 kg
70 lb
2. Install articulation lock. See Locking Machine
Frame. (Operator’s Manual.) 9. Remove cap screws (1) from steering support
console and remove from cab.
4. Remove steering wheel, column, and valve. See
Steering Wheel, Column, and Valve Remove and 11. Install steering support console with cap screws.
Install—Standard Controls. (Group 0960.)
12. Install control linkage. See Control Linkage
5. Remove inching pedal assemble. See Inching Remove and Install. (Group 3415.)
Pedal Remove and Install. (Group 1815.)
13. Install inching pedal assemble. See Inching Pedal
6. Remove control linkage. See Control Linkage Remove and Install. (Group 1815.)
14. Install steering wheel, column, and valve. See
7. Disconnect harness connector. See Cab Interior Steering Wheel, Column, and Valve Remove and
Harness (W15) Component Location—6WD, or See Install—Standard Controls. (Group 0960.)
Cab Interior Harness (W16) Component Location—
Non 6WD. (Group 9015-10.) 15. Turn battery disconnect switch to ON position.
CAUTION: Avoid crushing injury. Use 16. Remove articulation lock.

appropriate lifting device when removing
steering support console.
8. Attach appropriate lifting device to steering support

console.
AS79221,0000053 –19–04MAY09–2/2
TM11207 (11MAY09) 18-1816-3

051809
PN=349
Steering Support Console Remove and Install—EH Controls
18
1816
4
–UN–26MAR09
TX1057631
Steering Support Console—EH Controls

Continued on next page AS79221,0000058 –19–04MAY09–1/2
TM11207 (11MAY09) 18-1816-4

051809
PN=350
1—Cap Screw (8 used) 15—Set Screw 27—Bracket 43—Nut (4 used)

2—Cap Screw (4 used) 16—Washer (2 used) 28—Front Console Support 44—Nut (4 used)
3—Cap Screw (2 used) 17—Washer (9 used) 30—Rear Console Support 45—Grommet
4—Cap Screw (4 used) 18—Spring Pin 34—Washer (4 used) 46—Washer (10 used)
5—Cap Screw (10 used) 20—Bracket 35—Spacer 47—Nut (2 used)
6—Cap Screw (6 used) 21—Bushing (8 used) 36—Pin Fastener 48—Side Cover
10—Flange Nut (9 used) 22—Bushing (8 used) 37—Spacer 49—Side Cover
12—Cap Screw (8 used) 25—Bottom Console Support 40—Bracket 50—Grommet
13—Cap Screw (2 used) 26—Tilt Console Support 41—Top Console Cover 51—Plate
14—Cap Screw Bracket 42—Bracket 52—Back Cover 18
1816
Specification 5
attachments to ground. Steering Support Console—
Weight ......................................................................................... 32 kg
70 lb
Frame. (Operator’s Manual.) 8. Remove cap screws (2) from steering support
console and remove from cab.
4. Remove steering wheel, column, and valve. See
Steering Wheel, Column, and Valve Remove and 10. Install steering support console with cap screws
Install—EH Controls. (Group 0960.) (2).
5. Remove inching pedal assemble. See Inching 11. Install inching pedal assemble. See Inching Pedal
Pedal Remove and Install. (Group 1815.) Remove and Install. (Group 1815.)
6. Disconnect harness connector. See Cab Interior 12. Install steering wheel, column, and valve. See
Harness (W15) Component Location—6WD, or See Steering Wheel, Column, and Valve Remove and
Cab Interior Harness (W16) Component Location— Install—EH Controls. (Group 0960.)
Non 6WD. (Group 9015-10.)
appropriate lifting device when removing 14. Remove articulation lock.
steering support console.
7. Attach appropriate lifting device to steering support

console.
AS79221,0000058 –19–04MAY09–2/2
TM11207 (11MAY09) 18-1816-5

051809
PN=351
Console Tilt Remove and Install
2 1
18
1816
6
24
23
22
3
25
26
21
20
4
15
8
19 18 17
16
10
–UN–06MAR09
13 11
14
TX1056711
12
TX1056711
Console Tilt
Continued on next page AS79221,0000055 –19–04MAR09–1/2
TM11207 (11MAY09) 18-1816-6

051809
PN=352
1—Nut (2 used) 8—Jam Nut 15—Pin Fastener 21—Side Panel (2 used)

2—Bushing (2 used) 9—Lower Bracket 16—Cotter Pin 22—Cap Screw (2 used)
3—Console Support Front 10—Ball Bearing 17—Bushing (2 used) 23—Washer (2 used)
4—Cotter Pin 11—Spring 18—Bushing (2 used) 24—Bushing (2 used)
5—Pin Fastener 12—Pedal 19—Cap Screw (2 used) 25—Upper Bracket
6—Gas Cylinder 13—Nut (2 used) 20—Cap Screw (6 used) 26—Console Support Rear
7—Washer 14—Washer (2 used)
1. Park machine on flat level surface. Lower all 13. Remove ball bearing (10) from the end of gas 18
attachments to ground. cylinder. 1816
7
2. Install articulation lock. See Locking Machine 14. Remove bracket (9), jam nut (8), and washer (7).
16. Install washer and jam nut.
4. Position steering column forward.
17. Install bracket (9) onto gas cylinder rod.
5. Remove both side panels (21).
18. Install ball bearing (10) to end of rod.
6. Position steering column rearward.
19. Install gas cylinder, pedal, and pin fastener (15).
7. Remove spring (11).
20. Install cotter pin.
8. Remove nuts and cap screws (13 and 19).
21. Align gas cylinder to upper bracket (25).
9. Pull bottom of console support (3) rearward and
support. 22. Install pin fastener (5) and retain with cotter pin.
NOTE: Position steering column so the gas cylinder is 23. Install console support and cap screws.
almost in the full retracted position. This will
aid in the assemble of the tilt console. 24. Install spring.
10. Remove upper cotter pin (4) and pin fastener (5). 25. Install side panels and cap screws.
11. Remove lower cotter pin (16). 26. Turn battery disconnect switch to ON position.
NOTE: When removing the pedal take note of the 27. Remove articulation lock.
small ball bearing (10). It is not retained and
can be lost during disassembly. 28. Check function of steering column.
12. Remove pin fastener (15), pedal (12), and gas

cylinder (6)
AS79221,0000055 –19–04MAR09–2/2
TM11207 (11MAY09) 18-1816-7

051809
PN=353
Steering Tilt Assembly Remove and Install
18
1816
8
–UN–26MAR09
TX1057577
TX1057577
Steering Tilt Assembly
NOTE: Standard steering tilt assembly shown EH Standard Controls or see Steering Support Console
similar. Remove and Install—EH Controls, and see Console
Tilt Remove and Install. (Group 1816.)
1. Remove console tilt assembly and steering
supports to remove steering tilt assembly. See 2. Thoroughly clean and inspect bushing and washers
Steering Support Console Remove and Install— for wear or damage. Replace parts as necessary.
AS79221,0000054 –19–04MAR09–1/1
TM11207 (11MAY09) 18-1816-8

051809
PN=354
Group 1821
Seat and Seat Belt
Seat Remove and Install

3. Remove armrests. See Armrest Remove and Install, or 18

see Armrest Remove and Install—EH Controls. (Group 1821
1821.) 1
4. Disconnect harness from seat heater (if equipped).
5. Disconnect harness from seat suspension.
6. Lift seat cushion and remove.
7. Move seat to the full forward position.
AS79221,000005C –19–29APR09–1/4
8. Remove nuts (1 and 2).
9. Remove cap screws and nuts (3).
Specification
Seat Back—Weight ........................................................................... 19 kg
42 lb
10. Remove seat pan with back from machine.
1—Nut (2 used)
2—Nut (2 used) –UN–05JAN05
3—Cap Screw and Nut (2 used)
T206685A
Seat Pan
Continued on next page AS79221,000005C –19–29APR09–2/4
TM11207 (11MAY09) 18-1821-1

051809
PN=355
Seat and Seat Belt
11. Remove cab air filter assembly cover.
4—Screw
5—Cab Air Filter Assembly Cover
18
1821
2
–UN–16FEB09
TX1055863A
Cab Air Filter Assembly Cover
Continued on next page AS79221,000005C –19–29APR09–3/4
TM11207 (11MAY09) 18-1821-2

051809
PN=356
Seat and Seat Belt
NOTE: Access to one of the cap screws is through a plug

(7) in the cab air filter assembly box.
12. Remove access plug (7).
13. Remove cap screws from under seat suspension.
CAUTION: Avoid crushing injury. Use 18

1821
appropriate lifting device when removing seat 3
suspension.
14. Use appropriate lifting device to remove seat

suspension.
–UN–19FEB09
Specification
Seat Suspension—Weight................................................................. 31 kg
68 lb
TX1055749A
16. Install seat suspension and connect harness. Access Plug
6—Seat Suspension
17. Install seat pan with back tighten cap screws and 7—Access Plug
nuts.
18. Install seat cushion.
19. Install armrests. See Armrest Remove and Install, or

see Armrest Remove and Install—EH Controls.
(Group 1821.)
IMPORTANT: Make sure that the plug and cab air

filter assembly cover is installed
correctly. Contamination can cause
debris buildup in the heater and air
conditioner system and reduce heater
and air conditioner performance.
20. Install access plug and cab air filter assembly cover.
AS79221,000005C –19–29APR09–4/4
Seat Belt Remove and Install

Continued on next page AS79221,000005D –19–29APR09–1/3
TM11207 (11MAY09) 18-1821-3

051809
PN=357
Seat and Seat Belt
2. Remove cap screw (1) and seat belt buckle (2).
1—Cap Screw
2—Seat Belt Buckle
18
1821
4
–UN–05JAN05
T206686A
Seat Belt Buckle
AS79221,000005D –19–29APR09–2/3
3. Remove cap screw (5) and seat belt (4).
5. Install seat belt and cap screw (1).
Specification
Seat Belt—Torque ................................................................... 32—46 N•m
24—34 lb-ft
6. Install seat belt buckle and cap screws (5).
–UN–16APR09
Specification
Seat Belt Buckle—Torque ....................................................... 32—46 N•m
24—34 lb-ft
TX1058269A
4—Seat Belt
5—Cap Screw
Seat Belt
AS79221,000005D –19–29APR09–3/3
TM11207 (11MAY09) 18-1821-4

051809
PN=358
Seat and Seat Belt
Armrest Remove and Install
NOTE: Left side shown, right side is similar.

2. Remove nuts (1). 18

1821
3. Repair or replace parts as necessary. 5
4. Install armrest and nuts.
–UN–19FEB09
5. Adjust armrest height and tighten nuts. See Adjusting
Premium Seat—Grade Pro Machines Only. (Operator’s
Manual.)
TX1056006A
1—Nut (4 used)
Armrest
AS79221,000004A –19–04MAY09–1/1
TM11207 (11MAY09) 18-1821-5

051809
PN=359
Seat and Seat Belt
Armrest Remove and Install—EH Controls

18 3. Tilt seat back forward.

1821
6 4. Disconnect wiring harnesses from seat. See
Electrohydraulic (EH) Main Cab Harness (W38)
–UN–19FEB09
6. Remove right side armrest.
TX1056010A
8. Remove left side armrest.

Armrest Mount With Seat Back Tilted Forward
9. Repair or replace parts as necessary. For disassembly,
see Armrest Disassemble and Assemble—EH 2—Cap Screw (4 used)
Controls. (Group 1821.)
10. Install armrests and tighten cap screws.
11. Connect all harnesses. See Electrohydraulic (EH)

Main Cab Harness (W38) Component Location.
(Group 9015-10.)
12. Adjust armrest. See Adjusting Premium Seat—Grade

Pro Machines Only. (Operator’s Manual.)
AS79221,000004B –19–04MAY09–1/1
TM11207 (11MAY09) 18-1821-6

051809
PN=360
Seat and Seat Belt
18
1821
7
TM11207 (11MAY09) 18-1821-7

051809
PN=361
Seat and Seat Belt
Armrest Disassemble and Assemble—EH Controls
28
26
27 1
18 23
1821
8
22
21
20 21
3
19
20
4
24
19 5
11
18 6
17 12
25
16 9
15 7
14 8
10
–UN–20FEB09
13
TX1056078
TX1056078
Left Side Armrest Disassemble and Assemble
TM11207 (11MAY09) 18-1821-8

051809
PN=362
Seat and Seat Belt
1—Cap Screw (4 used) 9—Armrest Interlock Switch 16—Plate 23—Cap Screw (4 per
2—Armrest 10—Cap Screw (4 used) 17—Cap Screw (2 used) controller)
3—Armrest Bracket 11—Armrest Assembly 18—Arm Kit 24—Cap Screw (3 used)
4—Washer (4 used) 12—Lower Console 19—Controller (4 used) 25—Cap Screw (5 used)
5—Screw (2 used) 13—Cap Screw (4 used) 20—Boot (4 used) 26—Horn Button
6—Cover 14—Screw 21—Knob (4 used) 27—Nut
7—Bushing 15—Bushing 22—Upper Console 28—Switch
8—Screw
18
NOTE: Left side shown, right side is similar. 2. Repair or replace parts as necessary. 1821
9
NOTE: When removing controller note location and 3. Adjust armrest. See Adjusting Premium Seat—
orientation for install. Grade Pro Machines Only. (Operator’s Manual.)
1. Disassemble armrest.
AS79221,000004E –19–04MAY09–2/2
TM11207 (11MAY09) 18-1821-9

051809
PN=363
Seat and Seat Belt
Standard Seat Disassemble and Assemble
18
1821
10
–UN–17MAR09
TX1057195
Standard Seat
Continued on next page AS79221,0000051 –19–20FEB09–1/2
TM11207 (11MAY09) 18-1821-10

051809
PN=364
Seat and Seat Belt
1—Headrest 7—Handle 13—Cap Screw (2 used) 19—Seat Cushion

2—Seat Back Cushion 8—Rod 14—Knob 20—Spring
3—Holder 9—Back Support 15—Track Slide (4 used) 21—Torsion Spring
4—Rivet (6 used) 10—Seat Pan 16—Spring 22—Seat Slide Control
5—Roll Pin (2 used) 11—Nut (3 used) 17—Snap Ring 23—Snap Ring
6—Cap Screw 12—Tilt Assemble 18—Seat Lock (2 used)
18
1821
11
AS79221,0000051 –19–20FEB09–2/2
TM11207 (11MAY09) 18-1821-11

051809
PN=365
Seat and Seat Belt
Deluxe Seat Disassemble and Assemble
18
1821
12
–UN–17MAR09
TX1057196
Deluxe Seat
TM11207 (11MAY09) 18-1821-12

051809
PN=366
Seat and Seat Belt
1—Headrest 5—Tilt Assemble 10—Spring 15—Seat Lock (2 used)

2—Seat Back Cushion 6—Nut (3 used) 11—Spring 16—Seat Slide Control
3—Head Restraint Holders (2 7—Cap Screw (2 used) 12—Torsion Spring 17—Snap Ring
used) 8—Knob 13—Track Slide (4 used) 18—Spring
4—Seat Pan 9—Snap Ring 14—Seat Cushion 19—Back Support
AS79221,0000050 –19–20FEB09–2/2
18
1821
13
TM11207 (11MAY09) 18-1821-13

051809
PN=367
Seat and Seat Belt
Air Suspension Disassemble and Assemble
18
1821
14
–UN–08APR09
TX1058080
Seat Air Suspension

TM11207 (11MAY09) 18-1821-14

051809
PN=368
Seat and Seat Belt
1—Upper Seat Pan 15—Arm 27—Lock Nut 39—Nut

2—Lever Kit (2 used) 16—Housing 28—Cap Screw 40—Lock Nut (2 used)
3—Frame 17—Cap Screw (2 used) 29—Tie Band (2 used) 41—Washer (5 used)
4—Cap Screw (24 used) 18—Lock Nut (2 used) 30—Lock Nut 42—Valve
5—Cover 19—Shock Absorber 31—Washer 43—Fitting
6—Bottom Seat Pan 20—Bracket 32—Bearing (2 used) 44—Air Spring Seat Kit
9—Shaft (2 used) 21—Lock Nut 3 33—Washer (2 used) 45—Elbow Fitting
10—Lock Nut (2 used) 22—Bolt (2 used) 34—Cap Screw 46—Cap Screw
11—Washer (2 used) 23—Knob 35—Cap Screw 47—Cap Screw
12—Bearing (4 used) 24—Bearing 36—Bumper 48—Compressor 18
13—Rod 25—Spring 37—Bumper (2 used) 49—Clamp 1821
14—Lock Nut (2 used) 26—Cap Screw 38—Screw (2 used) 50—Cap Screw (2 used) 15
AS79221,0000052 –19–20FEB09–2/2
TM11207 (11MAY09) 18-1821-15

051809
PN=369
Seat and Seat Belt
18
1821
16
TM11207 (11MAY09) 18-1821-16

051809
PN=370
Group 1830
Heating and Air Conditioning
Refrigerant Cautions and Proper Handling
R134a is used in the air conditioning

CAUTION: DO NOT allow liquid refrigerant to
system. Because it does not contain
contact eyes or skin. Liquid refrigerant will
chlorine, R134a is not detrimental to
freeze eyes or skin on contact. Wear
the ozone in the atmosphere.
goggles, gloves and protective clothing.
However, it is illegal to discharge
any refrigerant into the atmosphere. 18
If liquid refrigerant contacts eyes or skin, DO
It must be recovered using the 1830
NOT rub the area. Splash large amounts of 1
appropriate recovery stations.
COOL water on affected area. Go to a
physician or hospital immediately for
Use correct refrigerant recovery,
treatment.
recycling and charging stations.
Never mix refrigerants, hoses,
DO NOT allow refrigerant to contact open
fittings, components or refrigerant
flames or very hot surfaces such as electric
oils.
welding arc, electric heating element and
lighted smoking materials.
Use only John Deere approved
R134a refrigerant products. Mixing of
DO NOT heat refrigerant over 52°C (125°F) in
products not compatible will cause
a closed container. Heated refrigerant will
system damage and contaminate
develop high pressure which can burst the
recovery, recycling and charging
container.
station equipment. Care must be
taken to identify and use equipment,
Keep refrigerant containers away from heat
refrigerant oil and refrigerant
sources. Store refrigerant in a cool place.
designed only for R134a refrigerant
systems. Refrigerant should be
DO NOT handle damp refrigerant container
tested for type and purity before
with your bare hands. Skin may freeze to
recovery, recycling or charging of
container. Wear gloves.
system. JT02167A refrigerant test
instrument should be used before
If skin freezes to container, pour COOL
any testing or repair to system is
water over container to free the skin. Go to a
preformed.
physician or hospital immediately for
treatment.
IMPORTANT: To meet government standards

relating to the use of refrigerants,
Continued on next page TX,9031,DY5073 –19–21JUL06–1/2
TM11207 (11MAY09) 18-1830-1

051809
PN=371
Prism Pro Refrigerant Identification

Instrument . . . . . . . . . . . . . . . . . . . . . . . JT02167A
To safely identify type and check purity of refrigerant

prior to recovery, recycling and recharging of A/C
systems.
18
1830
2
TX,9031,DY5073 –19–21JUL06–2/2
TM11207 (11MAY09) 18-1830-2

051809
PN=372
Flush and Purge Air Conditioner System
CAUTION: Liquid refrigerant will freeze eyes or

skin on contact. Wear goggles, gloves and
protective clothing.
See Refrigerant Cautions and Proper Handling.

(Group 1830.) 18
1830
3
NOTE: Flushing can be performed on machine.
1. See R134a System Recover. (Group 1830.)
Add flushing solvent to system with JT02075 Flusher

and JT02098 Flusher Fitting Kit.
2. Remove and discard receiver/dryer.
3. Connect flusher outlet hose to inlet end of compressor

discharge line using JT02102 Adapter.
4. Fill flusher tank with solvent and fasten all connections.

Dispose of solvent properly.
Specification
Flusher Tank—Capacity ........................................................................ 4 L
1 gal
NOTE: Air pressure must be at least at specification for

flushing and purging.
Specification
Air Pressure—Minimum Pressure ......... 620 kPa for flushing and purging
90 psi for flushing and purging
6.2 bar for flushing and purging
5. Connect supply line of moisture-free compressed air or

dry nitrogen to flusher air valve.
6. Open air valve to force flushing solvent into condenser

circuit. Flusher tank is empty when hose pulsing stops.
Additional flushing cycles are required if system is
heavily contaminated with burned oil or metal particles.
7. Clean compressor as follows:
a. Remove compressor and measure oil drained from

both manifold ports.
TM11207 (11MAY09) 18-1830-3

051809
PN=373
b. Connect flusher outlet hose to inlet end of

compressor discharge line using JT02102 Adapter.
c. Pour flushing solvent into suction port and discharge

port. Plug both ports in compressor manifold, using
JT02099 and JT03194 Caps.
Specification
18
Flushing Solvent in Suction
1830
Port—Volume ................................................................................. 240 mL
4
8 fl oz
Flushing Solvent in Discharge
Port—Volume ................................................................................. 120 mL
4 fl oz
d. Turn compressor end for end and roll it side to side.
e. Remove both plugs from manifold ports and drain

solvent from compressor.
f. Connect battery power to compressor clutch coil.

Rotate pulley at least five revolutions to move
solvent out of cylinders.
g. Invert compressor. Roll end for end and side to

side. Drain thoroughly.
h. Repeat previous two steps at least three times.
8. Divide system into two circuits:
• Condenser circuit, including inlet and outlet hoses.

• Evaporator circuit, including inlet and outlet hoses.
9. Condenser:
IMPORTANT: DO NOT attempt to flush through

compressor or receiver/dryer. Flushing
through expansion valve is acceptable
if refrigerant oil has a normal odor and
appearance.
a. Flush/Purge Condenser:
b. Remove and discard receiver/dryer.
TM11207 (11MAY09) 18-1830-4

051809
PN=374
c. Connect flusher outlet hose to inlet end of

compressor discharge line using JT02102 Adapter.
d. Fill flusher tank with solvent and fasten all

connections.
Specification
1 gal 18
1830
5
NOTE: Air pressure must be at least to specification for

Specification
Air Pressure—Minimum Pressure ........ 620 kPa for flushing and purging.
90 psi for flushing and purging.
6.2 bar for flushing and purging.
e. Connect supply line of moisture-free compressed air

or dry nitrogen to flusher air valve.
f. Open air valve to force flushing solvent into

condenser circuit. Flusher tank is empty when hose
pulsing stops. Additional flushing cycles are required
if system is heavily contaminated with burned oil or
metal particles.
g. Attach return hose and aerator nozzle to end of

receiver/dryer inlet hose using JT03197 Adapter.
Put nozzle in container to collect flushing solvent.
NOTE: Purging the condenser circuit takes 10—12

minutes to thoroughly remove solvent.
h. Disconnect hose from aeration nozzle to check

circuit for solvent. Hold hose close to piece of
cardboard; continue purging until cardboard is dry.
10. See flush evaporator, if evaporator requires flushing.
If system is contaminated with burned refrigerant oil

or debris, remove and bench flush evaporator. See
following steps to flush evaporator through expansion
valve, if oil appears normal.
11. Flush evaporator:
TM11207 (11MAY09) 18-1830-5

051809
PN=375
a. Remove evaporator and expansion valve. See

Heater and Air Conditioner Remove and Install.
(Group 1830.)
b. Force flushing solvent through evaporator inlet with

compressed air.
18 c. Purge system until dry.

1830
6 d. Install evaporator and then go to step 13.
12. Flush evaporator through expansion valve:
a. Connect flusher outlet hose to connection of

receiver/dryer outlet hose using JT03188 adapter.
b. Fill flusher tank and fasten all connections.
Specification
1 gal
NOTE: Air pressure must be at least to specification for

Specification
Air Pressure—Minimum Pressure ......... 620 kpa for flushing and purging.
90 psi for flushing and purging.
6.2 bar for flushing and purging.
c. Connect supply line of moisture-free compressed

air or dry nitrogen to flusher air valve.
d. Attach hose and aerator nozzle to compressor inlet

line using JT02101 Adapter. Put nozzle in
container to collect solvent.
NOTE: Purging evaporator circuit takes 12—15 minutes

to thoroughly remove solvent.
13. Disconnect hose from aeration nozzle to check circuit

for solvent. Hold hose close to piece of cardboard
and continue purging until cardboard is dry.
TM11207 (11MAY09) 18-1830-6

051809
PN=376
14. Install new receiver/dryer compatible with R134a

refrigerant. Fasten connections and mounting bracket.
See Receiver-Dryer Remove and Install. (Group
1830.)
15. Add required oil. See R134a Refrigerant Oil

Information. (Group 1830.)
18
16. Install compressor and connect refrigerant lines to 1830
manifold. 7
17. Connect clutch coil wire and install drive belt.
AS79221,0000035 –19–02FEB09–5/5
TM11207 (11MAY09) 18-1830-7

051809
PN=377
R134a Refrigerant Oil Information
CAUTION: All new compressors are charged

with a mixture of nitrogen, R134a refrigerant
and TY22025 (R134a) Refrigerant Oil. Wear
safety goggles and discharge the compressor
slowly to avoid possible injury.
18
1830
8
IMPORTANT: Do not add any more oil than required
or maximum cooling will be reduced.
DO NOT leave system or R134a

compressor oil containers open.
Refrigerant oil easily absorbs moisture.
DO NOT spill R134a compressor oil on
acrylic or ABS plastic. This oil will
deteriorate these materials rapidly.
Identify R134a oil containers and
measures to eliminate accidental mixing
of different oils.
New compressor from parts depot contains new oil. Oil

level visible through suction port normally is below drive
shaft.
Normal operating oil level of compressor removed from

operation cannot be seen through suction port of
compressor.
Compressors can be divided into three categories when

determining correct oil charge for system.
• New compressor from parts depot

• Used compressor removed from operation
• Compressor internally washed with flushing solvent
Determining amount of system oil charge prior to

installation of compressor on machine.
When complete system, lines, and components are

flushed add correct amount of oil as described.
Specification
Oil—Total System Volume ............................................................. 307 mL
10.4 fl oz
R134a—Weight ............................................................................... 1928 g
4.25 lb
TM11207 (11MAY09) 18-1830-8

051809
PN=378
If any section of hose is removed and flushed or replaced,

measure length of hose and use formula 3 mL per 30 cm
(0.1 fl oz per ft ) to determine correct amount of oil to be
added.
Drain compressor oil into graduated container while

rotating compressor shaft and record amount.
18
If oil drained from compressor removed from operation is 1830
very black or amount of oil is less than 6 mL (0.2 fl oz), 9
perform the following and discard oil properly:
❒ Determine if R134a leakage was detected, remove

component and repair or replace component. See
Refrigerant Leak Test. (Group 9031-25.)
❒ Remove and discard receiver/dryer. See
Receiver-Dryer Remove and Install. (Group 1830.)
❒ Flush complete system with TY16134 Air Conditioning
Flushing Solvent. See Flush and Purge Air Conditioner
System. (Group 1830.)
If component is serviceable, pour flushing solvent in ports

and internally wash out old oil and discard oil properly.
1. Install new receiver/dryer. See Receiver-Dryer Remove

2. Pour required amount of TY22025 Refrigerant Oil in

compressor.
3. Connect all components. See R134a System

Evacuate. (Group 1830.)
4. See R134a System Charge. (Group 1830.)
AS79221,0000036 –19–02FEB09–2/2
TM11207 (11MAY09) 18-1830-9

051809
PN=379
R134a Refrigerant Recovery/Recycling and

Charging Station Installation Procedure

18
1830
10 (Group 1830.)
IMPORTANT: Use only John Deere approved R134a

refrigerant products. Mixing of products
not compatible will cause system
damage and contaminate recovery,
recycling and charging station
equipment.
CAUTION: Do not remove high pressure relief

valve (D). Air conditioning station will discharge
–UN–06DEC93
rapidly causing possible injury.
IMPORTANT: Use only John Deere approved

refrigerant recovery/recycling and
T8118AG
charging stations. DO NOT mix
refrigerant, hoses, fittings, components
or refrigerant oils.
A—High Pressure Hose Charge Port Cap
1. Follow procedures. See Refrigerant Cautions and B—Red Hose
Proper Handling. (Group 1830.) C—Blue Hose
D—High Pressure Relief Valve
E—Refrigerant Recovery/Recycling and Charging
2. Close both high-side and low-side valves on refrigerant Station
recovery/recycling and charging station (E).
3. Remove cap from low-side charge port.
4. Connect blue hose (C) from refrigerant

recovery/recycling and charging station (E) to low-side
test port.
5. Remove cap (A) from charge port on high pressure

hose and connect red hose (B).
6. Follow the manufacturers’ instructions when using

refrigerant recovery/recycling and charging station.
AS79221,0000037 –19–02FEB09–1/1
TM11207 (11MAY09) 18-1830-10

051809
PN=380
R134a System Recover


(Group 1830.) 18
1830
11
valve. Air conditioning system will discharge
IMPORTANT: Use correct refrigerant

recovery/recycling and charging
stations. DO NOT mix refrigerant,
hoses, fittings, components or
refrigerant oils.
1. Run air conditioning system for 3 minutes to help in

recovery process. Turn air conditioning system off
before proceeding with recovery steps.
2. With engine OFF identify refrigerant type using

JT02167A Refrigerant Identification Instrument.
3. Connect refrigerant recovery system. See R134a

4. Follow manufacturers’ instructions when using

refrigerant recovery/recycling and charging station.
AS79221,0000046 –19–03FEB09–1/1
TM11207 (11MAY09) 18-1830-11

051809
PN=381
R134a System Evacuate


18 (Group 1830.)
1830
12
Do not remove high pressure relief valve. Air
conditioning system will discharge rapidly
causing possible injury.
1. Connect refrigerant recovery system. See R134a

2. Open low-side and high-side valves on refrigerant

recovery/recycling and charging station.
3. Follow manufacturers’ instructions and evacuate

system.
NOTE: Vacuum specifications listed are for sea level

conditions. Subtract 3.4 kPa (34 mbar) (1 in. Hg)
from 98 kPa (980 mbar) (29 in. Hg) for each 300
m (1000 ft) elevation above sea level.
Specification
Evacuate System—Vacuum .................. Subtract 3.4 kPa from 98 kPa for
each 300 m elevation above sea
level
Subtract 34 mbar from 980 mbar
for each 300 m elevation above
sea level
Subtract 1 in. Hg from 29 in. Hg
for each 1000 ft elevation above
sea level
4. Evacuate system until low-side gauge registers 98 kPa

(980 mbar) (29 in. Hg) vacuum.
Specification
Evacuate System—Vacuum ............................................................ 98 kPa
980 kPa
29 in. Hg
TM11207 (11MAY09) 18-1830-12

051809
PN=382
If specified vacuum cannot be obtained in 15 minutes, test

the system for leaks. See Refrigerant Leak Test. (Group
9031-25.)
5. When vacuum reaches specification, close low-side

and high-side valves. Turn vacuum pump off.
6. If vacuum decreases more than specification in 5 18

minutes, there is a leak in system. 1830
13
Specification
Evacuate System—Vacuum ........................................................... 3.4 kPa
34 mbar
1 in. Hg
7. Repair leak.
8. Evacuate system for 30 minutes after 98 kPa (980

mbar) (29 in. Hg) vacuum is reached.
9. Close low-side and high-side valves. Stop evacuation.
10. See R134a System Charge. (Group 1830.)
AS79221,0000047 –19–03FEB09–2/2
TM11207 (11MAY09) 18-1830-13

051809
PN=383
R134a System Charge


18 (Group 1830.)
1830
14
IMPORTANT: Use only John Deere approved
refrigerant recovery/recycling and
charging stations. DO NOT mix
refrigerant, hoses, fittings, components
or refrigerant oils.
1. Identify refrigerant type using JT02167A Refrigerant

Identification Instrument.
2. Connect R134a Refrigerant Recovery/Recycling and

Charging Station. See R134a Refrigerant
Recovery/Recycling and Charging Station Installation
Procedure. (Group 1830.)
3. See R134a System Evacuate. (Group 1830.)
NOTE: Before beginning to charge air conditioning

system, the following conditions must exist:
Engine STOPPED, the pump must be capable of
pulling at least 28.6 in. Hg vacuum (sea level).
Subtract 3.4 kPa (34 mbar) (1 in. Hg) from 98 kPa
(980 mbar) (29 in. Hg) for each 300 m (1000 ft)
elevation above sea level.
Specification
Evacuate System—Vacuum .................. Subtract 3.4 kPa from 98 kPa for
each 300 m elevation above sea
level
Subtract 34 mbar from 980 mbar
for each 300 m elevation above
sea level
Subtract 1 in. Hg from 29 in. Hg
for each 1000 ft elevation above
sea level
4. Follow manufacturer’s instructions and charge system.
TM11207 (11MAY09) 18-1830-14

051809
PN=384
5. Add refrigerant to system.
Specification
Air Conditioning System
Refrigerant—Refrigerant Quantity ................................................... 1928 g
4.25 lb
6. Check air conditioning for proper function. See

Diagnose Air Conditioning System Malfunctions. 18
(Group 9031-25.) 1830
15
AS79221,0000048 –19–03FEB09–2/2
Expansion Valve Remove and Install
1. Recover refrigerant from the system. See R134a

2. Remove screw (4) and cab air filter assembly cover

(5).
3. Remove rear panel behind seat.
4—Screw
–UN–16FEB09
TX1055863A
TM11207 (11MAY09) 18-1830-15

051809
PN=385
4. Disconnect air conditioner lines (1) from expansion

valve (2).
5. Remove expansion valve.
18 7. Install expansion valve.

1830 2
16 8. Connect air conditioner lines to expansion valve.
1
9. Install rear panel behind seat.
10. Install cab air filter assembly cover and secure with
–UN–19FEB09
screw.

TX1055823
(Group 1830.) Expansion Valve
1—Air Conditioner Line

2—Expansion Valve
(Group 1830.)
AS79221,0000038 –19–03FEB09–2/2
TM11207 (11MAY09) 18-1830-16

051809
PN=386
Freeze Control Switch Remove and Install

(2).
2. Remove access panel inside rear of cab below seat.
1—Screw 18
2—Cab Air Filter Assembly Cover 1830
17
–UN–28OCT08
TX1050175A
TM11207 (11MAY09) 18-1830-17

051809
PN=387
5
18
1830
18
4
B34
–UN–20MAR09
TX1057370
TX1057370
4—Cap Screw (2 used) 5—Probe B34—Air Conditioner Freeze

Control Switch
3. Disconnect wire harness from air conditioner freeze 8. Connect wire harness to freeze control switch
control switch (B34). connector.
4. Remove probe (5) of freeze control switch from 9. Insert freeze control switch probe into evaporator
evaporator coil. coil.
5. Remove cap screws (4) from heater/evaporator coil 10. Install access panel below seat.
top cover to remove freeze control switch (B34).
11. Install cab air filter assembly cover and secure
6. Test freeze control switch. See Air Conditioner with screw.
Freeze Control Switch Test. (Group 9031-25.)
7. Attach freeze control switch (B34) to

heater/evaporator coil top cover.
AS79221,0000039 –19–03FEB09–2/2
TM11207 (11MAY09) 18-1830-18

051809
PN=388
Air Conditioning High-Low Pressure Switch

Remove and Install
1. Remove screw (1).
2. Remove cab air filter assembly cover (2).
3. Remove rear panel. 18

1830
4. Disconnect electrical connector (4) from pressure 19
switch.
NOTE: A Schrader valve is located in the port connection
–UN–28OCT08
for the binary pressure switch to prevent the air
conditioning from discharging when the switch is
removed.
TX1050175A
5. Remove air conditioner pressure switch (B35).
6. Inspect and replace as necessary.

7. Install air conditioner pressure switch. Check for leaks.
See Refrigerant Leak Test. (Group 9031-25.)
8. Connect electrical connector to air conditioner pressure

switch.
9. Install rear panel.
screw.
1—Screw
4—Electrical Connector
–UN–19FEB09
B35—Air Conditioner Pressure Switch
TX1056007A
High-Low Pressure Switch
AS79221,000003A –19–03FEB09–1/1
TM11207 (11MAY09) 18-1830-19

051809
PN=389
Heater Control Valve Remove and Install
1. Remove screw (1).
2. Remove cab air filter assembly cover (2).
3. Remove rear panel.

18
1830 4. Disconnect temperature control switch cable (4) from
20 heater control valve (5).
5. Clamp heater hoses on either side of the heater control

valve.
–UN–28OCT08
6. Remove heater control valve and test. See Heater
Control Valve Leak Check. (Group 1830.)
TX1050175A
7. Inspect heater hoses and replace as necessary.
8. Install heater control valve, and hoses.

9. Tighten all hose connections.
10. Remove clamps from heater hoses.
11. Connect the temperature control cable.
12. Install rear panel behind seat.
screw.
14. Add coolant to the surge tank to account for any

coolant lose in the heater circuit. See Drain, Flush,
–UN–20FEB09
15. Start engine and run the heating system to check for
leaks. 5
TX1056089
1—Screw
2—Cab Air Filter Assembly Cover 4
4—Control Switch Cable
5—Heater Control Valve Heater Control Valve
AS79221,000003B –19–03FEB09–1/1
TM11207 (11MAY09) 18-1830-20

051809
PN=390
Heater Control Valve Leak Check
1. Before removal inspect valve for any cracks, leakage,

or pinched lines.
2. Remove heater control valve. See Heater Control

18
3. After removal perform a visual inspection of valve for 1830
cracks, debris, and free movement of the valve. 21
NOTE: The heater control valve is serviced as an

assembly.
4. Replace heater control valve if valve is damaged or

leaks.
5. Install heater control valve. See Heater Control Valve

AS79221,000003C –19–03FEB09–1/1
Blower Motor Assembly Remove and Install

2. Turn battery disconnect switch to the OFF position.
3. Remove heater and air conditioner (4). See Heater and

Air Conditioner Remove and Install. (Group 1800.)
4. Remove cap screws (3) and blower motor assembly

(M2).
–UN–16FEB09
6. Install blower motor assembly into heater and air

conditioner with cap screws.
TX1055805A
7. Install heater and air conditioner. See Heater and Air

Conditioner Remove and Install. (Group 1800.)
Blower Motor
8. Turn battery disconnect switch to the ON position.
4—Heater and Air Conditioner
M2—Blower Motor Assembly
R6—Blower Resistor
AS79221,000004C –19–10FEB09–1/1
TM11207 (11MAY09) 18-1830-21

051809
PN=391
Compressor Remove and Install—6.8L
18
1830
22
13
10
12
1
7
8 2
11
9
3
14
6
4
5
–UN–23MAR09
TX1057396
TX1057396
A/C Compressor, Receiver/Dryer, and Accumulator
TM11207 (11MAY09) 18-1830-22

051809
PN=392
1—Accumulator-to- Expansion 4—Accumulator 9—Compressor 12—Compressor-to-

Valve Low Pressure Gas 5—Receiver/Dryer 10—Cap Screw (3 used) Condenser High Pressure
Line 6—Cap Screw (2 used) 11—Compressor-to- Gas Line
2—Accumulator-to- 7—Receiver/Dryer-to- Accumulator Low 13—Connector
Compressor Low Pressure Expansion Valve High Pressure Gas Line 14—Compressor Bracket
Gas Line Pressure Liquid Line
3—Clamp 8—Receiver/Dryer-to-
Condenser High Pressure
Liquid Line
18
Specification 1830
1. Park machine on flat level surface. Lower all 23
Compressor-to-Condenser High
Pressure Line (12)—Torque ............................................... 20-27 N•m
15-20 lb.-ft.
Frame. (Operator’s Manual.) 11. Install engine accessory belt and connect harness.
See Inspecting Accessory Belt and Belt Tensioner
3. Recover refrigerant. See R134a System Recover. Spring. (Operator’s Manual.)
(Group 1800.)
12. Evacuate air conditioning system. See R134a
4. Disconnect connector (13) from air conditioner System Evacuate. (Group 1830.)
compressor (9).
13. Charge air conditioning system. See R134a
5. Remove refrigerant lines (11 and 12) from System Charge. (Group 1830.)
compressor.
6. Remove engine accessory belt. See Inspecting
Accessory Belt and Belt Tensioner Spring. 15. Run machine to verify proper operation.
7. Remove cap screws (10) and compressor.
9. Install compressor and cap screws.
10. Install refrigerant lines to compressor.
Specification
Compressor-to-Accumulator
Low Pressure Line (11)—
Torque................................................................................. 24-33 N•m
18-24 lb.-ft.
AS79221,0000056 –19–05MAR09–2/2
TM11207 (11MAY09) 18-1830-23

051809
PN=393
Compressor Remove and Install—9.0L
18
1830
24
13
12
11
10 9 7
8
3
6
–UN–27MAR09
4
TX1057303
TX1057303
A/C Compressor, Receiver/Dryer, and Accumulator
1—Accumulator-to- Expansion 4—Accumulator 8—Receiver/Dryer-to- 12—Compressor-to-

Valve Low Pressure Gas 5—Receiver/Dryer Condenser High Pressure Condenser High Pressure
Line 6—Cap Screw (2 used) Liquid Line Gas Line
2—Accumulator-to- 7—Receiver/Dryer-to- 9—Compressor 13—Connector
Compressor Low Pressure Expansion Valve High 10—Cap Screw (3 used)
Gas Line Pressure Liquid Line 11—Compressor-to-
3—Clamp Accumulator Low
Pressure Gas Line
TM11207 (11MAY09) 18-1830-24

051809
PN=394
1. Park machine on flat level surface. Lower all Specification

Compressor-to-Condenser High
Pressure Line (12)—Torque ............................................... 20-27 N•m
15-20 lb.-ft.
Frame. (Operator’s Manual.) 11. Install engine accessory belt and connect harness.
See Inspecting Accessory Belt and Belt Tensioner
3. Recover refrigerant. See R134a System Recover. Spring. (Operator’s Manual.)
(Group 1800.) 18
12. Evacuate air conditioning system. See R134a 1830
4. Disconnect connector (13) from air conditioner 25
System Evacuate. (Group 1830.)
compressor (9).
5. Remove refrigerant lines (11 and 12) from System Charge. (Group 1830.)
compressor.
6. Remove engine accessory belt. See Inspecting
Accessory Belt and Belt Tensioner Spring. 15. Run machine to verify proper operation.
7. Remove cap screws (10) and compressor.
9. Install compressor and cap screws.
10. Install refrigerant lines to compressor.
Specification
Compressor-to-Accumulator
Low Pressure Line (11)—
Torque................................................................................. 24-33 N•m
18-24 lb.-ft.
AS79221,0000057 –19–05MAR09–2/2
TM11207 (11MAY09) 18-1830-25

051809
PN=395
Condenser Remove and Install


18
1830 3. Recover refrigerant. See R134a System Recover.
26 (Group 1830.)
4. Open right rear access panel and position rod to hold

door open.
AS79221,000003E –19–03FEB09–1/4
5. Remove cap screws (2). Rotate cooler downward,

supporting it with one hand while pulling outward on
attached strap (3).
1—Condenser
3—Strap
4—Compressor-to- Condenser High Pressure Line
5—Condenser-to- Receiver/Dryer High Pressure Line
–UN–25MAR09
TX1057473A
Condenser (UP)
Continued on next page AS79221,000003E –19–03FEB09–2/4
TM11207 (11MAY09) 18-1830-26

051809
PN=396
18
1830
27
–UN–25MAR09
TX1057474A
Condenser (DOWN)
1—Condenser 5— 6—Cap Screw (2 used) Hinge 7—Cap Screws (2 used)

4—Compressor-to-Condenser Condenser-to-Receiver/Dryer Side
High Pressure Line High Pressure Line
6. Remove condenser-to-receiver/dryer high pressure 13. Install refrigerant lines.

line (5).
Specification
7. Remove compressor-to-condenser high pressure Compressor-to-Condenser High
Pressure Line (4)—Torque ................................................. 20-27 N•m
line (4). 133-177 lb.-in.
NOTE: Condenser is on a hinge and will swing freely Specification

after removing cap screws (7) Condenser-to-Receiver/Dryer
High Pressure Line (5)—Torque ........................................ 14-20 N•m
8. Remove cap screws (7). 89-133 lb.-in.
9. Support air conditioner condenser and remove cap 14. Lift cooler up and install cap screws (2).
screws (6).
15. Close access panels.
16. Evacuate air conditioning system. See R134a
11. Support air conditioner condenser and install cap System Evacuate. (Group 1830.)
screws (6).
12. Swing condenser close install cap screws (7). System Charge. (Group 1830.)
Continued on next page AS79221,000003E –19–03FEB09–3/4
TM11207 (11MAY09) 18-1830-27

051809
PN=397

AS79221,000003E –19–03FEB09–4/4
18 Heater and Air Conditioner Remove and

1830 Install
28



5. Recover refrigerant. See R134a System Recover.

(Group 1830.)
6. Remove seat. See Seat Remove and Install. (Group

1821.)
7. Remove floor mat.
Continued on next page AS79221,000003F –19–03FEB09–1/6
TM11207 (11MAY09) 18-1830-28

051809
PN=398

(2).
1—Screw
18
1830
29
–UN–28OCT08
TX1050175A
TM11207 (11MAY09) 18-1830-29

051809
PN=399
9. Remove cap screws (18) from rear lower panel (19).
10. Remove cap screws (22) from cab air filter plate (21).
11. Remove cap screws (24 and 27) from air ducts (23
and 25).
18 12. Lift center air duct to gain access to seat base cap
1830 screw (26).
30
–UN–06APR09
13. Remove cap screws (26) to remove seat base (20).
14. Remove cap screws from rear panel (28).
TX1058006A
19—Rear Lower Panel
20—Seat Base
21—Cab Air Filter Plate Cab Floor Without Seat
23—Left Air Duct
25—Center Air Duct
26—Seat Base Cap Screw (4 used)
27—Cap Screw (under plate not shown)
28—Rear Panel
TM11207 (11MAY09) 18-1830-30

051809
PN=400
15. Remove cap screws (5—10) and cab air filter

assembly intake duct (4) with filters.
4—Cab Air Filter Assembly Intake Duct 10

5—Cap Screw
6—Cap Screw 6 5
7—Cap Screw (2 used) 7
9—Cap Screw 18
10—Cap Screw (2 used) 1830
31
–UN–27APR09
4
9
TX1058290
Cab Air Filter Assembly Intake Duct
AS79221,000003F –19–03FEB09–4/6
16. Disconnect refrigerant lines from expansion valve

(15). Cap and plug lines.
17. Disconnect heater hot water lines (16) from heater

core.
18. Disconnect harness from blower motor, blower motor

resistor, and air conditioner freeze switch. See Heater
and Air Conditioner Harness (W12) Component
–UN–06JAN05
15—Expansion Valve
16—Heater Hot Water Lines
T206739A
Heater Hot Water Lines and Refrigerant Lines
TM11207 (11MAY09) 18-1830-31

051809
PN=401
19. Remove cap screws (11 and 12).
20. Remove heater and air conditioner.
–UN–05JAN05
22. Install heater and air conditioner.
18
1830 23. Connect harness. See Heater and Air Conditioner
32 Harness (W12) Component Location. (Group
T206692A
9015-10.)
24. Connect heater hot water lines, and refrigerant lines Air Conditioner and Heater
to heater and air conditioner.
12—Cap Screw
25. Install cab air filter assembly intake duct.
26. Install seat base and air ducts.
27. Install both rear panels.
28. Install seat. See Seat Remove and Install. (Group

1821.)
29. Install floor mat.
screw.

32. Evacuate air conditioning system. See R134a System

Evacuate. (Group 1830.)
33. Charge air conditioning system. See R134a System

Charge. (Group 1830.)
36. Operate machine and verify heater and air conditioner

functions. See Operational Checkout. (Group
9005-10.)
AS79221,000003F –19–03FEB09–6/6
TM11207 (11MAY09) 18-1830-32

051809
PN=402
Receiver-Dryer Remove and Install


18
3. Recover refrigerant. See R134a System Recover. 1830
(Group 1800.) 33
AS79221,0000040 –19–03FEB09–1/2
4. Remove refrigerant lines (3 and 4) from receiver/dryer

(1).
5. Remove cap screws (5) and receiver/dryer.
7. Install receiver/dryer and cap screws.
8. Install refrigerant lines.
–UN–10DEC04
Specification
Receiver/Dryer-to-Condenser
High Pressure Line (3)—Torque ............................................. 14—20 N•m
124—178 lb.-in.
T206130A
Specification
Receiver/Dryer-to-Expansion
Valve High Pressure Line (4)— Receiver/Dryer and Accumulator
Torque ..................................................................................... 14—20 N•m
124—178 lb-in. 1—Receiver/Dryer
2—Accumulator
3—Condenser-to-Receiver/Dryer High Pressure
9. Evacuate air conditioning system. See R134a System Line
Evacuate. (Group 1800.) 4—Receiver/Dryer-to-Evaporator High Pressure
Line
10. Charge air conditioning system. See R134a System 5—Cap Screw (2 used)
6—Accumulator-to-Compressor Low Pressure
Line
7—Evaporator-to-Accumulator Low Pressure Line
11. Remove articulation lock. 8—Cap Screw (2 used)
12. Run machine to verify proper operation.
AS79221,0000040 –19–03FEB09–2/2
TM11207 (11MAY09) 18-1830-33

051809
PN=403
Accumulator Remove and Install


18
1830 3. Recover refrigerant. See R134a System Recover.
34 (Group 1800.)
AS79221,0000041 –19–03FEB09–1/2
4. Remove refrigerant lines (6 and 7) from accumulator

(2).
5. Remove cap screws (8) and accumulator.
7. Install accumulator and cap screws.
8. Install refrigerant lines.
–UN–10DEC04
Specification
Accumulator-to-Compressor Low
Pressure Line (6)—Torque ........................................................ 35-42 N•m
26-31 lb.-ft.
T206130A
Specification
Accumulator-to-Evaporator Low
Pressure Line (7)—Torque ........................................................ 35-42 N•m Receiver/Dryer and Accumulator
26-31 lb.-ft.
1—Receiver/Dryer
2—Accumulator
9. Evacuate air conditioning system. See R134a System 3—Condenser-to-Receiver/Dryer High Pressure
Evacuate. (Group 1800.) Line
4—Receiver/Dryer-to-Evaporator High Pressure
10. Charge air conditioning system. See R134a System Line
6—Accumulator-to-Compressor Low Pressure
Line
11. Remove articulation lock. 7—Accumulator-to-Evaporator Low Pressure Line
12. Run machine to verify proper operation.
AS79221,0000041 –19–03FEB09–2/2
TM11207 (11MAY09) 18-1830-34

051809
PN=404
Compressor Clutch Disassemble and

Assemble
18
1830
35
–UN–14SEP07
TX1029375
–UN–14SEP07
TX1029376
1—JDG747 Compressor Clutch 3—Cap Screw 5—Snap Ring 7—Snap Ring

Spanner 4—Clutch Hub 6—Pulley 8—Clutch Coil
1. Mount compressor to DFRW20 Compressor 3. Hold clutch hub using JDG747 Compressor Clutch
Holding Fixture. Spanner (1) and remove cap screw (3).
2. Remove dust cover. 4. Remove clutch hub (4) and shims (2).
TM11207 (11MAY09) 18-1830-35

051809
PN=405
5. Remove and discard snap ring (5). Remove pulley 8. Install clutch coil and new snap ring with flat side of
(6) using JDG220 Puller, JDG748 Jaws, and snap ring down. Connect clutch coil lead wire.
JDG771 Hub Protector or a soft faced mallet.
9. Install pulley and new snap ring with flat side of
6. Disconnect clutch coil lead wire. Remove and snap ring down. Apply grease to shims and install
discard snap ring (7) and remove clutch coil (8). to clutch hub.
18 NOTE: The pulley bearing is not serviceable. Pulley 10. Install clutch hub and cap screw.
1830 and bearing must be replaced as a unit.
36 11. Install dust cover.
7. Check pulley bearing operation. Replace pulley and
bearing as required.
AS79221,0000042 –19–03FEB09–2/2
Compressor Manifold Inspect
1. Remove cap screws (1) and manifold (2).
2. Remove and discard seal (3). Inspect porting surfaces.
3. Lubricate and install a new seal.
4. Install manifold and tighten cap screws to specification.
Specification
Manifold Cap Screws—Torque ...................................................... 26 N•m
228 lb-in.
–UN–16FEB09
1—Manifold Cap Screw
2—Manifold
3—Manifold Seal
TX1055854
AS79221,0000044 –19–03FEB09–1/1
TM11207 (11MAY09) 18-1830-36

051809
PN=406
Compressor Relief Valve Remove and Install


(Group 1830.) 18
1830
37
valve. Air conditioning system will discharge
High pressure may exist at discharge fitting. If

this pressure is released too rapidly, there may
be considerable discharge of refrigerant and oil.
1. Follow refrigerant cautions and proper handling

procedures. See Refrigerant Cautions and Proper
Handling. (Group 1830.)
AS79221,0000045 –19–03FEB09–1/2
2. Do 134a system recovery of refrigerant. See R134a

3. Slowly remove relief valve (1) from compressor

manifold.
NOTE: The relief valve is not serviceable. Replace valve

as required.
4. Install relief valve and tighten to specification.
Specification
Compressor Relief Valve—
Torque ................................................................................... 12—16 N•m
–UN–16FEB09
108—144 lb-in.
5. Evacuate and charge air conditioning system. See

R134a System Evacuate, see R134a System Charge.
TX1055852A
(Group 1830.)
1—Relief Valve Compressor Relief Valve
AS79221,0000045 –19–03FEB09–2/2
TM11207 (11MAY09) 18-1830-37

051809
PN=407
18
1830
38
TM11207 (11MAY09) 18-1830-38

051809
PN=408
Section 19
Sheet Metal and Styling
Contents
Page
Group 1921—Grille and Grille Housing

Grille Housing Remove and Install . . . . . . . .19-1921-1
19
770G,
051809
PN=1
Contents
19
770G,
051809
PN=2
Group 1921
Grille and Grille Housing
Grille Housing Remove and Install

JW00603,00000F1 –19–20JAN09–1/5

device.
2. Support rear compartment hood (1).

19
Specification 1921
Rear Compartment Hood— 1
Weight................................................................................................ 41 kg
90 lb.
3. Remove cap screws (3) and rear compartment hood.
–UN–19FEB09
4. Attach identification tags and disconnect hydraulic lines
from fan door. Close all openings with caps and plugs.
1—Rear Compartment Hood
TX1055287A
Rear Compartment Hood
Continued on next page JW00603,00000F1 –19–20JAN09–2/5
TM11207 (11MAY09) 19-1921-1

051809
PN=411

device.
5. Support fan door (4).
Specification
Fan Door—Weight ............................................................................. 75 kg
165 lb.
6. Remove snap rings (10), pins (9) and fan door (4).
4—Fan Door
–UN–11FEB09
19
9—Pin (2 used)
1921
10—Snap Ring (2 used)
2
TX1055742A
Fan Door
TM11207 (11MAY09) 19-1921-2

051809
PN=412

device.
7. Support engine access doors (2 and 3).
Specification
Engine Access Door—Weight ........................................................... 24 kg
53 lb.
8. Remove engine access doors.
–UN–11FEB09
19
from heavy component. Use appropriate lifting 1921
device. 3
9. Support grille housing (5).
TX1055741A
Specification
Grille Housing—Weight ..................................................................... 70 kg
154 lb. Left Side of Machine
10. Remove cap screws (11) and grille housing.
11. Repair or replace grille housing as necessary.

device.
12. Install grille housing and cap screws.
Specification
Grille Housing—Weight ..................................................................... 70 kg
154 lb.
–UN–11FEB09
TX1055740A
device.
13. Install engine access doors.

Right Side of Machine
Specification
Engine Access Door—Weight ........................................................... 24 kg 2—Left Engine Access Door
53 lb. 3—Right Engine Access Door
5—Grille Housing
TM11207 (11MAY09) 19-1921-3

051809
PN=413

device.
14. Install fan door, pins and snap rings.
Specification
Fan Door—Weight ............................................................................. 75 kg
165 lb.
15. Connect hydraulic lines.

4 device.
16. Install rear compartment hood.
Specification
Rear Compartment Hood—
Weight................................................................................................ 41 kg
90 lb.

JW00603,00000F1 –19–20JAN09–5/5
TM11207 (11MAY09) 19-1921-4

051809
PN=414
Section 21
Main Hydraulic System
Contents
Page

Vacuum Pump Installation. . . . . . . . . . . . . . .21-2160-1
Hydraulic Pump Remove and Install . . . . . . .21-2160-1
Hydraulic Pump Disassemble and
Assemble. . . . . . . . . . . . . . . . . . . . . . . . . .21-2160-4
Hydraulic System Manifold Remove and
Install. . . . . . . . . . . . . . . . . . . . . . . . . . . .21-2160-10
Hydraulic System Manifold Disassemble and
Assemble. . . . . . . . . . . . . . . . . . . . . . . . .21-2160-12 21
Soft Start Valve Remove and Install . . . . . .21-2160-13
Soft Start Valve Disassemble and
Assemble. . . . . . . . . . . . . . . . . . . . . . . . .21-2160-16
Hydraulic Fan Pump Remove and Install. . .21-2160-17
Hydraulic Fan Motor Remove and Install. . .21-2160-18
Hydraulic Fan Valve Remove and Install . . .21-2160-19
General Oil Cleanup Procedure. . . . . . . . . .21-2160-23
Hydraulic/Hydrostatic Component Failure
Cleanup Procedure . . . . . . . . . . . . . . . . .21-2160-26
770G,
051809
PN=1
Contents
21
770G,
051809
PN=2
Group 2160
Hydraulic System
Vacuum Pump Installation
SERVICE EQUIPMENT AND TOOLS

JT05510 Vacuum Pump (Air Operated)
NOTE: This installation will minimize hydraulic oil leakage

when disconnecting hydraulic lines.
Attach vacuum hose (3) to hydraulic oil tank breather

hose (1) and vacuum pump (4).
1—Hydraulic Oil Tank Breather Hose

2—Hydraulic Oil Tank Breather Filter
–UN–14NOV08
3—Vacuum Hose
4—Vacuum Pump
TX1051174A
21
2160
Vacuum Pump 1
JW00603,000018E –19–22JAN09–1/1
Hydraulic Pump Remove and Install

4. Drain hydraulic oil tank. See Changing Hydraulic Tank

5. Remove fan charge pump. See Hydraulic Fan Pump

TM11207 (11MAY09) 21-2160-1

051809
PN=417
Hydraulic System
7. Disconnect hydraulic hoses (2, 5, 6, and 10) from

hydraulic pump.
10 2 3
8. Close all openings using caps and plugs. 9
1
device.
9. Support hydraulic pump.
–UN–03APR09
Specification
Hydraulic Pump—Weight ............................................................... 34.9 kg 7 4
8
77 lbs
6
5
10. Remove hydraulic pump cap screws.
TX1057763
21
2160 NOTE: The coupler connecting the transmission charge
2 pump (7) and hydraulic pump (1) may stay with Hydraulic Pump and Hydraulic Fan Pump
the hydraulic pump on removal.
1—Hydraulic Pump
2—Hydraulic Pump-to-Hydraulic System Manifold
11. Slide hydraulic pump rearward to slide spline out of Hose
coupler in transmission charge pump. 3—Hydraulic Fan Charge Pump Supply Hose
4—Hydraulic Fan Pump
12. Inspect, repair, or replace parts as necessary. See 5—Hydraulic Pump Supply Hose
6—Hydraulic Pump-to-Hydraulic Oil Cooler
Hydraulic Pump Disassemble and Assemble. (Group
Bypass Hose
2160.) 7—Transmission Charge Pump
8—Hydraulic Pump Load Sense-to-Left Control
Valve Hose
CAUTION: Prevent possible crushing injury 9—Hydraulic Pump Cap Screw (4 used)
from heavy component. Use appropriate lifting 10—Hydraulic Pump-to-Hydraulic Oil Tank Return
device. Hose
NOTE: Make sure coupler connecting transmission

charge pump and hydraulic pump is installed in
place.
13. Install hydraulic pump and cap screws.
Specification
Hydraulic Pump—Weight ............................................................... 34.9 kg
77 lbs
14. Connect hydraulic oil hoses to hydraulic pump.
15. Install fan pump. See Hydraulic Fan Pump Remove

TM11207 (11MAY09) 21-2160-2

051809
PN=418
Hydraulic System
16. Fill hydraulic oil tank. See Changing Hydraulic Tank


JW00603,00000F2 –19–20JAN09–3/3
21
2160
3
TM11207 (11MAY09) 21-2160-3

051809
PN=419
Hydraulic System
Hydraulic Pump Disassemble and Assemble
55
53
7 20
22
49
48
7
52 22
60
22
59 54
2 7
58
22
21
2160
4 1
32
30
31 26
25
24 23
19 57
21
19 22
58 17
59
60 16
18 61
40
41
42
15
33
14
10
22
13
12
11
8
63
22
–UN–16APR09
6
10
4
62
TX1058362
5
TX1058362
Hydraulic Pump Assembly
TM11207 (11MAY09) 21-2160-4

051809
PN=420
Hydraulic System
1—Cap Screw (4 used) 11—O-Ring 24—Seal 49—Cap Screw

2—Washer (4 used) 12—Bearing Kit 25—Snap Ring 52—Spool
3—O-Ring (used with auxiliary 13—Valve Plate 26—Snap Ring (used with 53—O-Ring
drive) 14—Rotate Group auxiliary drive) 54—O-Ring (4 used)
4—Cap Screw (4 used with 15—Drive Shaft 30—O-Ring 55—Screw (4 used)
auxiliary drive) 16—Swashplate 31—Control Piston Cap 57—O-Ring (2 used)
5—Adapter Plate (auxiliary 17—Bearing Kit 32—Control Piston 58—Plug Fitting (2 used)
drive) 18—Bias Piston Assembly 33—Piston (10 used) 59—O-Ring (2 used)
6—Coupler (4 used with 19—Swashplate Bearing (2 40—Backup Ring 60—Plug (2 used)
auxiliary drive) used) 41—O-Ring 61—Spring
7—Plug (3 used) 20—Plug 42—O-Ring 62—O-Ring
8—Screw (4 used with 21—O-Ring 48—Load Sense Control 63—O-Ring
auxiliary drive) 22—O-Ring (6 used) Assembly
10—Fitting Plug (2 used) 23—Sleeve (used with
auxiliary drive)
21
JW00603,0000160 –19–21JAN09–2/7 2160
5
1. Mark pump housing as shown to show orientation to

pump end cap cover (9) and location of control piston
cap (31).
2. Remove load sense control valve (48). Inspect and
–UN–20APR09
replace parts as necessary.
3. Position pump upright on table. Remove pump end

cover.
TX1058395A
9—Pump End Cover
31—Control Piston Cap
34—Pump Housing Locating Marks on Pump
48—Load Sense Control Valve
TM11207 (11MAY09) 21-2160-5

051809
PN=421
Hydraulic System
IMPORTANT: Mark orientation of valve plate before

disassembly.
IMPORTANT: Make sure that gap in dowel pin (32)

faces either directly towards or directly
away from center of end cover.
–UN–16NOV01
4. Remove valve plate (13).
5. Inspect valve plate for cracks or scratches. Valve plate
T146607B
thickness must be no less than specification.
Specification Valve Plate and Timing Pin

Valve Plate—Thickness
(minimum) ................................................................................... 4.950 mm 13—Valve Plate
0.195 in 32—Dowel Pin
6. Remove bias piston assembly (18). Inspect and

replace parts as necessary.
21
2160 7. Remove control piston (32). Inspect for damage in the
6
bore and on the piston. If it is damaged. Replace pump
assembly.
TM11207 (11MAY09) 21-2160-6

051809
PN=422
Hydraulic System
NOTE: Rotate group consists of cylinder block and

pistons.
8. Position pump on its side. Remove drive shaft (15) and

rotate group so that pistons (33) do not come out of
cylinder block (14).
–UN–16NOV01
9. Remove drive shaft from rotate group. Inspect splines
for wear or damage.
T146620B
10. Inspect rotate group. Check slippers on end of pistons
for wear and excessive end play. Check cylinder
block height. Rotate Group and Drive Shaft
Specification 14—Cylinder Block

Piston Slipper Thickness— 15—Drive Shaft
Thickness (minimum) ................................................................... 2.23 mm 33—Pistons
0.127 in.
Specification 21
Slipper End Play—Thickness 2160
(minimum) ................................................................................... 0.102 mm 7
0.004 in.
Specification
Cylinder Block Height—Thickness
(minimum) ................................................................................... 62.23 mm
2.450 in.
NOTE: Mark swash plate orientation before disassembly.
11. Position pump upright. Remove swash plate (16).
IMPORTANT: Mark orientation and location of swash

plate bearings before disassembly.
12. Remove swash plate bearings (19). Inspect and

replace as necessary.
13. Remove bearing and bearing cups (12, 17). Inspect

and replace as needed.
14. Remove retaining ring (25) and shaft seal (24).
15. Clean and lubricate all pump components using clean

hydraulic oil before assembly.
16. Install front bearing kit (17).
TM11207 (11MAY09) 21-2160-7

051809
PN=423
Hydraulic System
17. Install swash plate bearings in original location and

orientation.
18. Install swash plate in its original orientation.
19. Install pump drive shaft.
20. Install control piston. Torque plug to specification.
Specification
Control Piston Plug—Torque........................................................ 230 N•m
170 lb-ft
21. Install bias piston assembly (18). Torque plug to

specification.
Specification
Bias Piston Assembly Plug—
Torque .......................................................................................... 230 N•m
170 lb-ft
21
2160
8 22. Position pump on side. Install rotate group.
NOTE: Rotate group should be flush with shoulder of

drive shaft when installed.
23. Install bearing kit (12).
24. Install valve plate (13) in its original orientation.
25. Install end cap (9). Torque cap screws (7) to

specification.
Specification
Main Hydraulic Pump End
Cap-to-Pump Housing Cap
Screw—Torque ............................................................................... 96 N•m
71 lb-ft
TM11207 (11MAY09) 21-2160-8

051809
PN=424
Hydraulic System
26. Inspect sealing area of pump shaft and polish if 1

required.
2
27. Apply grease to pump shaft and oil seal lips. 3
28. Install shaft seal (24) with cupped side toward shaft 4
–UN–16APR08
bearing just far enough to install retaining ring (25).
29. Install load sense control valve assembly (48).
TX1040162
1—Retaining Ring
2—Oil Seal
3—Pump Shaft Pump Shaft Seal
4—Pump Housing
21
JW00603,0000160 –19–21JAN09–7/7 2160
9
TM11207 (11MAY09) 21-2160-9

051809
PN=425
Hydraulic System
Hydraulic System Manifold Remove and Install
1 5
21 2
2160
–UN–17APR09
10
TX1058401
TX1058401
Hydraulic System Manifold
1—Cap Screw (3 used) 3—Hydraulic System Manifold 4—Mounting Bracket 5—Mounting Stud
2—Washer (3 used)
1. Lower all attachments to the ground. reference a knowledgeable medical source.

Such information is available from Deere &
2. Install articulation lock pin. Company Medical Department in Moline,
Illinois, U.S.A.
4. If equipped with secondary steering, operate
steering function until front wheels stop steering to
relieve the secondary steering accumulator of
stored hydraulic oil.
other lines. Tighten all connections before CAUTION: To avoid injury from escaping
applying pressure. Search for leaks with a fluid under pressure, stop engine and relieve
piece of cardboard. Protect hands and body the pressure in the system before
from high pressure fluids. disconnecting or connecting hydraulic or
If an accident occurs, see a doctor applying pressure.
must be surgically removed within a few 5. To relieve pressure in the system, slowly loosen all
hours or gangrene may result. Doctors fittings on hoses at hydraulic system manifold (3).
TM11207 (11MAY09) 21-2160-10

051809
PN=426
Hydraulic System
6. Install vacuum pump to hydraulic oil tank to 12. Install cap screws and washers to the mounting
minimize hydraulic oil loss during repair. See studs.
13. Connect all hydraulic hoses. See Hydraulic
7. Disconnect and tag all hydraulic hoses from System Component Location or see Hydraulic
hydraulic system manifold. See Hydraulic System System Component Location—EH Controls.
Component Location or see Hydraulic System (Group 9025-15.)
9025-15.) 14. Remove vacuum pump from hydraulic oil tank.
8. Remove cap screws (1) and washers (2) from Installation. (Group 2160.)
mounting studs (5).
9. Remove hydraulic system manifold (3) and
mounting bracket (4) from main frame. 16. Remove articulation lock pin.
10. Repair or replace components as needed. See 17. Check hydraulic oil level. See Checking Hydraulic
Hydraulic System Manifold Disassemble and Tank Oil Level. (Operator’s Manual.)
Assemble. (Group 2160.) 21
18. Return machine to service. 2160
11. Install hydraulic system manifold and mounting 11
bracket to the main frame.
JW00603,0000161 –19–21JAN09–2/2
TM11207 (11MAY09) 21-2160-11

051809
PN=427
Hydraulic System
Hydraulic System Manifold Disassemble and Assemble
1
2
6
4
5
21
2160
–UN–17APR09
12
7
10
9
TX1058402
13 11 8
12
TX1058402
Hydraulic System Manifold
1—Plug 5—Isolator (3 used) 8—Pressure Reducing Valve 11—System Relief Valve

2—Hydraulic System Manifold 6—Cap Screw (3 used) 9—Check Valve 12—Plug (2 used)
3—Mounting Bracket 7—Saddle Lock Solenoid 10—Plug 13—Plug (2 used)
4—Washer (4 used)
1. Remove hydraulic system manifold (2) from 6. Install plugs, saddle lock solenoid, pressure
machine. See Hydraulic System Manifold Remove reducing valve, check valve, and system relief valve
and Install. (Group 2160.) as shown.
2. Remove cap screws (6) and washers (4) from 7. Install mounting bracket and isolators to hydraulic
hydraulic system manifold. system manifold.
3. Remove mounting bracket (3) and isolators (5) from 8. Install cap screws and washers to hydraulic system
hydraulic system manifold. manifold.
4. Remove plugs (1, 10, 12, and 13), saddle lock 9. Install hydraulic system manifold to machine. See
solenoid (7), pressure reducing valve (8), check Hydraulic System Manifold Remove and Install.
valve (9), and system relief valve (11) as shown. (Group 2160.)
5. Repair or replace parts as needed.
JW00603,0000162 –19–21JAN09–1/1
TM11207 (11MAY09) 21-2160-12

051809
PN=428
Hydraulic System
Soft Start Valve Remove and Install
NOTE: Soft start valve is located above the main

hydraulic pump behind the left rear access door.
21
2160
13
TM11207 (11MAY09) 21-2160-13

051809
PN=429
Hydraulic System

4. To relieve pressure in the system, slowly loosen fittings

on hydraulic hoses (1) at soft start valve (2).
–UN–20APR09
TX1058430A
6. Disconnect and tag hydraulic hoses from soft start
valve. Cap and plug all openings. See Hydraulic
System Component Location or see Hydraulic System
Component Location—EH Controls. (Group 9025-15.) Soft Start Valve
21 1—Hydraulic Hose (2 used)

7. Disconnect soft start solenoid (Y2) from wire harness.
2160 2—Soft Start Valve
14 3—Cap Screws (2 used)
8. Remove cap screws (3). Y2—Soft Start solenoid
9. Remove soft start valve from machine.
10. Repair or replace components as needed. See Soft

Start Valve Disassemble and Assemble. (Group
2160.)
11. Install soft start valve to machine.
12. Install cap screws.
13. Connect soft start solenoid (Y2) to wire harness. See

Midstructure Harness (W34) Component Location for
wire harness connections. (Group 9015-10.)
14. Connect hydraulic hoses to soft start valve. See

Hydraulic System Component Location or see
Hydraulic System Component Location—EH Controls.
(Group 9025-15.)

(Group 2160.)
TM11207 (11MAY09) 21-2160-14

051809
PN=430
Hydraulic System

JW00603,0000165 –19–21JAN09–3/3
21
2160
15
TM11207 (11MAY09) 21-2160-15

051809
PN=431
Hydraulic System
Soft Start Valve Disassemble and Assemble
21
2160
16
–UN–29NOV04
T205434
Soft Start Valve

TM11207 (11MAY09) 21-2160-16

051809
PN=432
Hydraulic System
1—Solenoid Valve 3—Solenoid Retaining Nut 5—Soft Start Valve 7—Solenoid Kit
2—Solenoid Coil 4—Seal Kit 6—Solenoid Valve Assembly 8—Housing
1. Remove soft start valve from machine. See Soft 6. Replace seal kit (4) and install solenoid valve into
Start Valve Remove and Install. (Group 2160.) housing.
2. Remove solenoid retaining nut (3) from soft start 7. Install solenoid coil over solenoid valve and install
valve (5). solenoid retaining nut.
3. Remove solenoid coil (2) from solenoid valve (1). 8. Install soft start valve to machine. See Soft Start
4. Remove solenoid valve from housing (8).
5. Inspect solenoid valve for damage, replace if

scratched or damaged.
21
JW00603,0000166 –19–21JAN09–2/2 2160
17
Hydraulic Fan Pump Remove and Install



3. Drain hydraulic oil tank. See Changing Hydraulic Tank

TM11207 (11MAY09) 21-2160-17

051809
PN=433
Hydraulic System
4. Remove supply hose clamp (2) and supply hose (1).

5. Remove hydraulic hose to hydraulic fan valve (4). Cap

1
2
7. Remove hydraulic fan pump.
8. Inspect and replace all parts as necessary. 3
9. Install hydraulic fan pump.
–UN–30APR09
10. Install cap screws. 4
5
11. Install supply hose and hose to fan valve.
TX1058977
21 12. Fill hydraulic oil tank. See Changing Hydraulic Tank
2160 Oil. (Operator’s Manual.)
18 Hydraulic Fan Pump
13. Run engine and check for leaks.
1—Supply Hose from Tank

2—Clamp
3—Hydraulic Fan Pump
4—Hydraulic Hose-to-Hydraulic Fan Valve
JW00603,0000167 –19–14MAY09–2/2
Hydraulic Fan Motor Remove and Install

2. Remove fan blade. See Fan Blade Remove and Install.

(Group 0510.)
TM11207 (11MAY09) 21-2160-18

051809
PN=434
Hydraulic System
3. Attach identification tags and disconnect hydraulic

hoses (1 and 4) from fan motor (3).
4. Remove hydraulic fan motor cap screws (2).
5. Attach identification tag and disconnect hydraulic hose

(5) from motor.
6. Inspect and replace motor as necessary.
7. Install return hose to tank on motor.
8. Install hydraulic fan motor cap screws.
–UN–25FEB09
9. Install hydraulic hoses from fan valve to motor.
10. Install fan blade. See Fan Blade Remove and Install.
TX1055047A
(Group 0510.)
21
11. Check hydraulic oil level. See Checking Hydraulic 2160
Tank Oil Level. (Operator’s Manual.) Fan Motor 19
1—From Hydraulic Fan Valve

2—Hydraulic Fan Motor Mounting Cap Screw
3—Hydraulic Fan Motor
4—From Hydraulic Fan Valve
5—Return to Hydraulic Oil Tank
JW00603,0000169 –19–14MAY09–2/2
Hydraulic Fan Valve Remove and Install
Continued on next page BR70016,0000064 –19–17APR09–1/4
TM11207 (11MAY09) 21-2160-19

051809
PN=435
Hydraulic System
4. Disconnect transmission filter restriction switch (B49)

from wire harness.
6. Remove transmission oil filter housing (2) from oil filter

mounting bracket (3).

2—Transmission Oil Filter Housing
3—Oil Filter Mounting Bracket
B49—Transmission Filter Restriction Switch
–UN–20APR09
TX1058439A
21
2160
20 Transmission Oil Filter Housing
TM11207 (11MAY09) 21-2160-20

051809
PN=436
Hydraulic System
7. Secure oil filter housing to allow for access to hydraulic

fan valve (6).
8. Disconnect fan pressure sensor (B40), hydraulic fan

speed solenoid (Y4), and hydraulic fan direction
–UN–20APR09
solenoid (Y5) from wire harness.

TX1058440A
connections before applying pressure. Hydraulic Fan Valve
9. To relieve pressure in the system, slowly loosen fittings 4—Hydraulic Hose (3 used)
on hydraulic hoses (4) and hydraulic line (7) at 5—Cap Screw (2 used)
6—Hydraulic Fan Valve
hydraulic fan valve. 7—Hydraulic Line
B40—Fan Pressure Sensor
10. Install vacuum pump to hydraulic oil tank to minimize Y4—Hydraulic Fan Speed Solenoid
hydraulic oil loss during repair. See Vacuum Pump Y5—Hydraulic Fan Direction Solenoid 21
2160
Installation. (Group 2160.) 21
11. Disconnect and tag hydraulic hoses and hydraulic line

from hydraulic fan valve. Cap and plug all openings.
13. Remove hydraulic fan valve from machine.
15. Install hydraulic fan valve to machine.
16. Install cap screws (5).
17. Connect hydraulic hoses and hydraulic line to

hydraulic fan valve.

(Group 2160.)
19. Connect fan pressure sensor (B40), hydraulic fan

speed solenoid (Y4), and hydraulic fan direction
solenoid (Y5) to wire harness. See Midstructure
Harness (W34) Component Location for wire harness
connections. (Group 9015-10.)
TM11207 (11MAY09) 21-2160-21

051809
PN=437
Hydraulic System
20. Install transmission oil filter housing to oil filter

mounting bracket.
21. Install cap screws (1) to transmission oil filter housing.
22. Connect transmission filter restriction switch (B49) to

wire harness. See Midstructure Harness (W34)
Component Location for wire harness connections.
(Group 9015-10.)


21
2160
22
BR70016,0000064 –19–17APR09–4/4
TM11207 (11MAY09) 21-2160-22

051809
PN=438
Hydraulic System
General Oil Cleanup Procedure
This procedure is to be used on machines that have

had hydraulic system repair without a catastrophic
component failure. Filter caddy procedure must be
done prior to starting machine after a component has
been repaired or replaced.
IMPORTANT: Intermixing of oils can cause premature

hydraulic component damage and oil
contamination. Oil types and filters
must not be intermixed. Use filter
element in same type oil to avoid
intermixing of oils.
Oil contamination could result if filter

caddy is used in dusty or wet
conditions. Instrument cleanliness and
clean work practices are critical when 21
filtering oil. 2160
23
NOTE: Filter oil at 27°C (80°F) or above for best filter
caddy performance. Reduce flow rate to filter oil
below 27°C (80°F).
Filter caddy requires a 20 amp electric circuit. Use

of electrical extension cord is not recommended.
1. Park machine on a flat level surface.
2. Clean oil fill cap and area surrounding it to prevent

contamination.
3. With machine off, remove tank fill cap.
4. Clean fill cap and store in sealed plastic bag.
5. Remove strainer from oil fill tube, clean and store in a

sealed plastic bag.
TM11207 (11MAY09) 21-2160-23

051809
PN=439
Hydraulic System
NOTE: When installing suction and discharge wands into

the hydraulic oil tank, locate the submerged ends
of the wands as far away from each other as
possible to ensure maximum oil movement during
cleanup procedure.
6. Install suction and discharge wands (1 and 2) from

Super Caddy JDG10712 into the hydraulic oil tank
through the oil fill tube (3).
–UN–22APR09
7. Seal suction and discharge wands to oil fill tube to
secure wands to hydraulic oil tank and prevent
contamination.
TX1058608A
8. Use Super Caddy JDG10712 to remove oil
contaminants. Refer to the operator’s manual included
with the super caddy or see super caddy in Service
Super Caddy Installation
ADVISOR for operating procedure.
21 1—Discharge Wand
2160 9. Remove super caddy wands from machine. 2—Suction Wand
24 3—Oil Fill Tube
10. Install new hydraulic oil filter for cleanup procedure.
See Replacing Hydraulic Oil Filter. (Operator’s
Manual.)
CAUTION: Prevent possible personal injury

from unexpected machine movement. Clear all
persons from area before operating machine.
CAUTION: Avoid entanglement and possible

electrocution from filter caddy power cord. Do
not operate machine while filter caddy is
connected to machine.
11. Make sure area is clear and large enough to operate

all functions of machine.
12. Fill hydraulic oil tank to operating level. See Checking

Hydraulic Tank Oil Level. (Operator’s Manual.)
Service ADVISOR is a trademark of Deere & Company Continued on next page JW00603,000016B –19–21JAN09–2/3
TM11207 (11MAY09) 21-2160-24

051809
PN=440
Hydraulic System
IMPORTANT: Avoid additional oil contamination. Do

not force the hydraulic system over
system relief or over the hydraulic oil
cooler bypass.
13. Run machine at slow idle. Operate each circuit a

minimum of 2 minutes in each direction to flush any
remaining contaminants back through hydraulic oil
filter.
14. Stop machine and install filter caddy wands.
15. Repeat super caddy operation procedure until

contaminant value is at specifications per super caddy
operation manual. Refer to the operator’s manual
included with the super caddy or see super caddy in
Service ADVISOR for operating procedure.
16. When oil reaches acceptable level of cleanliness, 21

install new hydraulic oil filter. See Replacing Hydraulic 2160
Oil Filter. (Operator’s Manual.) 25
NOTE: Instrument cleanliness and clean work practices

are critical when filtering oil or taking oil samples.
Dust, wind, and moisture, as well as contaminated
sample pumps, bottles and tubing can affect
results.
17. Obtain oil sample for fluid analysis. Oil sample must
be taken from system before oil passes through the
return filter when oil is warm. See Fluid Sampling
Test Ports. (Operator’s Manual.)
18. Fill tank to proper operating level. See Checking

Service ADVISOR is a trademark of Deere & Company JW00603,000016B –19–21JAN09–3/3
TM11207 (11MAY09) 21-2160-25

051809
PN=441
Hydraulic System
Hydraulic/Hydrostatic Component Failure

Cleanup Procedure
This procedure is to be used on machines that have

had a system catastrophic component failure.
Cleanup procedure must be done prior to starting
machine after a component has been repaired or
replaced. The use of attachments increase the need to
monitor and filter oil to a safe contamination value.
IMPORTANT: Intermixing of oils can cause premature

hydraulic component damage and oil
contamination. Oil types and filters
must not be intermixed. Use filter
element in same type oil to avoid
intermixing of oils.
Oil contamination could result if filter

21 caddy is used in dusty or wet
2160 conditions. Instrument cleanliness and
26 clean work practices are critical when
filtering oil.
NOTE: Filter oil at 27°C (80°F) or above for best filter

caddy performance. Reduce flow rate to filter oil
below 27°C (80°F).
Filter caddy requires a 20 amp electric circuit. Use

of electrical extension cord is not recommended.
1. Park machine on a flat level surface.
2. Clean oil fill cap and area surrounding it to prevent

contamination.
3. With machine off, remove tank fill cap.
4. Clean fill cap and store in sealed plastic bag.
5. Remove strainer from oil fill tube, clean and store in a

sealed plastic bag.
TM11207 (11MAY09) 21-2160-26

051809
PN=442
Hydraulic System
6. Drain hydraulic oil tank or remove hydraulic oil using

Super Caddy JDG10712. Refer to the operator’s
manual included with the super caddy or see super
caddy in Service ADVISOR for operating procedure.
See Changing Hydraulic Tank Oil if manually draining
hydraulic oil tank. (Operator’s Manual.)
7. Clean hydraulic oil tank.
8. Remove each hydraulic/hydrostatic component from

the machine. Disassemble, clean and inspect
components working one circuit at a time. Repair or
replace damaged components.
• Hydraulic Oil Cooler—See Hydraulic and Differential

Oil Cooler Remove and Install. (Group 0510.)
• Hydraulic Oil Cooler Bypass Valve
• Hydraulic Fan Pump—See Hydraulic Fan Pump
Remove and Install. (Group 2160.) 21
• Hydraulic Pump—See Hydraulic Pump Remove and 2160
• Soft Start Valve—See Soft Start Valve Remove and
• Hydraulic System Manifold—See Hydraulic System
Manifold Remove and Install. (Group 2160.)
• Steering Valve—See Steering Wheel, Column, and
Valve Remove and Install—Standard Controls or see
Steering Wheel, Column, and Valve Remove and
• Service Brake Valve—See Service Brake Valve
• Brake Accumulator—See Brake Accumulator
• Saddle Locking Cylinder—See Saddle Locking
• Grader Control Valves—See Grader Control Valve
Remove and Install or see Draft Frame Mount
Grader Control Valve Remove and Install—EH
Controls and see Cab Mount Grader Control Valve
Remove and Install—EH Controls. (Group 3460.)
• Rotate Motor—See Circle Drive Gearbox Remove
• Rotary Manifold—See Rotary Manifold Remove and
Service ADVISOR is a trademark of Deere & Company Continued on next page BR70016,0000065 –19–21APR09–2/5
TM11207 (11MAY09) 21-2160-27

051809
PN=443
Hydraulic System
• All Hydraulic Cylinders—See Blade Lift, Blade Pitch,

and Circle Side Shift Cylinders Remove and Install.
(Group 3460.) See Blade Side Shift Cylinder Remove
and Install. (Group 3460.) See Steering Cylinder
Remove and Install. (Group 0960.) See Wheel Lean
• Hydraulic Oil Filter Manifold—See Hydraulic Fan Valve
• Hydraulic Oil Filter Bypass Valve
• Hydraulic Fan Valve—See Hydraulic Fan Valve Remove
• Hydraulic Fan Motor—See Hydraulic Fan Motor
Optional Equipment
• EH Controls Steering Canceling Valve—See EH

Controls Steering Canceling Valve Remove and
2160 • Secondary Steering Accumulator—See Secondary
28 Steering Accumulator Remove and Install—If
Equipped. (Group 0960.)
• Left and Right 6WD Pump—See 6WD Pump
• 6WD Engagement Manifold—See 6WD Engagement
Manifold Remove and Install. (Group 0260.)
• Left and Right 6WD Motor—See 6WD Motor
• Auxiliary Hydraulic Attachments
IMPORTANT: Debris trapped then later dislodged

from oil coolers can cause premature
hydraulic/hydrostatic component failure.
If system contains a large amount of
debris oil cooler can not be completely
cleaned of contamination and it must be
replaced.
9. Replace hydraulic oil cooler when required. See

Hydraulic and Differential Oil Cooler Remove and
TM11207 (11MAY09) 21-2160-28

051809
PN=444
Hydraulic System
IMPORTANT: Disconnect hoses and lines from all tee

fittings before cleaning. Cleaning
sponge will become trapped in hose as
it passes through a tee fitting.
10. Disconnect and tag all hydraulic/hydrostatic hoses

and lines. Cap and plug all openings. See Hydraulic
System Component Location or See Hydraulic
System Component Location—EH Controls. (Group
9025-15.)
11. Clean all hydraulic lines and hoses using JDG1770

Ultra Clean hose kit.
IMPORTANT: Airborne foreign debris can cause

premature hydraulic/hydrostatic
component failure. Close all openings
with caps and plugs to minimize
additional contamination. 21
2160
12. Install a new hydraulic oil filter. See Replacing 29
Hydraulic Oil Filter. (Operator’s Manual.)
IMPORTANT: Damage to 6WD pump will result if

engine is started without oil in 6WD
pump case.
13. Fill 6WD pump case with oil (if equipped). See 6WD
Start-Up Procedure. (Group 9016-20.)
IMPORTANT: Trapped air suddenly compressed in a

cylinder can make enough heat to ignite
the oil used for assembly causing cap
seal and ring damage. Start with
cylinder rod retracted and the rod end
filled with clean oil. Operate function to
slowly extend rod. Procedure will
eliminate most of the air and reduce the
possibility of damage.
14. Install all cleaned components.
15. With all components installed fill tank to proper

operating level. See Changing Hydraulic Tank Oil.
TM11207 (11MAY09) 21-2160-29

051809
PN=445
Hydraulic System
16. Remove residual oil contaminants using Super Caddy

JDG10712. See General Oil Cleanup Procedure.
(Group 2160.)
BR70016,0000065 –19–21APR09–5/5
21
2160
30
TM11207 (11MAY09) 21-2160-30

051809
PN=446
Section 34
Grading Device
Contents
Page Page
Auxiliary Valve Section Disassemble and

Group 3415—Controls Linkage Assemble—EH Controls . . . . . . . . . . . . .34-3460-26
Control Linkage Remove and Install . . . . . . .34-3415-1 Wheel Lean, Articulation, Circle Side Shift,
Blade Pitch, and Blade Side Shift Valve
Group 3440—Frames Section Disassemble and Assemble . . . .34-3460-28
NeverGrease Pin Joints . . . . . . . . . . . . . . .34-3440-1 Wheel Lean, Articulation, Circle Side Shift,
Lift Arms Remove and Install . . . . . . . . . . . .34-3440-6 Blade Pitch, Blade Side Shift, and Steering
Saddle Locking Cylinder Remove and Valve Section Disassemble and
Install. . . . . . . . . . . . . . . . . . . . . . . . . . . .34-3440-10 Assemble—EH Controls . . . . . . . . . . . . .34-3460-30
Saddle Frame Remove and Install . . . . . . .34-3440-13 Circle Rotate Valve Section Disassemble and
Blade Pitch Frame Remove and Install . . . .34-3440-16 Assemble. . . . . . . . . . . . . . . . . . . . . . . . .34-3460-32
Draft and Circle Frame Remove and Circle Rotate Valve Section Disassemble
Install. . . . . . . . . . . . . . . . . . . . . . . . . . . .34-3440-20 and Assemble—EH Controls . . . . . . . . . .34-3460-34
Circle Adjustment . . . . . . . . . . . . . . . . . . . .34-3440-24 Return Check Poppets Disassemble and
Blade Side Shift Wear Inserts Remove Assemble. . . . . . . . . . . . . . . . . . . . . . . . .34-3460-36
34
and Install . . . . . . . . . . . . . . . . . . . . . . . .34-3440-29 Rotate Motor Disassemble and
Assemble. . . . . . . . . . . . . . . . . . . . . . . . .34-3460-37
Rotary Manifold Remove and Install . . . . . .34-3460-39
Group 3450—Circle Gearbox Blade Lift, Blade Pitch, and Circle Side
Circle Drive Gearbox Remove and Install . . .34-3450-1 Shift Cylinders Remove and Install . . . . .34-3460-42
Circle Drive Gearbox Disassemble and Blade Side Shift Cylinder Remove and
Assemble. . . . . . . . . . . . . . . . . . . . . . . . . .34-3450-4 Install. . . . . . . . . . . . . . . . . . . . . . . . . . . .34-3460-44
Circle Drive Gearbox (With Slip Clutch) Articulation Cylinders Remove and
Disassemble and Assemble. . . . . . . . . . .34-3450-10 Install. . . . . . . . . . . . . . . . . . . . . . . . . . . .34-3460-47

Grader Control Valve Remove and Install . . .34-3460-1
Draft Frame Mount Grader Control Valve
Remove and Install—EH Controls . . . . . . .34-3460-5
Cab Mount Grader Control Valve Remove
and Install—EH Controls . . . . . . . . . . . . . .34-3460-9
Grader Control Valve Disassemble and
Assemble. . . . . . . . . . . . . . . . . . . . . . . . .34-3460-12
Midmount Scarifier Valve Section
Disassemble and Assemble. . . . . . . . . . .34-3460-14
Disassemble and Assemble—EH
Controls . . . . . . . . . . . . . . . . . . . . . . . . . .34-3460-16
Blade Lift Valve Section Disassemble and
Assemble. . . . . . . . . . . . . . . . . . . . . . . . .34-3460-18
Assemble—EH Controls . . . . . . . . . . . . .34-3460-20
Auxiliary (With Float) Valve Section
Auxiliary (Without Float) Valve Section
770G,
051809
PN=1
Contents
34
770G,
051809
PN=2
Group 3415
Controls Linkage
Control Linkage Remove and Install
1
1
6
3 4 5 5 4 3 2
–UN–19MAR09
34
TX1057309
3415
TX1057309 1
Control Linkage Exploded View
1—Linkage Rod Cap Screw (8 3—Washer (2 used) 5—Control Lever (8 used) 7—Control Linkage Rod
used) 4—Bushing (16 used) 6—Control Lever Mounting
2—Control Lever Retaining Rod
Cap Screw (2 used)
NOTE: Standard control levers shown. Auxiliary 6. Remove control lever retaining cap screw (2) and
control levers will be mounted to the outside of washer (3).
the standard control levers. Removal and
installation of auxiliary control levers is the 7. Remove bushings (4) and control levers from
same. control lever mounting rod (6).
1. Lower all attachments to the ground. 8. Repair or replace components as needed.
2. Install articulation lock pin. 9. Install control levers and bushings as shown.
3. Turn battery disconnect switch to OFF position. 10. Install control lever cap screw and washer on
control lever mounting rod.
4. Remove linkage rod cap screws (1) from control
levers (5) and linkage rods (7) being removed. 11. Connect linkage rods to control levers with linkage
rod cap screws.
5. For removal of linkage rods from control valve, see
Grader Control Valve Remove and Install. (Group
3460.)
Continued on next page BR70016,000005B –19–18MAR09–1/2
TM11207 (11MAY09) 34-3415-1

051809
PN=449
Controls Linkage
12. If removed, connect linkage rods to control valve. 14. Turn battery disconnect switch to ON position.
See Grader Control Valve Remove and Install.
(Group 3460.) 15. Return machine to service.
13. Remove frame articulation lock pin.
BR70016,000005B –19–18MAR09–2/2
34
3415
2
TM11207 (11MAY09) 34-3415-2

051809
PN=450
Group 3440
Frames
NeverGrease Pin Joints
NOTE: Machines equipped with NeverGrease Pin Joints

do not require lubrication. Machines with this
option still require some service maintenance
points for grease in specified areas. These are
listed on the periodic maintenance chart on the
machine and in the operator’s manual listed under
service intervals.
IMPORTANT: Replacement of NeverGrease pin

joints require special methods for
replacement of bushings and shims. If
not followed the service life may be
decreased.
NeverGrease pin joints consist of two types. They are a

bushing (sliding element) type or a bearing (rolling
element or roller bearing) type. The application determines
what type is used. Both types require the same
replacement methods.
Throughout this information the term “bushing” will be

used to simplify procedures, with the exception when a
special instruction is needed for a certain type bushing 34
3440
such as “bearing type” it will be called out specifically. 1
Cleanliness
Cleanliness is very critical. The bushing must be kept

clean at all times. Nothing should come in contract with
the bushing surfaces which can contaminate or damage
the surfaces. If replacing with new service bushing keep in
clean shipping containers until installation. No lubrication
should be used on any surfaces of the bore, pin or
bushing itself when installing.
No lubrication should be used on any components of joint

including pin when servicing. This may decrease life of
joint.
Removal and Replacement of Pins
NeverGrease is a trademark of Deere & Company Continued on next page JW00603,0000102 –19–20JAN09–1/4
TM11207 (11MAY09) 34-3440-1

051809
PN=451
Frames
IMPORTANT: Removal and reinstallation of any pin

requires extra cleanliness attention to
the area supported by the pin. Any
debris inside of the joint will severely
affect the life of the joint.
Prior to pin removal, all material must be completely

removed from both ends of the pin and from the area
surrounding the structures connected by the pin by means
of a thorough power wash. Prior to pin reinstallation, any
remaining material on the pin or surrounding structure
must be removed. The NeverGrease bushing must also
be inspected and any material must be removed through
the use of compressed air or a clean dry rag only. Any
debris inside of the joint will severely affect the life of the
joint.
34
3440
2
TM11207 (11MAY09) 34-3440-2

051809
PN=452
Frames
Removal and Replacement of Bushings 1

2 3
IMPORTANT: Only use a hydraulic puller for removal
and installing bushing. Never use slide
hammer or impact type puller. 4
–UN–03APR07
Shimming is required where specified.
Some joints are more critical and will be
specified when required. Alignment in
TX1020245
the joint is important to prevent
premature wear.
Installing Bushing
1. Remove the old bushing from bore with Hydraulic
Puller Set D01047AA or Hydraulic Press D01013AA for
1 5 6
larger bushings.
2. Clean up bores thoroughly.
3. Check to make sure bore and bushing are perfectly
–UN–03APR07
clean and dry. Do not apply lubrication to any 10
components in joint.
2 9
4. Measure bore I.D. for size to determine what disk (3)
TX1020247
size will be required for installation of bushing. It must
pass through the bore I.D. for proper centering in 34
7 3440
frame bore with a hydraulic puller. 3
Bushing Type Joint
IMPORTANT: No lubrication should be used on any

1 6
components of joint including pin. This 8 8
may decrease life of joint.
5. Assemble Hydraulic Puller Set D01047AA and rod (4)

through center of bushing and bore and attach proper
–UN–03APR07
size disk (3). Support tooling to not come in contact
with bushing surfaces.
IMPORTANT: Must have the bushing aligned square
TX1020248
to the bore while installing. This will
keep from having misalignment in bore
and damage to bushing. Bushing Type Joint with External Split Seal (optional type seals
shown)
6. Make sure the bushing (2) is square to the bore. With
hydraulic puller install bushing into bore or frame. Keep 1—Boss
2—Bushing
perfectly square and aligned to bore while installing. 3—Disk
Center bushing in bore by pulling slightly past face of 4—Hydraulic Puller Rod
boss. Check each side to make sure bushing is 5—Shim (as required)
centered in bore. 6—Frame
7—Clearance
8—Split Seal (as required)
9—Pin
10—Internal Bushing Seal
TM11207 (11MAY09) 34-3440-3

051809
PN=453
Frames
7. Make sure pin (9) and bore are clean.
8. Align frame with bore.
9. Using different size shims (5) from service, place shims

at frame and boss joint for setting up proper clearance.
Center boss in frame (6) by shimming evenly. Add
shims as required to reduce clearance but not bind
joint.
Bearing type joints (roller bearing type) require a

specified clearance (7), see specification. Use a
smaller size shim as gauge to check final clearance
between boss and frame joint when required on
specified tolerances.
Specification
Bearing Type Joint (roller
bearing)—Clearance (maximum
total of both sides) ............................................................................. 1 mm
.040 in

parts of joint including pin. This may
decrease life of joint.
34
3440
4 10. Check for alignment, cleanliness of joint and install
clean pin. No interference should be felt while
installing pin when proper alignment is established.
If restriction or interference is noted make sure of

proper alignment in joint. Also, when using the
bushing type which has internal edge lip seals (10)
make sure they are in the retracted position to allow
for smooth pin installation. Note art work item (10).
11. Install external split seals (8) if required.
Split seals that have a larger lip are installed with

large O.D. lip away form bushing center. Seal must
be placed tight against boss face.
Split seals with O-ring configuration are placed tight

against the boss face. Tighten banding screw.
JW00603,0000102 –19–20JAN09–4/4
TM11207 (11MAY09) 34-3440-4

051809
PN=454
Frames
34
3440
5
TM11207 (11MAY09) 34-3440-5

051809
PN=455
Frames
Lift Arms Remove and Install
14 15
13 16
12
9 20
11 17
21
10
9
8
7 20 15
6
20
18
5 17
4 21
22 20
3 19
1
34 2 28
3440
6 14
13
12
9
11
29 30
23
24
25
24
10
27 26 9
24 2 8 –UN–26MAR09
25 1 7
6
5
24 4
TX1057378
TX1057378
Continued on next page BR70016,000005D –19–23MAR09–1/4
TM11207 (11MAY09) 34-3440-6

051809
PN=456
Frames
1—Saddle Locking Bar Cap 8—O-Ring (2 used) 16—Saddle-to-Lift Arm Pin 23—Saddle Locking Bar Ball
Screw (4 used) 9—Seal (4 used) Cap Screw (2 used) 24—Saddle Locking Bar Seal
2—Saddle Locking Bar Washer 10—Rear Yoke Bushing (2 17—Saddle-to-Lift Arm Pin (4 used)
(4 used) used) Washer (4 used) 25—Saddle Locking Bar
3—Left Lift Arm 11—Front Yoke Bushing (2 18—Saddle Mounting Pin Bushing (2 used)
4—Yoke Retainer Cap Screw used) 19—Saddle-to-Lift Arm Pin Nut 26—Saddle Locking Bar Pin
(4 used) 12—O-Ring (2 used) (2 used) 27—Saddle Locking Bar
5—Yoke Retainer Washer (4 13—Thrust Washer (2 used) 20—Saddle Bushing (4 used) 28—Right Lift Arm
used) 14—Blade Lift Yoke (2 used) 21—Saddle-to-Lift Arm Seal (4 29—Saddle Position Indicator
6—Yoke Retainer (2 used) 15—Saddle-to-Lift Arm Pin (2 used) 30—Saddle Position Indicator
7—Thrust Washer (2 used) used) 22—Saddle Nut
1. Lower all attachments to the ground. 9. Remove blade lift cylinders. See Blade Lift, Blade
Pitch, and Circle Side Shift Cylinders Remove and
2. Install articulation lock pin. Install. (Group 3460.)
3. Retract saddle locking pin.

10. Use an appropriate lifting device to support yokes
5. Remove circle side shift cylinder. See Blade Lift,
(14) during removal.
Blade Pitch, and Circle Side Shift Cylinders
Remove and Install. (Group 3460.) Specification
Blade Lift Yoke—Weight
(approximate) .............................................................................. 26 kg
CAUTION: Avoid crushing injury. Use 57 lb.
3440
11. Remove yoke retainer cap screws (4), yoke 7
6. Use an appropriate lifting device to support saddle retainer (6) and yoke (14) as shown. See
locking bar (27) during removal. NeverGrease Pin Joints. (Group 3440.)
Specification
Saddle Locking Bar—Weight CAUTION: Avoid crushing injury. Use
(approximate) .............................................................................. 50 kg appropriate lifting device.
110 lb.
12. Use an appropriate lifting device to support

7. Remove saddle locking bar cap screws (1), saddle
saddle-to-lift arm pins (15) during removal.
locking bar ball (23), saddle locking bar pin (26)
and saddle locking bar (27). See NeverGrease Specification
Pin Joints. (Group 3440.) Saddle Arm Pin—Weight
(approximate) .............................................................................. 32 kg
70 lb.
appropriate lifting device. 13. Remove saddle-to-lift arm pin cap screws (16) and
saddle-to-lift arm pin nuts (19).
8. Use an appropriate lifting device to support left and
right lift arms (3 and 28). 14. Remove saddle-to-lift arm pins (15), and lift arms
(3 and 28). See NeverGrease Pin Joints. (Group
Specification
Left or Right Lift Arm—Weight
3440.)
(approximate) ............................................................................ 132 kg
291 lb. 15. Repair or replace components as needed.
Continued on next page BR70016,000005D –19–23MAR09–2/4
TM11207 (11MAY09) 34-3440-7

051809
PN=457
Frames
16. If removed, install front and rear yoke bushings Specification

(11 and 10) to specified depth on both lift arms. Saddle Locking Bar Bushing
Installation—Depth...................................................... 10.5—12.5 mm
See NeverGrease Pin Joints. (Group 3440.) 0.41—0.49 in.
Specification
Front Yoke Bushing
25. Install saddle locking bar seals (24) into saddle
Installation—Depth......................................................... 8.4—10.4 mm locking bar (25) bushing holes.
0.33—0.41 in.
Rear Yoke Bushing 26. Apply a heavy coat of John Deere NEVER-SEEZ
Installation—Depth......................................................... 8.4—10.4 mm Lubricant or an equivalent to saddle locking bar
0.33—0.41 in.
holes.
17. If removed, install saddle bushings (20) to
27. Install saddle locking bar ball (23), saddle locking
specified depth on both saddle arms. See
bar pin (26) and saddle locking bar (27) to lift
NeverGrease Pin Joints. (Group 3440.)
arms as shown. See NeverGrease Pin Joints.
Specification
(Group 3440.)
Saddle Bushing Installation—
Depth .............................................................................. 7.5—9.5 mm 28. Install saddle locking bar cap screws (1) and
0.30—0.37 in. saddle locking bar washers (2).
18. Install lift arms (3 and 28), saddle-to-lift arm seals 29. Install circle side shift cylinders. See Blade Lift,
(21), and saddle-to-lift arm pins (15). See Blade Pitch, and Circle Side Shift Cylinders
NeverGrease Pin Joints. (Group 3440.) Remove and Install. (Group 3460.)
19. Install saddle-to-lift arm pin cap screws (16), 30. Turn battery disconnect switch to ON position.
34
3440
saddle-to-lift arm pin washers (17), and
8 saddle-to-lift arm pin nuts (19) as shown. 31. Remove articulation lock pin.
20. Install thrust washers (13), O-rings (12), and seals 32. Lock saddle locking bar pin in center hole of
(9) on both yokes (14). saddle locking bar.
21. Install yokes (14) in saddle arms (3 and 28). See 33. Install saddle position indicator (29) on right lift
NeverGrease Pin Joints. (Group 3440.) arm (28). Point indicator to middle drill point on
saddle (22). Adjust saddle position indicator nut
22. Install seals (9), thrust washers (7), O-rings (8), (30) to specified clearance.
retainers (6), washers (5) and cap screws (4) to
yoke (14), as shown. See NeverGrease Pin Specification
Joints. (Group 3440.) Rear Face of
Saddle-to-Indicator—Clearance ...................................... 6.4—9.5 mm
0.25—.0375 in.
23. Install blade lift cylinders. See Blade Lift, Blade
Pitch, and Circle Side Shift Cylinders Remove and
34. Calibrate machine sensors (GP machines only).
See Display Unit—Main Menu—Machine
Configuration (Grade Pro Machines Only).
24. If removed, install saddle locking bar bushings
(25) to specified depth. See NeverGrease Pin
NEVER-SEEZ is a trademark of Emhart Chemical Group. Continued on next page BR70016,000005D –19–23MAR09–3/4
TM11207 (11MAY09) 34-3440-8

051809
PN=458
Frames
BR70016,000005D –19–23MAR09–4/4
34
3440
9
TM11207 (11MAY09) 34-3440-9

051809
PN=459
Frames
Saddle Locking Cylinder Remove and Install
34
3440
10
–UN–14APR09
TX1057481
Saddle Locking Cylinder
1—Saddle 3—Shim (as required) 6—Saddle Locking Cylinder 7—Saddle Locking Cylinder
2—Saddle Locking Cylinder 4—Saddle Locking Cylinder Bracket Washers (6 used) Bracket Cap Screws (6
Bracket 5—Saddle Locking Cylinder used)
Cap Screws (6 used)
1. Lower all attachments to the ground. 2. Install articulation lock pin.
Continued on next page BR70016,000005F –19–23MAR09–1/3
TM11207 (11MAY09) 34-3440-10

051809
PN=460
Frames
3. Retract saddle locking pin. Specification

Saddle Locking Cylinder and
Bracket Combined—Weight
4. Turn battery disconnect switch to OFF position. (approximate) .............................................................................. 72 kg
136 lb.
CAUTION: To avoid injury from escaping
fluid under pressure, stop engine and relieve 10. Remove saddle locking cylinder bracket cap
the pressure in the system before screws (7) and washers (6).
disconnecting or connecting hydraulic or
other lines. Tighten all connections before 11. Remove saddle locking cylinder bracket and
applying pressure. cylinder from machine.
5. To relieve pressure in the system, slowly loosen 12. Remove saddle locking cylinder cap screws (5).
fittings on hoses at saddle locking cylinder (4).
NOTE: Note number and position of shims for ease of
6. Install vacuum pump to hydraulic oil tank to assembly.
Vacuum Pump Installation. (Group 2160.) 13. Remove saddle locking cylinder and shims (3)
from saddle locking cylinder bracket.
7. Label and disconnect hydraulic hoses at saddle
locking cylinder. Cap and plug all openings. See 14. Repair or replace components as needed.
Hydraulic System Component Location—EH 15. Install saddle locking pin cylinder and shims to
Controls for hydraulic line location. (Group saddle locking cylinder bracket.
9025-15.) 34
16. Install saddle locking cylinder cap screws. 3440
8. Disconnect saddle locking pin indicator switch 11
(S11). See Front Platform Harness (W25) 17. Connect hydraulic lines and electrical connector to
Component Location for switch location. (Group saddle lock pin cylinder. See Hydraulic System
9015-10.) Component Location or see Hydraulic System
Component Location—EH Controls for hydraulic
line location. (Group 9025-15.) See Front Platform
CAUTION: Avoid crushing injury. Use Harness (W25) Component Location for switch
appropriate lifting device. location. (Group 9015-10.)
9. Use an appropriate lifting device to support saddle 18. Tighten rear then front saddle locking bracket cap
locking cylinder bracket (2) and saddle locking screws to initial torque specification. Repeat
cylinder assembly during removal. sequence and tighten to final torque specification.
Specification Specification
Saddle Locking Cylinder Saddle Locking Bracket Cap
Bracket—Weight (approximate) .................................................. 50 kg Screws—Initial Torque............................................................. 28 N•m
110 lb. 21 lb-ft
Final Torque........................................................................... 229 N•m
Specification 169 lb-ft
Saddle Locking Cylinder
(approximate)—Weight ............................................................... 12 kg
26 lb.
Continued on next page BR70016,000005F –19–23MAR09–2/3
TM11207 (11MAY09) 34-3440-11

051809
PN=461
Frames
19. Measure distance between saddle locking cylinder (4)

and saddle locking bar pad (8). Add or remove shims
(3) as required. 8
4
Specification
Saddle Locking
–UN–09APR09
3
Cylinder-to-Saddle Locking Bar
Pad Gap (9)—Distance ............................................................ 0.3—2 mm 9
0.01—0.08 in.
TX1058129
(Group 9025-25.)
Saddle Locking Pin Gap
21. Turn battery disconnect switch to ON position. 3—Shim (as required)

4—Saddle Locking Cylinder
22. Remove articulation lock pin. 8—Saddle Locking Bar Pad
9—Saddle Locking Cylinder-to-Saddle Locking
Bar Pad Gap
34
3440
12
BR70016,000005F –19–23MAR09–3/3
TM11207 (11MAY09) 34-3440-12

051809
PN=462
Frames
Saddle Frame Remove and Install
34
3440
13
–UN–14APR09
TX1057479
Saddle Frame
1—Saddle Frame 2—Cap Screw (2 used) 3—Washer (2 used) 4—Saddle Pin
1. Remove lift arms. See Lift Arms Remove and 2. Remove saddle locking cylinder. See Saddle
Install. (Group 3440.) Locking Cylinder Remove and Install. (Group 3440.)
Continued on next page BR70016,000005E –19–23MAR09–1/2
TM11207 (11MAY09) 34-3440-13

051809
PN=463
Frames

9. Install saddle pin to main frame.
3. Use an appropriate lifting device to support saddle
10. Lift saddle frame onto machine. Mate saddle
frame (1) during removal.
frame to saddle pin.
Specification
Saddle Frame—Weight 11. Install cap screws and washers.
(approximate) ............................................................................ 109 kg
240 lb. 12. Install saddle locking cylinder. See Saddle Locking
4. Remove caps screws (2) and washers (3) from
saddle pin (4) and saddle frame. 13. Install lift arms. See Lift Arms Remove and Install.
(Group 3440.)
5. Remove saddle frame from machine.
CAUTION: Avoid crushing injury. Use Tank Oil Level. (Operator’s Manual.)
6. Use an appropriate lifting device to support saddle See Display Unit—Main Menu—Machine
pin during removal. Configuration (Grade Pro Machines Only).
Specification
Saddle Pin—Weight 16. Return machine to service.
34 (approximate) .............................................................................. 44 kg
3440 97 lb.
14
7. Remove saddle pin from main frame.
BR70016,000005E –19–23MAR09–2/2
TM11207 (11MAY09) 34-3440-14

051809
PN=464
Frames
34
3440
15
TM11207 (11MAY09) 34-3440-15

051809
PN=465
Frames
Blade Pitch Frame Remove and Install
34
3440
16
–UN–09APR09
TX1057642
Blade Pitch Frame

Continued on next page BR70016,0000060 –19–26MAR09–1/3
TM11207 (11MAY09) 34-3440-16

051809
PN=466
Frames
1—Cap Screw (2 used) 11—Nut (2 used) 20—Wear Insert 29—Snap Ring (2 used)
2—Washer (2 used) 12—Pin 21—Cap Screws (6 used) 30—Pin
3—Spacer (2 used) 13—Spacer 22—Washers (6 used) 31—Moldboard
4—Pin (2 used) 14—Washer 23—Blade Retainer (2 used) 32—Blade Pitch Frame
5—Bushing (6 used) 15—Cap Screw 24—Pin 33—Pin
6—Circle Frame 16—Blade Pitch Cylinder 25—Spacer 34—Spacer
7—Spacer (4 used) 17—Cap Screw (12 used) 26—Washer 35—Washer
8—Spacer (10 used) 18—Washer (12 used) 27—Cap Screw 36—Cap Screw
9—Spacer (2 used) 19—Wear Insert Retaining 28—Shims (as required) 37—Blade Side Shift Cylinder
10—Washer (2 used) Plate (4 used)
1. Move draft frame and moldboard (31) to one side to 9. Use an appropriate lifting device to support blade
allow for easier access to blade pitch frame. Lower pitch frame (32) during removal.
all attachments to ground.
Specification
Blade Pitch Frame—Weight
(approximate) ............................................................................ 245 kg
540 lb
NOTE: Note the number and position of washers (2
CAUTION: Avoid crushing injury. Use and 10) and spacers (3, 7, 8, and 9) to aid in
appropriate lifting device. assembly.
4. Use an appropriate lifting device to support 10. Remove cap screws (1), lock nuts (11), washers
moldboard (31) during removal. (2 and 10), spacers (3, 7, 8, and 9), and pin (4)
holding blade pitch frame (32) to circle frame (6).
Specification See NeverGrease Pin Joints. (Group 3440.) 34
Moldboard—Weight 3440
(approximate) ............................................................................ 953 kg 17
11. Remove blade pitch frame (32) from circle frame
2100 lb.
(6).
5. Remove blade side shift cylinder (37) from
12. Repair or replace components as required.
machine. See Blade Side Shift Cylinder Remove
13. Install bushing to specified depth. See
NeverGrease Pin Joints. (Group 3440.)
NOTE: Note the number and position of shims (28) to
aid in assembly. Specification
Bushing—Depth ........................................................... Flush—1.5 mm
6. Remove retainers (23) and shims (28) from blade Flush—0.06 in.
pitch frame (32).
NOTE: Spacers (7) are used to center the tilt frame
7. Remove moldboard (31) from pitch frame (32). between the circle frame. Spacers (8) are used
to reduce the excess play in the pins (4).
8. Remove blade pitch cylinder (16) from machine. Shims and washers should be able to rotate
See Blade Lift, Blade Pitch, and Circle Side Shift freely.
Cylinders Remove and Install. (Group 3460.)
14. Install pin (4) through circle frame, spacers (7), tilt
frame and spacers (8). See NeverGrease Pin
CAUTION: Avoid crushing injury. Use lifting
device.
TM11207 (11MAY09) 34-3440-17

051809
PN=467
Frames
15. Install cap screws (1), washers (2), spacers (3), 19. Place moldboard on lower wear inserts.
spacers (9), washers (10), and nuts (11). Tighten
to specification. 20. Install retainers (23) and shims (28) on to blade
pitch frame (32).
Specification
Blade Pitch Frame-to-Circle 21. Install cap screws (21).
Frame Cap Screw Nut—Torque ............................................. 800 Nm
590 lb-ft
22. Install blade side shift wear inserts. See Blade
16. Install blade pitch cylinder. See Blade Lift, Blade Side Shift Wear Inserts Remove and Install.
Pitch, and Circle Side Shift Cylinders Remove and (Group 3440.)
17. Place moldboard onto tilt frame and install retainer
and cap screws. 24. Remove articulation lock pin.

CAUTION: Avoid crushing injury. Use Tank Oil Level. (Operator’s Manual.)
18. Use an appropriate lifting device to support See Display Unit—Main Menu—Machine
moldboard (31) during installation. Configuration (Grade Pro Machines Only).
Specification
Moldboard—Weight
(approximate) ............................................................................ 953 kg 27. Return machine to service.
34
2100 lb.
3440
18
BR70016,0000060 –19–26MAR09–3/3
TM11207 (11MAY09) 34-3440-18

051809
PN=468
Frames
34
3440
19
TM11207 (11MAY09) 34-3440-19

051809
PN=469
Frames
Draft and Circle Frame Remove and Install
34
3440
20
–UN–02APR09
TX1057407
Draft and Circle Frame Removed

TM11207 (11MAY09) 34-3440-20

051809
PN=470
Frames
1—Cap Screw (18 used) 8—Shim (as required) 14—Circle Support 18—Wear Strip Retainer Cap
2—Bushing (18 used) 9—Draft Frame Retainer 15—Horizontal Wear Strip (6 Screw (12 used)
3—Cap Screw (10 used) 10—Draft Frame used) 19—Support-to-Draft Frame
4—Lock Washer (10 used) 11—Circle Frame 16—Wear Strip Retainer (6 Cap Screw (12 used)
5—Draft Frame Retainer 12—Shims (as required) used) 20—Support-to-Draft Frame
6—Washer (6 used) 13—Vertical Wear Strip (15 17—Wear Strip Retainer Washer (12 used)
7—Cap Screw (6 used) used) Washer (12 used)
1. Remove moldboard and blade pitch frame. See 8. If equipped—disconnect electrohydraulic (EH) draft
Blade Pitch Frame Remove and Install. (Group frame harness (W40) from main frame harness
3440.) (W39). See Electrohydraulic (EH) Main Frame
Harness (W39) Component Location. (Group
9015-10.)
9. If equipped—Remove draft frame mount grader
control valve. See Draft Frame Mount Grader
2. Use an appropriate lifting device to support circle
Control Valve Remove and Install—EH Controls.
frame (11) during removal.
(Group 3460.)
Specification
Circle Frame—Weight 10. Remove rotary manifold. See Rotary Manifold
(approximate) ............................................................................ 990 kg Remove and Install. (Group 3460.)
2183 lb.
11. Remove circle drive gearbox and rotate motor.
3. Remove support-to-draft frame cap screws (19) and See Circle Drive Gearbox Remove and Install.
circle supports (14). (Group 3450.)
34
4. Remove circle frame (11) from machine. 3440
CAUTION: Avoid crushing injury. Use 21
fluid under pressure, stop engine and relieve 12. Use an appropriate lifting device to support draft
the pressure in the system before frame (10) during removal.
other lines. Tighten all connections before Specification
applying pressure. Draft Frame—Weight
(approximate) .......................................................................... 1155 kg
2550 lb.
fittings all hydraulic lines on the draft frame.
13. Remove blade lift and blade side shift cylinders.
See Blade Lift, Blade Pitch, and Circle Side Shift
6. Install vacuum pump to hydraulic oil tank to
Cylinders Remove and Install. (Group 3460.)
NOTE: Note the number and position of shims (8) for
ease of assembly.
7. Disconnect and tag all hydraulic lines from draft
frame. Cap and plug all openings. See Hydraulic
14. Remove cap screws (3) from draft frame retainer
System Component Location or see Hydraulic
(9).
System Component Location—EH Controls. (Group
9025-15.)
TM11207 (11MAY09) 34-3440-21

051809
PN=471
Frames
15. Remove draft frame from machine. 25. Remove vacuum pump from hydraulic oil tank.
16. Repair or replace components as needed. Installation. (Group 2160.)
17. Install shims (8) and retainer (9) to draft frame ball
assembly to permit turning by hand. Lubricate
assembly. Apply John Deere NEVER-SEEZ
Lubricant or an equivalent to retainer (5).
26. Use an appropriate lifting device to lift circle frame
(11) into place under draft frame (10).
18. Adjust ball assembly end play to specification. Add
or remove shims (8) as required. Specification
Circle Frame—Weight
Specification (approximate) ............................................................................ 990 kg
Draft Frame Ball Assembly— 2183 lb.
Maximum End Play.................................................................. 1.5 mm
0.059 in.
27. Install circle supports (14), support-to-draft frame
washers (20), and support-to-draft frame cap
19. Connect blade lift and blade side shift cylinders to
screws (19).
draft frame. See Blade Lift, Blade Pitch, and Circle
Side Shift Cylinders Remove and Install and see
IMPORTANT: Prevent possible machine damage
Blade Side Shift Cylinder Remove and Install.
due to a misaligned circle frame. If
(Group 3460.)
cap screws (20) are overtightened,
support will not move when support
20. Install circle drive gearbox and rotate motor. See
is adjusted. If cap screws are too
Circle Drive Gearbox Remove and Install. (Group
34 loose, support will move excessively
3440 3450.)
when final torque is applied.
22
21. Install rotary manifold. See Rotary Manifold
28. Tighten support-to-draft frame cap screws to initial
torque specification.
22. If equipped—install draft frame mount grader Specification
control valve. See Draft Frame Mount Grader Support-to-Draft Frame Cap
Control Valve Remove and Install—EH Controls. Screw (initial adjustment)—
(Group 3460.) Torque............................................................................... 27—55 N•m
20—40 lb-ft
23. If equipped—connect electrohydraulic (EH) draft

frame harness (W40). See Electrohydraulic (EH) 29. Adjust circle position on draft frame. See Circle
Main Frame Harness (W39) Component Location. Adjustment. (Group 3440.)
(Group 9015-10.)
30. Install moldboard and blade pitch frame. See
24. Connect all hydraulic lines to draft frame. See Blade Pitch Frame Remove and Install. (Group
Hydraulic System Component Location or see 3440.)
Hydraulic System Component Location—EH
Controls. (Group 9025-15.)
NEVER-SEEZ is a trademark of Emhart Chemical Group. Continued on next page BR70016,0000061 –19–26MAR09–3/4
TM11207 (11MAY09) 34-3440-22

051809
PN=472
Frames
31. Check hydraulic oil level. See Checking Hydraulic Configuration (Grade Pro Machines Only).
Tank Oil Level. (Operator’s Manual.) (Operator’s Manual.)
32. Calibrate machine sensors (GP machines only). 33. Return machine to service.
See Display Unit—Main Menu—Machine
BR70016,0000061 –19–26MAR09–4/4
34
3440
23
TM11207 (11MAY09) 34-3440-23

051809
PN=473
Frames
Circle Adjustment 11
1
NOTE: It may be easier and less time consuming to
replace wear strips than adjust circle. If circle 10
adjustment is at factory setting, replacing wear
strips should adjust circle back to original
–UN–01APR09
specifications.
9
2
1. Measure the thickness of all wear strips (1 and 5) 8
before adjusting circle clearance. If wear strips are 3
TX1057737
7 5
worn to less than minimum thickness, replace wear 6 4
strips.
Circle Support Cross Section
Specification
Vertical Wear Strips (1)—New
Thickness......................................................................................... 16 mm
0.63 in. 12
Minimum Thickness ........................................................................ 11 mm
0.433 in. 3
Horizontal Wear Strips (5)—New
–UN–14APR09
Thickness........................................................................................... 8 mm
0.31 in.
Minimum Thickness ........................................................................... 2 mm 13
0.08 in.
TX1057738
2. If all wear strips are within specification, raise blade
34
3440
and rotate 90° to main frame. Turn circle drive pinion
24 (13) until a tooth is pointed directly forward and into the Circle Drive Pinion-to-Circle Frame Distance
root of the circle gear as shown on the drawing
illustrating pinion-to-circle distance (12). 1—Vertical Wear Strip (15 used)
2—Vertical Clearance
3—Circle Frame
3. Ensure that the circle frame (3) is rearward as far as it
4—Horizontal Clearance
will go in the draft frame (11). 5—Horizontal Wear Strip (6 used)
6—Support-to-Draft Frame Cap Screw (12 used)
4. Measure the distance between circle drive 7—Circle Support (6 used)
pinion-to-circle frame (12). 8—Jam Nut
9—Adjustment Cap Screw
5. Compare distance to specifications. 11—Draft Frame
12—Circle Drive Pinion-to-Circle Frame Distance
Specification 13—Circle Drive Pinion
Circle Drive Pinion-to-Circle
Frame—Distance (12) .............................................................. 76—79 mm
3.0—3.11 in.
6. If circle drive pinion-to-circle frame distance is out of

specification, adjust the two front supports (7) to set
the circle drive pinion-to-circle frame minimum distance
(12):
a. Loosen support-to-draft frame cap screws (6).
TM11207 (11MAY09) 34-3440-24

051809
PN=474
Frames
b. Tighten support-to-draft frame cap screws (6) to

initial adjustment torque.
Specification
Support-to-Draft Frame Cap
Screw (initial adjustment)—
Torque ..................................................................................... 27—55 N•m
20—40 lb-ft
IMPORTANT: Prevent possible machine damage due

to a misaligned circle frame. If
support-to-draft frame cap screws (6)
are overtightened, support will not
move when adjustment cap screw (9) is
adjusted. If support-to-draft frame cap
screws are too loose, support will move
excessively when final torque is
applied.
c. Loosen jam nuts (8).
d. Use adjustment cap screws (9) to move supports to

achieve the minimum pinion-to-circle distance (12).
34
3440
e. Tighten support-to-draft frame cap screws (6). 25
f. Hold adjustment cap screws (9) in place and tighten

jam nuts (8).
TM11207 (11MAY09) 34-3440-25

051809
PN=475
Frames
NOTE: Circle frame must be centered within the draft

frame to ensure an accurate horizontal clearance
measurement.
7. Center the circle frame (3) within the draft frame using
a pry bar or C-clamps. Distance (14) from locating hole 3
(15) to the circle frame (3) must be within 3 mm (0.12
in.) of each other at both rear support locations.
14
8. With the circle pulled back against the two front
supports and centered with the two rear supports,
adjust the horizontal clearance (4) to specification at all
support locations:
Specification
Horizontal—Clearance (4) ................................................. 0.25—0.76 mm 15
0.010—0.030 in.
a. Loosen support-to-draft frame cap screws (6).
–UN–14APR09
IMPORTANT: Prevent possible machine damage due
to a misaligned circle frame. If
support-to-draft frame cap screws (6)
TX1057739
are overtightened, support will not
34 move when adjustment cap screw (9) is
3440 adjusted. If support-to-draft frame cap Rear Support Location (1 of 2)
26 screws are too loose, support will move
excessively when final torque is 3—Circle Frame
14—Locating Hole-to-Circle Dimension
applied.
15—Locating Hole
b. Tighten support-to-draft frame cap screws to initial

adjustment torque.
Specification
Screw (initial adjustment)—
Torque ..................................................................................... 27—55 N•m
20—40 lb-ft
c. Loosen jam nuts (8).
d. Use adjustment cap screws (9) to move supports to

achieve horizontal clearance (4).
e. Tighten support-to-draft frame cap screws (6).
TM11207 (11MAY09) 34-3440-26

051809
PN=476
Frames
f. Hold adjustment cap screws (9) in place and tighten

jam nuts (8).
NOTE: All of the vertical clearance at the lower vertical

wear strips allows for an accurate measurement
of vertical clearance (2).
9. Place all of the vertical clearance at the lower vertical

wear strips:
34
3440
27
TM11207 (11MAY09) 34-3440-27

051809
PN=477
Frames
a. Raise front of machine off of the ground using the 11

blade lift functions. Install appropriate support 1
device under machine to secure front of circle frame
(3) against upper vertical wear strips. See Machine 10
Specifications for machine weight. (Operator’s
Manual.)
–UN–01APR09
b. Tilt the top of the blade (16) forward. Lower the 9
2
blade to push rear of circle up against upper vertical 8
wear strips. 3
TX1057737
7 5
6 4
10. Measure and adjust each support individually. Add or
remove shims (10) to adjust vertical clearance (2) to Circle Support Cross Section
specification.
Specification 12
Vertical—Clearance (2) ......................................................... 0.2—1.0 mm
0.01—0.04 in.
3
IMPORTANT: Prevent possible machine damage.
–UN–14APR09
Ensure that shims will clear circle teeth
while circle is being rotated. 13
11. Check for adequate clearance between shims and
TX1057738
34 circle teeth. Tighten the support-to-draft frame cap
3440 screws to specification.
28 Circle Drive Pinion-to-Circle Frame Distance
Specification
Screw—Final Torque .................................................................... 850 N•m
625 lb-ft
12. After all adjustments are made, rotate the blade

through working range in both directions to check for
–UN–16APR09
binding. If circle binds, stop circle at the tight spot.
1—Vertical Wear Strip (15 used)
2—Vertical Clearance
TX1058283A
3—Circle Frame
4—Horizontal Clearance
5—Horizontal Wear Strip (6 used)
6—Support-to-Draft Frame Cap Screw (12 used)
7—Circle Support (6 used) Vertical Clearance Measurement Position
8—Jam Nut
9—Adjustment Cap Screw
11—Draft Frame
12—Circle Drive Pinion-to-Circle Frame Distance
13—Circle Drive Pinion
16—Blade
TM11207 (11MAY09) 34-3440-28

051809
PN=478
Frames
13. Adjust any supports that are binding until circle

rotates freely.
14. Calibrate machine sensors (GP machines only). See

Display Unit—Main Menu—Machine Configuration
(Grade Pro Machines Only). (Operator’s Manual.)
JW00603,0000171 –19–21JAN09–6/6
Blade Side Shift Wear Inserts Remove and Install
34
2 4
3 3440
1 5 29
6
–UN–18MAR09
8
7
TX1057264 TX1057264
Blade Side Shift Wear Inserts
1—Blade Pitch Frame 4—Wear Insert Adjustment 6—Top Wear Insert (2 used) 8—Bottom Wear Insert (4
2—Top Wear Insert Cap Cap Screws (4 used) 7—Bottom Wear Insert used)
Screws (12 used) 5—Jam Nut (4 used) Retaining Cap Screws (12
3—Top Wear Insert Retaining used)
Plate (4 used)
TM11207 (11MAY09) 34-3440-29

051809
PN=479
Frames
NOTE: Right blade side shift wear inserts shown

removed. Removal for left blade side shift wear
inserts is similar.
NOTE: Wear inserts need to be replaced when
–UN–16APR09
moldboard is too loose and there is no adjustment
left in the system.
1. Rotate circle until moldboard is approximately 90° to
TX1058284A
main frame.
2. Slide the moldboard (9) to the approximate center of

the blade pitch frame. Blade Side Shift Remove and Install Position
9—Moldboard
3. Center the circle side shift so the blade lift cylinders 10—Support Block (2 used)
are approximately vertical with the cutting edge on the 11—Bottom Moldboard Slide Bar
ground. 12—Top Moldboard Slide Bar
4. Adjust blade pitch so the top moldboard slide bar (12)

is directly above the bottom moldboard slide bar (11).
5. Raise blade pitch frame (1) to take the weight of the

blade off the top wear inserts.
34 6. Loosen jam nut (5) and turn adjusting cap screws (4)
3440
30
out.
8. Remove top wear insert retaining plates (3).
9. Remove top wear insert (6) from blade pitch frame.
10. Clean and inspect top wear inserts. Replace inserts if

needed.
11. Install top wear inserts in blade pitch frame.
12. Install top wear insert retaining plates.
13. Apply NEVER-SEEZ to threads of cap screws (2).
NEVER-SEEZ is a trademark of Bostik Findley, Inc. Continued on next page JW00603,0000172 –19–21JAN09–2/3
TM11207 (11MAY09) 34-3440-30

051809
PN=480
Frames
14. Install cap screws (2) and tighten to specification.
Specification
Top Wear Insert Cap Screws—
Torque ............................................................................................ 59 N•m
43 lb-ft
15. Lower blade onto support blocks (10) to take the load
of the blade off the bottom wear inserts (8).
17. Remove bottom wear insert from blade pitch frame.
18. Clean and inspect bottom wear inserts. Replace

inserts if needed.
19. Install bottom wear inserts in blade pitch frame.
20. Apply NEVER-SEEZ to threads of cap screws (7).
Specification
Bottom Wear Insert Cap
Screws—Torque ............................................................................. 59 N•m 34
43 lb-ft 3440
31
22. Raise blade off of support blocks.
23. Slide blade left and right several times to seat blade
slide rail in bottom wear inserts.
24. After blade side shift wear insert remove and install
procedure has been performed blade side shift wear
insert adjustment must be performed. Perform Blade
Side Shift Wear Insert Adjustment. (Operator’s
Manual.)
25. Calibrate machine sensors (GP machines only). See

Display Unit—Main Menu—Machine Configuration
(Grade Pro Machines Only). (Operator’s Manual.)
NEVER-SEEZ is a trademark of Bostik Findley, Inc. JW00603,0000172 –19–21JAN09–3/3
TM11207 (11MAY09) 34-3440-31

051809
PN=481
Frames
34
3440
32
TM11207 (11MAY09) 34-3440-32

051809
PN=482
Group 3450
Circle Gearbox
Circle Drive Gearbox Remove and Install

34
3450
1
TM11207 (11MAY09) 34-3450-1

051809
PN=483
Circle Gearbox
4. Remove plugs (4, 7, and 8). Drain circle drive gearbox

(5). See Drain and Refill Capacities. (Operator’s
Manual.)

6. Disconnect and tag hydraulic hoses (11) from circle

rotate motor (1). Close all openings using caps and
plugs. See Hydraulic System Component Location or
see Hydraulic System Component Location—EH
Controls for circle rotate motor location. (Group
–UN–06APR09
9025-15.)
7. Remove circle rotate motor (1) from motor flange.
TX1057947A
8. Remove cap screws (6) and nut (10) holding circle
drive gearbox (5) to draft frame (9).
Circle Drive Gearbox

CAUTION: Prevent crushing injury. Use
appropriate lifting device. 1—Circle Rotate Motor
Specification 3—Nut (2 used)
34 4—Fill Plug
Circle Drive Gearbox—Weight
3450 5—Circle Drive Gearbox
(approximate)................................................................................... 150 kg
2 6—Mounting Cap Screw (3 used)
330 lb
7—Oil Level Plug
8—Oil Drain Plug
9. Use appropriate lifting device to remove circle drive 9—Draft Frame
gearbox (5) from machine. 10—Nut
11—Hydraulic Hoses (2 used)
10. Inspect and replace parts as necessary. See Circle
Drive Gearbox Disassemble and Assemble or See
Circle Drive Gearbox (With Slip Clutch) Disassemble
CAUTION: Prevent crushing injury. Use

Specification
Circle Drive Gearbox—Weight
(approximate)................................................................................... 150 kg
330 lb
11. Use appropriate lifting device to install circle drive

gearbox (5) to machine.
TM11207 (11MAY09) 34-3450-2

051809
PN=484
Circle Gearbox
12. Secure circle drive gearbox to draft frame with cap

screws (6) nut (10).
13. Install drain plug (8).
14. Fill housing with oil through fill plug (4) to oil level
plug (7). See Drain and Refill Capacities. (Operator’s
Manual.)
15. Install circle rotate motor (1) to motor flange.
16. Connect hydraulic hoses to circle rotate motor. See

Hydraulic System Component Location—EH Controls
for circle rotate motor location. (Group 9025-15.)

(Group 2160.)
20. Check hydraulic oil level. See Checking Hydraulic 34

3450
Tank Oil Level. (Operator’s Manual.) 3
BR70016,0000062 –19–02APR09–3/3
TM11207 (11MAY09) 34-3450-3

051809
PN=485
Circle Gearbox
Circle Drive Gearbox Disassemble and Assemble
34
3450
4
–UN–24OCT08
TX1050388
Circle Drive Gearbox

TM11207 (11MAY09) 34-3450-4

051809
PN=486
Circle Gearbox
1—Bearing Cone 10—Gear Case 23—Retaining Plate 31—Cap Screw (4 used)

2—Seal 11—Pinion Shaft 24—Thrust Washer (2 used) 32—Cap Screw (15 used)
3—Pressure Relief Fitting 12—Cover 25—O-Ring 33—Adapter
4—Bearing Cone 13—Worm Gear 26—Cap 34—O-Ring
5—Bearing Cone (2 used) 14—Motor Flange 27—Fill Plug 36—Circle Drive Gear Box
6—Bearing Cup (2 used) 15—Circle Gear 28—O-Ring (2 used) 37—Cap Screw
7—Bearing Cup 16—Shim (as required) 29—Plug (2 used) 38—Cap Screw (2 used)
8—Bearing Cup 19—Shim (as required) 30—Washer (4 used) 39—Nut
9—O-Ring 22—Plug
1. Park machine on flat level surface and lower all 10. Pull bearing cone (1) from pinion shaft (11).
11. Pull bearing cup (7) from cover (12) and bearing
2. Install articulation lock pin. cup (8) from gear case (10).
3. Turn battery disconnect switch to OFF position. 12. Remove seal (2) from gear case (10).
4. Remove circle drive gearbox from the draft frame. 13. Remove cap screws (31) and motor flange (14)
See Circle Drive Gearbox Remove and Install. from gear case (10).
(Group 3450.)
NOTE: Note number and position of shims (16) to aid
5. Remove cap (26). in assembly.
NOTE: Note number and position of shims (19) to aid 14. Remove shims (16) and O-ring (25).
in assembly.
15. Remove worm gear (13) with bearing cones (5). 34
6. Remove cap screws (32), retaining plate (23) and 3450
shims (19) from pinion shaft (11). 16. Pull bearing cones (5) from worm gear (13). 5
7. Remove cap screws (32) from cover (12). 17. If inner bearing cups (6) are replaced, plug (22)
must be tapped out of gear case (10) to drive
IMPORTANT: Prevent possible component bearing cup out.
damage. Make sure the pinion shaft
does not fall out of the bottom of the 18. Pull bearing cups (6) from gear case (10) and
gearbox when removing the cover motor flange (14).
and bearing cone.
8. Install three cap screws in tapped holes in cover
(12) and pull bearing cone (4) and bearing cup (7) 20. Determine worm gear (13) preload as follows:
with cover (12) from pinion shaft (11).
a. Install bearing cups (6) in gear case (10) and
9. Remove O-ring (9), thrust washers (24), circle gear motor flange (14).
(15) and shaft (11) with bearing cone (1).
TM11207 (11MAY09) 34-3450-5

051809
PN=487
Circle Gearbox
b. Install bearing cones (5) on worm gear (13).
c. Install worm gear (13) with bearing cones (5) in

gear case (10).
d. Position shims (16) removed during disassembly

between bearing cup (6) and motor flange (14).
e. Install O-ring (25) on motor flange (14).
f. Install motor mounting flange (14).
g. Tighten cap screws (31) finger tight.
–UN–27SEP99
NOTE: Shims come in 0.1 mm (0.004 in.) 0.2 mm (0.008
in.) and 0.5 mm (0.020 in.) thickness.
h. Add or remove shims (16) to obtain specified
T123980
worm gear end play.
Specification
Worm Gear—End Play ......................................................... 0—0.125 mm 5—Bearing Cone (2 used)
0—0.005 in. 10—Housing
13—Worm Gear
34
3450
6 i. Install plug (22).
21. Install bearing cup (8) in gear case (10).
22. Press bearing cone (1) on circle pinion shaft (11).
23. Install circle pinion shaft (11) in gear case (10).
24. Manually rotate circle gear (15) and worm gear (13)
to allow circle gear to fall into position.
25. Install lower thrust washer (24) and circle gear (15)
into gear case (10) aligning with worm gear (13).
26. Tighten cap screws (31) to specification.
Specification
Motor Flange-to-Gear Case Cap
Screw—Torque ............................................................................. 130 N•m
95 lb-ft
27. Install upper thrust washer (24).
28. Install bearing cup (7) into cover (12).
TM11207 (11MAY09) 34-3450-6

051809
PN=488
Circle Gearbox
29. Apply pipe sealant to threads of cap screws that

protrude through the cover into the oil cavity of gear
case.
30. Install O-ring (9) and cover (12) with cap screws (32).
Specification
Cover-to-Gear Case Cap
Screw—Torque ............................................................................... 70 N•m
51 lb-ft
31. Place bearing cone (4) and retaining washer (23) onto
shaft (11).
32. Pull bearing cone (4) onto pinion shaft (11) using cap
screws (32).
33. Remove cap screws (32) and retaining washer (23).
34. Install shims (19), retaining washer (23), cap screws

(32) and check for end play with dial indicator.
35. Add and subtract shims as required to set bearing

preload to specification. 34
3450
Specification 7
Shaft (worn) Bearing Preload—
End Play ................................................................................... 0.0675 mm
0.0025 in.
36. Install retaining washer (23) and cap screws (32).

Specification
Retaining Washer-to-Pinion Shaft
Cap Screw—Torque ....................................................................... 70 N•m
51 lb-ft
37. Apply PM37465 RTV Silicone Form-In-Place Gasket

to cap (26). Install cap.
IMPORTANT: Prevent possible seal damage due to

incorrect installation. Install oil seal to
the outer and inner case at the same
time. Use JDG1009 Seal Installer to
ensure correct installation.
38. Install seal (2) in gear case (10) around shaft (11)
from bottom of gearbox using JDG1009 Seal Installer.
TM11207 (11MAY09) 34-3450-7

051809
PN=489
Circle Gearbox
39. Install circle drive gearbox to draft frame. See Circle

Drive Gearbox Remove and Install. (Group 3450.)

JW00603,0000174 –19–21JAN09–5/5
34
3450
8
TM11207 (11MAY09) 34-3450-8

051809
PN=490
Circle Gearbox
34
3450
9
TM11207 (11MAY09) 34-3450-9

051809
PN=491
Circle Gearbox
Circle Drive Gearbox (With Slip Clutch) Disassemble and Assemble
34
3450
10
–UN–12NOV08
TX1050389
Circle Drive Gearbox (with slip clutch)

TM11207 (11MAY09) 34-3450-10

051809
PN=492
Circle Gearbox
1—Bearing Cone 13—Worm Gear 27—Fill Plug 39—Shim (as required)

2—Seal 14—Motor Flange 28—O-Ring (2 used) 42—O-Ring
3—Pressure Relief Fitting 15—Circle Gear 29—Plug (2 used) 43—Cap Screw (6 used)
4—Bearing Cone 16—Shim (as required) 30—Cap Screw (12 used) 44—Belleville Spring
5—Bearing Cone (2 used) 17—Washer (4 used) 31—Cap Screw (4 used) 45—Separator Plate (13 used)
6—Bearing Cup (2 used) 18—Nut 32—Cap Screw (3 used) 46—Clutch Disk (14 used)
7—Bearing Cup 19—Shim (as required) 33—Adapter 47—Cap Screw (3 used)
8—Bearing Cup 22—Plug 34—O-Ring 48—O-Ring
9—O-Ring 23—Retaining Plate 35—Splined Hub 50—Circle Drive Gear Box
10—Gear Case 24—Thrust Washer (2 used) 36—Backing Plate 51—Cap Screw (2 used)
11—Pinion Shaft 25—O-Ring 37—Pressure Plate 52—Cap Screw
12—Cover 26—Cover 38—Bearing Quill
1. Park machine on flat level surface and lower all 11. Remove separator plates (45), clutch disks (46),
attachments to ground. splined hub (35), circle gear (15), thrust washer
(24), backing plate (36), and shaft (11) with
2. Install articulation lock pin. bearing cone (1).
3. Turn battery disconnect switch to OFF position. 12. Pull bearing cone (1) from shaft (11).
4. Remove circle drive gearbox from draft frame. See 13. Pull bearing cup (7) from cover (12) and bearing
Circle Drive Gearbox Remove and Install. (Group cup (8) from gear case (10).
3450.)
14. Remove seal (2) from gear case (10).
5. Remove cap screws (43) and cover (26).
15. Remove cap screws (31) and motor flange (14)
6. Remove cap screws (32), retaining plate (23) and from gear case (10). 34
3450
shims (39) from bearing quill (38). 11
NOTE: Note number and position of shims (16) to aid
NOTE: Note number and position of shims (19) to aid in assembly.
in assembly.
16. Remove shims (16) and O-ring (25).
7. Remove cap screws (47), bearing (4), bearing quill
(38), and shims (19) from pinion shaft (11). 17. Remove worm gear (13) with bearing cones (5).
8. Remove cap screws (30) from cover (12). 18. Pull bearing cones (5) from worm gear (13).
IMPORTANT: Prevent possible component 19. If bearing cups (6) are replaced, plug (22) must be
damage. Make sure the pinion shaft tapped out of gear case (10) to drive bearing cup
does not fall out of the bottom of the out.
gearbox when removing the cover
and bearing cone. 20. Pull bearing cups (6) from gear case (10) and
motor flange (14).
9. Install three cap screws (30) in tapped holes in
cover (12) and pull bearing cup (7) with cover (12) 21. Repair or replace components as needed.
from shaft (11).
22. Determine worm gear (13) preload as follows:
10. Remove O-ring (9), Belleville spring (44), thrust
washer (24), and pressure plate (37).
TM11207 (11MAY09) 34-3450-11

051809
PN=493
Circle Gearbox
a. Install bearing cups (6) in gear case (10) and

motor flange (14).
JW00603,0000175 –19–21JAN09–3/24
b. Install bearing cones (5) on worm gear (13).
c. Install worm gear (13) with bearing cones (5) in

gear case (10).
d. Position shims (16) removed during disassembly

between bearing cup (6) and motor flange (14).
e. Install O-ring (25) on motor flange (14).
f. Install motor flange (14).
g. Tighten cap screws (31) finger tight.
–UN–27SEP99
NOTE: Shims come in 0.1 mm (0.004 in.) 0.2 mm (0.008
in.) and 0.5 mm (0.020 in.) thickness.
34
h. Add or remove shims (16) to obtain specified
T123980
3450
12 worm end play.
Specification
Worm—End Play .................................................................. 0—0.125 mm 5—Bearing Cone (2 used)
0—0.005 in. 10—Housing
13—Worm Gear
i. Install plug (22).
23. Install bearing cup (8) in gear case (10).
24. Press bearing cone (1) on circle pinion shaft (11).
25. Install circle pinion shaft (11) in gear case (10).
TM11207 (11MAY09) 34-3450-12

051809
PN=494
Circle Gearbox
26. Install backing plate (36).
36—Backing Plate
–UN–16SEP99
T123984
34
3450
13
JW00603,0000175 –19–21JAN09–5/24
NOTE: Make sure thrust washer (24) is centered and

seated on lower surface of backing plate.
28. Manually rotate circle gear (15) and worm gear (13)
to allow circle gear to fall into position.
24—Thrust Washer
–UN–16SEP99
T123985
TM11207 (11MAY09) 34-3450-13

051809
PN=495
Circle Gearbox
29. Install circle gear (15).
30. Tighten cap screws (31) to specification.
Specification
Motor Mounting Flange Cap
Screw—Torque ............................................................................ 130 N•m
96 lb-ft
15—Circle Gear
–UN–16SEP99
T123986
34
3450
14
JW00603,0000175 –19–21JAN09–7/24
31. Install splined hub (35) with inside recessed section

towards gear end of circle pinion shaft (11).
35—Splined Hub
–UN–16SEP99
T123987
TM11207 (11MAY09) 34-3450-14

051809
PN=496
Circle Gearbox
32. Install 14 clutch disks (46) and 13 separator plates

(45). Starting with a clutch disk, alternate clutch disks
and separator plates during installation.
45—Plate (13 used)

46—Clutch Disk (14 used)
–UN–16SEP99
T123989
34
3450
15
–UN–16SEP99
T123988
TM11207 (11MAY09) 34-3450-15

051809
PN=497
Circle Gearbox
33. Install pressure plate (37).
37—Pressure Plate
–UN–16SEP99
T123990
34
3450
16
JW00603,0000175 –19–21JAN09–10/24
NOTE: Make sure thrust washer is centered and seated

on lower surface of pressure plate.
24—Thrust Washer
–UN–16SEP99
T123991
TM11207 (11MAY09) 34-3450-16

051809
PN=498
Circle Gearbox
35. Install Belleville spring (44) concave side down.
36. Install bearing cup (7) in cover (12).
37. Apply pipe sealant to threads of cap screws that

protrude through the cover into the oil cavity of gear
case.
38. Install O-ring (9) and cover (12) with cap screws (30).
Specification
Cover-to-Gear Case Cap
Screw—Torque ............................................................................... 70 N•m
–UN–16SEP99
51 lb-ft
44—Belleville Spring
T123992
34
3450
17
JW00603,0000175 –19–21JAN09–12/24
39. Determine Belleville spring (44) preload and circle

pinion shaft (11) end play as follows:
a. Install bearing cone (4) on bearing quill (38).
4—Bearing Cone
38—Bearing Quill
–UN–16SEP99
T123995
TM11207 (11MAY09) 34-3450-17

051809
PN=499
Circle Gearbox
b. Install bearing cone (4) and quill (38). Tap quill into
position.
c. Install cap screws (47) and tighten to specification.
Specification
Quill-to-Circle Pinion Shaft Cap
Screw—Torque ............................................................................... 36 N•m
27 lb-ft
4—Bearing Cone
38—Bearing Quill
–UN–16SEP99
T123996
34
3450
18
JW00603,0000175 –19–21JAN09–14/24
d. Measure distance from top of quill to top of pinion

shaft through hole in center of quill.
e. Subtract 10 mm (0.394 in.) from measurement

made in previous step to obtain shim pack
thickness. Build shim pack.
–UN–16SEP99
T123997
TM11207 (11MAY09) 34-3450-18

051809
PN=500
Circle Gearbox
40. Remove cap screws (47), install shim pack (19)

determined in previous step under bearing quill (38).
–UN–03APR09
TX1057911A
Bearing Quill Shims
34
3450
19
JW00603,0000175 –19–21JAN09–16/24
41. Install cap screws (47). Tighten to specification in a

circular pattern.
Specification
Quill-to-Circle Pinion Shaft Cap
Screw—Final Torque .................................................................... 240 N•m
177 lb-ft
42. Install retaining plate (23).
43. Install cap screws (32) and tighten to specification
Specification
Retaining Plate-to-Circle Pinion
Shaft Cap Screw—Torque ............................................................. 70 N•m
–UN–16SEP99
52 lb-ft
.
T123999
TM11207 (11MAY09) 34-3450-19

051809
PN=501
Circle Gearbox
44. Measure distance from top of bearing (4) to top of

quill (38). Subtract 0.1 mm (0.004 in.) from
measurement and build shim pack.
4—Bearing Cone
38—Bearing Quill
–UN–07MAR00
T124001
34
3450
20
JW00603,0000175 –19–21JAN09–18/24
45. Remove cap screws (32) and retaining plate (23).

Install shim pack (39).
39—Shim Pack (as required)
–UN–03APR09
TX1057912A
Retaining Plate Shims
TM11207 (11MAY09) 34-3450-20

051809
PN=502
Circle Gearbox
46. Install retaining plate (23).
23—Retaining Plate
–UN–16SEP99
T124627
34
3450
21
JW00603,0000175 –19–21JAN09–20/24
Specification
Retaining Plate-to-Circle Pinion
Shaft Cap Screw—Torque ............................................................. 70 N•m
52 lb-ft
–UN–16SEP99
T124628
TM11207 (11MAY09) 34-3450-21

051809
PN=503
Circle Gearbox
48. Install O-ring (42).
42—O-Ring
–UN–16SEP99
T124629
34
3450
22
JW00603,0000175 –19–21JAN09–22/24
49. Position cover (26) on gear case as shown.
Specification
Cover-to-Cover Cap Screw—
Torque ............................................................................................ 40 N•m
30 lb-ft
26—Cover
–UN–16SEP99
T124630
TM11207 (11MAY09) 34-3450-22

051809
PN=504
Circle Gearbox
51. Install seal (2) in gear case (10) with JDG1009 seal
installer until seal is seated flush with edge of gear
case.
52. Install circle drive gearbox to draft frame. See Circle

Drive Gearbox Remove and Install. (Group 3450.)
–UN–16SEP99
2—Oil Seal
10—Gear Case
T123983
34
3450
23
JW00603,0000175 –19–21JAN09–24/24
TM11207 (11MAY09) 34-3450-23

051809
PN=505
Circle Gearbox
34
3450
24
TM11207 (11MAY09) 34-3450-24

051809
PN=506
Group 3460
Hydraulic System
Grader Control Valve Remove and Install
17 19 21
18 22
16
9 20
7 23
4 10
8
3 5
14
6 1 24
25
15
26
11
2
27
12
13
–UN–26FEB09
34
TX1055938
3460
TX1055938 1
Hydraulic System Manifold and Control Valves
1—Left Control Valve 7—Left Blade Lift Valve 16—Articulation Valve Section 22—Right Auxiliary Valve
Assembly Section 17—Circle rotate Valve Section Section (with float)
2—Left Control Valve End Cap 8—Blade Side Shift Valve 18—Wheel Lean Valve Section 23—Right Auxiliary Valve
3—Left Auxiliary Valve Section Section 19—Blade Lift Valve Section Section (without float)
(without float) 9—Circle Rotate Valve Section 20—Right Control Valve 25—Circuit Relief—Midmount
4—Left Auxiliary Valve Section 10—Blade Pitch Valve Section Assembly Mid-inlet Scarifier Only
(with float) 11—Left Control Valve End 21—Right Auxiliary Valve 26—Right Blade Lift Relief
5—Left Auxiliary Valve Section Cap Section (midmount Valve
(with float) 12—Left Blade Lift Relief Valve scarifier valve section—if 27—Hydraulic System
6—Left Control Valve 13—Load Sense Relief Valve equipped) Manifold
Assembly Mid-inlet Section 14—Right Control Valve
Assembly
1. Rotate blade away from control valve assembly

being removed.
fluid under pressure, stop engine and relieve
the pressure in the system before
2. Tilt blade all the way forward. Lower all attachments
to the ground.
applying pressure.
fittings on lines at control valve.
5. Install vacuum pump to hydraulic oil tank. See
TM11207 (11MAY09) 34-3460-1

051809
PN=507
Hydraulic System
7. Remove all hydraulic lines from control valve 9. Tilt steering console back towards the seat.
assembly and mark for ease of assembly. Cap and
plug all openings.
8. Remove floor mat retaining screws from the side of

the cab the control valve assembly is being
removed.
JW00603,0000176 –19–21JAN09–2/7
10. Remove cap screw (30) and air duct (32) to ease in
removal of linkage boots (33) and cover plate (35).
11. Remove linkage boot cap screws (34) and slide

linkage boots (33) up on the linkage rods (31).
–UN–11MAR09
30—Air Duct Cap Screw
31—Linkage Rod
32—Air Duct
TX1056373A
33—Linkage Boots (2 used)
34 34—Linkage Boot Cap Screw (8 used)
3460 35—Cover Plate
2
Control Valve Linkage Boots (right control valve shown)
JW00603,0000176 –19–21JAN09–3/7
12. Remove cover plate retaining cap screws (36) and

slide the cover plate (35) up on the linkage rods (31).
13. Secure cover plate to allow for access to opening.

–UN–27FEB09
14. Remove cap screws (37) connecting linkage rods (31)

to control valves at the valve levers (38).
15. Tie strap linkage rods away from opening.

TX1056374A
31—Linkage Rod
35—Cover Plate
36—Cover Plate Cap Screw (4 used) Control Valve Cover Plate (right control valve shown)
37—Linkage Rod Cap Screw
38—Valve Lever
TM11207 (11MAY09) 34-3460-2

051809
PN=508
Hydraulic System
CAUTION: Avoid crushing injury. Use a lifting

device.
16. Connect hoist to valve assembly (40) using lifting

strap (39).
–UN–27FEB09
Specification
Control Valve Assembly—Weight
(approximate)..................................................................................... 50 kg
TX1056375A
110 lb.
39—Lifting Strap
40—Valve Assembly Lifting Strap
JW00603,0000176 –19–21JAN09–5/7
17. Remove control valve mounting bracket cap screws

(42) and lower control valve assembly (40) from cab.
34
18. Repair grader control valve as needed. See Grader 3460
Control Valve Disassemble and Assemble. (Group 3
–UN–26FEB09
3460.)

device.
TX1056376A
19. Lift assembly into machine and install control valve
mounting hardware. Control valve Mounting Bracket (front view)
Specification
Control Valve Assembly—Weight
(approximate)..................................................................................... 50 kg
110 lb.
20. Connect linkage rods to the control valve assembly. –UN–27FEB09
21. Install cover plate over control valve assembly.
NOTE: When installing floor mat, make sure floor mat

TX1056400A
does not interfere with control levers, boots or

pedal.
Control Valve Mounting Bracket (rear view)
22. Install floor mat and cap screws.
39—Lifting Strap
23. Move steering console to forward position. 40—Valve Assembly
41—Cab
42—Mounting Bracket Cap Screws (3 used)
43—Mounting Bracket
TM11207 (11MAY09) 34-3460-3

051809
PN=509
Hydraulic System
NOTE: When linkage boot is out of specification lever

effort complaints can result. Position linkage boots
to specification to reduce lever effort variations.
24. Adjust linkage boots so neck (44) is above floor plate
–UN–05MAR09
(45) to specification.
Specification
Floor Plate to Top of Linkage
Boots—Length ................................................................................. 50 mm
TX1056421A
2 in.
25. Connect all lines.

Linkage Boot
26. Remove vacuum pump from hydraulic oil tank. Check 44—Boot Neck
for hydraulic oil leaks. See Vacuum Pump Installation. 45—Floor Plate
(Group 9025-25.)
27. Check hydraulic oil level in tank. See Drain and Refill
Capacities. (Operator’s Manual.)

34
3460 30. Return machine to service.
4
JW00603,0000176 –19–21JAN09–7/7
TM11207 (11MAY09) 34-3460-4

051809
PN=510
Hydraulic System
Draft Frame Mount Grader Control Valve Remove and Install—EH Controls
2
2
2
5
1
5
4 6 7
5
5 8
5
5
6 34
3460
5
10
10
–UN–13MAR09
10
TX1056916
TX1056916
Draft Frame Control Valve
1—Toolbox 4—Nut (2 used) 7—Solenoid 9—Draft Frame

2—Cap Screws (4 used) 5—Clamp (7 used) 8—Draft Frame Mount Control 10—Cap Screws (3 used)
3—Draft Frame Cover 6—Stud (2 used) Valve
1. Tilt blade forward. Lower all attachments to the 2. Install articulation lock pin.
ground.
Continued on next page BR70016,0000051 –19–04MAY09–1/4
TM11207 (11MAY09) 34-3460-5

051809
PN=511
Hydraulic System
3. Turn battery disconnect switch to OFF position. the pressure in the system before
4. Remove cap screws (2) from draft frame cover (3). other lines. Tighten all connections before
applying pressure.
5. Remove draft frame cover from draft frame (9).
6. Remove toolbox (1) from draft frame. fittings on lines at control valve.
7. Remove nuts (4) and clamps (5) from studs (6) to 9. Install vacuum pump to hydraulic oil tank. See
allow for removal of hydraulic lines. Vacuum Pump Installation. (Group 9025-25.)

34
3460
6
TM11207 (11MAY09) 34-3460-6

051809
PN=512
Hydraulic System
10. Remove and tag all hydraulic hoses (11) and lines
(12) from draft frame mount control valve (8). Cap
11. Remove wire harness (13) from solenoids (7).
12. Remove cap screws (10) from draft frame.
–UN–13MAR09
13. Using an appropriate lifting device, lift draft frame

mount control valve away from draft frame.
TX1057005A
Specification
Draft Frame Mount Control
Valve—Weight (approximate)............................................................ 82 kg
180 lb. Hydraulic Lines Wire Harness
7—Solenoid
14. Repair grader control valve as needed. See Grader 8—Draft Frame Mount Control Valve
Control Valve Disassemble and Assemble. (Group 11—Hydraulic Hoses
3460.) 12—Hydraulic Lines
13—Wire Harness
CAUTION: Avoid crushing injury. Use lifting 34

device. 3460
7
15. Lift draft frame mount control valve into machine and
install control valve mounting hardware.
Specification
Draft Frame Mount Control
Valve—Weight (approximate)............................................................ 82 kg
180 lb.
16. Install caps screws (10).
17. Connect wire harness to solenoids (7). See

Electrohydraulic (EH) Main Frame Harness (W39)
Component Location for wire harness location. (Group
9015-10.)
18. Connect all hydraulic lines and hoses.
19. Install nuts (4) and clamps (5) to studs (6).
20. Install toolbox (1) to draft frame.
21. Install draft frame cover to draft frame (9).
TM11207 (11MAY09) 34-3460-7

051809
PN=513
Hydraulic System
22. Install cap screws (2) to draft frame cover (3).
23. Remove vacuum pump from hydraulic oil tank. See

24. Check hydraulic oil level in tank. See Drain and Refill
Capacities. (Operator’s Manual.)
27. Calibrate valve (GP machines only). See Display

Unit—Main Menu—Machine Configuration—Valve
Cals (Grade Pro Machines Only). (Operator’s
Manual.)
34
3460
8
BR70016,0000051 –19–04MAY09–4/4
TM11207 (11MAY09) 34-3460-8

051809
PN=514
Hydraulic System
Cab Mount Grader Control Valve Remove

and Install—EH Controls
1. Rotate the blade away from the cab mount control

valve.
2. Tilt blade forward. Lower all attachments to the ground.


fittings on lines at control valve.
6. Install vacuum pump to hydraulic oil tank. See Vacuum

Pump Installation. (Group 9025-25.)
34
3460
9
TM11207 (11MAY09) 34-3460-9

051809
PN=515
Hydraulic System
–UN–14APR09
TX1057352A
34
3460 Cab Mount Control Valve
10
1—Cap Screws (3 used) 4—Solenoid 5—DFT1310 Cab Mount 6—Cab Mount Control Valve
2—Cab Mount Control Valve Control Valve Support Mounting Bracket
3—Hydraulic Hoses Bracket
7. Remove and tag all hydraulic hoses (3) from cab Specification
mount control valve. Cap and plug all openings. Cab Mount Control Valve—
Weight (approximate) ................................................................. 73 kg
160 lb.
8. Remove wire harness from all solenoids (4). See
Electrohydraulic (EH) Main Frame Harness (W39) 11. Remove cap screws (1).
Component Location for wire harness location.
(Group 9015-10.) 12. Using an appropriate lifting device, remove cab
mount control valve away from under the cab.
9. Install DFT1310 Cab Mount Control Valve Support
Bracket (5) to cab mount control valve mounting 13. Repair grader control valve as needed. See
bracket. Grader Control Valve Disassemble and Assemble.
(Group 3460.)
10. Secure DFT1310 Cab Mount Control Valve

Support Bracket to an appropriate lifting device.
TM11207 (11MAY09) 34-3460-10

051809
PN=516
Hydraulic System
correct hydraulic hose placement. (Group

9025-15.)
device.
14. Using DFT1310 Cab Mount Control Valve Support
Bracket and an appropriate lifting device place cab
Installation. (Group 9025-25.)
mount control valve in place under cab.
Specification 19. Check hydraulic oil level in tank. See Drain and
Cab Mount Control Valve— Refill Capacities. (Operator’s Manual.)
Weight (approximate) ................................................................. 73 kg
160 lb. 20. Turn battery disconnect switch to ON position.
15. Install caps screws (1). 21. Remove articulation lock pin.
16. Connect wire harness to solenoids (4). See 22. Calibrate valve (GP machines only). See Display
Electrohydraulic (EH) Main Frame Harness (W39) Unit—Main Menu—Machine Configuration—Valve
Component Location for wire harness location. Cals (Grade Pro Machines Only). (Operator’s
(Group 9015-10.) Manual.)
17. Connect all hydraulic hoses. See Hydraulic 23. Return machine to service.
System Component Location—EH Controls for
34
3460
11
BR70016,0000052 –19–04MAY09–3/3
TM11207 (11MAY09) 34-3460-11

051809
PN=517
Hydraulic System
Grader Control Valve Disassemble and Assemble
8
3
6
8 8
3
1
7
4
6
8
–UN–20FEB09
5
7
2
TX1056068
34
3460
12 TX1056068
Control Valve
1—Small Cap Screw (2 used) 3—Small Stud (2 used) 5—Large Stud 7—Large Nut (2 used)
2—Large Cap Screw 4—Large Stud 6—Small Stud (2 used) 8—Small Nut (4 used)
NOTE: Standard control valve is shown. Disassemble 4. Remove control valve to be disassembled from
and assemble procedure of EH controls control machine.
valves are the same as standard control valve.
See Grader Control Valve Remove and Install for
1. Park machine on flat level surface and lower all standard control machines. (Group 3460.)
See Draft Frame Mount Grader Control Valve
2. Install articulation lock pin. Remove and Install—EH Controls or see Cab
Mount Grader Control Valve Remove and Install—
3. Turn battery disconnect switch to OFF position. EH Controlsfor EH control machines. (Group 3460.)
TM11207 (11MAY09) 34-3460-12

051809
PN=518
Hydraulic System
6. Remove mounting bracket (9) from control valve (11). 9
7. Mark the valve sections configuration to aid assembly.

10
–UN–02MAR09
See Control Valve Operation—Standard Controls or
see Control Valve Operation—EH Controls. (Group
9025-05.) 10
TX1056356
NOTE: Depending on the number of valve sections, cap 11
screws (1 and 2) might be used in place of the 10
studs and nuts (5, 6, 7 and 8).
Control Valve Mounting Bracket (left control valve shown)
8. Remove nuts from each side of control valve.
9—Mounting Bracket
9. Separate valve sections. 11—Control Valve

necessary.
For disassemble and assemble procedures of

individual valve sections:
• See Midmount Scarifier Valve Section Disassemble

and Assemble. (Group 3460.) 34
3460
• See Midmount Scarifier Valve Section Disassemble 13
and Assemble—EH Controls. (Group 3460.)
• See Blade Lift Valve Section Disassemble and
• See Blade Lift Valve Section Disassemble and
Assemble—EH Controls. (Group 3460.)
• See Auxiliary (With Float) Valve Section
• See Auxiliary (Without Float) Valve Section
• See Auxiliary Valve Section Disassemble and
• See Wheel Lean, Articulation, Circle Side Shift,
Blade Pitch, and Blade Side Shift Valve Section
• See Wheel Lean, Articulation, Circle Side Shift,
Blade Pitch, Blade Side Shift, and Steering Valve
Section Disassemble and Assemble—EH Controls.
(Group 3460.)
• See Circle Rotate Valve Section Disassemble and
TM11207 (11MAY09) 34-3460-13

051809
PN=519
Hydraulic System
• See Circle Rotate Valve Section Disassemble and

11. Assemble valve sections in order removed.
12. Tighten control valve nuts (cap screws) accordingly.
Specification
Control Valve Nut (small)—
Torque ............................................................................................ 19 N•m
168 lb-in
Control Valve Nut (large)—
Torque ............................................................................................ 45 N•m
33 lb-ft
13. Install control valve to machine.
See Grader Control Valve Remove and Install for

standard control machines. (Group 3460.)
See Draft Frame Mount Grader Control Valve

Remove and Install—EH Controls or see Cab Mount
Controlsfor EH control machines. (Group 3460.)
34
3460
14
JW00603,0000177 –19–21JAN09–3/3

1. Remove control valve containing midmount scarifier

control valve section. See Grader Control Valve
2. Remove midmount scarifier control valve section from

control valve. See Grader Control Valve Disassemble
TM11207 (11MAY09) 34-3460-14

051809
PN=520
Hydraulic System
2 1
25 10
24 4
3
5
11 11 6
7
12 8
9
23 8
5
34
13 3460
14 16 15
15
17
17
5
19
18
22
–UN–20FEB09
20
22
21 TX1056016
TX1056016
1—Cap Screw (2 used) 8—Spring Seat (2 used) 13—Shuttle Valve Disk 20—O-Ring (2 used)
2—Detent Housing 9—Spring 14—Compensator Spool 21—Actuator Arm
3—Pressure Relief Valve 10—Check Valve (2 used) 15—Compensator Spring 22—Cap Screw (2 used)
4—Seal 11—Check Valve Spool (2 16—O-Ring 23—Spool
5—O-Ring (3 used) used) 17—O-Ring (2 used) 24—Plug
6—Float Detent 12—Midmount Scarifier Valve 18—Actuator Spring 25—Seal
7—Spring Housing Section 19—Actuator Housing
3. Remove check valves (10) and spools (11). 4. Remove shuttle valve disk (13).
TM11207 (11MAY09) 34-3460-15

051809
PN=521
Hydraulic System
5. Remove compensator spring (15) and compensator 17. Assemble valve.

spool (14).
18. Tighten parts to specification.
6. Remove actuator arm (21) from actuator housing
(19). Specification
Check Valve-to-Valve Body—
Torque...................................................................................... 45 N•m
7. Remove cap screws (22). 33 lb-ft
Pressure Relief Valve-to-Valve
8. Remove actuator housing (19) and actuator spring Body—Torque .......................................................................... 45 N•m
(18). 33 lb-ft
Plug-to-Valve Body—Torque ................................................... 45 N•m
33 lb-ft
9. Remove cap screws (1). Detent Housing-to-Spring
Housing-to-Valve Body—
10. Remove detent housing (2), float detent (6), and Torque..................................................................................... 9.5 N•m
spring housing (7). 84 lb-in.
Actuator Housing-to-Valve
Body—Torque ......................................................................... 9.5 N•m
11. Remove spring seats (8) and spring (9). 84 lb-in.
12. Slide spool (23) out of valve section (12). 19. Assemble midmount scarifier control valve section
to control valve. See Grader Control Valve
13. Remove pressure relief valve (3). Disassemble and Assemble. (Group 3460.)
14. Remove plug (24). 20. Install control valve containing midmount scarifier
34
control valve section to the machine. See Grader
15. Clean and inspect parts. Repair or replace parts Control Valve Remove and Install. (Group 3460.)
3460
16
as necessary.
16. Replace all O-rings (5, 16, 17, and 20) and seals
(4 and 25).
JW00603,0000103 –19–20JAN09–3/3

Disassemble and Assemble—EH Controls
1. Remove control valve containing midmount scarifier

valve section. See Draft Frame Mount Grader Control
Valve Remove and Install—EH Controls. (Group 3460.)
2. Remove midmount scarifier valve section from control

valve. See Grader Control Valve Disassemble and
TM11207 (11MAY09) 34-3460-16

051809
PN=522
Hydraulic System
4
3
2
1
7
7
5
7
7 5 9
6
6 14
34
8 9 3460
14 17
13 11 10
12 12
11 13
14
17
9 15 18
16
14 19
20
10 18
9
–UN–02MAR09
21
TX1056070
TX1056070
Midmount Scarifier Valve Section (EH controls)
1—Pressure Relief Valve 7—Cap Screw (4 used) 12—Spring Seat (2 used) 17—Shuttle Valve Disk
2—Seal 8—Solenoid Valve (2 used) 13—O-Ring (2 used) 18—O-Ring (2 used)
3—Seal 9—Cap Screw (4 used) 14—O-Ring (4 used) 19—Compensator Spool
4—Plug 10—Solenoid Valve Housing (2 15—Spool 20—Compensator Spring
5—Check Valve (2 used) used) 16—Midmount Scarifier Valve 21—O-Ring
6—Check Valve Spool (2 used) 11—Actuator Spring (2 used) Section
3. Remove check valves (5) and spools (6). 5. Remove compensator spring (20) and compensator
spool (19).
4. Remove shuttle valve disk (17).
TM11207 (11MAY09) 34-3460-17

051809
PN=523
Hydraulic System
6. Remove cap screws (7). Pressure Relief Valve-to-Valve

Body—Torque .......................................................................... 45 N•m
33 lb-ft
7. Remove solenoid valves (8). Plug-to-Valve Body—Torque ................................................... 45 N•m
33 lb-ft
8. Remove cap screws (9). Solenoid Valve-to-Solenoid
Valve Housing—Torque............................................................. 2 N•m
18 lb-in
9. Remove solenoid valve housings (10).
Solenoid Valve
10. Remove actuator springs (11) and spring seats Torque..................................................................................... 9.5 N•m
(12). 84 lb-in
11. Slide spool (15) out of valve section (16). 18. Assemble midmount scarifier valve section to
control valve. See Grader Control Valve
12. Remove pressure relief valve (1). Disassemble and Assemble. (Group 3460.)
13. Remove plug (4). 19. Install control valve containing midmount scarifier
valve section to the machine. See Draft Frame
14. Clean and inspect parts. Repair or replace parts Mount Grader Control Valve Remove and Install—
as necessary. EH Controls. (Group 3460.)
(2 and 3).
16. Assemble valve.

34
3460
18
Specification
Torque...................................................................................... 45 N•m
33 lb-ft
BR70016,0000053 –19–16FEB09–3/3

Assemble
1. Remove control valve containing blade lift valve

section. See Grader Control Valve Remove and Install.
(Group 3460.)
2. Remove blade lift valve section from control valve. See

Grader Control Valve Disassemble and Assemble.
(Group 3460.)
TM11207 (11MAY09) 34-3460-18

051809
PN=524
Hydraulic System
2 1
25 10
24 4
3
5
11 11 6
7
12 8
9
23 8
5
34
13 3460
14 16 19
15
17
17
5
19
18
22
–UN–20FEB09
20
22
21 TX1056016
TX1056016
1—Cap Screw (2 used) 8—Spring Seat (2 used) 14—Compensator Spool 20—O-Ring (2 used)
2—Detent Housing 9—Spring 15—Compensator Spring 21—Actuator Arm
3—Pressure Relief Valve 10—Check Valve (2 used) 16—O-Ring 22—Cap Screw (2 used)
4—Seal 11—Check Valve Spool (2 17—O-Ring (2 used) 23—Spool
5—O-Ring (3 used) used) 18—Actuator Spring 24—Plug
6—Float Detent 12—Blade Lift Valve Section 19—Actuator Housing 25—Seal
7—Spring Housing 13—Shuttle Valve Disk
TM11207 (11MAY09) 34-3460-19

051809
PN=525
Hydraulic System

spool (14).
(19). Specification
Torque...................................................................................... 45 N•m
(18). 33 lb-ft
33 lb-ft
spring housing (7). 84 lb-in
Body—Torque ......................................................................... 9.5 N•m
11. Remove spring seats (8) and spring (9). 84 lb-in
12. Slide spool (23) out of valve section (12). 19. Assemble blade lift valve section to control valve.
See Grader Control Valve Disassemble and
13. Remove pressure relief valve (3). Assemble. (Group 3460.)
14. Remove plug (24). 20. Install control valve containing blade lift valve
34
section to the machine. See Grader Control Valve
15. Clean and inspect parts. Repair or replace parts Remove and Install. (Group 3460.)
3460
20
as necessary.
(4 and 25).
JW00603,0000104 –19–20JAN09–3/3

Assemble—EH Controls
1. Remove control valve containing blade lift valve

section. See Cab Mount Grader Control Valve Remove
and Install—EH Controls. (Group 3460.)
2. Remove blade lift valve section from control valve. See

(Group 3460.)
TM11207 (11MAY09) 34-3460-20

051809
PN=526
Hydraulic System
4
3
2
1
7
7
5
7
7 5 9
6
6 14
34
8 9 3460
14 21
13 11 10
12 12
11 13
14
17
9 15 18
16
14 19
20
10 18
9
–UN–02MAR09
21
TX1056070
TX1056070
Blade Lift Valve Section (EH controls)
1—Pressure Relief Valve 7—Cap Screw (4 used) 12—Spring Seat (2 used) 17—Shuttle Valve Disk
2—Seal 8—Solenoid Valve (2 used) 13—O-Ring (2 used) 18—O-Ring (2 used)
3—Seal 9—Cap Screw (4 used) 14—O-Ring (4 used) 19—Compensator Spool
4—Plug 10—Solenoid Valve Housing (2 15—Spool 20—Compensator Spring
5—Check Valve (2 used) used) 16—Blade Lift Valve Section 21—O-Ring
6—Check Valve Spool (2 used) 11—Actuator Spring (2 used)
spool (19).
TM11207 (11MAY09) 34-3460-21

051809
PN=527
Hydraulic System
6. Remove cap screws (7). Pressure Relief Valve-to-Valve

Body—Torque .......................................................................... 45 N•m
33 lb-ft
7. Remove solenoid valves (8). Plug-to-Valve Body—Torque ................................................ 45.0 N•m
33 lb-ft
18 lb-in
Solenoid Valve
10. Remove actuator springs (11) and spring seats Torque..................................................................................... 9.5 N•m
(12). 84 lb-in
11. Slide spool (15) out of valve section (16). 18. Assemble blade lift valve section to control valve.
13. Remove plug (4). 19. Install control valve containing blade lift valve
section to the machine. See Cab Mount Grader
14. Clean and inspect parts. Repair or replace parts Control Valve Remove and Install—EH Controls.
as necessary. (Group 3460.)
(2 and 3).
16. Assemble valve.

34
3460
22
Specification
Torque...................................................................................... 45 N•m
33 lb-ft
BR70016,0000054 –19–16FEB09–3/3
Auxiliary (With Float) Valve Section

1. Remove control valve containing auxiliary valve

(Group 3460.)
2. Remove auxiliary valve section from control valve. See

(Group 3460.)
TM11207 (11MAY09) 34-3460-22

051809
PN=528
Hydraulic System
2 1
25 10
24 4
3
5
11 11 6
7
12 8
9
23 8
5
34
13 3460
14 16 23
15
17
17
5
19
18
22
–UN–20FEB09
20
22
21 TX1056016
TX1056016
Auxiliary (with float) Valve Section
1—Cap Screw (2 used) 8—Spring Seat (2 used) 13—Shuttle Valve Disk 20—O-Ring (2 used)
2—Detent Housing 9—Spring 14—Compensator Spool 21—Actuator Arm
3—Pressure Relief Valve 10—Check Valve (2 used) 15—Compensator Spring 22—Cap Screw (2 used)
4—Seal 11—Check Valve Spool (2 16—O-Ring 23—Spool
5—O-Ring (3 used) used) 17—O-Ring (2 used) 24—Plug
6—Float Detent 12—Auxiliary (with float) 18—Actuator Spring 25—Seal
7—Spring Housing Control Valve Section 19—Actuator Housing
TM11207 (11MAY09) 34-3460-23

051809
PN=529
Hydraulic System

spool (14).
(19). Specification
Torque...................................................................................... 45 N•m
(18). 33 lb-ft
33 lb-ft
spring housing (7). 84 lb-in
Body—Torque ......................................................................... 9.5 N•m
11. Remove spring seats (8) and spring (9). 84 lb-in
12. Slide spool (23) out of valve section (12). 19. Assemble auxiliary valve section to control valve.
14. Remove plug (24). 20. Install control valve containing auxiliary valve
34
15. Clean and inspect parts. Repair or replace parts Remove and Install. (Group 3460.)
3460
24
as necessary.
(4 and 25).
JW00603,0000178 –19–21JAN09–3/3
Auxiliary (Without Float) Valve Section


(Group 3460.)

(Group 3460.)
TM11207 (11MAY09) 34-3460-24

051809
PN=530
Hydraulic System
1 5
3 6
2
2 4 5
21 7
10 11
4 12
13 14
3
34
3460
25
15
9
16
20
17 18 19
–UN–24FEB09
TX1056115
TX1056115
Auxiliary (with float) Valve Section
1—Check Valve (2 used) 7—Spring Seat (2 used) 12—Compensator Spool 17—Actuator Housing
2—Check Valve Spool (2 used) 8—Spring 13—Compensator Spring 18—O-Ring (2 used)
3—Plug (2 used) 9—O-Ring (2 used) 14—O-Ring 19—Actuator Arm
4—Seal (2 used) 10—Auxiliary (without float) 15—O-Ring (2 used) 20—Cap Screw (2 used)
5—Cap Screw (2 used) Valve Section 16—Actuator Spring 21—Spool
6—Spring Housing 11—Shuttle Valve Disk
spool (12).
TM11207 (11MAY09) 34-3460-25

051809
PN=531
Hydraulic System
6. Remove actuator arm (19) from actuator housing 16. Assemble valve.
(17).
Specification
8. Remove actuator housing (17) and actuator spring Check Valve-to-Valve Body—
Torque...................................................................................... 45 N•m
(16). 33 lb-ft
Spring Housing-to-Valve
10. Remove spring housing (6). Body—Torque ......................................................................... 9.5 N•m
84 lb-in
11. Remove spring seats (7) and spring (8). Body—Torque ......................................................................... 9.5 N•m
84 lb-in
12. Slide spool (21) out of valve section (10).
18. Assemble auxiliary valve section to control valve.
13. Remove plugs (3). See Grader Control Valve Disassemble and
14. Clean and inspect parts. Repair or replace parts
as necessary. 19. Install control valve containing auxiliary valve
15. Replace all O-rings (9, 14, 15, and 18) and seals Remove and Install. (Group 3460.)
(4).
34
3460
26
BR70016,0000058 –19–19FEB09–3/3
Auxiliary Valve Section Disassemble and


section. See Draft Frame Mount Grader Control Valve
Remove and Install—EH Controls or see Cab Mount

(Group 3460.)
TM11207 (11MAY09) 34-3460-26

051809
PN=532
Hydraulic System
1
2
2
1
5
5
3
5
5 3 7
4
4 12
34
3460
6 7 27
12
11 9 8
10 10
9 11
12
15
7 13 16
14
12 17
18
8 16
7
–UN–02MAR09
19
TX1056129
TX1056129
Auxiliary Valve Section—EH Controls
1—Plug (2 used) 7—Cap Screw (4 used) 11—O-Ring (2 used) 15—Shuttle Valve Disk
2—Seal (2 used) 8—Solenoid Valve Housing (2 12—O-Ring (4 used) 16—O-Ring (2 used)
3—Check Valve (2 used) used) 13—Spool 17—Compensator Spool
4—Check Valve Spool (2 used) 9—Actuator Spring (2 used) 14—Auxiliary Valve Section— 18—Compensator Spring
5—Cap Screw (4 used) 10—Spring Seat (2 used) EH Controls 19—O-Ring
6—Solenoid Valve (2 used)
spool (17).
TM11207 (11MAY09) 34-3460-27

051809
PN=533
Hydraulic System
6. Remove cap screws (5). Plug-to-Valve Body—Torque ................................................... 45 N•m

33 lb-ft
Solenoid Valve-to-Solenoid
7. Remove solenoid valves (6). Valve Housing—Torque............................................................. 2 N•m
18 lb-in
8. Remove cap screws (7). Solenoid Valve
Torque..................................................................................... 9.5 N•m
84 lb-in
10. Remove actuator springs (9) and spring seats

17. Assemble auxiliary valve section to control valve.
(10).
18. Install control valve containing auxiliary valve
12. Remove plugs (1).
section to the machine. See Draft Frame Mount
Controls or see Cab Mount Grader Control Valve
as necessary.
(2).
15. Assemble valve.

34
3460 Specification
28 Check Valve-to-Valve Body—
Torque...................................................................................... 45 N•m
33 lb-ft
BR70016,0000059 –19–19FEB09–3/3
Wheel Lean, Articulation, Circle Side Shift,

Blade Pitch, and Blade Side Shift Valve
Section Disassemble and Assemble
1. Remove control valve containing valve section to be

disassembled. See Grader Control Valve Remove and
2. Remove valve section to be disassembled from control

TM11207 (11MAY09) 34-3460-28

051809
PN=534
Hydraulic System
3
1
1 2
2
9
7
4 5
8 6
10 11
12 13
19
14
34
15 3460
8 29
16
15
18
17
–UN–25FEB09
TX1056141
TX1056141
Wheel Lean Valve Section
1—Check Valve (2 used) 6—Actuator Arm 11—Compensator Spool 16—Spring

2—Check Valve Spool (2 used) 7—Actuator Spring 12—Compensator Spring 17—Spring Housing
3—Cap Screw (2 used) 8—O-Ring (2 used) 13—O-Ring 18—Cap Screw (2 used)
4—Actuator Housing 9—Wheel Lean Valve Section 14—O-Ring (2 used) 19—Spool
5—O-Ring (2 used) 10—Shuttle Valve Disk 15—Spring Seat (2 used)
TM11207 (11MAY09) 34-3460-29

051809
PN=535
Hydraulic System
NOTE: Wheel lean valve section is shown. 13. Clean and inspect parts. Repair or replace parts
Articulation, circle side shift, blade pitch, and as necessary.
blade side shift valve section disassemble and
assemble procedure is the same. 14. Replace all O-rings (5, 8, 13, and 14).
3. Remove check valves (1) and spools (2). 15. Assemble valve.
4. Remove shuttle valve disk (10). 16. Tighten parts to specification.
5. Remove compensator spring (12) and compensator Specification

spool (11). Check Valve-to-Valve Body—
Torque...................................................................................... 45 N•m
33 lb-ft
6. Remove actuator arm (6) from actuator housing (4). Spring Housing-to-Valve
Body—Torque ......................................................................... 9.5 N•m
7. Remove cap screws (3). 84 lb-in
Body—Torque ......................................................................... 9.5 N•m
8. Remove actuator housing (4) and actuator spring 84 lb-in
(7).
17. Assemble valve section to be disassembled to
9. Remove cap screws (18). control valve. See Grader Control Valve
10. Remove spring housing (17).
18. Install control valve containing valve section to the
11. Remove spring seats (15) and spring (16). machine. See Grader Control Valve Remove and
34
30
JW00603,0000179 –19–21JAN09–3/3
Wheel Lean, Articulation, Circle Side Shift,

Blade Pitch, Blade Side Shift, and Steering
Valve Section Disassemble and Assemble—
EH Controls
1. Remove control valve containing valve section to be

disassembled. See Draft Frame Mount Grader Control
Valve Remove and Install—EH Controls or see Cab
Mount Grader Control Valve Remove and Install—EH
2. Remove valve section to be disassembled from control

TM11207 (11MAY09) 34-3460-30

051809
PN=536
Hydraulic System
1
1
3
4
5
3 2
2
3
12 10 9
4
5
10 34
9 7 6 3460
10 8 31
13
5 14
7 8 10 11
15
16
6 14 17
5
–UN–23FEB09
TX1056154
TX1056154
Wheel Lean Valve Section—EH Controls
1—Check Valve (2 used) 6—Solenoid Valve Housing (2 10—O-Ring (4 used) 14—O-Ring (2 used)
2—Check Valve Spool (2 used) used) 11—Spool 15—Compensator Spool
3—Cap Screw (4 used) 7—Actuator Spring (2 used) 12—Wheel Lean Valve 16—Compensator Spring
4—Solenoid Valve (2 used) 8—Spring Seat (2 used) Section—EH Controls 17—O-Ring
5—Cap Screw (4 used) 9—O-Ring (2 used) 13—Shuttle Valve Disk
TM11207 (11MAY09) 34-3460-31

051809
PN=537
Hydraulic System
NOTE: Wheel lean valve section is shown. 13. Replace all O-rings (9, 10, 14, and 17).
Articulation, circle side shift, blade pitch, and
blade side shift valve section disassemble and 14. Assemble valve.
assemble procedure is the same.
3. Remove check valves (1) and spools (2).
Specification
4. Remove shuttle valve disk (13). Check Valve-to-Valve Body—
Torque...................................................................................... 45 N•m
33 lb-ft
5. Remove compensator spring (16) and compensator Solenoid Valve-to-Solenoid
spool (15). Valve Housing—Torque............................................................. 2 N•m
18 lb-in
6. Remove cap screws (3). Solenoid Valve
Torque..................................................................................... 9.5 N•m
7. Remove solenoid valves (4). 84 lb-in
8. Remove cap screws (5). 16. Assemble valve section to be disassembled to

control valve. See Grader Control Valve
9. Remove solenoid valve housings (6). Disassemble and Assemble. (Group 3460.)
10. Remove actuator springs (7) and spring seats (8). 17. Install control valve containing valve section to the
machine. See Draft Frame Mount Grader Control
11. Slide spool (11) out of valve section (12). Valve Remove and Install—EH Controls or see
Cab Mount Grader Control Valve Remove and
34 12. Clean and inspect parts. Repair or replace parts
3460
32
as necessary.
BR70016,0000055 –19–16FEB09–3/3
Circle Rotate Valve Section Disassemble and

Assemble
1. Remove control valve containing circle rotate valve

(Group 3460.)
2. Remove circle rotate valve section from control valve.

See Grader Control Valve Disassemble and Assemble.
(Group 3460.)
TM11207 (11MAY09) 34-3460-32

051809
PN=538
Hydraulic System
1
2 4
2 3
4
3 10
8
5 6
7
9
11
12
13
20
34
15 3460
33
15
16
9 14
17
16
19
18
–UN–24FEB09
19
TX1056170
TX1056170
Circle Rotate Valve Section
1—Plug (2 used) 7—Actuator Arm 11—Shuttle Valve Disk 16—Spring Seat (2 used)
2—O-Ring (2 used) 8—Actuator Spring 12—Compensator Spool 17—Spring
3—Spool (2 used) 9—O-Ring (2 used) 13—Compensator Spring 18—Spring Housing
4—Cap Screw (2 used) 10—Circle Rotate Valve 14—O-Ring 19—Cap Screw (2 used)
5—Actuator Housing Section 15—O-Ring (2 used) 20—Spool
6—O-Ring (2 used)
3. Remove plugs (1) and spools (3). 5. Remove compensator spring (13) and compensator
spool (12).
TM11207 (11MAY09) 34-3460-33

051809
PN=539
Hydraulic System
6. Remove actuator arm (7) from actuator housing (5). 16. Tighten parts to specification.
7. Remove cap screws (4). Specification

33 lb-ft
8. Remove actuator housing and actuator spring (8). Spring Housing-to-Valve
Body—Torque ......................................................................... 9.5 N•m
9. Remove cap screws (19). 84 lb-in
10. Remove spring housing (18). Body—Torque ......................................................................... 9.5 N•m
84 lb-in
11. Remove spring seats (16) and spring (17).

17. Assemble circle rotate valve section to control
18. Install control valve containing circle rotate valve
as necessary.
14. Replace all O-rings (2, 6, 9, 14, and 15).
15. Assemble valve.
34
3460
34
JW00603,000017A –19–21JAN09–3/3
Circle Rotate Valve Section Disassemble and

1. Remove control valve containing circle rotate valve

section. See Draft Frame Mount Grader Control Valve
2. Remove circle rotate valve section from control valve.

See Grader Control Valve Disassemble and Assemble.
(Group 3460.)
TM11207 (11MAY09) 34-3460-34

051809
PN=540
Hydraulic System
1 4
4
1
2
2 5
4 6
4 3
3 11
5 13 10
6
11
10 8 7
11 9
14 15
6 12 34
9 11 16
8 17 18 3460
15 35
7
6
–UN–27FEB09
TX1056171
TX1056171
Circle Rotate valve Section—EH Controls
1—Plug (2 used) 6—Cap Screw (4 used) 10—O-Ring (2 used) 14—Shuttle Valve Disk
2—O-Ring (2 used) 7—Solenoid Valve Housing (2 11—O-Ring (4 used) 15—O-Ring (2 used)
3—Spool (2 used) used) 12—Spool 16—Compensator Spool
4—Cap Screw (4 used) 8—Actuator Spring (2 used) 13—Circle Rotate Valve 17—Compensator Spring
5—Solenoid Valve (2 used) 9—Spring Seat (2 used) Section—EH Controls 18—O-Ring
3. Remove plugs (1) and O-rings (2). 5. Remove compensator spring (17) and compensator
spool (16).
TM11207 (11MAY09) 34-3460-35

051809
PN=541
Hydraulic System

18 lb-in
7. Remove solenoid valves (5). Solenoid Valve
8. Remove cap screws (6). Torque..................................................................................... 9.5 N•m
84 lb-in
16. Assemble circle rotate valve section to control
10. Remove actuator springs (8) and spring seats (9). valve. See Grader Control Valve Disassemble and
17. Install control valve containing circle rotate valve
12. Clean and inspect parts. Repair or replace parts section to the machine. See Draft Frame Mount
as necessary. Grader Control Valve Remove and Install—EH
13. Replace all O-rings (2, 10, 11, 15, and 18).
14. Assemble valve.
Specification
33 lb-ft
34
3460
36
BR70016,0000056 –19–16FEB09–3/3
Return Check Poppets Disassemble and

Assemble
NOTE: Poppets are serviced as an assembly except

O-rings and backup rings.
1—Check Valve Spool

2—Backup Ring
3—O-Ring
4—Poppet Body
5—O-Ring
6—Check Poppet
7—Spring
8—O-Ring
–UN–05MAR09
9—Plug
TX1056642A
Disassemble and Assemble Return Poppets
JW00603,000017B –19–21JAN09–1/1
TM11207 (11MAY09) 34-3460-36

051809
PN=542
Hydraulic System
Rotate Motor Disassemble and Assemble
–UN–18MAR09
TX1057029
34
3460
37
Rotate Motor
1—Splined Coupling 10—Seal 18—O-Ring 26—Aligning Pin

2—O-Ring 11—Shaft and Bearing 19—Flow Control Shaft 27—Spring
3—Seal 12—Seal 20—Flow Direction Plate 28—Hydraulic Oil Ports (2
4—Nut (2 used) 13—Wear Plate 21—O-Ring used)
5—Lock Washer (2 used) 14—Aligning Mark 22—Oil Passage Housing 29—Cap Screw (4 used)
6—Cap Screw (2 used) 15—O-Ring 23—Backing Plate 30—Port Housing
7—Bearing Housing 16—Drive Shaft 24—Seal 31—O-Ring
8—O-Ring 17—Gerotor Housing 25—Seal 32—Plug
9—Back Up Seal
1. Park machine on flat level surface and lower all 4. To relieve pressure in the system, slowly loosen
attachments to ground. fittings on circle rotate motor.
2. Install articulation lock pin. 5. Install vacuum pump to hydraulic oil tank to
3. Turn battery disconnect switch to OFF position. Vacuum Pump Installation. (Group 2160.)
6. Disconnect and tag hydraulic oil lines from hydraulic

oil ports (28). Cap and plug all openings.
the pressure in the system before
7. Remove cap screws (6), lock washers (5), and nuts
(4) from bearing housing (7).
applying pressure.
TM11207 (11MAY09) 34-3460-37

051809
PN=543
Hydraulic System
8. Remove rotate motor from circle drive gearbox. Port Housing-to-Bearing

Housing Cap Screws—Final
Torque............................................................................... 40—50 N•m
9. Remove splined coupling (1) from rotate motor and 30—40 lb.-ft.
set aside for reassembly.
18. Install splined coupling (1) to rotate motor.
10. Remove cap screws (29) from port housing (30).
19. Connect rotate motor to circle drive gearbox.
11. Disassemble parts as shown.
20. Install cap screws (6), lock washers (5), and nuts
NOTE: Shaft and bearing is not serviceable. Replace (4).
entire component if needed.
21. Connect hydraulic oil lines to hydraulic oil ports
12. Remove shaft and bearing (11) from bearing (28).
housing (7) using a press.
13. Repair or replace components as needed. Check for hydraulic oil leaks. See Vacuum Pump
14. Press shaft and bearing into bearing housing.
IMPORTANT: Prevent possible machine damage.
Ensure that aligning marks (14) are 24. Remove articulation lock pin.
aligned while assembling motor.
15. Assemble parts as shown. Tank Oil Level. (Operator’s Manual.)
34
3460
38
16. Install cap screws (29). 26. Return machine to service.
17. Tighten cap screws in two steps.
Specification
Port Housing-to-Bearing
Housing Cap Screws— Initial
Torque............................................................................. 1.7—4.5 N•m
15—40 lb.-in.
JW00603,000017C –19–21JAN09–2/2
TM11207 (11MAY09) 34-3460-38

051809
PN=544
Hydraulic System
Rotary Manifold Remove and Install

4. If equipped, remove circle rotate sensor (B39). See

Electrohydraulic (EH) Main Frame Harness (W39)
34
3460
39
TM11207 (11MAY09) 34-3460-39

051809
PN=545
Hydraulic System
6. Remove cover (4) to allow for access to hydraulic

hoses (6).
–UN–08APR09
TX1058018A
7. To release pressure in the system, slowly loosen Rotary Manifold (bottom view)
fittings on lines at rotary manifold (2).
8. Install vacuum pump to hydraulic oil tank. See Vacuum

Pump Installation. (Group 9025-25.)
NOTE: Work port numbers are stamped on the side and

bottom of the rotary manifold. The numbers next
to each port represents flow through the rotary
manifold. For example: Work port 1 on the side of
the rotary manifold is the same passage as work
port 1 on the bottom of the rotary manifold.
–UN–08APR09
34
3460 9. Label and remove hydraulic hoses (6) from rotary
40 manifold. Cap and plug all openings.
TX1058019A
10. Remove cap screws (1) from rotary manifold (2).
CAUTION: Avoid crushing injury. Use Rotary Manifold (top view)

2—Rotary Manifold
11. Remove rotary manifold (2) from draft frame (5). 3—Cap Screw
4—Cover
Specification 5—Draft Frame
Rotary Manifold—Weight 6—Hydraulic Hose (8 used)
(approximate)..................................................................................... 38 kg
84 lb.
12. Rotary manifold is not serviceable. Replace rotary

manifold as needed.
TM11207 (11MAY09) 34-3460-40

051809
PN=546
Hydraulic System

13. Install rotary manifold (2) on draft frame (5).
Specification
Rotary Manifold—Weight
(approximate)..................................................................................... 38 kg
84 lb.
14. Install cap screws (1) in rotary manifold (2).
NOTE: Work port numbers are stamped on the side and

bottom of the rotary manifold. The numbers next
to each port represents flow through the rotary
manifold. For example: Work port 1 on the side of
the rotary manifold is the same passage as work
port 1 on the bottom of the rotary manifold.
15. Connect hydraulic hoses (6) to rotary manifold. See

Hydraulic System Component Location—EH Controls.
(Group 9025-15.)
16. Remove vacuum pump from hydraulic oil tank. Check 34

for hydraulic oil leaks. See Vacuum Pump Installation. 3460
41
(Group 9025-25.)
17. Install cover (4) and cap screw (3).
18. If equipped, install circle rotate sensor (B39) and

perform a circle rotate calibration.See Electrohydraulic
(EH) Main Frame Harness (W39) Component
Location. (Group 9015-10.) See Display Unit—Main
Menu—Machine Configuration—Cross Slope Sensor
Cal—Circle Rotate Cal (Grade Pro Machines Only).

JW00603,000017D –19–05MAY09–3/3
TM11207 (11MAY09) 34-3460-41

051809
PN=547
Hydraulic System
Blade Lift, Blade Pitch, and Circle Side Shift

Cylinders Remove and Install


on hoses at cylinders.


34
3460
42
The approximate weights of cylinders are:
If rebuilding a blade lift cylinder on the

machine, it must be held while lowering, or it
may swing down and cause injury.
6.• Blade Lift Cylinder:
Specification
Blade Lift Cylinder—Weight
(approximate)..................................................................................... 70 kg
155 lb.
• Blade Pitch Cylinder:
Specification
Blade Pitch Cylinder—Weight
(approximate)..................................................................................... 23 kg
51 lb.
TM11207 (11MAY09) 34-3460-42

051809
PN=548
Hydraulic System
• Circle Side Shift Cylinder:
Specification
Circle Side Shift Cylinder—
104 lb.
Disconnect and tag hydraulic lines.
7. Remove cylinder from machine.
8. Repair or replace parts as necessary. See 120 Series

Hydraulic Cylinders. (TM-H120A.)
9. Install cylinder and connect lines.

(Group 2160.)

3460
12. The ball and socket assemblies on the lift cylinder rod 43
ends and on the circle side shift cylinder rod and
head end are to be shimmed to 1.1 mm (0.045 in.) to
provide maximum travel relative to the stationary ball
without binding.
Specification
Ball and Socket, Lift Cylinder Rod
End and Circle Side Shift
Cylinder Rod and Head End—
Shimmed......................................................................................... 1.1 mm
0.045 in.
JW00603,000017F –19–21JAN09–2/2
TM11207 (11MAY09) 34-3460-43

051809
PN=549
Hydraulic System
Blade Side Shift Cylinder Remove and Install
34
3460
44
TM11207 (11MAY09) 34-3460-44

051809
PN=550
Hydraulic System
4. Remove cap screw (2) and pin (3) from moldboard (1).
See NeverGrease Pin Joints. (Group 3440.)
5. Retract the blade side shift cylinder until the rod end
clears the holding bracket
–UN–08APR09
6. Remove moldboard (1) from blade pitch frame (5). See
Blade Pitch Frame Remove and Install. (Group 3440.)
TX1058097A
pressure in the system before disconnecting or Blade Side Shift Cylinder (left side shown)

on hoses at blade side shift cylinder (4).
–UN–08APR09
TX1058099A
9. Label and disconnect hydraulic hoses (6). Cap and
plug all openings. 34
3460
Blade Side Shift Cylinder (right side shown)
10. Remove pin (7) from blade pitch frame (5). See 45
NeverGrease Pin Joints. (Group 3440.) 1—Moldboard
2—Cap Screw
3—Pin
CAUTION: Avoid crushing injury. Use 4—Blade Side Shift Cylinder
appropriate lifting device. 5—Blade Pitch Frame
11. Remove blade side shift cylinder (4) from machine. 7—Pin
Specification
Blade Side Shift Cylinder.—
128 lb.
12. Inspect blade side shift cylinder, bushings, and pins

for excessive wear or damage.
Specification
Blade Side Shift Cylinder End
Bushing Bore—Diameter ............................................... 44.62—44.74 mm
1.757—1.761 in.
TM11207 (11MAY09) 34-3460-45

051809
PN=551
Hydraulic System
Specification
Blade Side Shift Cylinder Pin—
Diameter ..................................................................................... 44.45 mm
1.75 in.


14. Install blade side shift cylinder (4) to machine.
Specification
Blade Side Shift Cylinder.—
128 lb.
15. Install pin (7) in blade pitch frame (5) and blade side
shift cylinder (4). See NeverGrease Pin Joints.
(Group 3440.)
16. Connect hydraulic hoses (6) to blade side shift

cylinder (4).
34
3460
46 for hydraulic oil leaks. See Vacuum Pump Installation.
(Group 2160.)
18. Install moldboard (1) to blade pitch frame (5). See

Blade Pitch Frame Remove and Install. (Group 3440.)
19. Install cap screw (2) and pin (3) to moldboard (1) and
blade side shift cylinder (4).See NeverGrease Pin

BR70016,0000063 –19–06APR09–3/3
TM11207 (11MAY09) 34-3460-46

051809
PN=552
Hydraulic System
Articulation Cylinders Remove and Install
NOTE: Right articulation cylinder is shown. Remove and

install procedure for left articulation cylinder is the
similar.


on hoses at articulation cylinder (4).

Installation. (Group 2160.) 34
3460
47
TM11207 (11MAY09) 34-3460-47

051809
PN=553
Hydraulic System
6. Disconnect and tag hydraulic hoses. Cap and plug all

openings.
7. Remove cap screw (5) and nut (7).
–UN–13APR09
8. Remove pin (6). See NeverGrease Pin Joints. (Group
3440.)
TX1058125A
10. Remove pin (1). See NeverGrease Pin Joints.
(Group 3440.)
Articulation Cylinder (right side shown)
CAUTION: Avoid crushing injury. Use 1—Pin (rod end)

appropriate lifting device. 2—Cap Screw
3—Hydraulic Hoses (3 used)
4—Articulation Cylinder
11. Remove articulation cylinder (4) from machine. 5—Cap Screw
6—Pin (head end)
Specification 7—Nut
Articulation Cylinder—Weight
(approximate)..................................................................................... 31 kg
69 lb.
12. Inspect articulation cylinder, bushings, and pins for

34 excessive wear or damage.
3460
48 Specification
Blade Side Shift Cylinder Boss
Bushing—Diameter........................................................ 49.67—49.77 mm
1.955—1.959 in.
Specification
Articulation Pin (head end)—
Diameter ........................................................................... 49.5—49.45 mm
1.949—1.947 in.
Specification
Blade Side Shift Cylinder Bushing
Bore (rod end)—Diameter ............................................. 49.67—49.77 mm
1.955—1.959 in.
Specification
Articulation Pin (rod end)—
Diameter ................................................................................... 49.475 mm
1.948 in.

TM11207 (11MAY09) 34-3460-48

051809
PN=554
Hydraulic System

14. Install articulation cylinder (4) to machine.
Specification
Articulation Cylinder.—Weight
(approximate)..................................................................................... 31 kg
69 lb.
15. Install pins (1 and 6), cap screws (2 and 5), and nut
(7). See NeverGrease Pin Joints. (Group 3440.)
16. Connect hydraulic hoses (3).

(Group 2160.)

3460
49
JW00603,0000181 –19–21JAN09–3/3
TM11207 (11MAY09) 34-3460-49

051809
PN=555
Hydraulic System
34
3460
50
TM11207 (11MAY09) 34-3460-50

051809
PN=556
Section 42
Ground Conditioning Tool
Contents
Page
Group 4240—Frames
NeverGrease Pin Joints . . . . . . . . . . . . . . .42-4240-1
Scarifier/Blade Remove and Install . . . . . . . .42-4240-5
Midmount Scarifier Remove and Install . . . . .42-4240-7
Midmount Scarifier Cylinder Remove and
Install. . . . . . . . . . . . . . . . . . . . . . . . . . . .42-4240-14
Ripper Remove and Install . . . . . . . . . . . . .42-4240-16
Ripper Cylinders Remove and Install . . . . .42-4240-19
Balderson Style Front Lift Group Remove
and Install . . . . . . . . . . . . . . . . . . . . . . . .42-4240-21
42
770G,
051809
PN=1
Contents
42
770G,
051809
PN=2
Group 4240
Frames
NeverGrease Pin Joints
NOTE: Machines equipped with NeverGrease Pin Joints

do not require lubrication. Machines with this
option still require some service maintenance
points for grease in specified areas. These are
listed on the periodic maintenance chart on the
machine and in the operator’s manual listed under
service intervals.
IMPORTANT: Replacement of NeverGrease pin

joints require special methods for
replacement of bushings and shims. If
not followed the service life may be
decreased.
NeverGrease pin joints consist of two types. They are a

bushing (sliding element) type or a bearing (rolling
element or roller bearing) type. The application determines
what type is used. Both types require the same
replacement methods.
Throughout this information the term “bushing” will be

used to simplify procedures, with the exception when a
special instruction is needed for a certain type bushing
such as “bearing type” it will be called out specifically.
Cleanliness
Cleanliness is very critical. The bushing must be kept 42

clean at all times. Nothing should come in contract with 4240
the bushing surfaces which can contaminate or damage 1
the surfaces. If replacing with new service bushing keep in
clean shipping containers until installation. No lubrication
should be used on any surfaces of the bore, pin or
bushing itself when installing.
No lubrication should be used on any components of joint

including pin when servicing. This may decrease life of
joint.
Removal and Replacement of Pins
NeverGrease is a trademark of Deere & Company Continued on next page JW00603,0000102 –19–20JAN09–1/4
TM11207 (11MAY09) 42-4240-1

051809
PN=559
Frames
IMPORTANT: Removal and reinstallation of any pin

requires extra cleanliness attention to
the area supported by the pin. Any
debris inside of the joint will severely
affect the life of the joint.
Prior to pin removal, all material must be completely

removed from both ends of the pin and from the area
surrounding the structures connected by the pin by means
of a thorough power wash. Prior to pin reinstallation, any
remaining material on the pin or surrounding structure
must be removed. The NeverGrease bushing must also
be inspected and any material must be removed through
the use of compressed air or a clean dry rag only. Any
debris inside of the joint will severely affect the life of the
joint.
42
4240
2
TM11207 (11MAY09) 42-4240-2

051809
PN=560
Frames
Removal and Replacement of Bushings 1

2 3
IMPORTANT: Only use a hydraulic puller for removal
and installing bushing. Never use slide
hammer or impact type puller. 4
–UN–03APR07
Shimming is required where specified.
Some joints are more critical and will be
specified when required. Alignment in
TX1020245
the joint is important to prevent
premature wear.
Installing Bushing
1. Remove the old bushing from bore with Hydraulic
Puller Set D01047AA or Hydraulic Press D01013AA for
1 5 6
larger bushings.
2. Clean up bores thoroughly.
3. Check to make sure bore, bushing is perfectly clean
–UN–03APR07
and dry. Do not apply any lubrication to any 10
components in joint.
2 9
4. Measure bore I.D. for size to determine what disk (3)
TX1020247
size will be required for installation of bushing. It must
pass through the bore I.D. for proper centering in 7
frame bore with a hydraulic puller.
Bushing Type Joint

1 6
components of joint including pin. This 8 8
may decrease life of joint. 42
4240
5. Assemble Hydraulic Puller Set D01047AA and rod (4) 3
through center of bushing and bore and attach proper
–UN–03APR07
size disk. Support tooling to not come in contact with
bushing surfaces.
IMPORTANT: Must have the bushing aligned square
TX1020248
to the bore while installing. This will
keep from having misalignment in bore
and damage to bushing. Bushing Type Joint with External Split Seal (optional type seals
shown)
6. Make sure the bushing (2) is square to the bore. With
hydraulic puller install bushing into bore or frame. Keep 1—Boss
2—Bushing
perfectly square and aligned to bore while installing. 3—Disk
Center bushing in bore by pulling slightly past face of 4—Hydraulic Puller Rod
boss. Check each side to make sure bushing is 5—Shim (as required)
centered in bore. 6—Frame
7—Clearance
8—Split Seal (as required)
9—Pin
10—Internal Bushing Seal
TM11207 (11MAY09) 42-4240-3

051809
PN=561
Frames
7. Make sure pin (9) and bore are clean.
8. Align frame with bore.
9. Using different size shims (5) from service, place shims

at frame and boss joint for setting up proper clearance.
Center boss in frame (6) by shimming evenly. Add
shims as required to reduce clearance but not bind
joint.
Bearing type joints (roller bearing type) require a

specified clearance (7), see specification. Use a
smaller size shim as gauge to check final clearance
between boss and frame joint when required on
specified tolerances.
Specification
Bearing Type Joint (roller
bearing)—Clearance (maximum
total of both sides) ............................................................................. 1 mm
.040 in

parts of joint including pin. This may
decrease life of joint.
10. Check for alignment, cleanliness of joint and install

clean pin. No interference should be felt while
installing pin when proper alignment is established.
42 If restriction or interference is noted make sure of

4240 proper alignment in joint. Also, when using the
4 bushing type which has internal bushing seals (10)
make sure they are in the retracted position to allow
for smooth pin installation. Note art work item (10).
11. Install external split seals (8) if required.
Split seals that have a larger lip are installed with

large O.D. lip away form bushing center. Seal must
be placed tight against boss face.
Split seals with O-ring configuration are placed tight

against the boss face. Tighten banding screw.
JW00603,0000102 –19–20JAN09–4/4
TM11207 (11MAY09) 42-4240-4

051809
PN=562
Frames
Scarifier/Blade Remove and Install
1. Park machine on flat level surface.
42
4240
5
TM11207 (11MAY09) 42-4240-5

051809
PN=563
Frames
2. Remove scarifier shanks (5) if equipped and lower all

4. Support links (4).

4

3
device.
5. Use an appropriate lifting device to support

scarifier/blade (1) during removal. 2
–UN–14MAY09
1
Specification
Scarifier (if equipped)—Weight
(approximate)................................................................................. 1797 kg
815 lb.
TX1059429
Blade (if equipped)—Weight 5
(approximate)................................................................................. 2944 kg
1334 lb.
Scarifier
6. If equipped, remove snap rings (2).

3
7. If equipped, remove cap screws and nuts (6 and 7).
6 4
8. Remove pins (3) from scarifier/blade to remove.
7
9. Inspect and replace parts as necessary. 1
42
device.
10. Install scarifier/blade and pins.
–UN–13MAY09
Specification
Scarifier (if equipped)—Weight
(approximate)................................................................................. 1797 kg
815 lb.
TX1059430
Blade (if equipped)—Weight

(approximate)................................................................................. 2944 kg
1334 lb.
Blade
11. If equipped, install snap rings.
1—Scarifier/Blade
2—Snap Ring (8 used)
12. If equipped, install cap screws and nuts. 3—Pin (4 used)
4—Link (2 used)
13. Turn battery disconnect switch to ON position. 5—Shank
7—Nut (4 used)
TM11207 (11MAY09) 42-4240-6

051809
PN=564
Frames
14. Operate scarifier/blade up and down to check

function.
JW00603,0000186 –19–14MAY09–3/3
Midmount Scarifier Remove and Install

JW00603,0000187 –19–21JAN09–1/8
2. Place wood blocks (1) under midmount scarifier tool

bar (2) as shown.
3. Lower midmount scarifier onto wood blocks.


on hoses for scarifier fittings.
–UN–05FEB09
4240
6. Remove midmount scarifier cylinder. See Midmount
TX1055394A
7
Scarifier Cylinder Remove and Install. (Group 4240.)
1—Wood Block Midmount Scarifier Resting on Blocks

2—Midmount Scarifier Tool Bar
TM11207 (11MAY09) 42-4240-7

051809
PN=565
Frames

device.
7. Support support rods (3).
Specification
Support Rod—Weight
(approximate)..................................................................................... 29 kg
64 lb.
NOTE: Record position of shims on support rod ends to

aid in assembly.
–UN–05FEB09
8. Remove cap screws (4) and remove support rod (3).
Repeat procedure for opposite side.
TX1055395A
3—Support Rod (2 used)
Midmount Scarifier Support Rods
42
4240
8
TM11207 (11MAY09) 42-4240-8

051809
PN=566
Frames

device.
9. Support midmount scarifier tool bar (2).
Specification
Midmount Scarifier Tool Bar—
448 lb.

–UN–05FEB09
device.
10. Support midmount scarifier arms (5).
TX1055396A
Specification
Midmount Scarifier Arm—Weight
(approximate)................................................................................... 149 kg
329 lb. Midmount Scarifier Tool Bar Arms
11. Remove cap screws (6). 2—Midmount Scarifier Tool Bar

5—Midmount Scarifier Arm (2 used)
12. Remove midmount scarifier tool bar.
42
4240
9
TM11207 (11MAY09) 42-4240-9

051809
PN=567
Frames
13. Remove nut (10), cap screw (7), and collar (8).
14. Remove midmount scarifier arm (5).
15. Repeat previous procedure for opposing side

midmount scarifier arm.

device.
16. Support midmount scarifier mount/push block (12).
–UN–05FEB09
Specification
Midmount Scarifier Mount/Push
block—Weight (approximate) .......................................................... 609 kg
1342 lb.
TX1055397A
IMPORTANT: To prevent damage to hydraulic lines, Front of Midmount Scarifier

watch that hydraulic lines are free of
midmount scarifier mount/push block. 5—Midmount Scarifier Arm (2 used)
8—Collar (2 used)
18. Remove midmount scarifier mount/push block. 9—Pin
10—Nut (2 used)
11—Set Screw (2 used)
12—Midmount Scarifier Mount/Push Block
42
4240
10
TM11207 (11MAY09) 42-4240-10

051809
PN=568
Frames

device.
19. Support bellcrank (14).
Specification
Bellcrank—Weight (approximate) .................................................... 172 kg
379 lb.
20. Remove nuts (16), cap screws (15).
21. Remove bellcrank bearing housings (17) from
–UN–05FEB09
bellcrank (14).
22. Remove bellcrank.
TX1055398A
23. Inspect and repair or replace parts as necessary.
CAUTION: Prevent possible crushing injury Midmount Scarifier Bellcrank

device. 14—Bellcrank
16—Nut (4 used)
24. Install bellcrank bearing housings and bellcrank.
17—Bellcrank Bearing Housing (4 used)
Specification
Bellcrank—Weight (approximate) .................................................... 172 kg
379 lb.
25. Install cap screws and nuts. 42

4240
11
TM11207 (11MAY09) 42-4240-11

051809
PN=569
Frames

device.
IMPORTANT: To prevent damage to hydraulic lines,

watch that hydraulic lines are free of
midmount scarifier mount/push block.
26. Install midmount scarifier mount/push block (12).
Specification
Midmount Scarifier Mount/Push
block—Weight (approximate) .......................................................... 609 kg
–UN–05FEB09
1342 lb.

TX1055397A
device.
27. Install midmount scarifier arms (5).

Front of Midmount Scarifier
Specification
Midmount Scarifier Arm—Weight
(approximate)................................................................................... 149 kg
8—Collar (2 used)
329 lb.
9—Pin
10—Nut (2 used)
11—Set Screw (2 used)
12—Midmount Scarifier Mount/Push Block
42
4240
12
TM11207 (11MAY09) 42-4240-12

051809
PN=570
Frames

device.
28. Install midmount scarifier tool bar (2).
Specification
Midmount Scarifier Tool Bar—
448 lb.

–UN–05FEB09
device.
IMPORTANT: Install shims in previously noted

location.
TX1055396A
29. Install support rods (3).
Midmount Scarifier Tool Bar Arms
Specification
Support Rod—Weight
(approximate)..................................................................................... 29 kg
64 lb.
30. Install midmount scarifier cylinder. See Midmount

Scarifier Cylinder Remove and Install. (Group 4240.)
31. Operate midmount scarifier to bleed air from hydraulic

cylinder.
42
4240
32. Check hydraulic tank oil level. See Checking 13
JW00603,0000187 –19–21JAN09–8/8
TM11207 (11MAY09) 42-4240-13

051809
PN=571
Frames
Midmount Scarifier Cylinder Remove and

Install



on hoses for scarifier cylinders.
42
4240
14
TM11207 (11MAY09) 42-4240-14

051809
PN=572
Frames
4. Attach identification tags to scarifier raise hydraulic line

(2) and scarifier lower hydraulic line (3).

caps and plugs.

device.
6. Support scarifier cylinder (1).
Specification
–UN–05FEB09
Scarifier Cylinder—Weight
(approximate)..................................................................................... 37 kg
81 lb.
TX1055408A
7. Remove cap screws (4), pins (5) and scarifier cylinder.
8. Inspect and repair parts as necessary. See 120 Series

Hydraulic Cylinders. (TMH120A.) Scarifier Cylinder
1—Scarifier Cylinder
CAUTION: Prevent possible crushing injury 2—Scarifier Raise Hydraulic Line
from heavy component. Use appropriate lifting 3—Scarifier Lower Hydraulic Line
device. 4—Cap Screw (2 used)
5—Pin (2 used)
9. Install scarifier cylinder, pins and cap screws.
Specification
Scarifier Cylinder—Weight 42
(approximate)..................................................................................... 37 kg 4240
81 lb. 15
10. Connect hydraulic lines to scarifier cylinder.
11. Operate midmount scarifier to bleed air from scarifier

cylinder.

JW00603,0000190 –19–03FEB09–2/2
TM11207 (11MAY09) 42-4240-15

051809
PN=573
Frames
Ripper Remove and Install



on hoses for ripper.
JW00603,000018A –19–21JAN09–1/4
4. Attach identification tags to hydraulic lines (1—4).

caps and plugs.
1—Left Cylinder Down Hydraulic Line

2—Right Cylinder Up Hydraulic Line
3—Right Cylinder Down Hydraulic Line
42 4—Left Cylinder Up Hydraulic Line
4240
16
–UN–04FEB09
TX1055286A
Ripper Hydraulic Lines
TM11207 (11MAY09) 42-4240-16

051809
PN=574
Frames

device.
6. Support ripper support arm (5).
–UN–06APR09
Specification
Ripper Support Arm—Weight
(approximate)..................................................................................... 34 kg
TX1057949A
75 lb.
7. Remove pins (6) from support arms.

Ripper Support Arm (right side shown)
8. Lower support arms to ground.
5—Ripper Support Arm (2 used)
6—Pin (2 used)
42
4240
17
TM11207 (11MAY09) 42-4240-17

051809
PN=575
Frames

device.
9. Support ripper (7).
Specification
Ripper—Weight (approximate) ...................................................... 1790 kg
3946 lb.
11. Remove ripper.
–UN–06APR09
12. Inspect and repair parts as necessary.
TX1055285A
device.
Ripper Assembly
13. Install ripper and cap screws.
7—Ripper
Specification 8—Cap Screw (10 used)
Ripper—Weight (approximate) ...................................................... 1790 kg
3946 lb.

device.
42
4240
14. Install ripper support arms and pins.
18
Specification
Ripper Support Arm—Weight
(approximate)..................................................................................... 34 kg
75 lb.
15. Connect hydraulic hoses.
16. Operate ripper up and down.
17. Check hydraulic tank oil level. See Checking

JW00603,000018A –19–21JAN09–4/4
TM11207 (11MAY09) 42-4240-18

051809
PN=576
Frames
Ripper Cylinders Remove and Install

2. Shut machine off and operate ripper control lever to

relieve hydraulic pressure.
JW00603,000018B –19–21JAN09–1/3
4. Attach identification tags to hydraulic lines (1—4).

caps and plugs.

2—Right Cylinder Up Hydraulic Line
3—Right Cylinder Down Hydraulic Line
4—Left Cylinder Up Hydraulic Line
–UN–04FEB09
42
4240
TX1055286A
19
Ripper Hydraulic Lines
TM11207 (11MAY09) 42-4240-19

051809
PN=577
Frames

device.
6. Support ripper cylinders.
Specification
Ripper Cylinder—Weight
(approximate)..................................................................................... 40 kg
88 lb.
7. Remove cap screws (7), nuts (6), and collars (8). Slide
ripper cylinder off pins (9).
–UN–12FEB09
8. Inspect and repair ripper cylinders as necessary. See
120 Series Hydraulic Cylinders. (TMH120A.)
TX1055628A
device.
Left Ripper Cylinder Head End
9. Install ripper cylinders.
Specification
Ripper Cylinder—Weight
(approximate)..................................................................................... 40 kg
88 lb.
10. Install collars, cap screws, and nuts.

42
4240
11. Connect hydraulic lines to ripper cylinders.
20
12. Operate ripper up and down to bleed air from ripper
cylinders.
–UN–12FEB09

TX1055629A
4—Left Cylinder Up Hydraulic Line

5—Ripper Cylinder
6—Nut (4 used)
7—Cap Screw (4 used) Left Ripper Cylinder Rod End
8—Collar (4 used)
9—Pin (4 used)
JW00603,000018B –19–21JAN09–3/3
TM11207 (11MAY09) 42-4240-20

051809
PN=578
Frames
Balderson Style Front Lift Group Remove

and Install


3. To relieve pressure slowly loosen fittings on hoses at

hydraulic lift cylinder (6).
42
4240
21
TM11207 (11MAY09) 42-4240-21

051809
PN=579
Frames
4. Attach identification tags to attachment raise hydraulic

line (2) and attachment lower hydraulic line (3).
5. Disconnect hydraulic lines from hydraulic cylinder.

Close all openings using caps and plugs.

device.
6. Support Balderson Style Front Lift Group.
Specification
–UN–03APR09
Balderson Style Front Lift
Group—Weight (approximate)....................................................... 1100 kg
2425 lb.
TX1055529A
8. Remove Balderson style front lift group mount (5).

Balderson Style Front Lift Group
9. Inspect and repair as necessary.
1—Balderson Style Front Lift Group Frame
2—Attachment Raise Hydraulic Line
CAUTION: Prevent possible crushing injury 3—Attachment Lower Hydraulic Line
from heavy component. Use appropriate lifting 4—Cap Screw (12 used)
5—Balderson Style Front Lift Group Mount
device. 6—Hydraulic Cylinder
10. Install Balderson style front lift group and cap screws.
42 11. Connect hydraulic lines.

4240
22
13. Operate Balderson style front lift group to bleed

hydraulic cylinder.

Balderson is a registered trademark of Caterpillar, Inc. JW00603,0000191 –19–15MAY09–2/2
TM11207 (11MAY09) 42-4240-22

051809
PN=580
Section 99
Dealer Fabricated Tools
Contents
Page
Group 9900—Dealer Fabricated Tools

DF1017—Axle Lift Eye . . . . . . . . . . . . . . . . .99-9900-1
DF1057—Axle Adjusting Tool . . . . . . . . . . . .99-9900-2
DFRW20 Compressor Holding Fixture. . . . . .99-9900-3
DFRW103—Yoke Holding Tool1 . . . . . . . . . .99-9900-4
DFT1101 Cab and ROPS Lift Bracket . . . . . .99-9900-5
DFT1151—Outboard Bearing Driver . . . . . . .99-9900-6
DFT1152—Inboard Bearing Driver . . . . . . . .99-9900-7
DFT1153—Oil Seal Driver. . . . . . . . . . . . . . .99-9900-7
DFT1225—Rolling Torque Measurement
Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .99-9900-8
DFT1250 Lifting Bracket . . . . . . . . . . . . . . . .99-9900-9
DFT1282—King Pin Torque Adapter . . . . . .99-9900-10
DFT1308 Transmission Support Bracket . . .99-9900-12
DFT1310—Cab Mount Control Valve Support
Bracket . . . . . . . . . . . . . . . . . . . . . . . . . .99-9900-14
DFT1311—Extension for DFT1250 . . . . . . .99-9900-16
99
770G,
051809
PN=1
Contents
99
770G,
051809
PN=2
Group 9900
DF1017—Axle Lift Eye
–19–22MAY89
99
T6401FS
9900
1
Axle Lift Eye is used for removal and installation of • 12.7 mm (0.50 in.) 1020 mild steel.
axle housing.
Material required:
T29,9900,M3 –19–06JAN05–1/1
TM11207 (11MAY09) 99-9900-1

051809
PN=583
DF1057—Axle Adjusting Tool
99 –UN–22OCT91
RW18932
9900
2 A—660.4 mm (26 in.) G—250.8 mm (9.87 in.) L—0.1875 x 2 x 2 in. Tube S—355.6 mm (14 in.)
B—225.4 mm (8.87 in.) H—223.8 mm (8.81 in.) M—25.4 mm (1 in.) T—425.2 mm (16.74 in.)
C—1/2 in. Drilled Hole (2 I—25.4 mm (1 in.) N—25.4 mm (1 in.) U—25.4 mm (1 in.)
places) J—0.25 x 1 x 1.38 in. Each O—11/16 in. Drilled Hole V—3/4 in. Drilled Hole (2
D—Welded Nut (Centered) Chain Link P—104.7 mm (4.13 in.) places)
E—300 mm (11.81 in.) K—3/4 in. Drilled Hole (8 Q—50.8 mm (2 in.) W—25.4 mm (1 in.)
F—274.1 mm (10.79 in.) Places) R—307.9 mm (12.12 in.) X—88.9 mm (3.5 in.)
Material Required: Use an odd number of links in the section of chain.
• 2 x 2 in. Steel Tube Tool is used to remove axle shaft and adjust axle
• 2 x 1/2 in. Flat Steel bearings.
RX,DF1057 –19–06JAN05–1/1
TM11207 (11MAY09) 99-9900-2

051809
PN=584
DFRW20 Compressor Holding Fixture
–UN–20SEP89
RW13619
A—102 mm (4 in.) D—6.4 mm (0.25 in.) G—254 mm (10 in.) J—Weld
B—76 mm (3 in.) E—19 mm (0.75 in.) H—114 mm (4.5 in.) K—Two Holes
C—70 mm (2.75 in.) F—152 mm (6 in.) I—178 mm (7 in.)
This tool is used to hold the air conditioning • Two pieces of threaded rod, 13 mm (1/2 in.) threads
compressor during disassembly and assembly. x 178 mm (7 in.) long and four lock washers and
nuts.
MATERIALS:
99
• Two pieces of steel plate, approximately 70 x 120 9900
mm (2-3/4 x 4 in.) and 152 x 254 mm (6 x 10 in.). 3
NX,19905,F –19–06JAN05–1/1
TM11207 (11MAY09) 99-9900-3

051809
PN=585
DFRW103—Yoke Holding Tool1
–UN–14JUN95
RW25384
Material Required: Tool is used to retain input shaft during yoke retaining
nut remove and installation.
• 3/8 in. Flat Steel
Fabricate holding tool as illustrated.
1
Tool may be purchased. Order JDG924.
TX19495,000016E –19–06JAN05–1/1
99
9900
4
TM11207 (11MAY09) 99-9900-4

051809
PN=586
DFT1101 Cab and ROPS Lift Bracket
–UN–23SEP98
T117366
A—Drill Six Holes (0.625 in.) B—Weld C—U46161 Lift Eyes Welded to
Tube with 0.25 in. Fillet
Weld
Used to remove and install cab or ROPS. • U46161 U-Bolts (4 used)

• JT01748 Lift Brackets (2 used)
Material: • 0.625 in. x 3.00 in. "F" Grade Cap Screws (2 used) 99
9900
5
• 2.0 in. x 2.0 in. x 0.250 in. Square Tube
TX,18,QQ9298 –19–01SEP06–1/1
TM11207 (11MAY09) 99-9900-5

051809
PN=587
DFT1151—Outboard Bearing Driver
–UN–21JUL97
T110629
Material Required: • Steel tubing or equivalent
• 114.4 mm OD x 9.5 mm wall (4.50 in. OD x 0.375

in. wall)
TX,02,DU2626 –19–06JAN05–1/1
99
9900
6
TM11207 (11MAY09) 99-9900-6

051809
PN=588
DFT1152—Inboard Bearing Driver
–19–21JUL97
T110630
Material Required: • Barrel—114.4 mm OD x 9.5 mm wall (4.50 in. OD x
0.375 in. wall)
• Cap—20 mm (0.75 in.) mild steel plate • Steel tubing or equivalent
TX,02,DU2626 –19–06JAN05–1/1
DFT1153—Oil Seal Driver
99
9900
7
–19–21JUL97
T110631
Materials Required: • Driver—152 mm (6.0 in.) mild steel bar

• Handle—51 mm (2.0 in.) mild steel bar
• Driver—38 mm (1.50 in.) mild steel plate, or
TX,02,DU2627 –19–18JUL97–1/1
TM11207 (11MAY09) 99-9900-7

051809
PN=589
DFT1225—Rolling Torque Measurement Tool
–UN–16NOV01
T148180
A—580 mm (23 in) (minimum) D—262 mm (10.3 in) F—10 mm (3/8 in) threaded rod H—10 mm (3/8 in) cap screw
B—523 mm (20.6 in) E—10 mm (3/8 in) nut and G—230 mm (9 in)
C—10 mm (3/8 in) flat steel bar washer (8 used)
Material Required: • 10 mm (3/8 in) cap screw (H)
99 • 10 mm (3/8 in) flat steel bar (C) Tool is used to measure rolling torque on HFWD wheel
9900 • 10 mm (3/8 in) threaded rod (F) drive hubs.
8
• 10 mm (3/8 in) nuts and washers (E) (8 used)
TX19495,000016F –19–06JAN05–1/1
TM11207 (11MAY09) 99-9900-8

051809
PN=590
DFT1250 Lifting Bracket
99
9900
9
–UN–01DEC04
T202517
DFT1250 Lifting Bracket

Continued on next page MM16284,0000DBA –19–22APR09–1/2
TM11207 (11MAY09) 99-9900-9

051809
PN=591
Lifting bracket is used to remove and install final drives • 50 x 50 mm (2 x 2 in.) 1020 Steel Bar Stock
and other heavy components with limited access. • 20 x 50 mm (0.75 x 2 in.) 1020 Steel Plate
• 7018 Electrodes for welding
Material required:
MM16284,0000DBA –19–22APR09–2/2
DFT1282—King Pin Torque Adapter
B C
D
E G
–UN–19DEC06
J
TX1016357
TX1016357
A—173 mm (6.8 in.) D—70.5 mm (2.78 in.) G—24 mm Nut J—19 mm (0.750 in.)
99 B—70.5 mm (2.78 in.) E—Weld H—13 mm (0.5 in.) K—38 mm (1.5 in.)
9900 C—86.5 mm (3.41 in.) F—6 mm (0.25 in.)
10
Material Required: Tool is used to measure rolling torque of lean yoke on
lower king pin of front hubs.
• 6 mm (1/4 in.) flat steel bar
• 24 mm Nut
AC12469,000003C –19–19DEC06–1/1
TM11207 (11MAY09) 99-9900-10

051809
PN=592
99
9900
11
TM11207 (11MAY09) 99-9900-11

051809
PN=593
2
3
6
Ø21 mm
(0.827 in.) 1
101.6 mm
(4.0 in.)
244.5 mm
(9.625 in.)
23 mm 57 mm
(0.906 in.) (2.25 in.)
75 mm
20 mm (2.95 in.)
(0.787 in.)
99
9900
12 45 mm
101.6 mm
(4.0 in.) (1.77 in.)
3
5 5
5 Ø18 mm
200 mm 16 mm (0.70 in.)
(7.87 in.) (0.625 in.) 20 mm
(0.78 in.)
101.6 mm
(4.0 in.)
–UN–30APR09
TX1049290
TX1049290
Continued on next page MM16284,0000DAC –19–02FEB09–1/2
TM11207 (11MAY09) 99-9900-12

051809
PN=594
1—18 mm Unplated Nut 3—203.5 mm (8.0 in.) x 101.6 4—101.6 mm x 101.6 mm (4 5—Weld
2—244.5 mm (9.625 in.) x 101.6 mm (4 in.) x 15.88 mm in.) x 15.88 mm (0.625 in.) 6—18 mm x 65 mm Cap
mm (4 in.) x 15.88 mm (0.625 in.) Plate Plate Screw
(0.625 in.) Plate
Material Required: Transmission support bracket is used to hold

transmission in chassis when engine is removed. Right
• 244.5 mm (9.625 in.) x 101.6 mm (4 in.) x 15.88 mm side bracket is shown. Left side bracket is a mirror
(0.625 in.) 1020 HR Steel image of the right. Left side of transmission requires a
• 203.5 mm (8.0 in.) x 101.6 mm (4 in.) x 15.88 mm spacer plate drilled to the same 4 hole pattern as
(0.625 in.) 1020 HR Steel bracket. Nut is welded on bottom of plate and cap
• 101.6 mm x 101.6 mm (4 in.) x 15.88 mm (0.625 in.) screw is threaded from bottom for adjustment purpose
1020 HR Steel cut diagonal of bracket.
• 18 mm Nut
• 18 mm x 65 mm Cap Screw
MM16284,0000DAC –19–02FEB09–2/2
99
9900
13
TM11207 (11MAY09) 99-9900-13

051809
PN=595
DFT1310—Cab Mount Control Valve Support Bracket
25.4 mm 25.4 mm
25.4 mm (1.0 in.) (1.0 in.) 25.4 mm
(1.0 in.) (1.0 in.)
5 mm
(0.197 in.) 3 3
3
152.4 mm
(6.0 in.)
25.4 mm
(1.0 in.)
45˚
5 mm
(0.197 in.)
1 1
1
304.8 mm
(12.0 in.)
2
99
9900
14
2
–UN–30APR09
304.8 mm
(12.0 in.)
TX1057327
TX1057327
DFT1310—Cab Mount Control Valve Support Bracket
1—3.81 cm (1-1/2 in.) x 30.5 2—5.08 cm (2 in.) x 30.5 cm 3—Weld Joints

cm (12 in.) x 0.635 cm (1/4 (12 in.) x 0.635 cm (1/4 in.)
in.) angle iron (2 used) angle iron
Material Required:
Continued on next page BR70016,000005C –19–19MAR09–1/2
TM11207 (11MAY09) 99-9900-14

051809
PN=596
• 3.81 cm (1-1/2 in.) x 30.5 cm (12 in.) x 0.635 cm Tool is used to support cab mount control valve during
(1/4 in.) angle iron (2 used) removal and installation procedure.
• 5.08 cm (2 in.) x 30.5 cm (12 in.) x 0.635 cm (1/4
in.) angle iron
BR70016,000005C –19–19MAR09–2/2
99
9900
15
TM11207 (11MAY09) 99-9900-15

051809
PN=597
DFT1311—Extension for DFT1250
457.2 mm
(18.0 in.)
1
52.4 mm
(2.06 in.)
50.2 mm
(2.0 in.) 9.53 mm
2 1 (0.375 in.)
457.2 mm 457.2 mm
(18.0 in.) (18.0 in.)
152.4 mm
38.1 mm (6.0 in.) 31.75 mm 3 3
(1.5 in.) (1.25 in.)
63.5 mm
(2.5 in.)
–UN–30APR09
457.2 mm Ø20 mm Ø20 mm 3
(18.0 in.) (0.787 in.) (0.787 in.)
TX1058734
TX1058734
99
Extension for DFT1250
9900
16
1—457.2 mm (18 in.) x 63.5 2—50.2 mm (2 in.) x 76.2 mm 3—Weld Joints (4 used)
mm (2.5 in.) x 9.53 mm (2 in.) x 152.4 mm (6 in.)
(0.375 in.) Flat Steel (2 Squared Tube
used)
Material Required • 18 mm (0.706 in.) Nut (2 used)

• 18 mm (0.706 in.) Washer (4 used)
• 457.2 mm (18 in.) x 63.5 mm (2.5 in.) x 9.53 mm
(0.375 in.) Flat Steel (2 used) Tool is mounted to DFT1250 with cap screws and nuts
• 50.2 mm (2 in.) x 76.2 mm (2 in.) x 152.4 mm (6 in.) to allow for removal and installation of transmission.
Squared Tube
• 18 mm (0.706 in.) x 100 mm (3.937 in.) Cap Screw
(2 used)
BR70016,0000066 –19–23APR09–1/1
TM11207 (11MAY09) 99-9900-16

051809
PN=598
Index
Page Page
Articulation bearing
A Replacement. . . . . . . . . . . . . . . . . . . . .17-1740-10
Articulation cylinders
Accumulator Remove and install . . . . . . . . . . . . . . . .34-3460-47
Air conditioner, remove and install . . . .18-1830-34 Articulation joint
Brake, remove and install . . . . . . . . . . . .10-1060-4 Separate frame . . . . . . . . . . . . . . . . . . . .17-1740-3
Secondary steering, remove and Attachments
install. . . . . . . . . . . . . . . . . . . . . . . . .09-0960-17 Adding safely . . . . . . . . . . . . . . . . . . . . . . . 001-10
Adjustment Operating safely . . . . . . . . . . . . . . . . . . . . . 001-10
Circle clearance . . . . . . . . . . . . . . . . . .34-3440-24 Auxiliary
Air conditioner Valve section-EH controls, disassemble and
Accumulator remove and install . . . . . .18-1830-34 assemble . . . . . . . . . . . . . . . . . . . . . .34-3460-26
Compressor relief valve remove and Auxiliary with float
install. . . . . . . . . . . . . . . . . . . . . . . . .18-1830-37 Valve section, disassemble and
Compressor remove and install-6.8L. . .18-1830-22 assemble . . . . . . . . . . . . . . . . . . . . . .34-3460-22
Compressor remove and install-9.0L. . .18-1830-24 Auxiliary without float
Condener remove and install . . . . . . . .18-1830-26 Valve section, disassemble and
Receiver-dryer remove and install . . . . .18-1830-33 assemble . . . . . . . . . . . . . . . . . . . . . .34-3460-24
Air conditioner and heater Axle
Remove and install . . . . . . . . . . . . . . . .18-1830-28 Final drive, disassemble and
Air conditioner system assemble . . . . . . . . . . . . . . . . . . . . . .02-0250-29
Flush and purge . . . . . . . . . . . . . . . . . . .18-1830-3 Final drive, remove and install . . . . . . .02-0250-22
Refrigerant cautions and proper Front, non 6WD, remove and install . . . .02-0230-7
handling. . . . . . . . . . . . . . . . . . . . . . . .18-1830-1 Front, 6WD, remove and install. . . . . . .02-0240-42
R134a refrigerant oil information . . . . . . .18-1830-8 Planet pinion carrier, remove and
Air conditioning install. . . . . . . . . . . . . . . . . . . . . . . . .02-0250-34
Blower motor assembly remove and Rear, disassemble and assemble . . . . . .02-0250-6
install. . . . . . . . . . . . . . . . . . . . . . . . .18-1830-21 Rear, remove and install . . . . . . . . . . . . .02-0250-1
Expansion valve . . . . . . . . . . . . . . . . . .18-1830-15 Tandem and wheel assembly, remove and
Freeze control switch . . . . . . . . . . . . . .18-1830-17 install. . . . . . . . . . . . . . . . . . . . . . . . .02-0250-10
Heater control valve . . . . . . . . . . . . . . .18-1830-20 Tandem wheel assembly, disassemble and
Heater control valve leak check . . . . . .18-1830-21 assemble . . . . . . . . . . . . . . . . . . . . . .02-0250-12
R134a station installation . . . . . . . . . . .18-1830-10 Axle adjusting tool
R134a system charge . . . . . . . . . . . . . .18-1830-14 DF1057. . . . . . . . . . . . . . . . . . . . . . . . . .99-9900-2
R134a system evacuate . . . . . . . . . . . .18-1830-12 Axle lift eye
R134a system recover . . . . . . . . . . . . .18-1830-11 DF1017. . . . . . . . . . . . . . . . . . . . . . . . . .99-9900-1
Air conditioning high-low pressure switch
Remove and install . . . . . . . . . . . . . . . .18-1830-19
Air suspension
Disassemble and assemble . . . . . . . . .18-1821-14 B Indx
Armrest 1
Disassemble and assemble-EH machine Balderson style
only . . . . . . . . . . . . . . . . . . . . . . . . . . .18-1821-8 Lift group, remove and install . . . . . . . .42-4240-21
Remove and install . . . . . . . . . . . . . . . . .18-1821-5 Balderson style lift group
Remove and install-EH machine only . . .18-1821-6 Remove and install . . . . . . . . . . . . . . . .42-4240-21
Arms Battery explosions
Lift, remove and install . . . . . . . . . . . . . .34-3440-6 Prevent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 001-4
Articulation Bearing
Cylinder, disassemble and assemble . .09-0960-11 6WD, remove and install . . . . . . . . . . . .02-0240-29
Valve section, disassemble and Bearing, articulation
assemble . . . . . . . . . . . . . . . . . . . . . .34-3460-28 Replacement. . . . . . . . . . . . . . . . . . . . .17-1740-10
Valve section-EH controls, disassemble and Blade
assemble . . . . . . . . . . . . . . . . . . . . . .34-3460-30 Remove and install . . . . . . . . . . . . . . . . .42-4240-5
TM11207 (11MAY09) Index-1

051809
PN=1
Index
Page Page
Side shift wear inserts, remove and Cab mount

install. . . . . . . . . . . . . . . . . . . . . . . . .34-3440-29 Grader control valve-EH controls remove and
Blade lift install. . . . . . . . . . . . . . . . . . . . . . . . . .34-3460-9
Cylinder, disassemble and assemble . .09-0960-11 Cab mount control valve support bracket
Cylinder, remove and install . . . . . . . . .34-3460-42 DFT1310. . . . . . . . . . . . . . . . . . . . . . . .99-9900-14
Valve section, disassemble and Chain
assemble . . . . . . . . . . . . . . . . . . . . . .34-3460-18 Drive, remove and install. . . . . . . . . . . .02-0250-41
Valve section-EH controls, disassemble and Charge
assemble . . . . . . . . . . . . . . . . . . . . . .34-3460-20 R134a system. . . . . . . . . . . . . . . . . . . .18-1830-14
Blade pitch Charge pump
Cylinder, disassemble and assemble . .09-0960-11 6WD, remove and install . . . . . . . . . . . .02-0260-42
Cylinder, remove and install . . . . . . . . .34-3460-42 Charged air cooler
Valve section, disassemble and Remove and install . . . . . . . . . . . . . . . .05-0510-14
assemble . . . . . . . . . . . . . . . . . . . . . .34-3460-28 Circle
Valve section-EH controls disassemble and Clearance adjust . . . . . . . . . . . . . . . . . .34-3440-24
assemble . . . . . . . . . . . . . . . . . . . . . .34-3460-30 Circle drive gearbox
Blade pitch frame Disassemble and assemble . . . . . . . . . .34-3450-4
Remove and install . . . . . . . . . . . . . . . .34-3440-16 Remove and install . . . . . . . . . . . . . . . . .34-3450-1
Blade side shift Circle drive gearbox (with slip clutch)
Cylinder, remove and install . . . . . . . . .34-3460-44 Disassemble and assemble . . . . . . . . .34-3450-10
Valve section, disassemble and Circle frame
assemble . . . . . . . . . . . . . . . . . . . . . .34-3460-28 Remove and install . . . . . . . . . . . . . . . .34-3440-20
Valve section-EH controls, disassemble and Circle rotate
assemble . . . . . . . . . . . . . . . . . . . . . .34-3460-30 Valve section, disassemble and
Blade side shift wear inserts assemble . . . . . . . . . . . . . . . . . . . . . .34-3460-32
Remove and install . . . . . . . . . . . . . . . .34-3440-29 Valve section-EH controls, disassemble and
Blade slide assemble . . . . . . . . . . . . . . . . . . . . . .34-3460-34
Cylinder, disassemble and assemble . .09-0960-11 Circle side shift
Blower motor assembly Cylinder, remove and install . . . . . . . . .34-3460-42
Remove and install . . . . . . . . . . . . . . . .18-1830-21 Valve section, disassemble and
Brake assemble . . . . . . . . . . . . . . . . . . . . . .34-3460-28
Accumulator, remove and install . . . . . . .10-1060-4 Valve section-EH controls, disassemble and
Components, remove and install . . . . . .02-0250-33 assemble . . . . . . . . . . . . . . . . . . . . . .34-3460-30
Park, Disassemble and assemble . . . . . .11-1111-1 Circle sideshift
Park, remove and install . . . . . . . . . . . . .11-1111-1 Cylinder, disassemble and assemble . .09-0960-11
Service valve, remove and install . . . . . .10-1060-1 Cleanup procedure
Service, bleeding . . . . . . . . . . . . . . . . . .10-1060-3 General oil . . . . . . . . . . . . . . . . . . . . . .21-2160-23
Service, disassemble and assemble . . . .10-1011-1 Hydraulic/hydrostatic component
Service, remove and install . . . . . . . . . . .10-1011-1 failure . . . . . . . . . . . . . . . . . . . . . . . .21-2160-26
Indx Brake accumulator Clutch
2 Remove and install . . . . . . . . . . . . . . . . .10-1060-4 Compressor, disassemble and
assemble . . . . . . . . . . . . . . . . . . . . . .18-1830-35
Component failure
Hydraulic/hydrostatic, cleanup
C procedure . . . . . . . . . . . . . . . . . . . . .21-2160-26
Compressor
Cab Air conditioner, remove and
Remove and install . . . . . . . .18-1800-1, 18-1800-9 install-6.8L . . . . . . . . . . . . . . . . . . . . .18-1830-22
Cab and ROPS lift bracket Air conditioner, remove and
DFT1101. . . . . . . . . . . . . . . . . . . . . . . . .99-9900-5 install-9.0L . . . . . . . . . . . . . . . . . . . . .18-1830-24
Cab door Clutch, disassemble and assemble . . . .18-1830-35
Handle remove and install. . . . . . . . . . . .18-1810-2 Manifold, inspect . . . . . . . . . . . . . . . . . .18-1830-36
Latch remove and install . . . . . . . . . . . . .18-1810-3 Relief valve remove and install . . . . . . .18-1830-37

051809
PN=2
Index
Page Page
Compressor holding fixture DFT1151 outboard bearing driver . . . . . .99-9900-6

DFRW20 . . . . . . . . . . . . . . . . . . . . . . . . .99-9900-3 DFT1152 inboard bearing driver . . . . . . .99-9900-7
Condenser DFT1153 oil seal driver. . . . . . . . . . . . . .99-9900-7
Air conditioner, remove and install . . . .18-1830-26 DFT1225 rolling torque measurement
Control linkage tool . . . . . . . . . . . . . . . . . . . . . . . . . . .99-9900-8
Remove and install . . . . . . . . . . . . . . . . .34-3415-1 DFT1250 Lifting bracket . . . . . . . . . . . . .99-9900-9
Control valve DFT1282 king pin torque adapter . . . . .99-9900-10
Cab mount-EH controls remove and DFT1308 transmission support
install. . . . . . . . . . . . . . . . . . . . . . . . . .34-3460-9 bracket . . . . . . . . . . . . . . . . . . . . . . .99-9900-12
Disassemble and assemble . . . . . . . . .34-3460-12 DFT1310 cab mount control valve support
Draft frame mount-EH controls remove and bracket . . . . . . . . . . . . . . . . . . . . . . .99-9900-14
install. . . . . . . . . . . . . . . . . . . . . . . . . .34-3460-5 DFT1311extension for DFT1250 . . . . . .99-9900-16
Remove and install . . . . . . . . . . . . . . . . .34-3460-1 DF1017 axle lift eye . . . . . . . . . . . . . . . .99-9900-1
Cooler DF1057 axle adjusting tool . . . . . . . . . . .99-9900-2
Charged air, remove and install . . . . . .05-0510-14 Deluxe seat
Fuel, remove and install . . . . . . . . . . . .05-0510-13 Disassemble and assemble . . . . . . . . .18-1821-12
Cylinder DFRW103
Articulation, disassemble and Yoke holding tool . . . . . . . . . . . . . . . . . .99-9900-4
assemble . . . . . . . . . . . . . . . . . . . . . .09-0960-11 DFRW20
Articulation, remove and install . . . . . . .34-3460-47 Compressor holding fixture . . . . . . . . . . .99-9900-3
Blade lift, disassemble and DFT1101
assemble . . . . . . . . . . . . . . . . . . . . . .09-0960-11 Cab and ROPS lift bracket . . . . . . . . . . .99-9900-5
Blade lift, remove and install . . . . . . . . .34-3460-42 DFT1151
Blade pitch, disassemble and Outboard bearing driver . . . . . . . . . . . . .99-9900-6
assemble . . . . . . . . . . . . . . . . . . . . . .09-0960-11 DFT1152
Blade pitch, remove and install . . . . . . .34-3460-42
Inboard bearing driver . . . . . . . . . . . . . . .99-9900-7
Blade side shift, remove and install. . . .34-3460-44
DFT1153
Blade slide, disassemble and
Oil seal driver . . . . . . . . . . . . . . . . . . . . .99-9900-7
assemble . . . . . . . . . . . . . . . . . . . . . .09-0960-11
DFT1225
Circle sideshift, disassemble and
Rolling torque measurement tool. . . . . . .99-9900-8
assemble . . . . . . . . . . . . . . . . . . . . . .09-0960-11
DFT1282
Circle sideshift, remove and install . . . .34-3460-42
King pin torque adapter. . . . . . . . . . . . .99-9900-10
Disassemble and assemble . . . . . . . . .09-0960-11
DFT1308
Front steering, disassemble and
Transmission support bracket . . . . . . . .99-9900-12
assemble . . . . . . . . . . . . . . . . . . . . . .09-0960-11
DFT1310
Midmount scarifier, remove and
install. . . . . . . . . . . . . . . . . . . . . . . . .42-4240-14 Cab mount control valve support
Ripper, disassemble and assemble. . . .09-0960-11 bracket . . . . . . . . . . . . . . . . . . . . . . .99-9900-14
Ripper, remove and install . . . . . . . . . .42-4240-19 DFT1311
Saddle locking, remove and install . . . .34-3440-10 Extension for DFT 1250 . . . . . . . . . . . .99-9900-16 Indx
DF1017 3
Scarifier, disassemble and assemble . .09-0960-11
Steering, remove and install . . . . . . . . . .09-0960-8 Axle lift eye . . . . . . . . . . . . . . . . . . . . . . .99-9900-1
Wheel lean, disassemble and DF1057
assemble . . . . . . . . . . . . . . . . . . . . . .09-0960-11 Axle adjusting tool. . . . . . . . . . . . . . . . . .99-9900-2
Wheel lean, remove and install . . . . . . .09-0960-12 DF180 transmission . . . . . . . . . . . . . . . . . .03-0300-1
Differential
Oil cooler, remove and install . . . . . . . . .05-0510-8
Differential lock pump
D Remove and install . . . . . . . . . . . . . . . .02-0260-45
Door handle
Dealer fabricated tool Remove and install . . . . . . . . . . . . . . . . .18-1810-2
DFRW20 compressor holding fixture. . . .99-9900-3 Door latch
DFT1101 cab and ROPS lift bracket . . . .99-9900-5 Remove and install . . . . . . . . . . . . . . . . .18-1810-3

051809
PN=3
Index
Page Page
Draft frame Extension for DFT1250

Remove and install . . . . . . . . . . . . . . . .34-3440-20 DFT1311. . . . . . . . . . . . . . . . . . . . . . . .99-9900-16
Draft frame mount
Grader control valve-EH controls remove and
install. . . . . . . . . . . . . . . . . . . . . . . . . .34-3460-5
Drive chain F
Drive hub
6WD, disassemble and assemble . . . . .02-0240-18 Fan
Drive shaft Blade, remove and install . . . . . . . . . . . .05-0510-1
Disassemble and assemble . . . . . . . . . .02-0225-2 Hydraulic pump, remove and install . . .21-2160-17
Remove and install . . . . . . . . . . . . . . . . .02-0225-1 Hydraulic valve, remove and install . . . .21-2160-19
Tandem, Remove and install. . . . . . . . .02-0250-36 Hydrualic motor, remove and install . . .21-2160-18
Transmission-to-rear axle, disassemble and Fan blade
assemble . . . . . . . . . . . . . . . . . . . . . . .02-0225-2 Remove and install . . . . . . . . . . . . . . . . .05-0510-1
Transmission-to-rear axle, remove and Final drive axle
install. . . . . . . . . . . . . . . . . . . . . . . . . .02-0225-1 Disassemble and assemble . . . . . . . . .02-0250-29
Driving metal pins. . . . . . . . . . . . . . . . . . . . . . 001-13 Remove and install . . . . . . . . . . . . . . . .02-0250-22
Fire prevention . . . . . . . . . . . . . . . . . . . . . . . . . 001-4
Flush air conditioner system . . . . . . . . . . . .18-1830-3
Frame
E Blade pitch, remove and install . . . . . . .34-3440-16
Circle, remove and inastall . . . . . . . . . .34-3440-20
EH controls Draft, remove and install . . . . . . . . . . . .34-3440-20
Steering canceling valve, remove and Saddle, remove and install . . . . . . . . . .34-3440-13
install. . . . . . . . . . . . . . . . . . . . . . . . . .09-0960-6 Frames
Steering wheel, column, and valve, remove and Separate at articulation joint . . . . . . . . . .17-1740-3
install. . . . . . . . . . . . . . . . . . . . . . . . . .09-0960-4 Freeze control switch
EH controls steering canceling valve Remove and install . . . . . . . . . . . . . . . .18-1830-17
Remove and install . . . . . . . . . . . . . . . . .09-0960-6 Front axle
EH machine only Non 6WD, remove and install . . . . . . . . .02-0230-7
Armrest disassemble and assemble . . . .18-1821-8 6WD, remove and install . . . . . . . . . . . .02-0240-42
Armrest remove and install . . . . . . . . . . .18-1821-6 Front steering
Emergency preparation . . . . . . . . . . . . . . . . . . 001-5 Cylinder, disassemble and assemble . .09-0960-11
Engagement manifold
Front wheel
6WD, remove and install . . . . . . . . . . . .02-0260-42
Non 6WD hub and spindle, disassemble and
Engine
assemble . . . . . . . . . . . . . . . . . . . . . . .02-0230-4
Powertech plus 9.0L Stage II . . . . . . . . .04-0400-1
Non 6WD hub and spindle, remove and
Powertech plus 9.0L Tier 3/Stage IIIA . . .04-0400-1
install. . . . . . . . . . . . . . . . . . . . . . . . . .02-0230-1
Indx 9.0L Stage II, remove and install. . . . . .04-0400-11
4 Engine coupler 6WD hub and spindle, disassemble and
Remove and install . . . . . . . . . . . . . . . . .07-0752-1 assemble . . . . . . . . . . . . . . . . . . . . . . .02-0240-5
Engine 9.0L Stage II 6WD hub and spindle, disassemble and
Remove and install . . . . . . . . . . . . . . . .04-0400-11 assemble with steering angle
Engine 9.0L Tier 3/Stage IIIA sensor . . . . . . . . . . . . . . . . . . . . . . . .02-0240-11
Remove and install . . . . . . . . . . . . . . . . .04-0400-2 6WD hub and spindle, remove and
Evacuate install. . . . . . . . . . . . . . . . . . . . . . . . . .02-0240-1
R134a system. . . . . . . . . . . . . . . . . . . .18-1830-12 Fuel
Exhaust fumes . . . . . . . . . . . . . . . . . . . . . . . . . 001-4 Fast fill system, disassemble and
Expansion valve assemble . . . . . . . . . . . . . . . . . . . . . . .05-0560-6
Remove and install . . . . . . . . . . . . . . . .18-1830-15 Tank, remove and install . . . . . . . . . . . . .05-0560-1
Explosion Fuel cooler
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 001-4 Remove and install . . . . . . . . . . . . . . . .05-0510-13

051809
PN=4
Index
Page Page
Fuel tank 6WD front, remove and install. . . . . . . . .02-0240-1

Fast fill fuel system, disassemble and Hydraulic
assemble. . . . . . . . . . . . . . . . . . . . . . .05-0560-6 Component faliure cleanup
Remove and install . . . . . . . . . . . . . . . . .05-0560-1 procedure . . . . . . . . . . . . . . . . . . . . .21-2160-26
Fan motor, remove and install. . . . . . . .21-2160-18
Fan pump, remove and install. . . . . . . .21-2160-17
Fittings, 30° cone seat. . . . . . . . . . . . . 0003-5
G
Fittings, 37° flare . . . . . . . . . . . . . . . . . 0003-5
Oil cooler, remove and install . . . . . . . . .05-0510-8
Gearbox
Hydraulic cylinder
Circle drive (with slip clutch), disassemble and
assemble . . . . . . . . . . . . . . . . . . . . . .34-3450-10
Hydraulic fan valve
Circle drive, disassemble and
assemble . . . . . . . . . . . . . . . . . . . . . . .34-3450-4
Hydraulic fitting
Circle drive, remove and install . . . . . . . .34-3450-1
Flared connections . . . . . . . . . . . . . . . . . . . 0003-8
General oil
Non-restricted banjo (adjustable). . . . . . . . 0003-20
Cleanup procedure . . . . . . . . . . . . . . . .21-2160-23
O-ring boss with shoulder . . . . . . . . . . . . . 0003-22
GP machine only
Hydraulic pump
Cab remove and install . . . . . . . . . . . . . .18-1800-9
Disassemble and assemble . . . . . . . . . .21-2160-4
Grader control valve
Remove and install . . . . . . . . . . . . . . . . .21-2160-1
Cab mount-EH controls Remove and
Hydraulic system manifold
install. . . . . . . . . . . . . . . . . . . . . . . . . .34-3460-9
Draft frame mount-EH controls Remove and
Hydrostatic
install. . . . . . . . . . . . . . . . . . . . . . . . . .34-3460-5
Component failure cleanup
procedure . . . . . . . . . . . . . . . . . . . . .21-2160-26
Grille housing
I
H Inboard bearing driver
DFT1152. . . . . . . . . . . . . . . . . . . . . . . . .99-9900-7
Handhold use . . . . . . . . . . . . . . . . . . . . . . . . . . 001-6 Inch bolt and cap screw
Heater Torque value. . . . . . . . . . . . . . . . . . . . . . . . 0003-4
Blower motor assembly remove and Inch series four bolt flange fitting
install. . . . . . . . . . . . . . . . . . . . . . . . .18-1830-21 Service recommendation, torque value for high
Heater and air conditioner pressure . . . . . . . . . . . . . . . . . . . . . . . . 0003-19
Remove and install . . . . . . . . . . . . . . . .18-1830-28 Inching pedal
Heater control valve Remove and install . . . . . . . . . . . . . . . . .18-1815-1
Leak check . . . . . . . . . . . . . . . . . . . . . .18-1830-21 Indx
Inspect machine . . . . . . . . . . . . . . . . . . . . . . . . 001-3 5
High-pressure oils
Avoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 001-3
Housing K
Grille, remove and install. . . . . . . . . . . . .19-1921-1
Hub King pin torque adapter
Non 6WD front, disassemble and DFT1282. . . . . . . . . . . . . . . . . . . . . . . .99-9900-10
assemble . . . . . . . . . . . . . . . . . . . . . . .02-0230-4
Non 6WD front, remove and install . . . . .02-0230-1
6WD front, disassemble and L
assemble . . . . . . . . . . . . . . . . . . . . . . .02-0240-5
6WD front, disassemble and assemble with Lift
steering angle sensor . . . . . . . . . . . .02-0240-11 Arms remove and install . . . . . . . . . . . . .34-3440-6

051809
PN=5
Index
Page Page
M Oil
General, cleanup procedure . . . . . . . . .21-2160-23
Machine inspection. . . . . . . . . . . . . . . . . . . . . . 001-3 Oil cooler
Manifold Hydraulic and differentail, remove and
Hydraulic system, disassemble and install. . . . . . . . . . . . . . . . . . . . . . . . . .05-0510-8
assemble . . . . . . . . . . . . . . . . . . . . . .21-2160-12 Transmission, remove and install . . . . .05-0510-10
Hydraulic system, remove and Oil information
install. . . . . . . . . . . . . . . . . . . . . . . . .21-2160-10 R134a refrigerant . . . . . . . . . . . . . . . . . .18-1830-8
Rotary, remove and install . . . . . . . . . .34-3460-39 Oil seal driver
Metal face seals, 6WD DFT1153. . . . . . . . . . . . . . . . . . . . . . . . .99-9900-7
Remove and install . . . . . . . . . . . . . . . .02-0240-34 Operation qualification . . . . . . . . . . . . . . . . . . . 001-2
Metal pins. . . . . . . . . . . . . . . . . . . . . . . . . . . . 001-13 Operator enclosure
Metric bolt and cap screw Remove and install . . . . . . . .18-1800-1, 18-1800-9
Torque value. . . . . . . . . . . . . . . . . . . . . . . . 0003-1 Outboard bearing driver
Midmount DFT1151. . . . . . . . . . . . . . . . . . . . . . . . .99-9900-6
Scarifier valve section, disassemble and
assemble . . . . . . . . . . . . . . . . . . . . . .34-3460-14 P
Scarifier valve section-EH controls, disassemble
and assemble . . . . . . . . . . . . . . . . . .34-3460-16 Park brake
Midmount scarifier Disassemble and assemble . . . . . . . . . .11-1111-1
Remove and install . . . . . . . . . . . . . . . . .42-4240-7 Remove and install . . . . . . . . . . . . . . . . .11-1111-1
Midmount scarifier cylinder Pedal
Remove and install . . . . . . . . . . . . . . . .42-4240-14 Inching, remove and install . . . . . . . . . . .18-1815-1
Motor Pin joints
Hydraulic fan, remove and install . . . . .21-2160-18 NeverGrease. . . . . . . . . . . . . . . . . . . . . .34-3440-1
Rotate, disassemble and assemble. . . .34-3460-37 Planet pinion carrier
6WD, disassemble and assemble . . . . .02-0260-48 Remove and install . . . . . . . . . . . . . . . .02-0250-34
6WD, remove and install . . . . . . . . . . . .02-0260-46 Planetary brake
Moving parts Disassemble and assemble . . . . . . . . .02-0240-24
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 001-3 Planetary drive
Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 001-3 Disassemble and assemble . . . . . . . . .02-0240-20
Pressure switch
Air conditioning high-low . . . . . . . . . . . .18-1830-19
Protective equipment . . . . . . . . . . . . . . . . . . . . 001-2
N Pump
Differential lock, remove and install. . . .02-0260-45
NeverGrease Hydraulic fan, remove and install . . . . .21-2160-17
Pin Joints . . . . . . . . . . . . . . . . . . . . . . . .34-3440-1 Hydraulic, disassemble and assemble. . .21-2160-4
Hydraulic, remove and install . . . . . . . . .21-2160-1
Indx Transmission charge, remove and
6 install. . . . . . . . . . . . . . . . . . . . . . . . . .03-0360-1
O Vacuum, installation . . . . . . . . . . . . . . . .21-2160-1
6WD motor flushing, remove and
O-ring boss fittings . . . . . . . . . . . . . . . . . . . . . 0003-6 install. . . . . . . . . . . . . . . . . . . . . . . . . .02-0260-1
O-ring face seal fitting 6WD, assemble. . . . . . . . . . . . . . . . . . .02-0260-22
Inch hex nut and stud end for high pressure torque 6WD, disassemble . . . . . . . . . . . . . . . . .02-0260-4
values . . . . . . . . . . . . . . . . . . . . . . . . . . 0003-11 6WD, remove and install . . . . . . . . . . . . .02-0260-1
Metric hex nut and stud end for high pressure Purge air conditioner system . . . . . . . . . . .18-1830-3
torque values. . . . . . . . . . . . . . . . . . . . . 0003-15
Metric hex nut and stud end for standard pressure R
torque values. . . . . . . . . . . . . . . . . . . . . 0003-13
O-ring seal, metric 24 Radiator
Service recommendation. . . . . . . . . . . . . . 0003-25 Remove and install . . . . . . . . . . . . . . . . .05-0510-3

051809
PN=6
Index
Page Page
Rear axle S
Disassemble and assemble . . . . . . . . . .02-0250-6
Drive shaft, disassemble and Saddle
assemble . . . . . . . . . . . . . . . . . . . . . . .02-0225-2 Frame remove and install . . . . . . . . . . .34-3440-13
Drive shaft, remove and install . . . . . . . .02-0225-1 Locking cylinder remove and install. . . .34-3440-10
Final drive, disassemble and Safety
assemble . . . . . . . . . . . . . . . . . . . . . .02-0250-29 Operator’s seat . . . . . . . . . . . . . . . . . . . . . . . 001-6
Final drive, remove and install . . . . . . .02-0250-22 Safety equipment . . . . . . . . . . . . . . . . . . . . . . . 001-2
Planet pinion carrier, remove and Safety information
install. . . . . . . . . . . . . . . . . . . . . . . . .02-0250-34 Recognizing . . . . . . . . . . . . . . . . . . . . . . . . . 001-1
Remove and install . . . . . . . . . . . . . . . . .02-0250-1 Safety symbols . . . . . . . . . . . . . . . . . . . . . . . . . 001-1
Receiver-dryer Scarifier
Cylinder, disassemble and assemble . .09-0960-11
Air conditioner, remove and install . . . .18-1830-33
Midmount cylinder, remove and
Recover
install. . . . . . . . . . . . . . . . . . . . . . . . .42-4240-14
R134a system. . . . . . . . . . . . . . . . . . . .18-1830-11
Midmount valve section, disassemble and
Refrigerant
assemble . . . . . . . . . . . . . . . . . . . . . .34-3460-14
Cautions and proper handling . . . . . . . . .18-1830-1
Midmount valve section-EH controls, disassemble
Refrigerant oil information and assemble . . . . . . . . . . . . . . . . . .34-3460-16
R134a . . . . . . . . . . . . . . . . . . . . . . . . . . .18-1830-8 Midmount, remove and install . . . . . . . . .42-4240-7
Refrigerant recovery/recycling and charging Remove and install . . . . . . . . . . . . . . . . .42-4240-5
Charging station installation Seat
procedure . . . . . . . . . . . . . . . . . . . . .18-1830-10 Belt, remove and install. . . . . . . . . . . . . .18-1821-3
Remove and install Deluxe, disassemble and assemble . . .18-1821-12
Control linkage . . . . . . . . . . . . . . . . . . . .34-3415-1 Remove and install . . . . . . . . . . . . . . . . .18-1821-1
Hydraulic fan valve . . . . . . . . . . . . . . . .21-2160-19 Standard, disassemble and
Lift arms . . . . . . . . . . . . . . . . . . . . . . . . .34-3440-6 assemble . . . . . . . . . . . . . . . . . . . . . .18-1821-10
Ripper . . . . . . . . . . . . . . . . . . . . . . . . . .42-4240-16 Suspension, disassemble and
Saddle frame . . . . . . . . . . . . . . . . . . . .34-3440-13 assemble . . . . . . . . . . . . . . . . . . . . . .18-1821-14
Saddle locking cylinder . . . . . . . . . . . . .34-3440-10 Seat belt
Scarifier/blade . . . . . . . . . . . . . . . . . . . . .42-4240-5 remove and install. . . . . . . . . . . . . . . . . .18-1821-3
Secondary steering accumulator . . . . . .09-0960-17 Use and maintenance . . . . . . . . . . . . . . . . . . 001-6
Tandem and wheel axle assembly . . . . .02-0250-7 Secondary steering accumulator
Wheel axle, tandem assembly . . . . . . . .02-0250-7 Remove and install . . . . . . . . . . . . . . . .09-0960-17
Return check poppets Service brake
Disassemble and assemble . . . . . . . . .34-3460-36 Bleeding . . . . . . . . . . . . . . . . . . . . . . . . .10-1060-3
Ripper Components, remove and install . . . . . .02-0250-33
Cylinder, disassemble and assemble . .09-0960-11 Disassemble and assemble . . . . . . . . . .10-1011-1
Remove and install . . . . . . . . . . . . . . . .42-4240-16 Indx
Service brake valve
Ripper cylinders 7
Service recommendation
Rolling torque measurement tool Inch series four bolt flange fitting for high
DFT1225. . . . . . . . . . . . . . . . . . . . . . . . .99-9900-8 pressure . . . . . . . . . . . . . . . . . . . . . . . . 0003-19
Rotary manifold O-ring face seal fittings with inch hex nut and
Remove and install . . . . . . . . . . . . . . . .34-3460-39 stud end for high pressure. . . . . . . . . . . 0003-11
Rotate motor O-ring face seal fittings with metric hex nut and
Disassemble and assemble . . . . . . . . .34-3460-37 stud end for high pressure. . . . . . . . . . . 0003-15
R134a refrigerant recovery and charging station O-ring face seal fittings with metric hex nut and
Installation procedure . . . . . . . . . . . . . .18-1830-10 stud end for standard pressure . . . . . . . 0003-13
R134a system charge. . . . . . . . . . . . . . . .18-1830-14 O-ring seal, metric 24 . . . . . . . . . . . . . . . . 0003-25
R134a system evacuate . . . . . . . . . . . . . .18-1830-12 Soft start valve
R134a system recover . . . . . . . . . . . . . . .18-1830-11 Disassemble and assemble . . . . . . . . .21-2160-16

051809
PN=7
Index
Page Page
Remove and install . . . . . . . . . . . . . . . .21-2160-13 Tire

Spindle Remove and install . . . . . . . . . . . . . . . . .01-0110-2
Non 6WD front, disassemble and Toe-in check and adjustment
assemble . . . . . . . . . . . . . . . . . . . . . . .02-0230-4 Non 6WD . . . . . . . . . . . . . . . . . . . . . . . .09-0920-1
Non 6WD front, remove and install . . . . .02-0230-1 6WD . . . . . . . . . . . . . . . . . . . . . . . . . . . .09-0920-1
6WD front, disassemble and Tool, dealer fabricated
assemble . . . . . . . . . . . . . . . . . . . . . . .02-0240-5 DFT1250 Lifting bracket . . . . . . . . . . . . .99-9900-9
6WD front, disassemble and assemble with Torque value
steering angle sensor . . . . . . . . . . . .02-0240-11 Flared connections . . . . . . . . . . . . . . . . . . . 0003-8
6WD front, remove and install. . . . . . . . .02-0240-1 Flat face O-ring seal fitting . . . . . . . . . . . . . 0003-9
Standard controls Inch SAE four bolt flange fitting. . . . . . . . . 0003-18
Steering wheel, column, and valve, remove and Inch series four bolt flange fitting for high
install. . . . . . . . . . . . . . . . . . . . . . . . . .09-0960-1 pressure . . . . . . . . . . . . . . . . . . . . . . . . 0003-19
Standard seat Metric bolt and cap screw . . . . . . . . . . . . . . 0003-1
Disassemble and assemble . . . . . . . . .18-1821-10 Metric cap screw. . . . . . . . . . . . . . . . . . . . . 0003-2
Steering Metric four bolt flange fitting . . . . . . . . . . . 0003-17
Valve section-EH controls, disassemble and Non-restricted banjo fittings. . . . . . . . . . . . 0003-20
assemble . . . . . . . . . . . . . . . . . . . . . .34-3460-30 O-Ring boss fitting . . . . . . . . . . . . . . . . . . . 0003-6
Steering column, EH controls O-ring boss fittings with shoulder . . . . . . . 0003-22
Remove and install . . . . . . . . . . . . . . . . .09-0960-4 O-ring face seal fittings with inch hex nut and
Steering column, standard controls stud end for high pressure. . . . . . . . . . . 0003-11
Remove and install . . . . . . . . . . . . . . . . .09-0960-1 O-ring face seal fittings with metric hex nut and
Steering cylinder stud end for high pressure. . . . . . . . . . . 0003-15
Remove and install . . . . . . . . . . . . . . . . .09-0960-8 O-ring face seal fittings with metric hex nut and
Steering valve, EH controls stud end for standard pressure . . . . . . . 0003-13
Remove and install . . . . . . . . . . . . . . . . .09-0960-4 O-ring seal, metric 24 . . . . . . . . . . . . . . . . 0003-25
Steering valve, standard controls Unified inch bolt and cap screw . . . . . . . . . 0003-4
Remove and install . . . . . . . . . . . . . . . . .09-0960-1 30° cone seat hydraulic fittings . . . . . . 0003-5
Steering wheel, EH controls 37° flare hydraulic fittings . . . . . . . . . . 0003-5
Remove and install . . . . . . . . . . . . . . . . .09-0960-4 Torsional isolator
Steering wheel, standard controls Remove and install . . . . . . . . . . . . . . . . .07-0752-1
Remove and install . . . . . . . . . . . . . . . . .09-0960-1 Transmission
Steps use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 001-6 Charge pump, remove and install . . . . . .03-0360-1
Suspension Disassemble and assemble . . . . . . . . . .03-0300-1
Air, disassemble and assemble. . . . . . .18-1821-14 Drive shaft, disassemble and
assemble . . . . . . . . . . . . . . . . . . . . . . .02-0225-2
Drive shaft, remove and install . . . . . . . .02-0225-1
Oil cooler, remove and install . . . . . . . .05-0510-10
T Transmission coupler
Indx
8 Remove and install . . . . . . . . . . . . . . . . .07-0752-1
Tandem Transmission support bracket
Pivot, disassemble and assemble . . . . .02-0250-18 DFT1308. . . . . . . . . . . . . . . . . . . . . . . .99-9900-12
Wheel axle assembly, disassemble and
assemble . . . . . . . . . . . . . . . . . . . . . .02-0250-12
Wheel axle assembly, remove and
install. . . . . . . . . . . . . . . . . . . . . . . . .02-0250-10 V
Tandem and wheel axle assembly
Remove and install . . . . . . . . . . . . . . . . .02-0250-7 Vacuum pump
Tandem drive shaft Installation. . . . . . . . . . . . . . . . . . . . . . . .21-2160-1
Remove and install . . . . . . . . . . . . . . . .02-0250-36 Valve
Tank Articulation section, disassemble and
Fuel, remove and install . . . . . . . . . . . . .05-0560-1 assemble . . . . . . . . . . . . . . . . . . . . . .34-3460-28

051809
PN=8
Index
Page Page
Articulation section-EH controls, disassemble and W

assemble . . . . . . . . . . . . . . . . . . . . . .34-3460-30
Auxiliary section-EH controls, disassemble and Waste disposal . . . . . . . . . . . . . . . . . . . . . . . . . 001-5
assemble . . . . . . . . . . . . . . . . . . . . . .34-3460-26 Wear inserts
Auxiliary with float section, disassemble and Blade side shift, remove and install. . . .34-3440-29
assemble . . . . . . . . . . . . . . . . . . . . . .34-3460-22 Welding
Auxiliary without float section, disassemble and Repair of major structure. . . . . . . . . . . . .17-1740-2
assemble . . . . . . . . . . . . . . . . . . . . . .34-3460-24 Welding or heating
Blade lift section, disassemble and Paint removal . . . . . . . . . . . . . . . . . . . . . . . 001-12
assemble . . . . . . . . . . . . . . . . . . . . . .34-3460-18 Welding repairs . . . . . . . . . . . . . . . . . . . . . . . 001-12
Blade lift section-EH controls, disassemble and Wheel
assemble . . . . . . . . . . . . . . . . . . . . . .34-3460-20 Non 6WD front hub and spindle, disassemble and
Blade pitch section, disassemble and assemble . . . . . . . . . . . . . . . . . . . . . . .02-0230-4
assemble . . . . . . . . . . . . . . . . . . . . . .34-3460-28 Non 6WD front hub and spindle, remove and
Blade pitch section-EH controls, disassemble and install. . . . . . . . . . . . . . . . . . . . . . . . . .02-0230-1
Blade side shift section, disassemble and 6WD front hub and spindle, disassemble and
assemble . . . . . . . . . . . . . . . . . . . . . .34-3460-28 assemble . . . . . . . . . . . . . . . . . . . . . . .02-0240-5
Blade side shift section-EH controls, disassemble 6WD front hub and spindle, disassemble and
and assemble . . . . . . . . . . . . . . . . . .34-3460-30 assemble with steering angle
Cab mount grader control-EH controls, remove and sensor . . . . . . . . . . . . . . . . . . . . . . . .02-0240-11
install. . . . . . . . . . . . . . . . . . . . . . . . . .34-3460-9 6WD front hub and spindle, remove and
Circle rotate, disassemble and install. . . . . . . . . . . . . . . . . . . . . . . . . .02-0240-1
assemble . . . . . . . . . . . . . . . . . . . . . .34-3460-32 Wheel axle
Circle rotate-EH controls, disassemble and Tandem assembly, disassemble and
assemble . . . . . . . . . . . . . . . . . . . . . .34-3460-34 assemble . . . . . . . . . . . . . . . . . . . . . .02-0250-12
Circle side shift section, disassemble and Tandem assembly, remove and
assemble . . . . . . . . . . . . . . . . . . . . . .34-3460-28 install. . . . . . . . . . . . . . . . . . . . . . . . .02-0250-10
Circle side shift section-EH controls, disassemble Wheel lean
and assemble . . . . . . . . . . . . . . . . . .34-3460-30 Cylinder, disassemble and assemble . .09-0960-11
Draft frame mount grader control-EH controls, Remove and install . . . . . . . . . . . . . . . .09-0960-12
remove and install . . . . . . . . . . . . . . . .34-3460-5 Valve section, disassemble and
Grader control, disassemble and assemble . . . . . . . . . . . . . . . . . . . . . .34-3460-28
assemble . . . . . . . . . . . . . . . . . . . . . .34-3460-12 Valve section-EH controls, disassemble and
Grader control, remove and install . . . . .34-3460-1 assemble . . . . . . . . . . . . . . . . . . . . . .34-3460-30
Midmount scarifier section, disassemble and Windowpanes
Midmount scarifier section-EH controls,
disassemble and assemble . . . . . . . .34-3460-16
Service brake, remove and install . . . . . .10-1060-1 Indx
9
Soft start, disassemble and Y
assemble . . . . . . . . . . . . . . . . . . . . . .21-2160-16
Soft start, remove and install. . . . . . . . .21-2160-13 Yoke holding tool
Steering EH controls, remove and DFRW103 . . . . . . . . . . . . . . . . . . . . . . . .99-9900-4
install. . . . . . . . . . . . . . . . . . . . . . . . . .09-0960-4 6WD
Steering section-EH controls, disassemble and Bearings, remove and install . . . . . . . . .02-0240-29
assemble . . . . . . . . . . . . . . . . . . . . . .34-3460-30 Charge pump, remove and install . . . . .02-0260-42
Steering standard controls, remove and Drive hub, disassemble and
install. . . . . . . . . . . . . . . . . . . . . . . . . .09-0960-1 assemble . . . . . . . . . . . . . . . . . . . . . .02-0240-18
Wheel lean section, disassemble and Engagement manifold, remove and
assemble . . . . . . . . . . . . . . . . . . . . . .34-3460-28 install. . . . . . . . . . . . . . . . . . . . . . . . .02-0260-42
Wheel lean section-EH controls, disassemble and Front wheel hub and spindle, disassemble and
assemble . . . . . . . . . . . . . . . . . . . . . .34-3460-30 assemble . . . . . . . . . . . . . . . . . . . . . . .02-0240-5

051809
PN=9
Index
Page
Front wheel hub and spindle, disassemble and

assemble with steering angle
sensor . . . . . . . . . . . . . . . . . . . . . . . .02-0240-11
Front wheel hub and spindle, remove and
install. . . . . . . . . . . . . . . . . . . . . . . . . .02-0240-1
Motor flushing pump, remove and
install. . . . . . . . . . . . . . . . . . . . . . . . . .02-0260-1
Motor, disassemble and assemble . . . .02-0260-48
Motor, remove and install . . . . . . . . . . .02-0260-46
O-ring metal face seal, remove and
install. . . . . . . . . . . . . . . . . . . . . . . . .02-0240-34
Planetary brake, disassemble and
assemble . . . . . . . . . . . . . . . . . . . . . .02-0240-24
Planetary drive, disassemble and
assemble . . . . . . . . . . . . . . . . . . . . . .02-0240-20
Pump, assemble . . . . . . . . . . . . . . . . . .02-0260-22
Pump, disassemble. . . . . . . . . . . . . . . . .02-0260-4
Pump, remove and install . . . . . . . . . . . .02-0260-1
Toe-in check and adjustment . . . . . . . . .09-0920-1
9.0L Tier 3/Stage IIIA
Engine, remove and install . . . . . . . . . . .04-0400-2
Indx
10
TM11207 (11MAY09) Index-10

051809
PN=10

John Deere

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Copyright:

Available Formats

John Deere

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Copyright:

Available Formats

770G, 770GP, 772G, and

For complete service information also see:

SECTION 07—Torsional Isolator

SECTION 09—Steering System

SECTION 10—Service Brakes

SECTION 11—Park Brake

SECTION 17—Frame, Chassis or Supporting 10

Group 001—Safety . . . . . . . . . . . . . . . . . . . . . . 001-1

Group 0003—Torque Values

This is the safety alert symbol. When this symbol is

Follow the precautions and safe operating practices

A signal word — DANGER, WARNING, or CAUTION — is

Follow Safety Instructions

Read the safety messages in this manual and on the

Be sure all operators of this machine understand every

TM11207 (11MAY09) 001-1

001 Operate Only If Qualified

Wear Protective Equipment

Guard against injury from flying pieces of metal or debris;

Wear close fitting clothing and safety equipment

Avoid Unauthorized Machine Modifications

TM11207 (11MAY09) 001-2

Inspect Machine 001

Inspect machine carefully each day by walking around it

Keep all guards and shields in good condition and

Stay Clear of Moving Parts

Stop engine before examining, adjusting or maintaining

Avoid High-Pressure Oils

This machine uses a high-pressure hydraulic system.

TM11207 (11MAY09) 001-3

001 Beware of Exhaust Fumes

Prevent asphyxiation. Engine exhaust fumes can cause

Keep A Fire Extinguisher Available: Always keep a

Prevent Battery Explosions

Battery gas can explode. Keep sparks, lighted matches,

Never check battery charge by placing a metal object

Do not charge a frozen battery; it may explode. Warm

TM11207 (11MAY09) 001-4

Handle Chemical Products Safely 001

Exposure to hazardous chemicals can cause serious

Dispose of Waste Properly

Improper disposal of waste can threaten the environment.

Never pour waste onto the ground, down a drain, or into

Air conditioning refrigerants can damage the atmosphere.

If uncertain about the safe disposal of waste, contact your

Prepare for Emergencies

Be prepared if an emergency occurs or a fire starts.

Keep a first aid kit and fire extinguisher handy.

Keep emergency numbers for doctors, ambulance service,

hospital, and fire department near your telephone.

TM11207 (11MAY09) 001-5

001 Use Steps and Handholds Correctly

Prevent falls by facing the machine when getting on and

Use extra care when mud, snow, or moisture present

Start Only From Operator’s Seat

Use and Maintain Seat Belt

Use seat belt when operating machine. Remember to

The complete seat belt assembly should be replaced

TM11207 (11MAY09) 001-6

Prevent Unintended Machine Movement 001

Be careful not to accidentally actuate controls when

Lower all equipment to the ground during work

Avoid Work Site Hazards

Avoid contact with gas lines, buried cables and water