TM12141

770G, 770GP, 772G, and
772GP Motor Grader (SN.

634380—656507) Repair
REPAIR TECHNICAL MANUAL
Graders (SN. 634380—656507) models 770G, 770GP, 772G, 772GP w.Engines

6090HDW11, 6090HDW16
TM12141 22 DEC 15 (ENGLISH)
For complete service information also see:

770G, 770GP, 772G, and 772GP Motor Grader (SN. 634380—656507) Diagnostic TM12139
JDLink (MTG) Technical Manual TM114519
TeamMate II 1200, 1400,and 1600 Series Inboard Planetary Axles CTM43
Super Caddy Oil Cleanup Procedure CTM310
DF180 Series Powershift Transmission Repair Manual CTM308
TeamMate II 1400 Series Inboard Planetary Axles CTM138619
120 Series Hydraulic Cylinders CTM120519
120 Series Hydraulic Cylinders CTM114319
6090 PowerTech Diesel Engine (Interim Tier 4) Level 21 ECU CTM104819
JDLINK/ZXLINK Machine Monitoring System CTM10006
John Deere Construction and Forestry

Pinted by Belgreen
TM12141-REPAIR TECHNICAL MANUAL (g) by Belgreen v2.5
Table of contents
FOREWORD
MANUAL IDENTIFICATION—READ THIS FIRST!
Section 00 - GENERAL INFORMATION
Group 001 - Safety
Group 0003 - Torque Values
Section 01 - WHEELS
Group 0110 - Powered Wheels and Fasteners
Section 02 - AXLES AND SUSPENSION SYSTEMS
Group 0225 - Input Drive Shafts and U-Joints
Group 0230 - Non-Powered Wheel Axles
Group 0240 - Powered Wheel Axles
Group 0250 - Axle Shafts, Bearings, and Reduction Gears
Group 0260 - Hydraulic System
Section 03 - TRANSMISSION
Group 0300 - Removal and Installation
Section 04 - ENGINE
Section 05 - ENGINE AUXILIARY SYSTEM
Group 0510 - Cooling System
Group 0530 - External Exhaust System
Group 0560 - External Fuel Supply Systems
Section 07 - TORSIONAL ISOLATOR
Group 0752 - Elements
Section 09 - STEERING SYSTEM
Group 0920 - Power Steering
Section 10 - SERVICE BRAKES
Group 1011 - Active Elements
Section 11 - PARK BRAKE
Section 17 - FRAME, CHASSIS OR SUPPORTING STRUCTURE
Group 1740 - Frame Installation
Section 18 - OPERATOR’S STATION
Group 1810 - Operator Enclosure
Group 1815 - Pedal Assembly
Group 1816 - Steering Tilt Console
Group 1821 - Seat and Seat Belt
Group 1830 - Heating and Air Conditioning
Section 19 - SHEET METAL AND STYLING
Group 1910 - Engine Enclosure
Group 1921 - Grille and Grille Housing
Section 21 - MAIN HYDRAULIC SYSTEM
Section 34 - GRADING DEVICE
Group 3415 - Controls Linkage
Group 3440 - Frames
Group 3450 - Circle Gearbox
Section 42 - GROUND CONDITIONING TOOL
<- Go to Global Table of contents TM12141-REPAIR TECHNICAL MANUAL
Group 4240 - Frames

Section 99 - DEALER FABRICATED TOOLS
Group 9900 - Dealer Fabricated Tools

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

Manual Identification—READ THIS FIRST!

IMPORTANT:
Use only supporting manuals designated for your specific machine. If incorrect manual is chosen,
improper service may occur. Verify product identification number (PIN) and engine model number when
choosing the correct manual.
Choosing the Correct Supporting Manuals
John Deere motor graders are available in different machine configurations based on the various markets into which they are
sold. Different supporting manuals exist for different machine configurations.
When necessary, product serial numbers and engine model numbers are listed on the front covers of motor grader manuals.
These numbers are used to identify the correct supporting manual for your machine.
Product Serial Number Identification
PIN Plate Location
PIN Plate (13 Digit)

PIN Plate (17 Digit)

LEGEND:
1 PIN Plate
2 13 Digit PIN
3 17 Digit PIN
The product identification number (PIN) plate (1) is located on the left-side of equipment frame under operator′s station. Each
machine has a 13 digit PIN (2) or 17 digit PIN (3) shown on PIN plate. The last 6 digits of the PIN represent the machine’s
product serial number.
Engine Model Number Identification
Engine Serial Number Plate

Engine Serial Nuimber Plate Location—6090HDW04
Engine Serial Number Plate Location—6090HDW01
Engine Serial Number Plate Location—6090HDW11 and 6090HDW16

LEGEND:
4 Engine Serial Number Plate
5 Engine Model Number
The engine serial number plate (4) is located on left or right-side of the engine depending on engine model. Each engine has a
9 digit engine model number (5) shown on this plate.
Engine Emissions Level Identification
The 9 digit engine model number corresponds to a specific engine emissions level.

GENERAL INFORMATION (g) by Belgreen v2.0
Engine Model Number
Engine Model Number Engine Emission Level
6090HDW11 and 6090HDW16 Interim Tier 4/Stage III B
6090HDW01 Tier 3/Stage III A
6090HDW04 Stage II
For machines equipped with a 17 digit PIN, where the 11th digit is “E,” “D,” or “C,” this digit corresponds to a specific engine
emissions level.
→NOTE:
Earlier machines with a 17 digit PIN do not identify engine emissions level with the 11th digit.
PIN Classification
th
17 Digit PIN (11 digit) Engine Emissions Level
xxxxxxxxxx E xxxxxx Interim Tier 4/Stage III B
xxxxxxxxxx D xxxxxx Tier 3/Stage III A
xxxxxxxxxx C xxxxxx Stage II
<- Go to Section TOC Section 00 page 4 TM12141-REPAIR TECHNICAL MANUAL

Section 00 - GENERAL INFORMATION

Table of contents
Group 001 - Safety ................................................................................................................................... 1
Recognize Safety Information ............................................................................................................... 1
Follow Safety Instructions ..................................................................................................................... 1
Operate Only If Qualified ...................................................................................................................... 2
Wear Protective Equipment .................................................................................................................. 3
Avoid Unauthorized Machine Modifications .......................................................................................... 3
Inspect Machine ................................................................................................................................... 3
Stay Clear of Moving Parts ................................................................................................................... 4
Avoid High-Pressure Fluids ................................................................................................................... 4
Avoid High-Pressure Oils ...................................................................................................................... 5
Work In Ventilated Area ........................................................................................................................ 5
Prevent Fires ........................................................................................................................................ 6
Prevent Battery Explosions ................................................................................................................... 7
Handle Chemical Products Safely ......................................................................................................... 7
Decommissioning: Proper Recycling and Disposal of Fluids and Components ..................................... 7
Exhaust Filter Ash Handling and Disposal ............................................................................................ 8
Prepare for Emergencies ...................................................................................................................... 8
Clean Debris from Machine .................................................................................................................. 9
Use Steps and Handholds Correctly ..................................................................................................... 9
Start Only From Operator′s Seat ......................................................................................................... 10
Use and Maintain Seat Belt ................................................................................................................ 10
Prevent Unintended Machine Movement ............................................................................................ 10
Avoid Work Site Hazards .................................................................................................................... 11
Keep Riders Off Machine .................................................................................................................... 12
Avoid Backover Accidents .................................................................................................................. 13
Avoid Machine Tip-Over ...................................................................................................................... 13
Operating Or Traveling On Public Roads ............................................................................................ 14
Inspect and Maintain ROPS ................................................................................................................. 14
Add and Operate Attachments Safely ................................................................................................ 15
Park and Prepare for Service Safely ................................................................................................... 15
Clean Exhaust Filter Safely ................................................................................................................. 16
Service Cooling System Safely ........................................................................................................... 17
Remove Paint Before Welding or Heating ........................................................................................... 18
Make Welding Repairs Safely ............................................................................................................. 18
Drive Metal Pins Safely ....................................................................................................................... 19
Service Tires Safely ............................................................................................................................ 20
Group 0003 - Torque Values ................................................................................................................. 21
Metric Bolt and Cap Screw Torque Values .......................................................................................... 21
Additional Metric Cap Screw Torque Values ....................................................................................... 22
Unified Inch Bolt and Cap Screw Torque Values ................................................................................. 24
Service Recommendations for 37° Flare and 30° Cone Seat Connectors ........................................... 25
Service Recommendations for O-Ring Boss Fittings ........................................................................... 26
Service Recommendations For Flared Connections—Straight or Tapered Threads ............................ 28
Service Recommendations For Flat Face O-Ring Seal Fittings ............................................................ 30
O-Ring Face Seal Fittings With SAE Inch Hex Nut And Stud End For High Pressure Service
Recommendations ....................................................................................................................... 31
O-Ring Face Seal Fittings With Metric Hex Nut And Stud End For Standard Pressure Service
O-Ring Face Seal Fittings With Metric Hex Nut And Stud End For High Pressure Service

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

Section 00 - GENERAL INFORMATION Group 001: Safety
Group 001 - Safety

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

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

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

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

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

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

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

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

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

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

Components

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

First Aid Kit
Be prepared if a fire starts.

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

Prevent falls by facing the machine when getting on and off. Maintain 3-point contact with steps and handrails. Never use
machine controls as handholds.
Use extra care when mud, snow, or moisture present slippery conditions. Keep steps clean and free of grease or oil. Never
jump when exiting machine. Never mount or dismount a moving machine.
Start Only From Operator′s Seat
Operate Only From Operators Seat
Avoid unexpected machine movement. Start engine only while sitting in operator′s seat. Ensure all controls and working tools
are in proper position for a parked machine.
Never attempt to start engine from the ground. Do not attempt to start engine by shorting across the starter solenoid
terminals.
Use and Maintain Seat Belt
Use and Maintain Seat Belt
Use seat belt when operating machine . Remember to fasten seat belt when loading and unloading from trucks and during
other uses.
Examine seat belt frequently. Be sure 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.
Prevent Unintended Machine Movement

Prevent Unintended Machine Movement
Be careful not to accidentally actuate controls when coworkers are present.

Lower all equipment to the ground during work interruptions. Place transmission control and park brake lever in park position P
before allowing anyone to approach the machine.
Follow these same precautions before standing up, leaving the operator′s seat, or exiting the machine.
Avoid Work Site Hazards
Contact With Gas Line

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

Keep Riders Off Machine
Only allow operator on machine.

Riders are subject to injury. They may fall from machine, be caught between machine parts, or be struck by foreign objects.
Riders may obstruct operator’s view or impair his ability to operate machine safely.
Avoid Backover Accidents
Avoid Backover Accidents
Before moving machine, be sure that all persons are clear of machine path. Turn around and look directly for best
visibility. Use mirrors to assist in checking all around machine. Keep windows and mirrors clean, adjusted, and in good repair.
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.
Do not rely on the rear camera and radar object detection systems to determine if personnel are behind the machine. The
system has limitations due to maintenance practices, environmental conditions, and operating range.
Avoid Machine Tip-Over
Use Seat Belt

Ensure Solid Footing
Use seat belt at all times.

Do not jump if the machine tips. You will be unlikely to jump clear and the machine may crush you.
Load and unload from trucks or trailers carefully. Be sure truck is wide enough and 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 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.
Ensure solid footing. Do not operate close to banks or open excavations that may cave in and cause machine to tip or fall.
Operating Or Traveling On Public Roads
Operating or Traveling On Public Roads
Machines that work near vehicle traffic or travel slower than normal highway speeds must have proper lighting and markings to
assure they are visible to other drivers.
Install additional lights, beacons, slow moving vehicle (SMV) emblems, or other devices and use as required to make the
machine visible and identify it as a work machine. Check state and local regulations to assure compliance. Keep these devices
clean and in working condition.
Inspect and Maintain ROPS

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

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

Always verify compatibility of attachments by contacting your authorized dealer. Adding unapproved attachments may affect
machine stability or reliability, and may create a hazard for others near the machine.
Ensure that a qualified person is involved in attachment installation. Add guards to machine if operator protection is required or
recommended. Verify that all connections are secure and attachment responds properly to controls.
Carefully read attachment manual and follow all instructions and warnings. In an area free of bystanders and obstructions,
carefully operate attachment to learn its characteristics and range of motion.
Park and Prepare for Service Safely
Do Not Operate Tag
Support Machine Properly
Warn others of service work. Always park and prepare your machine for service or repair properly.
Park machine on a level surface and lower equipment to the ground.

Place transmission control and park brake lever in P park position. Stop engine.
Attach a Do Not Operate tag in an obvious place in the operator′s station.
Securely support machine or attachment before working under it.
Do not support machine with any hydraulically actuated 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 devices that may slip out of place.
Understand service procedures before beginning repairs. Keep service area clean and dry. Use two people whenever the
engine must be running for service work.
Clean Exhaust Filter Safely
Fire Safety
Hand Over Flame
Moving Parts

Stop
During exhaust filter cleaning operations, the engine may run at elevated idle and hot temperatures for an extended period of
time. Exhaust gases and exhaust filter components reach temperatures hot enough to burn people, or ignite or melt common
materials.
Keep machine away from people, animals or structures which may be susceptible to harm or damage from hot exhaust gases
or components. Avoid potential fire or explosion hazards from flammable materials and vapors near the exhaust. Keep exhaust
outlet away from people and anything that can melt, burn or explode.
Closely monitor machine and surrounding area for smoldering debris during and after exhaust filter cleaning.
Adding fuel while an engine is running can create a fire or explosion hazard. Always stop engine before refueling machine and
clean up any spilled fuel.
Always make sure engine is stopped while hauling machine on a truck or trailer.
Contact with exhaust components while still hot can result in serious personal injury.
Avoid contact with these components until cooled to safe temperatures.
If service procedure requires engine to be running:
Only engage power-driven parts required by service procedure

Ensure that other people are clear of operator station and machine
Keep hands, feet and clothing away from power-driven parts.

Always disable movement (neutral), set the parking brake or mechanism and disconnect power to attachments or tools before
leaving the operator’s station.
Shut off the engine before leaving the machine unattended.
Service Cooling System Safely

Cooling System
Explosive release of fluids from pressurized cooling system can cause serious burns.
Do not service radiator through the radiator cap. Only fill through the surge tank filler cap. Shut off engine. Only remove surge
tank filler cap when cool enough to touch with bare hands. Slowly loosen cap to relieve pressure before removing completely.
Remove Paint Before Welding or Heating
Toxic Fumes
Avoid potentially toxic fumes and dust.

Hazardous fumes can be generated when paint is heated by welding, soldering, or using a torch.
Remove paint before heating:
Remove paint a minimum of 100 mm (4 in.) from area to be affected by heating. If paint cannot be removed, wear an
approved respirator before heating or welding.
If you sand or grind paint, avoid breathing the dust. Wear an approved respirator.
If you use solvent or paint stripper, remove stripper with soap and water before welding. Remove solvent or paint stripper
containers and other flammable material from area. Allow fumes to disperse at least 15 minutes before welding or
heating.
Do not use a chlorinated solvent in areas where welding will take place.
Do all work in an area that is well ventilated to carry toxic fumes and dust away.
Dispose of paint and solvent properly.
Make Welding Repairs Safely

Avoid Heating Near Pressurized Fluid Lines
IMPORTANT:
Disable electrical power before welding. Turn off main battery switch or disconnect positive battery
cable. Separate harness connectors to engine and vehicle microprocessors.
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.
Drive Metal Pins Safely
Hardened Metal Parts
Always wear protective goggles or safety glasses and other protective equipment before striking hardened parts. Hammering
hardened metal parts such as pins and bucket teeth may dislodge chips at high velocity.
Use a soft hammer or a brass bar between hammer and object to prevent chipping.

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

Group 0003 - Torque Values

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

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

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

Metric Cap Screw Torque Values
METRIC CAP SCREW TORQUE VALUES

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

Unified Inch Bolt and Cap Screw Torque Values

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

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

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

Service Recommendations for O-Ring Boss Fittings

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

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

Service Recommendations For Flared Connections—Straight or Tapered

Threads
Straight Thread
Tapered Thread
[1] - Inspect flare and flare seat. They must be free of dirt or obvious defects.
[2] - Defects in the tube flare cannot be repaired. Overtightening a defective flared fitting will not stop leaks.
[3] - Align the tube with the fitting before attempting to start the nut.
[4] - Lubricate the male threads with hydraulic fluid or petroleum jelly.
[5] - Index angle fittings and tighten by hand.
[6] - Tighten fitting or nut to torque value shown on the chart. Do not allow hoses to twist when tightening fittings.
Torque Chart
TORQUE CHART
Straight Thread
Tapered Thread
[ With seat face. ]
Thread Size N˙m lb-ft N˙m lb-ft
1/8 15 11
1/4 20 15 45 33
3/8 29 21 69 51
1/2 49 36 93 69
3/4 69 51 176 130
1 157 116 343 253

TORQUE CHART
Straight Thread Tapered Thread

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

Service Recommendations For Flat Face O-Ring Seal Fittings

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Service Recommendations For Non-Restricted Banjo (Adjustable)

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

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

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

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

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

Metric 24° O-Ring Seal DIN 20078 Service Recommendations

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

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

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

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

Section 01 - WHEELS
Table of contents
Group 0110 - Powered Wheels and Fasteners .................................................................................... 1
Wheel Remove and Install .................................................................................................................... 1
Tire Remove and Install ........................................................................................................................ 1

Section 01 - WHEELS Group 0110: Powered Wheels and Fasteners
Group 0110 - Powered Wheels and Fasteners

Wheel Remove and Install
[1] -
CAUTION:
Prevent crushing injury from heavy component. Use appropriate lifting device.
→NOTE:
Machines with (S.N. 640411 —) will have the stiffener plate (3) from the factory.
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.
[3] -
LEGEND:
1 Cap Screw (14 used)
2 Washer (14 used)
3 Stiffener Plate ( 2 used)
4 Wheel
Wheel Remove and Install

Remove cap screws (1), washers (2), and stiffener plates (3) 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.
Item Measurement Specification
Wheel Cap Screw Torque 444 N·m
328 lb-ft
Tire Remove and Install

Section 01 - WHEELS Group 0110: Powered Wheels and Fasteners
CAUTION:
Tire repair should only be performed by a qualified tire repair service. Do not attempt to mount or
demount a tire unless you have the proper equipment and experience to perform the job safely. Failure
to follow proper procedures when mounting or demounting a tire from a wheel or rim can result in
explosive separation of a tire and rim parts, causing serious injury or death
Explosive Single Piece Rim and Tire
Explosive Multi-Piece Rim and Tire
Always maintain the correct tire pressure. Do not inflate the tires above the recommended pressure. Never weld or heat a
wheel and tire assembly, as heating can increase air pressure and result in tire explosion. Welding can also structurally weaken
or deform the wheel.
AXLES AND SUSPENSION SYSTEMS (g) by Belgreen v2.0
For initial inflation, always use a clip-on chuck and extension hose long enough to allow you to stand to one side and NOT in
front of, or over, the tire assembly. Inflate in a safety cage if available. Use safety chains, cables, or equivalent restraining
devices during inflation.
CAUTION:
Stand clear when using a cable or chain sling. These devices can snap and lash out, causing serious
injury or death.
Check tire and wheel assemblies for low pressure, cuts, bubbles, damaged rim components, or missing lug bolts and nuts.
Check that the tire size exactly matches the rim size. Improperly-sized tires may not perform as intended.
Wheels may contain multi-piece rim components. Inspect all rim components and replace those that are cracked, worn,
damaged, or severely rusted. Use only rim components designed to work with one another. Do not combine rim components
from different rim types or rim manufacturers. Incorrectly assembled or mismatched rim components can fly apart with
explosive force.
→NOTE:
See supplied Off-The-Road Tire Maintenance Manual to remove tire from wheel.

Section 02 - AXLES AND SUSPENSION SYSTEMS

Table of contents
Group 0225 - Input Drive Shafts and U-Joints ..................................................................................... 1
Transmission-to-Rear Axle Drive Shaft Remove and Install .................................................................. 1
Transmission-to-Rear Axle Drive Shaft Disassemble and Assemble ..................................................... 2
Group 0230 - Non-Powered Wheel Axles ............................................................................................. 3
Front Wheel Hub and Spindle Remove and Install—Non 6WD .............................................................. 3
Front Wheel Hub and Spindle Disassemble and Assemble—Non 6WD ................................................. 7
Front Axle Remove and Install—Non 6WD .......................................................................................... 13
Group 0240 - Powered Wheel Axles .................................................................................................... 18
Front Wheel Hub and Spindle Remove and Install—6WD ................................................................... 18
Front Wheel Hub and Spindle Disassemble and Assemble—6WD ...................................................... 22
Front Wheel Hub and Spindle Disassemble and Assemble with Steering Angle Sensor—6WD ........... 28
6WD Drive Hub Disassemble and Assemble ....................................................................................... 35
Planetary Drive Disassemble and Assemble ....................................................................................... 36
Planetary Brake Disassemble and Assemble ...................................................................................... 39
6WD Bearings Remove and Install ..................................................................................................... 45
6WD O-Ring Metal Face Seal Remove and Install ............................................................................... 48
Front Axle Remove and Install—6WD ................................................................................................. 55
Group 0250 - Axle Shafts, Bearings, and Reduction Gears ............................................................. 61
TeamMate™ II 1400 Series Inboard Planetary Axle—Use CTM138619 ............................................... 61
Rear Axle Remove and Install ............................................................................................................. 62
Tandem and Wheel Axle Assembly Remove and Install ..................................................................... 67
Tandem Wheel Axle Assembly Remove and Install ............................................................................ 70
Tandem Wheel Axle Assembly Disassemble and Assemble ............................................................... 73
Tandem Pivot Disassemble and Assemble ......................................................................................... 78
Final Drive Axle Remove and Install ................................................................................................... 86
Tandem Drive Shaft Remove and Install ............................................................................................ 94
Drive Chain Remove and Install ......................................................................................................... 99
Group 0260 - Hydraulic System ......................................................................................................... 102
6WD Pump Remove and Install ........................................................................................................ 102
6WD Pump Disassemble ................................................................................................................... 106
6WD Pump Assemble ....................................................................................................................... 120
6WD Charge Pump Remove and Install ............................................................................................ 137
6WD Engagement Manifold Remove and Install ............................................................................... 138
Differential Lock Pump Remove and Install ...................................................................................... 141
6WD Motor Remove and Install ........................................................................................................ 143
6WD Motor Disassemble and Assemble ........................................................................................... 145

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

Transmission-to-Rear Axle Drive Shaft Remove and Install
Transmission-to-Rear Axle Drive Shaft

LEGEND:
2 Axle Yoke
3 Drive Shaft Assembly
4 Transmission Yoke
CAUTION:
When drive shaft assembly is removed, park brake is inoperative. Chock wheels to prevent unexpected
machine movement.
[1] - Park machine on flat level surface and lower all attachments to ground.
[2] - Loosen cap screws (1 and 5). Do not remove.
[3] - Remove cap screws (1) and push transmission yoke (4) into transmission as far as possible.
[4] - Remove cap screws (5) and remove drive shaft assembly (3).
[5] -
→NOTE:
Universal joints are “Lube for Life” and are not serviceable or repairable. Replace if worn.
Clean and inspect parts. Replace parts as necessary. See Transmission-to-Rear Axle Drive Shaft Disassemble and Assemble .
(Group 0225.)
[6] - Install drive shaft and cap screws. Tighten cap screws to specification.

Section 02 - AXLES AND SUSPENSION SYSTEMS Group 0230: Non-Powered Wheel Axles
Transmission-to-Rear Axle Drive Shaft Cap Screw Torque 111 N·m
82 lb-ft
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.)
[2] -
LEGEND:
2 Cross and Bearing Assembly (2 used)
3 Coupling
4 Drive Shaft Assembly
Rear Axle Drive Shaft

Remove cap screws (1) and separate cross and bearing assemblies (2) from coupling (3).
[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.
Clean and inspect parts. Replace parts as necessary.
[4] - Position cross and bearing assemblies on coupling and install cap screws. Tighten cap screws to specification.
Transmission-to-Rear Axle Drive Shaft Cap Screw Torque 111 N·m
82 lb-ft
[5] - Install drive shaft. See Transmission-to-Rear Axle Drive Shaft Remove and Install . (Group 0225.)

Group 0230 - Non-Powered Wheel Axles

Front Wheel Hub and Spindle Remove and Install—Non 6WD
[2] -
CAUTION:
Prevent possible crushing injury from unexpected machine movement. Install articulation lock pin when
machine is raised or when working in articulation joint area.
Install articulation lock pin. See Locking Machine Frame . (Operator′s Manual.)
[3] - Raise front of machine and install appropriate shop stands. For machine weight see Machine Specifications . (Operator′s
Manual.)
[4] - Remove front wheel. See Wheel Remove and Install . (Group 0110.)
[5] -
CAUTION:
Prevent possible crushing injury from heavy component. Use appropriate lifting device.
LEGEND:
29 Support Strap
30 Lean Angle Linkage Assembly
31 Front Wheel Hub, Spindle, and Yoke
Support Wheel Hub, Spindle, and Yoke

Support wheel hub, spindle, and yoke assembly.
Wheel Hub, Spindle, and Yoke Weight (approximate) 125 kg
275 lb
[6] -

Front Tie Rod Ends

LEGEND:
3 Yoke
8 Wheel Hub
24 Upper Tie Rod End
25 Steering Cylinder Tie Rod End
26 Steering Cylinder Rod
27 Cotter Pin (2 used)
28 Nut (2 used)
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.
[8] -

Wheel Hub, Spindle, and Yoke—Non 6WD (right side shown)

LEGEND:
1 Yoke Pin Cap Screw
2 Yoke Pin
3 Yoke
4 Lower King Pin Assembly
5 Lower King Pin Cap Screw (8 used)
6 Threaded Hole (2 used)
7 Spindle
8 Wheel Hub
9 Upper King Pin Assembly with Steering Angle Sensor
10 Lean Bar Linkage Cap Screw (6 used)
11 Lean Bar Linkage Pin
12 Lean Bar Linkage Retainer
13 Steering Angle Sensor Cap Screw (2 used)
14 Snap Ring
15 Spacer Plate Cap Screw (2 used)
16 Spacer Plate
17 Seal
18 Upper King Pin
19 Steering Angle Sensor Locating Pin
20 Bearing Assembly
B37 Steering Angle Sensor
Remove lower king pin cap screws (5).
[9] - Insert cap screw into threaded hole (6) on opposite sides of king pin assembly (4) to remove king pin.
[10] - Remove steering angle sensor (B37) (right side only). See Steering Angle Sensor Remove and Install . (Group 9015-20.)

[11] - Remove upper king pin (18) and bearing assembly (20) using appropriate puller.
[12] - Remove steering angle sensor locating pin (19).
[13] - Remove wheel hub (8) and spindle (7) assembly from yoke (3).
[14] - Clean, inspect and replace parts as necessary.
[15] - Install wheel hub and spindle assembly into yoke.
[16] - Install steering angle sensor locating pin.
[17] - Install upper king pin and bearing assembly.
[18] - Install steering angle sensor. See Steering Angle Sensor Remove and Install . (Group 9015-20.)
[19] - Install lower king pin assembly.
[20] - Install front wheel. See Wheel Remove and Install . (Group 0110.)
[21] - Remove shop stand and lower machine.
[22] - Remove articulation lock pin. See Locking Machine Frame . (Operator′s Manual.)

Front Wheel Hub and Spindle Disassemble and Assemble—Non 6WD

Specifications
SPECIFICATIONS
125 kg
Wheel Hub, Spindle, and Yoke Assembly Weight (approximate)
275 lb.
30 kg
Front Yoke Weight (approximate)
66 lb.
138 N·m
Upper King Pin Cap Screw Torque
102 lb.-ft.
20 N·m
Lower King Pin Cap Screw Bearing Adjustment Torque
177 lb.-in.
138 N·m
Lower King Pin Cap Screw Final Torque
102 lb.-ft.
15—25 N·m in each direction with no more than 5 N·m difference

Front Axle Lean Yoke Rolling Drag Torque
133—221 lb.-in. in each direction with no more than 44 lb.-in. difference
Front Wheel Hub, Spindle, and Yoke (non 6WD)

LEGEND:
1 Snap Ring
2 Cap Screw
3 Grease Fitting
4 Spacer
5 Upper King Pin
6 Bearing
7 Lean Angle Linkage Retainer (2 used)
10 Spindle
11 Oil Cup
12 Seal
13 Bearing Cone
14 Bearing Cup
15 Wheel Hub
16 Bearing Cup
17 Bearing Cone
18 Washer
19 Nut
21 Lower King Pin
22 Shim
23 Bearing
24 Yoke
25 Yoke Pin
26 Yoke Pin Bushing (2 used)
27 Key
34 Bushing
35 Cap Screw
36 Cotter Pin
37 Gasket
38 Hub Cap
39 Lock Washer (3 used)
[1] - Remove wheel hub, spindle, and yoke assembly. See Front Wheel Hub and Spindle Remove and Install—Non 6WD .
(Group 0240.)
[2] -
CAUTION:
Using appropriate support device, position wheel hub (15) horizontally on a level surface.
Wheel Hub, Spindle, and Yoke Assembly Weight (approximate) 125 kg
275 lb.
[3] - Position yoke (24) vertically using appropriate lifting device.
[4] -
→NOTE:
Note position and quantity of shims for assembly if bearing is not replaced.

LEGEND:
28 Threaded Hole
Lower King Pin Removal (6WD hub shown)

Remove lower king pin cap screws (20). Use two cap screws in threaded holes (28) to push lower king pin (21) from yoke.
[5] - Remove cap screw (2) and grease fitting (3).
[6] - Remove spacer (4).
[7] - Remove snap ring (1).
[8] -
IMPORTANT:
Avoid possible damage to king pin. Attach gear puller with longer cap screws to allow for full thread
engagement.
LEGEND:
5 Upper King Pin
24 Yoke
29 Gear Puller
Puller Attached to Upper King Pin

Attach appropriate gear puller (29) to upper king pin (5) using cap screws (30). Remove king pin using slide hammer.
M6x25 Cap Screw
Attaches gear puller to upper king pin
Gear Puller

Attaches slide hammer to upper king pin

Slide Hammer
Attaches to gear puller to remove king pin
[9] -
CAUTION:
Lift yoke straight up to separate it from spindle and hub.

Front Yoke Weight (approximate) 30 kg
66 lb.
[10] - Inspect upper and lower king pins and bearings (6 and 23). Replace parts as necessary.
[11] - Inspect bushings (26). Replace if necessary.
[12] - Position yoke on spindle and hub.
[13] - Install upper king pin.
[14] - Install snap ring.
[15] - Install spacer and cap screw. Tighten to specification.

Upper King Pin Cap Screw Torque 138 N·m
102 lb.-ft.
[16] -
→NOTE:
If bearings are not replaced, original shim pack can be used.
Install lower king pin without shims using four cap screws (20) evenly spaced. Tighten cap screws to specification.
Lower King Pin Cap Screw Bearing Adjustment Torque 20 N·m
177 lb.-in.
[17] -
→NOTE:
Make sure that upper king pin is against snap ring.
Rotate yoke back and forth a minimum of five times. Tighten cap screws again to specification. Repeat this sequence until
torque is maintained.
[18] -
LEGEND:
21 Lower King Pin
24 Yoke

Shim Adjustment
Measure gap between lower king pin and yoke in three places.
[19] - Use shims as required to obtain the average measured clearance.
→NOTE:
If the exact shim thickness cannot be obtained, set clearance to the next thinnest size using available
shims.
[20] - Remove lower king pin and install shims.
[21] - Install lower king pin using four evenly spaced cap screws. Tighten to specification.
Lower King Pin Cap Screw Final Torque 138 N·m
102 lb.-ft.
[22] - Rotate yoke back and forth a minimum of five times.
[23] -
LEGEND:
21 Lower King Pin
24 Yoke
32 DFT1282 King Pin Torque Adapter
33 Angle Finder
Rolling Torque Measurement (6WD hub shown)

Attach DFT1282 King Pin Torque Adapter (32) to king pin as shown. See DFT1282—King Pin Torque Adapter . (Group 9900.)
King Pin Torque Adapter
DFT1282
Adapts torque wrench to lower king pin
Angle Finder
Measures angle of lean yoke while torque reading is being performed
M20x12 Flanged Cap Screw
Attaches King Pin Torque Adapter to lower king pin
[24] - Position angle finder (33) as shown.
[25] - Measure rolling drag torque in both directions from 5—15° clockwise from vertical using torque wrench as shown.
Measurement must be within specification.
Front Axle Lean Yoke Rolling Drag Torque 15—25 N·m in each direction with no more than 5 N·m difference
[26] - If rolling drag torque is not within specification, adjust shim thickness. Rotate yoke and repeat rolling torque

measurement.
[27] - If rolling drag torque is within specification, install remaining four cap screws and tighten to final torque specification.
102 lb.-ft.
[28] -
CAUTION:
Install wheel hub, spindle, and yoke assembly. See Front Wheel Hub and Spindle Remove and Install—Non 6WD . (Group 0240.)
Wheel Hub, Spindle, and Yoke Assembly Weight (approximate) 125 kg
275 lb.

Front Axle Remove and Install—Non 6WD

Specifications
SPECIFICATIONS
542 kg
Front Axle Assembly Weight (approximate)
1194 lb.
320 N·m
Axle Pin Cap Screw Torque
236 lb.-ft.
[1] - If equipped, remove push block, scarifier or front attachment.
[2] -
CAUTION:
Prevent possible crushing injury from unexpected machine movement. Install articulation locking pin
when machine is raised or when working in articulation joint area.
Install articulation locking pin. See Locking Machine Frame . (Operator′s Manual.)
[3] - Raise front of machine and install appropriate shop stands. For machine weight, see Machine Specifications . (Operator′s
Manual.)
[4] - Remove front wheels. See Wheel Remove and Install . (Group 0110.)
[5] -
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.
To release pressure in the system, slowly loosen fittings on hoses at cylinders.
[6] -
IMPORTANT:
Hose routing is critical. To avoid damage, mark location and routing of each hose.

Front Axle Hoses

LEGEND:
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 Steering Cylinder Rod End Hose
7 Pressure Hose-to-Right Steering Cylinder
Attach identification tags on hydraulic oil hoses.
[7] - Disconnect hoses (1—3 and 5—7). Cap and plug all openings.
[8] -
CAUTION:
Support axle with appropriate lifting device.

Front Axle Assembly Weight (approximate) 542 kg
1194 lb.
[9] -

Steering Angle Sensor Wire Connector

LEGEND:
4 Axle
9 Clamp (4 used)
W24 Steering Angle Sensor Harness
Disconnect steering angle sensor harness (W24) from steering angle sensor (B37). Also remove cap screws (8) and clamps (9).
[10] -

Axle Pin
LEGEND:
4 Axle
10 Axle Pin Cap Screw
11 Axle Pin
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 and tighten to specification.

Axle Pin Cap Screw Torque 320 N·m
236 lb.-ft.
[14] - Connect steering angle sensor harness to sensor. Install cap screws and clamps to secure wire.
[15] -
IMPORTANT:
Hose routing is critical. Route hoses as noted earlier to prevent damage.
Connect hoses to steering cylinders and lean cylinder.
[16] - Install front wheels. See Wheel Remove and Install . (Group 0110.)
[17] - Remove shop stands and lower machine.
[18] - Remove articulation locking pin. See Locking Machine Frame . (Operator′s Manual.)

Section 02 - AXLES AND SUSPENSION SYSTEMS Group 0240: Powered Wheel Axles
[19] - If equipped, install push block, scarifier or front attachment.
[20] - Check hydraulic oil level. See Checking Hydraulic Tank Oil Level . (Operator′s Manual.)

Group 0240 - Powered Wheel Axles

Front Wheel Hub and Spindle Remove and Install—6WD
[2] -
CAUTION:
Manual.)
[5] -
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.)
LEGEND:
1 Support Strap
2 Lean Angle Linkage Assembly
3 Front Wheel Hub, Spindle, and Yoke
Support Wheel Hub, Spindle, and Yoke Assembly

Support wheel hub, spindle, and yoke assembly (3).
Front Wheel Hub, Spindle and Yoke Weight (approximate) 390 kg

860 lb
[6] -
LEGEND:
4 Hose Guard
6 Hose Guard Wheel Assembly
Hose Guards
Remove cap screws (7) and front hose guard (6) from wheel assembly.
[7] - Remove cap screws (5) and hose guard (4) from axle.
[8] -
→NOTE:
Right side is shown, left side is the same unless noted.
LEGEND:
8 Wheel Lean Linkage Tie Rod End
9 Tie Rod End Nut
10 Cotter Pin
11 Steering Cylinder Tie Rod End
12 Right Motor Drain Hose
13 Right Reverse Pressure Hose
14 Right Forward Pressure Hose
15 Flushing Valve Pressure Hose
16 Right Brake Hose
Tie Rod Ends and 6WD Hoses (right side shown)

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).
[10] -

LEGEND:
17 Spindle Yoke Pin
18 Cap Screw
19 Spindle Yoke Pin Grease Hose (2 used)
20 Wire Clip (3 used)
21 Wheel Lean Linkage Retainer (2 used)
W18 Wheel Speed Sensor Harness
Y79 Wheel Lean Solenoid
Wire Connectors and Spindle Yoke Pin
Wheel Lean Linkage and Grease Hoses

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.
[14] - Remove spindle yoke pin cap screw (18). Remove spindle yoke pin (17).
[15] - Remove wheel hub, spindle and yoke assembly.
[16] - Clean and inspect. Repair or replace parts as 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.

Spindle Yoke Pin Cap Screw Torque 140 N·m
130 lb.-ft.
[19] - Install wheel lean linkage and retainers. Tighten cap screws to specification.

Wheel Lean Linkage Retainer Cap Screw Torque 133 N·m
98 lb.-ft.
[20] - Install yoke pin grease hoses.
[21] - Connect steering angle sensor wire harness and wire clips.
[22] - Connect wheel speed sensor harness and wheel lean sensor.
[23] - Install 6WD motor hoses.
[24] - Install both tie rod ends. Tighten nut to specification. If cotter pin hole does not line up, tighten nut to first available
hole.
Steering Cylinder and Wheel Lean Linkage Tie Rod Nut Torque 170 N·m
125 lb.-ft.
[26] - Lower machine to ground and remove articulation pin.
[27] - Run machine to check for leaks.

Front Wheel Hub and Spindle Disassemble and Assemble—6WD
Front Hub and Spindle

LEGEND:
1 Snap Ring
2 Cap Screw
3 Grease Zerk
4 Spacer
5 Upper King Pin
6 Bearing
10 Spindle
12 Hose Guard
13 Bearing Assembly
14 Wheel Seal O-Ring

15 Bearing Assembly
16 Wheel Hub
17 Nut
18 Hose Guard
21 Lower King Pin
22 Shim
23 Bearing
24 Yoke
25 Yoke Pin
26 Yoke Pin Bushing (2 used)
27 Key
[1] -
→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.
See Front Wheel Hub and Spindle Remove and Install—6WD . (Group 0240.)
[2] -
CAUTION:
Position yoke (24) vertically using appropriate lifting device.

6WD Front Wheel Hub, Spindle, and Yoke Weight (approximate) 390 kg
860 lb
[3] -
→NOTE:
Note position of shims and quantity for reassembly if bearing is not replaced.
LEGEND:
28 Threaded Hole
Lower King Pin Remove

[4] - Remove cap screw (2) and grease zerk (3).

[5] - Remove spacer (4).
[7] -
IMPORTANT:
Attach gear puller with longer cap screws to allow for full thread engagement.
LEGEND:
5 Upper King Pin
24 Yoke
29 Gear Puller
30 Cap Screw

Attach appropriate gear puller (29) to upper king pin using cap screws (30). Remove king pin using slide hammer.
M6x25 Cap Screw
Gear Puller
Slide Hammer
Attaches to gear puller to remove king pin
[8] -
CAUTION:
Lift yoke straight up to separate it from spindle and hub.

66 lb.
[9] - Inspect upper and lower king pin and bearing assemblies (6 and 23). Replace parts as necessary.

[14] - Install spacer and cap screw. Tighten to specification.

Upper King Pin Cap Screw Torque 138 N·m
102 lb.-ft.
[15] -
→NOTE:
Install lower king pin without shims using four cap screws (21) evenly spaced. Tighten cap screws to specification.
177 lb.-in.
[16] -
→NOTE:
Rotate lean yoke back and fourth a minimum of five times. Tighten cap screws again to specification. Repeat this sequence
until torque is maintained.
[17] -
LEGEND:
21 Lower King Pin
24 Yoke
Shim Adjustment
Measure gap between lower king pin and yoke in three places.
→NOTE:
If the exact shim thickness can not be obtained, set clearance to the next thinnest size using available
shims.
102 lb.-ft.
[21] - Rotate yoke back and fourth a minimum of five times.
[22] -

LEGEND:
21 Lower King Pin
24 Yoke
31 M12x20 Flanged Cap Screw
33 Angle Finder
Rolling Torque Measurement

DFT1282
Angle Finder
[24] - Measure rolling drag torque in both directions from 5-15° clockwise from vertical using torque wrench as shown.
measurement.
102 lb.-ft.
[27] -
CAUTION:
Install wheel hub spindle and yoke assembly. See Front Wheel Hub and Spindle Remove and Install—6WD . (Group 0240.)
860 lb.

[28] - Fill wheel hub assembly with appropriate oil. See Replacing 6WD Hub Oil—If Equipped . (Operator′s Manual.)

Front Wheel Hub and Spindle Disassemble and Assemble with Steering
Angle Sensor—6WD
Specifications
SPECIFICATIONS
390 kg
6WD Front Wheel Hub, Spindle, and Yoke Weight (approximate)
860 lb.
30 kg
Front Yoke Weight (approximate)
66 lb.
20 N·m
Lower King Pin Cap Screw Bearing Adjustment Torque
177 lb.-in.
138 N·m
Lower King Pin Cap Screw Final Torque
102 lb.-ft.
15—25 N·m in each direction with no more than 5 N·m difference

Front Axle Lean Yoke Rolling Drag Torque

Front Hub and Spindle with Steering Angle Sensor

LEGEND:
1 Snap Ring
3 Spacer
6 Grease Fitting
7 Upper King Pin
8 Key
9 Bearing
10 Dowel Pin
11 Seal
12 Steering Angle Sensor Pin
13 Yoke
14 Yoke Pin Retainer
15 Bushing (2 used)
16 Bearing
17 Shim
18 Lower King Pin
20 Bearing Assembly
22 Bearing Assembly
23 Hose Guard
25 Spindle
26 Hose Guard
31 Nut (3 used)
[1] -
→NOTE:
See Front Wheel Hub and Spindle Remove and Install—6WD . (Group 0240.)
[2] -
CAUTION:
Position yoke (13) vertically using appropriate lifting device.

860 lb.
[3] -
→NOTE:
Note position of shims and quantity for reassembly if bearing is not replaced.

LEGEND:
31 Threaded Hole
Lower King Pin Remove

[4] - Remove steering angle sensor (B37). See Steering Angle Sensor Remove and Install . (Group 9015-20.)
[6] -
IMPORTANT:
Attach gear puller with longer cap screws to allow for full thread engagement.
LEGEND:
7 Upper King Pin
13 Yoke
31 Gear Puller
32 Cap Screw

Attach appropriate gear puller (31) to upper king pin using cap screws (32). Remove king pin.
M6x25 Cap Screw
Gear Puller
[7] - Drive dowel pin (10) from steering angle sensor pin (12).

[8] - Remove steering angle sensor pin.
[9] -
CAUTION:
Using appropriate lifting device, lift yoke straight up to separate it from spindle and hub.
66 lb.
[10] -
→NOTE:
Bearing, seal, and bearing cup are serviced as an assembly.
Inspect upper and lower king pins, steering angle sensor seal (11) and bearing assemblies (9 and 16). Replace parts as
necessary.
[13] - Apply PM37421 Thread Lock and Sealer (high strength) to dowel pin and install in bore.
Number Name Use

• PM37421 (us)
• PM38623 (canadian) Thread Lock and Sealer (High Strength) Secures dowel pin in casting.
• 271 LOCTITE ™ (loctite)
[14] - Install steering angle sensor pin.
[17] -
→NOTE:
Steering angle sensor connector must face front of machine.
Install steering angle sensor and tighten cap screws. See Steering Angle Sensor Remove and Install . (Group 9015-20.)
[18] -
→NOTE:
Install lower king pin without shims using four cap screws evenly spaced. Tighten cap screws to specification.
177 lb.-in.
[19] -
→NOTE:
Rotate lean yoke back and forth a minimum of five times. Tighten cap screws again to specification. Repeat this sequence until
torque is maintained.

[20] -
LEGEND:
13 Lean Yoke
18 Lower King Pin
Shim Measurement
Measure gap between lower king pin and lean yoke in three places.
→NOTE:
If the exact shim thickness can not be obtained, set clearance to the next thinnest size using available
shims.
102 lb.-ft.
[24] - Rotate lean yoke back and forth a minimum of five times.
[25] -
LEGEND:
13 Lean Yoke
19 Lower King Pin
33 M12x20 Flanged Cap Screw
35 Angle Finder
Rolling Torque Measurement

DFT1282
Angle Finder

[27] - Measure rolling drag torque in both directions from 5—15° clockwise from vertical using torque wrench as shown.
measurement.
102 lb.-ft.
[30] -
CAUTION:
Install wheel hub spindle and yoke assembly. See Front Wheel Hub and Spindle Remove and Install—6WD . (Group 0240.)
860 lb.
[31] - Fill wheel hub assembly with appropriate oil. See Replacing 6WD Hub Oil—If Equipped . (Operator′s Manual.)

6WD Drive Hub Disassemble and Assemble

[2] -
CAUTION:
Manual.)
[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.)
[7] -
LEGEND:
1 Cap Screw Plug (3 used)
6WD Drive Hub

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.
Drive Hub Cap Screws Torque 80 N˙m
59 lb-ft
[10] - Install 6WD drive hub. See Front Wheel Hub and Spindle Remove and Install—6WD . (Group 0240.)
[11] - Fill 6WD drive hub with oil. See Replacing 6WD Hub Oil—If Equipped . (Operator′s Manual.)
[12] - Install front wheel. Remove front wheel. See Wheel Remove and Install . (Group 0110.)
[13] - Calibrate 6WD control unit. See 6WD Controller Calibration . (Group 9015-20.)

Planetary Drive Disassemble and Assemble
Planetary Drive Exploded View

LEGEND:
4 Second Stage Carrier Cap Screw (12 used)
11 Snap Ring
12 Snap Ring
15 First Stage Planet Gear Roller Bearing (3 used)
16 Needle Bearing
17 Wheel Hub
18 Dowel Pin (3 used)
19 Second Stage Planet Gear Roller Bearing (3 used)
29 First Stage Drive Shaft
30 First Stage Planet Gear (3 used)
31 First Stage Planet Gear Shaft (3 used)
32 Pin Retainer (3 used)
33 First Stage Carrier
34 Second Stage Sun Gear
35 Thrust Washer (2 used)
36 Second Stage Planet Gear (3 used)
37 Second Stage Planet Gear Pin (3 used)
38 Pin Retainer (3 used)
39 Second Stage Carrier
41 Bearing Race (2 used)
[1] - Park and prepare machine for service. See Park and Prepare for Service Safely . (Group 001.)
[2] -
CAUTION:

Manual.)
[5] - Remove drive hub. See 6WD Drive Hub Disassemble and Assemble . (Group 0240.)
[6] - Remove second stage carrier cap screws (4). Remove second stage carrier assembly (39) from hub (17).
[7] - Remove retaining cap screws (7) and pin retainers (38).
[8] - Remove second stage planet gear pins (37) using a press.
[9] - Remove second stage planet gears (36) and planet bearings (19).
[10] - Repeat above steps for first stage planet gears.
[11] -
LEGEND:
11 Snap Ring
12 Snap Ring
29 Drive Shaft
33 First Stage Carrier
34 Second Stage Sun Gear
35 Thrust Washer
First Stage Carrier, Second Stage Sun Gear, and Drive

Shaft Assembly
Second Stage Sun Gear Snap Ring

Remove snap ring (11).
[12] - Remove thrust washer (35).
[13] - Remove snap ring (12) from second stage sun gear (34).
[14] - Remove drive shaft (29).
[15] - Remove second stage sun gear from carrier (33).
[16] - Remove thrust bearing (16) and bearing races (41) from hub.
[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 stage carrier.
[20] - Install one thrust washer on drive shaft.

[21] - Install drive shaft into first stage carrier assembly. Install second washer and snap ring.
[22] - Assemble first and second carrier assemblies. Use press to install pins.
[23] - Install pin retainers, cap screws, and backing plates.

Tighten cap screws to specification.
Planet Pin Retainer Cap Screws Torque 50 N·m
37 lb.-ft.
[24] - Install needle bearing with bearing races.
[25] - Install first stage carrier assembly into hub.
[26] - Install second stage carrier assembly.

Tighten cap screws (7) to specification.
Second Stage Carrier Mounting Cap Screws Torque 340 N·m
251 lb.-ft.
[27] - Install drive hub. See 6WD Drive Hub Disassemble and Assemble . (Group 0240.)

Planetary Brake Disassemble and Assemble

Specifications
SPECIFICATIONS
20 N·m
Planetary Brake Pressure Plate Cap Screw Torque
177 lb.-in.
Planetary Brake Pressure Plate Cap Screw Torque Turn 1/6 turn
138 N·m
Carrier Brake Retaining Plate Cap Screw Torque
102 lb.-ft.
2000 kPa
Brake Pressure Test (1) Pressure 20 bar
290 psi
10 000 kPa
1450 psi
40 000 kPa
5800 psi
[1] -

Planetary Brake Assembly (exploded view)

LEGEND:
6 Cap screw
8 Washer
9 Spring Pin
13 Roller Bearing
14 Friction Disk (3 used)
21 Bearing Cup
24 Wear Plate (3 used)
25 Spring (12 used)
26 Plate
27 Ring Gear
28 Snap Ring
40 Seal
42 Shim (3 used)
43 Shim (2 used)
44 Shim
45 Spindle
46 Seal
47 Brake Piston Carrier
51 Cover
52 Piston
53 Brake Pressure Plate
54 Back-Up Ring
55 Back-Up Ring
Place spindle assembly on blocks to level ring gear.
[2] - Remove cap screws (2), plate (26), and shims (42—44).
[3] -
Chain and Lifting Eyelets

LEGEND:
27 Ring Gear
59 Mark Position
60 Lift Eyelet (3 used)
61 Hoist Lift Chain (3 used)
Install three lifting eyelets (60).
[4] -
IMPORTANT:
Damage to brake pressure tube will occur if planetary brake is not lined up appropriately.
Mark position (59) as shown to aid assembly.
[5] -
CAUTION:

Lift planetary brake using hoist chains (61).
[6] -
LEGEND:
48 Brake Pressure Tube
49 O-Ring (2 used)
50 Back-Up Washer (2 used)
Brake Pressure Tube

Remove brake pressure tube (48). Replace O-rings (49).
[7] -
LEGEND:
62 Straight Edge
63 Cap Screw for Leveling (3 used)
Leveling Cap Screws

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.
[9] -
IMPORTANT:
Pressure plate retaining cap screws (1) must be replaced with new cap screws after disassembly.
Remove cap screws (1) and pressure plate (53). Discard cap screws.
[10] -
→NOTE:
Springs (25) alternate every other three holes.
LEGEND:
14 Friction Disk
25 Spring (12 used)
28 Snap Ring

Snap Ring, Friction Disk, and Springs

Remove springs.
[12] - Remove friction disks (14) and wear plates (24).
[13] - Remove ring gear (27).
[14] - Turn brake piston assembly over.
[15] - Remove piston (52) with rubber hammer.
[16] - Remove backup rings (54 and 55) and brake piston seals (46).
[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.
[23] -
→NOTE:
Holes for springs must line up when assembling friction disks and brake plates.
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. Tighten cap screws to specification.
Planetary Brake Pressure Plate Cap Screw Torque 20 N·m
177 lb.-in.
Torque Turn 1/6 turn
[27] - See 6WD Bearings Remove and Install to service bearings. (Group 0240.)
[28] - Install brake pressure tube.
[29] - Install brake assembly to spindle.
[30] - Install shims (42—44).
[31] - Install plate. Tighten cap screws to specification.

Carrier Brake Retaining Plate Cap Screw Torque 138 N·m
102 lb.-ft.
[32] -

LEGEND:
65 Brake Pressure Port
Brake Pressure Port

Install JT07192 Hydraulic Pump to brake port (65).
Hydraulic Pump
JT07192
Pressurize brake to check for leakage
[33] - Pressurize brake to specification (1). Pressure must hold for 60 seconds.
Brake Pressure Test (1) Pressure 2000 kPa
20 bar
290 psi
Brake Pressure Test (2) Pressure 10 000 kPa
100 bar
1450 psi
Brake Pressure Test (3) Pressure 40 000 kPa
400 bar
5800 psi
If pressure drop occurs, check brake seals and brake pressure tube.

6WD Bearings Remove and Install
Hub Cover and Face Seals

LEGEND:
44 Cover
47 Roller Bearing
48 Metal Face Seals (2 used)
49 Wheel Spindle Assembly
50 Alignment Pin
51 O-ring
52 Backup Ring
[1] - Remove wheel. See Wheel Remove and Install . (Group 0110.)
[2] - Remove 6WD drive hub. See Front Wheel Hub and Spindle Remove and Install—6WD . (Group 0240.)
[3] - Remove cover (44) from wheel spindle assembly (49).
[4] - Inspect roller bearing (47) and bearing cups. Replace if necessary.
[5] -
→NOTE:
If roller bearings are replaced, adjust bearing preload.
Adjust bearing preload:
a. Remove metal face seal from cover (44). Face seal in wheel spindle assembly can remain installed during preload
adjustment.
b. Install cover (44).

LEGEND:
c.
Brake Pressure Tube
Remove brake pressure tube (27).
d. Apply oil to spindle and install carrier brake assembly.
LEGEND:
25 Retaining Plate Cap Screws
26 Retaining Plate
49 Spindle
e.
Shim Measurement
Install retaining plate (26).
f. Install four cap screws (25). Cross tighten to specification.
Carrier Brake Retaining Plate Cap Screws to Adjust Bearing Preload. Torque 20 N·m
177 lb-in.
g. Rotate cover (44) two revolutions in both directions.

h. Torque cap screws to above specification.
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.
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.
Carrier Brake Retaining Plate Cap Screws Torque 138 N·m
102 lb-ft
n. Rotate cover two revolutions in each direction.

→NOTE:
Make sure DFT1225 tool is installed with center nut (56) directly over motor shaft (57).

LEGEND:
55 DFT1225 Rolling Torque Measurement Tool
56 Center Nut
57 Motor Shaft
Measure Rolling Torque

Install rolling torque measurement tool DFT1225 (55). Measure rolling torque using torque wrench on center nut (56).
Rolling torque must be within specification.
6WD Bearing Rolling Drag Torque 3—10 N·m
27—89 lb-in.
Rolling Torque Measurement Tool

DFT1225
Measure rolling torque on 6WD front wheel drives
If rolling torque is not within specification, adjust shim pack thickness.
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. Tighten cap screws to specification.
Carrier Brake Retaining Plate Cap Screws Torque 138 N˙m
102 lb-ft
[7] - Install wheel. See Wheel Remove and Install for lug nut torque specification. (Group 0110.)

6WD O-Ring Metal Face Seal Remove and Install

[1] - Lean top of wheel hub approximately five degrees inward towards machine frame.
[3] - Drain 6WD drive hub. See Replacing 6WD Hub Oil—If Equipped . (Operator′s Manual.)
[4] -
LEGEND:
1 Brake Pressure Supply Line
Brake Pressure Supply Line

Disconnect brake pressure supply line (1). Cap and plug line.
[5] -
CAUTION:

Wheel End Weight (approximate) 48 kg
105 lb
Support wheel end using hoist and strap.
[6] -
→NOTE:
6WD hub assembly shown removed from machine for clarity.
LEGEND:
45 Hub Mounting Cap Screws
46 Plug
Wheel End Cap Screws

Remove cap screws (45) and plug (46). Use cap screw (45) in threaded hole for plug (46) to separate wheel drive hub.
[7] -

CAUTION:
Prevent possible injury from crushing. Support cover with floor jack.
LEGEND:
5 Floor Jack
6 Cover
7 Hoist Strap
8 Brake Clutch Assembly
Brake Clutch Assembly

Support cover (6) using floor jack (5).
Floor Jack
NA (U.S.)
Used to support wheel end cover.
[8] -
CAUTION:
Support brake clutch assembly (8) using hoist and strap (7).
[9] -
IMPORTANT:
Avoid damage to timing pin by marking an index position on brake clutch assembly.
LEGEND:
9 Index Position
10 Hub
Index Position
Mark index position (9) on brake clutch assembly (8) and hub (10) to aid in assembly.

[10] -
→NOTE:
Keep brake clutch in hoist strap for ease of assembly.
Remove brake clutch assembly.
[11] -
CAUTION:
LEGEND:
5 Floor Jack
6 Cover
Cover
Remove cover (6).
[12] - Remove metal face seal by prying on edges to remove from wheel axle and discard seal.
[13] -
IMPORTANT:
Use extreme care not to scratch metal face seal surface throughout this procedure.
Thoroughly clean O-ring pockets of both seals and exposed surfaces using TY16041 Brake and Clutch Cleaner.
Number Name Use

• TY16041 (us) Brake and Clutch Cleaner Used to clean O-ring pockets.
[14] -
→NOTE:
Seal installing tool is shown expanded to show proper installation.

LEGEND:
7 JDG1824 Seal Installing Tool
8 JDG1824 Tool Lip
9 Seal
Seal Installing Tool

Install JDG1824 Seal Installing Tool (7) to seal (9). Check that lip (8) is fully inserted around entire seal.
Seal Installer
JDG1824
Used to install 6WD seals.
[15] -
IMPORTANT:
Use only rubbing alcohol on seals. Damage could occur to seals if other lubricants are used.
Spray rubbing alcohol on O-ring seal and pockets for lubrication.
Number Name Use

• NA (U.S.) (us) Rubbing Alcohol Lubricating O-ring seal.
[16] -
LEGEND:
7 JDG1824 Seal Installing Tool
8 Seal
Seal Installing Tool

Before alcohol evaporates, install seal (8) by pushing evenly and firmly on tool (7) until tool bottoms out all way around
housing.
[17] -
IMPORTANT:
Damage will occur to O-ring seal if unseated during tool removal. Use care when removing tool from seal.
Remove seal installing tool.

[18] - Inspect O-ring to see that it is seated at same height all the way around.
[19] -
IMPORTANT:
Failure to properly lubricate outer zone of seals may result in seal failure.
LEGEND:
13 Outer Zone of Seal
Metal Face of Seal

Lubricate outer zone (13) of metal face on seal using TY6354 HY-GARD ™ oil.
Number Name Use

• TY6354 (us) HY-GARD Pre-lubricate outer zone of 6WD seal.
[20] - Repeat procedure for remaining seal.
[21] -
CAUTION:
LEGEND:
5 Floor Jack
6 Cover
Cover and Floor Jack

Raise cover (6) into position.
[22] -
IMPORTANT:
Damage will occur to seals if not properly aligned. Seals must be aligned top-to-bottom and left-to-right
to avoid damage.
LEGEND:
11 Seal Half (2 used)
Seal Alignment
Adjust floor jack height until seal halves (11) are at same height and aligned left-to-right.
[23] -
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.
LEGEND:
5 Floor Jack
6 Cover
7 Hoist Strap
Clutch Assembly
Install brake clutch assembly (8) using hoist strap (7).
[24] - Use indexing position to line up brake clutch assembly and hub.
[25] - With correct indexing and role pin in center of through hole slide brake clutch assembly onto splines on spindle. Install
retainer plate and shims.
→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.
[26] - Using three evenly spaced cap screws carefully turn each cap screw, one turn at a time until retainer plate is 3 mm
(0.125 in) from being fully seated.
[27] - Remove floor jack and hoist strap on brake clutch when brake clutch is within 3 mm (0.125 in.) of retainer plate pattern
on spindle.
[28] - Install remaining cap screws. Cross tighten cap screws to 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.
[30] -
LEGEND:
11 Sun Gear Shaft
Wheel End
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.
Wheel End Cap Screw Torque 80 N˙m
59 lb-ft
[32] -
LEGEND:
1 Brake Pressure Supply Line
Brake Pressure Supply Line

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 lug nut torque specification. (Group 0110.)

Front Axle Remove and Install—6WD

Specifications
SPECIFICATIONS
1123 kg
Front Axle Assembly Weight (approximate)
2475 lb.
320 N·m
Axle Pin Cap Screw Torque
236 lb.-ft.
[1] - Park machine on flat, level surface and lower all attachments to ground.
[2] - If equipped, remove push block, scarifier, or front attachment.
[3] -
CAUTION:
[4] -
→NOTE:
Do not install shop stands under axle assembly.
Raise front of machine and install appropriate shop stands. For machine weight, see Machine Specifications . (Operator′s
Manual.)
[5] - Remove front wheels. See Wheel Remove and Install . (Group 0110.)
[6] -
Tie Rod Assembly

LEGEND:
1 Axle
2 Tie Rod Assembly
3 Tie Rod End (2 used)
4 Nut and Cotter Pin (2 used)
Remove nut and cotter pin (4) and tie rod ends (3). Remove tie rod assembly (2).
[7] -
LEGEND:
6 Hose Guard
8 Hose Guard
Hose Guards
Remove cap screws (5 and 7) and hose guards (6 and 8).
[8] -
LEGEND:
9 Clamp (4 used)
W18 Wheel Speed Sensor Harness
Y79 Wheel Lean Solenoid
Steering Angle Sensor

Wheel Speed Sensor

Remove clamps (9). Disconnect steering angle sensor harness (W24).
[9] - Disconnect wheel speed sensor harness (W18) and wheel lean solenoid (Y79).
[10] -
IMPORTANT:
LEGEND:
10 Right Motor Drain Hose
11 Right Reverse Pressure Hose
12 Right Forward Pressure Hose
13 Flushing Valve Pressure Hose
14 Right Brake Hose
6WD Hoses (right side shown)

Attach identification tags on hydraulic oil hoses. Remove 6WD hoses (10—14). Cap and plug all openings.
[11] -
CAUTION:
pressure.
To release pressure in the system, slowly loosen fittings on hoses at cylinders.
[12] -
IMPORTANT:

Front Axle Hoses

LEGEND:
1 Axle
15 Right Steering Cylinder Head End-to-Left Steering Cylinder Rod End Hose
16 Pressure Hose-to-Right Steering Cylinder
17 Pressure Hose-to-Left Steering Cylinder
18 Left Steering Cylinder Head End-to-Right Steering Cylinder Rod End Hose
19 Wheel Lean Cylinder Head End
20 Wheel Lean Cylinder Rod End
Attach identification tags on hydraulic oil hoses. Remove front axle hoses (15—20). Cap and plug all openings.
[13] -
CAUTION:
Support axle with appropriate lifting device.

Front Axle Assembly Weight (approximate) 1123 kg
2475 lb.
[14] -

Front Axle Pin

LEGEND:
1 Axle
21 Axle Pin Cap Screw
22 Axle Pin
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 and tighten to specification.

Axle Pin Cap Screw Torque 320 N·m
236 lb.-ft.
[18] -
IMPORTANT:
Hose routing is critical. Route hoses as noted earlier to prevent damage.
Install front axle hoses.
[19] - Install 6WD hoses.
[20] - Connect wheel speed sensor and wheel lean solenoid on both sides of axle.
[21] - Connect steering angle sensor on right side of axle. Install clamps to hold wiring in place.
[22] - Install hose guards and cap screws.

Section 02 - AXLES AND SUSPENSION SYSTEMS Group 0250: Axle Shafts, Bearings, and Reduction Gears
[23] - Install tie rod assembly.
[24] - Install front wheels. See Wheel Remove and Install . (Group 0110.)
[25] - Lower machine.
[27] - If equipped, install push block, scarifier, or front attachments.

Group 0250 - Axle Shafts, Bearings, and Reduction Gears

TeamMate™ II 1400 Series Inboard Planetary Axle—Use CTM138619
Component Technical Manual (CTM)
For complete TeamMate ™ II repair information, the component technical manual (CTM) is also required.
Use the CTM in conjunction with this machine manual. See TeamMate™ II 1400 Series Inboard Planetary Axle . (CTM138619.)

Rear Axle Remove and Install

Specifications
SPECIFICATIONS
1100 kg
Rear Axle Assembly Weight (approximate)
2500 lb
620 N·m
Front Support-to-Axle Cap Screws Torque
460 lb·ft
1070 N·m
Engine Frame-to-Axle Cap Screws Torque
790 lb·ft
[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.)
[5] -
CAUTION:
Raise rear of machine and place appropriate supporting device under engine frame. For machine weights, see Machine
Specifications . (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.)
[9] -

Rear Axle (top view)

LEGEND:
1 Hydraulic Hose (7 used)
2 Rear Axle
3 Rear Axle-to-Engine Frame Cap Screws (8 used)
4 Transmission-to-Rear Axle Drive Shaft
5 Engine Frame
Y6 Differential Lock Solenoid
Remove transmission-to-rear axle drive shaft (4). See Transmission-to-Rear Axle Drive Shaft Remove and Install . (Group 0225.)
[10] - Disconnect wire harness from differential lock solenoid (Y6). See Rear Platform Harness (W26) Component Location .
(Group 9015-10.)
[11] -
CAUTION:
Escaping fluid under pressure can penetrate the skin causing serious injury. Avoid the hazard by
relieving pressure before disconnecting hydraulic or other lines. Tighten all connections before applying
pressure. Search for leaks with a piece of cardboard. Protect hands and body from high-pressure fluids.
If an accident occurs, see a doctor immediately. Any fluid injected into the skin must be surgically
removed within a few hours or gangrene may result. Doctors unfamiliar with this type of injury should
reference a knowledgeable medical source. Such information is available from Deere & Company Medical
Department in Moline, Illinois, U.S.A.
→NOTE:
It takes at least 60 cycles of the brake pedal to discharge brake accumulator.

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.)
[13] -
CAUTION:
pressure.
To release pressure in the system, slowly loosen fittings on hoses at differential lock valve and differential.
[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] -
CAUTION:
Support rear axle (2) with appropriate lifting device.

Rear Axle Assembly Weight (approximate) 1100 kg
2500 lb
[16] -

Rear Axle Front Supports

LEGEND:
2 Rear Axle
3 Rear Axle-to-Engine Frame Cap Screws (8 used)
5 Engine Frame
6 Rear Axle-to-Front Support Cap Screws (6 used)
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 TeamMate ™ II components as needed. See TeamMate™ II 1400 Series Inboard Planetary Axles .
(CTM138619.)
[20] -
CAUTION:
Avoid crushing injury. Use appropriate lifting device.
Lift rear axle in place under machine using an appropriate lifting device.
2500 lb
[21] - Loosely install rear axle-to-front support cap screws (6).
[22] - Loosely install rear axle-to-engine frame cap screws (3).

[23] - With rear axle held against the engine frame at the top mounts and front mount (no gaps), tighten cap screws to
specification.
Front Support-to-Axle Cap Screws Torque 620 N·m
460 lb·ft
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.)
[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 Install . (Group
0225.)
[28] - Install left and right tandem and wheel axle assemblies. See Tandem and Wheel Axle Assembly Remove and Install .
(Group 0250.)
[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 Install . (Group 4240.)
[32] - Turn battery disconnect switch to ON position.
[33] - Remove articulation lock pin.
[35] - Return machine to service.

Tandem and Wheel Axle Assembly Remove and Install

[1] - Park machine on hard level surface. Lower all attachments.
[2] -
CAUTION:
Prevent possible injury from unexpected machine movement. Install articulation locking pin when
[4] - Drain tandem housing. See Changing Tandem Oil . (Operator′s Manual.)
[5] -
CAUTION:
Raise rear of machine and install shop stands under rear of engine frame. See Machine Specifications . (Operator′s Manual.)
[6] - Remove wheels from tandem being removed. See Wheel Remove and Install . (Group 0110.)
[7] -
Tandem Access Panels

LEGEND:
5 Platform
6 Top Access Panel (2 used)
7 Side Access Panel (4 used)
Remove platform (5), top access panels (6) and side access panels (7).
[8] -

LEGEND:
1 Tandem Assembly
2 Retaining Ring
Drive Sprocket Retaining Ring

Remove drive sprocket retaining ring (2).
[9] -
CAUTION:
Install appropriate lifting device.

Tandem and Wheel Axle Assembly Weight 726 kg
1600 lb
[10] -
LEGEND:
1 Tandem Assembly
Tandem Pivot
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.

[13] -
IMPORTANT:
Carefully align tandem drive sprocket with tandem drive shaft for ease of installation.
Lubricate O-ring on tandem pivot housing pilot diameter and mating surface in tandem housing with petroleum jelly.
[14] - Install tandem housing onto tandem pivot housing. Apply PM37418 Thread Lock and Sealer (medium strength) to
threads of cap screws and tighten to specification.
Number Name Use

• PM37418 (us)
• PM38621 (canadian) Thread Lock and Sealer (Medium Strength) Apply to tandem housing cap screws.
Pivot Housing Retaining Ring Cap Screw Torque 258 N˙m
190 lb-ft
[15] - Install drive sprocket retaining ring.
[16] - Install top access cover and side access cover on tandem assembly. Apply PM37418 Thread Lock and Sealer (medium
strength) to threads of cap screws and tighten to specification.
Number Name Use

• PM37418 (us)
• PM38621 (canadian) Thread Lock and Sealer (Medium Strength) Apply to tandem housing cap screws.
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 Remove and Install . (Group 0110.)
[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.)
[21] - Remove articulation locking pin.

Tandem Wheel Axle Assembly Remove and Install

[1] - Park machine on level surface.
[2] -
CAUTION:
Prevent possible injury from unexpected machine movement. Install articulation lock pin when machine
is raised or when working in articulation joint area.
[4] -
LEGEND:
1 Tandem Assembly
2 O-Ring
3 Axle Assembly
4 Oil Collection Cup
Tandem Wheel Assembly (front shown)

Drain tandem assembly (1). See Changing Tandem Oil . (Operator′s Manual.)
[5] -
CAUTION:
Raise back of machine using appropriate lifting device.
[6] - Support each end of tandem housing using appropriate supporting device.
[7] - Remove wheel. See Wheel Remove and Install . (Group 0110.)
[8] -
IMPORTANT:
Excessive lifting force can split flange on wheel axle assembly.
Install appropriate lifting device to wheel axle flange and tire mounting flange.
[9] -

Tandem Access Panels

LEGEND:
5 Platform
6 Top Access Panel (2 used)
Remove platform (5), top access panels (6) and side access panels (7).
[10] - Remove drive chain from wheel axle sprocket. See Drive Chain Remove and Install . (Group 0250.)
[11] -
CAUTION:

Wheel Axle Assembly Weight (approximate) 145 kg
320 lb
Remove cap screws and washers from wheel axle assembly flange and remove wheel axle assembly.
[12] - Repair or replace parts as necessary. See Tandem Wheel Axle Assembly Disassemble and Assemble . (Group 0250.)
[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.
Number Name Use

• T43512 (us)
• TY9473 (canadian) Thread Lock and Sealer (Medium Strength) Apply to tandem housing cap screws.
Wheel Axle Housing-to-Tandem Cap Screw Torque 258 N˙m
190 lb-ft
[17] - Install drive chain. See Drive Chain Remove and Install . (Group 0250.)
[18] - Install wheel and tighten to specification. See Wheel Remove and Install . (Group 0110.)
[19] - Fill tandem housing flush to bottom of oil level check plug. See Drain and Refill Capacities . (Operator′s Manual.)

Tandem Wheel Axle Assembly Disassemble and Assemble
Tandem Wheel Axle Assemblies

LEGEND:
1 Cotter Pin
2 Slotted Nut
3 Sprocket Retainer
4 Wheel Axle Sprocket

5 Thrust Washer
6 Inner Bearing Cone
7 Inner Bearing Cup
8 Outer Bearing Cup
9 Outer Bearing Cone
10 Metal Face Oil Seal
11 Wheel Axle
12 Cap Screw (2 used per axle)
13 Tandem Front Wheel Axle
14 Tandem Rear Wheel Axle
16 Clearance—Wheel Axle Flange-to-Housing
17 Oil Collection Plate (front axle)
18 Oil Collection Cup (rear axle)
19 Wheel Axle Housing
20 O-Ring
23 Magnet
Bearing Cups Position

Wheel Axle Press
[1] -
CAUTION:
Remove parts (1—5 and 12, 17 or 18, and 23).

Tandem Wheel Axle Assembly Weight (approximate) 145 kg
320 lb.
[2] - Press wheel axle (11) through inner bearing cone (6) and out of wheel axle housing (19).
[3] -
→NOTE:
Metal face oil seal will be destroyed when installing puller.
Pull outer bearing cone (9) off wheel axle using puller.
[4] - Remove metal face oil seal (10) from wheel axle and discard seal.
[5] - Drive inner bearing cup (7) and outer bearing cup (8) out of wheel axle housing.
[6] - Inspect and replace parts as necessary.
[7] - Position inner bearing cup and outer bearing cup in wheel axle housing and press firmly against shoulders in housing.
[8] -
→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.
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 oil seal using a lint-free cloth.
[11] - Clean wheel axle and wheel axle housing bores at seal mounting surfaces using denatured or isopropyl alcohol using a
lint-free cloth.
[12] - Install half of seal in wheel axle seal bore. Metal oil 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.
[14] -

CAUTION:
Handle Fluids Safely—Avoid Fires

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.
IMPORTANT:
Do not heat bearing for longer than a 1 hour time period.
Heat bearing cones (6 and 9) to 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).
[19] -
→NOTE:
When assembling tandem front wheel axle (13), position sprocket (4) with teeth toward wheel axle
housing as shown.
When assembling tandem rear wheel axle (14), position sprocket (4) with teeth away from wheel axle
housing as shown.
Install sprocket.
[20] - Install sprocket retainer (3) and slotted nut (2) loosely.
[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.
[23] - Partially tighten slotted nut on wheel axle housing.

→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] - Measure rolling drag torque with end play on bearings.
[25] - Preload bearings by tightening slotted nut again until rolling torque increases more than rolling torque with end play.
After tightening turn to check for smooth rotation of assembly.
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
[26] - Install cotter pin (1) to axle shaft.
[27] - Apply PM38657 High Flex Form-In-Place Gasket to oil collector plate (17) and/or oil collection cup (18).
Number Name Use

• PM38657 (us)
Apply to tandem wheel axle oil collector cup and oil collector
• PM38628 (canadian) High Flex Form-In-Place Gasket
plate.
• 17430 Loctite ™ (loctite)
[28] - Install oil collection cup (rear wheel axle) or oil collection plate (front wheel axle) with cap screws (12).
[29] - Lubricate bearings and flood oil seal cavity with John Deere HY-GARD ™ oil.
[30] - Operate machine in first gear, slow idle for ten minutes to allow proper break-in of seal.

Tandem Pivot Disassemble and Assemble

Tandem Pivot Disassemble and Assemble (S.N. —XXXXXX)
LEGEND:
1 Pivot Retainer
2 Shim
3 Outboard Thrust Washer Segment (3 used)
5 Tandem Pivot Housing
6 Grease Line
7 O-Ring (2 used)
8 Inboard Thrust Washer Segment (3 used)
9 Tandem Pivot Bushing (2 used)
10 Final Drive Axle Housing
Outboard Thrust Washer
Inboard Thrust Washer
[1] - Remove tandem and wheel axle assembly. See Tandem Wheel Axle Assembly Disassemble and Assemble . (Group 0250.)
[2] - Remove grease line (6). Close all openings using caps and plugs.
[3] - Remove cap screws (4).
[4] - Remove pivot retainer (1), shims (2) and outboard thrust washer segments (3). Retain shims for installation.
[5] -
CAUTION:

Remove tandem pivot housing (5) by pulling straight off final drive axle housing (10).
Tandem Pivot Housing Weight (approximate) 91 kg
200 lb.
[6] - Remove inboard thrust washer segments (8) and tandem pivot bushings (9).
[8] - Lubricate O-rings (7) on final drive axle housing and mating surface on tandem pivot housing with grease.
[9] - 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 into position to secure.
[10] - Lubricate tandem pivot bushings with oil and install on final drive axle housing. Stagger bushing openings 180° apart.
[11] - Position tandem pivot housing with sloping flange to top and install halfway. Push in slowly, making sure thrust washer
segments remain in position. Continue installing until contact with O-rings is made and tandem pivot housing becomes difficult
to move by hand.
[12] - Lubricate outboard thrust washer segments with oil and install with corner chamfer facing outward so it is visible when
installed.
[13] - 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.
[14] -

Tandem Pivot Component Identification

LEGEND:
1 Pivot Retainer
2 Shim
7 O-Ring (2 used)
11 Hardened Washer (16 used)
12 Clearance
13 End Play Clearance
Using a feeler gauge, check clearance (12) between tandem pivot housing (5) and final drive axle housing (10). It should
measure approximately 2.5 mm (0.098 in.) when tandem pivot housing stops moving and torque on cap screws (4) begins to
rise.

Tandem Pivot Housing-to-Final Drive Axle Housing Clearance (approximate) 2.5 mm
0.098 in.
If clearance (12) measures approximately 8.5 mm (0.335 in.), inboard thrust washer segments (8) have moved and must be
repositioned.
Inboard Thrust Washer Segments Clearance (approximate) 8.5 mm
0.335 in.
[15] - When clearance between tandem pivot housing and main drive axle housing measures approximately 2.5 mm (0.098
in.) install four more cap screws (evenly spaced). Tighten all eight cap screws to specification to extrude excess grease from
surfaces of inboard thrust washer segments.
Tandem Pivot Housing-to-Main Drive Axle Housing Clearance (approximate) 2.5 mm
0.098 in.
Inboard Thrust Washer Segments Torque 140 N·m
103 lb.-ft.
[16] - Remove pivot retainer (1) and install with previously removed shims (2) and eight evenly spaced cap screws (4) and
washers (11). Torque to specification.
Pivot Housing Retaining Ring Cap Screw Torque 278 N·m
205 lb.-ft.
[17] - Using a feeler gauge, check end play clearance (13) between pivot retainer and outboard tandem pivot segments (3).
Move feeler gauge completely around joint. Add or subtract shims to establish correct end play.
Pivot Retainer-to-Outboard Tandem Pivot Segments End Play 0.26—0.40 mm
0.010—0.015 in.
[18] - Remove eight cap screws and discard. Dip threads of 16 new cap screws in oil and install with hardened washers after
allowing excess oil to drip off. Torque to specification. Go around bolt circle twice with torque wrench.
Wheel Axle Housing-to-Tandem Cap Screw Torque 258 N·m
190 lb.-ft.
[19] - Connect tandem pivot grease line.
[20] - Install tandem and wheel axle assembly. See Tandem Wheel Axle Assembly Disassemble and Assemble . (Group 0250.)
[21] - Grease tandem pivot. See Lubricate Tandem Pivots . (Operator’s Manual.)
[22] - Turn battery disconnect switch to the ON position. See Battery Disconnect Switch . (Operator’s Manual.)
Tandem Pivot Disassemble and Assemble (S.N. XXXXXX—)

LEGEND:
1 Pivot Retainer
2 Shim
6 Grease Line
Outboard Thrust Washer
[1] - Remove tandem and wheel axle assembly. See Tandem Wheel Axle Assembly Disassemble and Assemble . (Group 0250.)
[2] - Remove grease line (6). Close all openings using caps and plugs.
[4] - Remove pivot retainer (1), shims (2) and outboard thrust washer segments (3). Retain shims for installation.
[5] -
CAUTION:
Remove tandem pivot housing (5) by pulling straight off final drive axle housing (10).
Tandem Pivot Housing Weight (approximate) 91 kg
200 lb.
[6] -
LEGEND:
7 Seal (2 used)
Inboard Thrust Washer

Seal
Remove inboard thrust washer segments (8) and tandem pivot bushings (9).
[8] -
IMPORTANT:
Always use new O-rings and seals. Damaged or used O-rings and seals will leak.
Install new seals (7) on final drive axle housing (10) and lips of the seal should be facing away from each other.
[9] - 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 into position to secure.
[10] - Lubricate tandem pivot bushings with oil and install on final drive axle housing. Stagger bushing openings 180° apart.
[11] - Position tandem pivot housing with sloping flange to top and install halfway. Push in slowly, making sure thrust washer
segments remain in position. Continue installing until contact with seals is made and tandem pivot housing becomes difficult to
move by hand.
[12] - Lubricate outboard thrust washer segments with oil and install with corner chamfer facing outward so it is visible when
installed.
[13] - 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 seals.
[14] -

Tandem Pivot Component Identification

LEGEND:
1 Pivot Retainer
2 Shim
7 Seal (2 used)
11 Hardened Washer (16 used)
12 Clearance
13 End Play Clearance
Using a feeler gauge, check clearance (12) between tandem pivot housing (5) and final drive axle housing (10). It should
measure approximately 2.5 mm (0.098 in.) when tandem pivot housing stops moving and torque on cap screws (4) begins to
rise.
Tandem Pivot Housing-to-Final Drive Axle Housing Clearance (approximate) 2.5 mm
0.098 in.

If clearance (12) measures approximately 8.5 mm (0.335 in.), inboard thrust washer segments (8) have moved and must be
repositioned.
Inboard Thrust Washer Segments Clearance (approximate) 8.5 mm
0.335 in.
[15] - When clearance between tandem pivot housing and main drive axle housing measures approximately 2.5 mm (0.098
in.) install four more cap screws (evenly spaced). Tighten all eight cap screws to specification to extrude excess grease from
surfaces of inboard thrust washer segments.
Tandem Pivot Housing-to-Main Drive Axle Housing Clearance (approximate) 2.5 mm
0.098 in.
Inboard Thrust Washer Segments Torque 140 N·m
103 lb.-ft.
[16] - Remove pivot retainer (1) and install with previously removed shims (2) and eight evenly spaced cap screws (4) and
washers (11). Torque to specification.
Pivot Housing Retaining Ring Cap Screw Torque 278 N·m
205 lb.-ft.
[17] - Using a feeler gauge, check end play clearance (13) between pivot retainer and outboard tandem pivot segments (3).
Move feeler gauge completely around joint. Add or subtract shims to establish correct end play.
Pivot Retainer-to-Outboard Tandem Pivot Segments End Play 0.26—0.40 mm
0.010—0.015 in.
[18] - Remove eight cap screws and discard. Dip threads of 16 new cap screws in oil and install with hardened washers after
allowing excess oil to drip off. Torque to specification. Go around bolt circle twice with torque wrench.
Wheel Axle Housing-to-Tandem Cap Screw Torque 258 N·m
190 lb.-ft.
[19] - Connect tandem pivot grease line.
[20] - Install tandem and wheel axle assembly. See Tandem Wheel Axle Assembly Disassemble and Assemble . (Group 0250.)
[21] - Grease tandem pivot. See Lubricate Tandem Pivots . (Operator’s Manual.)

Final Drive Axle Remove and Install

Specifications
SPECIFICATIONS
1100 kg
Rear Axle Assembly Weight (approximate)
2500 lb
140 kg
Final Drive Weight (approximate)
310 lb
0.5—1.0 mm
Tandem Housing Clearance
0.02—0.04 in
81 N·m
Cap Screw and Nut—Initial Torque
60 lb·ft
136 N·m
Cap Screw and Nut—Intermediate Torque
100 lb·ft
Cap Screw Nut—Final Torque Turn 180°
1070 N·m
Final Drive-to-Engine Frame Cap Screw Torque
790 lb·ft
620 N·m
Final Drive-to-Front Support Cap Screw Torque
460 lb·ft
Other Material
OTHER MATERIAL
PM38657 U.S. Flexible Anaerobic Gasket Flange Sealant
PM38628 Canadian Flexible Anaerobic Gasket Flange Sealant
5127™ Loctite ™ Flexible Anaerobic Gasket Flange Sealant
[2] - Install articulation locking pin. See Locking Machine Frame . (Operator’s Manual.)
[3] - Turn battery disconnect switch to the OFF position. See Battery Disconnect Switch . (Operator’s Manual.)
[4] - Remove ripper, if equipped. See Ripper Remove and Install . (Group 4240.)
[5] -
CAUTION:
pressure. Search for leaks with a piece of cardboard. Protect hands and body from high-pressure fluids.
→NOTE:
It takes at least 60 cycles of the brake pedal to discharge brake accumulator.
Depress service brake pedal continuously until service brake pedal offers no resistance to discharge service brake
accumulator.
[6] -
CAUTION:
Raise rear of machine and place appropriate supporting device under engine frame. For machine weights, see Machine
Specifications . (Operator′s Manual.)
[7] - Drain axle housing oil. See Changing Axle Housing Oil . (Operator′s Manual.)
[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
[10] - Disassemble tandem pivot housing for side of machine being serviced. See Tandem Pivot Disassemble and Assemble .
(Group 0250.)
[11] -
CAUTION:

Final Drive Axle Component Location

LEGEND:
1 Differential Case
3 Final Drive Ring Gear
4 Brake Backing Plate
6 Sun Pinion Shaft
7 Brake Pack Retaining Snap Ring (2 used)
8 Brake Separator Plate (6 used)
9 Brake Disc (5 used)
10 Brake Pack Retaining Pin (2 used)
13 O-Ring
14 Cap Screw
15 Lock Plate
16 Planet Pinion Carrier Assembly
17 Snap Ring
18 Tandem Drive Shaft
19 Inboard Bearing Cone
20 Snap Ring
21 Oil Seal
22 Outboard Bearing Cup
23 Inboard Bearing Cup
Support rear axle with an appropriate lifting device.
2500 lb
[12] - Remove fuel tank. See Fuel Tank Remove and Install . (Group 0560.)
[13] -
CAUTION:
Support final drive axle housing (2) at bottom of front and rear mounting pads.
Final Drive Weight (approximate) 140 kg
310 lb
[14] - Remove three cap screws and washers that attach lower front mount of final drive axle housing to the front engine
frame support.
[15] - Remove four cap screws and washers that attach top mounts of final drive axle housing to engine frame.
[16] - Position hydraulic jack under center of tandem housing on opposite side and raise slightly.
[17] - Check for clearance between top mounts of final drive axle and engine frame on side of machine being serviced.
Tandem Housing Clearance 0.5—1.0 mm
0.02—0.04 in
a. If clearance exists , securely block ends of tandem housing on either side of jack to prevent tandems from rotating.
CAUTION:
Prevent injury from unexpected machine movement. Do not apply so much load that the engine
frame comes off other supports.
If clearance does not exist , apply just enough pressure on tandem with the jack to create specified clearance.
c. Block ends of tandem housing on either side of jack to prevent tandem from rotating.
[18] -

Final Drive Axle Housing

LEGEND:
26 Washer (12 used)
27 Nut (4 used)
28 Stud (4 used
Remove cap screws, washers, nuts, and studs (25—28). Discard cap screws and studs.
[19] - Use two pry bars at notches between differential case (1) and brake backing plate (4) to break sealed joint at this
location.
[20] -
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, do not allow these parts to separate from each other.
Pull final drive axle away from differential case as shown. Differential case-to-brake backing plate dowel pins (5) will stay with
the differential case.
[21] -
IMPORTANT:
The sun pinion shaft (6) is not retained in the differential or the final drive. Do not allow this shaft to fall
when final drive axle is moved away from differential case.
Remove sun pinion shaft.
[22] - Repair or replace TeamMate ™ II components as necessary. See TeamMate™ II 1400 Series Inboard Planetary Axles .

(CTM138619.)
[23] -
IMPORTANT:
When any final drive axle housing-to-differential case cap screws have been removed, all must be
removed to properly seal unit. Clean then apply high flex form-in-place gasket between differential case,
and final drive axle housing, prior to assembly.
Apply Loctite ™ 5127™ Flexible Anaerobic Gasket Flange Sealant onto the mounting surface of the differential case. Ensure the
mounting surface of the differential case contains two locating dowel pins (5).
Number Name Use

• PM38657 (us)
Flexible Anaerobic Gasket Flange Apply to final drive axle housing to ring gear to brake
• PM38628 (canadian)
Sealant backing plate to differential case.
• 5127™ Loctite ™ (loctite)
[24] - Install final drive axle onto differential case.
[25] - Rotate differential input yoke to align splines on sun pinion shaft with splines in differential side gears.
[26] -
IMPORTANT:
Prevent possible damage to final drive axle housing (2) and differential case (1). Cap screws (25) and
studs (28) are torqued to yield and must be replaced.
Final Drive Axle Housing to Differential Case Tightening Pattern

Loosely install studs, washers, nuts, and cap screws.
[27] - Tighten cap screws and nuts to initial torque specification in alternating pattern shown.
Cap Screw and Nut—Initial Torque 81 N·m
60 lb·ft
[28] - Tighten cap screws and nuts to intermediate torque specification in alternating pattern shown.

Cap Screw and Nut—Intermediate Torque 136 N·m
100 lb·ft
[29] -
Torque to Yield
LEGEND:
1 Marks on Housing
2 Mark on Head of Cap Screw
3 Washer
4 Head of Cap Screw
9 Starting Position After Tightening to Intermediate —Torque
10 Final Position After Turning Cap Screw Final — Torque Turn
Mark cap screws as shown. Tighten each cap screw an additional torque turn as specification in same alternating pattern.
Cap Screw Nut—Final Torque Turn 180°
[30] - Lower jack under opposite tandem housing.
[31] - Loosely install three cap screws and washers that attach the lower front mount of final drive axle housing.
[32] - Loosely install four cap screws and washers that attach the top mounts of the final drive axle housing to the engine
frame.
[33] - With axle held against the engine frame at the two top mounts and the front mount (no gaps), tighten cap screws to
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
[34] - Perform vacuum leakdown test on brake piston packing rings. Perform Brake Piston Packings — Vacuum Leakdown Test .
(CTM138619.)
[35] - Install fuel tank. See Fuel Tank Remove and Install . (Group 0560.)

[36] - Assemble tandem pivot housing. See Tandem Pivot Disassemble and Assemble . (Group 0250.)
[37] - Fill rear axle assembly with oil. See Changing Axle Housing Oil . (Operator′s Manual.)
[38] - If equipped, install ripper. See Ripper Remove and Install . (Group 4240.)
[40] - Remove articulation locking pin. See Locking Machine Frame . (Operator’s Manual.)

Tandem Drive Shaft Remove and Install
Final Drive Axle Component Location

LEGEND:
1 Differential Case
3 Final Drive Ring Gear
4 Brake Backing Plate
6 Sun Pinion Shaft
7 Brake Pack Retaining Snap Ring (2 used)
8 Brake Separator Plate (6 used)
9 Brake Disc (5 used)
10 Brake Pack Retaining Pin (2 used)
13 O-Ring
14 Cap Screw

15 Lock Plate
16 Planet Pinion Carrier Assembly
17 Snap Ring
18 Tandem Drive Shaft
19 Inboard Bearing Cone
20 Snap Ring
21 Oil Seal
22 Outboard Bearing Cone
23 Inboard Bearing Cup
Specifications
SPECIFICATIONS
203 kg
Final Drive Axle Housing With Tandem Drive Shaft Weight (approximate)
450 lb
27 kg
Tandem Drive Shaft Weight (approximate)
60 lb
116—127°C
Bearing Cone Temperature
240—260°F
Service Equipment and Tools
SERVICE EQUIPMENT AND TOOLS
DF1057 Axle Adjusting Tool
Thermometer
DFT1151 Outboard Bearing Driver
DFT1152 Inboard Bearing Driver
[1] - Remove final drive axle. See Final Drive Axle Remove and Install . (Group 0250.)
[2] - Remove brake components. See Multiple Disk Brake — Removal . (CTM138619.)
[3] - Remove planet pinion carrier. See Grader Planetary Carrier Assembly — Removal . (CTM138619.)
[4] -
IMPORTANT:
Protect all exposed machined surfaces on final drive axle housing (2) from damage.
Remove inboard (carrier end) bearing retaining snap ring (17).
[5] -
CAUTION:
Hoist final drive axle housing (2) to an upright position (bolting flange up).
Final Drive Axle Housing With Tandem Drive Shaft Weight (approximate) 203 kg
450 lb
Tandem Drive Shaft Weight (approximate) 27 kg
60 lb
[6] -

LEGEND:
26 Axle Adjusting Tool
Attach Axle Adjusting Tool and Chain Hoist

Attach axle DF1057 Axle Adjusting Tool (26) to final drive axle housing.
Axle Adjusting Tool
DF1057
To push tandem drive shaft through inboard bearing cone.
[7] - Attach chain hoist to DF1057 Axle Adjusting Tool.
[8] -
→NOTE:
While working with tandem drive shaft, protect sealing surface with a single wrap of electrical tape.
Put disks between hydraulic jack and tandem drive shaft (18).
[9] - Push tandem drive shaft through inboard bearing cone (19).
[10] - Remove outboard bearing cone retaining snap ring (20) and pull outboard bearing cone (22) off tandem drive shaft.
[11] -
→NOTE:
Tandem axle shaft bearings must be replaced with reassembly.
Inspect and replace as necessary.
[12] -

CAUTION:

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 of bearing retaining snap ring.
Bearing Cone Temperature 116—127°C
240—260°F
Thermometer
Measure oil temperature.
[13] - Install bearing retaining snap ring in groove next to outboard bearing cone. Be sure bearing retaining snap ring is firmly
seated in groove.
[14] -
→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.
Seat outboard bearing cone firmly against bearing cone retaining snap ring using DFT1151 Outboard Bearing Driver and
DFT1152 Inboard Bearing Driver.
Outboard Bearing Driver
DFT1151
To seat outboard tandem drive shaft bearing cone against bearing retaining snap ring.
Inboard Bearing Driver
DFT1152
To seat tandem drive shaft bearing cones against bearing retaining snap rings.
[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 oil 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 (24) into outboard (sprocket) end of final drive axle housing.
[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 outboard bearing cup (24) while rotating tandem drive shaft.
[19] - Remove electrical tape from shaft.
[20] -
CAUTION:

→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 in inboard bearing driver and into tapped hole in tandem drive shaft.
Use tandem drive sprocket as 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.
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.
Bearing Cone Temperature 116—127°C
240—260°F
Thermometer
Measure oil temperature.
[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 Grader Planetary Carrier Assembly — Assemble . (CTM138619.)
[23] - Install brake components. See Multiple Disk Brake — Installation . (CTM138619.)
[24] - Install final drive axle. See Final Drive Axle Remove and Install . (Group 0250.)

Drive Chain Remove and Install

→NOTE:
Right side is shown. Left side is similar.
[2] - Install articulation locking pin.
[3] -
CAUTION:
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 Install . (Group 0110.)
[5] - Drain tandem assembly. See Changing Tandem Oil . (Operator′s Manual.)
[6] -
Tandem Assembly Platforms

LEGEND:
2 Platform (2 used)
3 Tandem Assembly
Remove cap screws (1) and platforms (2) from tandem assembly (3).
[7] -

Tandem Assembly Access Covers

LEGEND:
5 Access Cover (6 used)
Remove cap screws (4) and access covers (5).
[8] -
CAUTION:
Avoid injury from unexpected machine movement. Ensure that differential lock switch is in OFF position
so the tandem assemblies are able to rotate independently from each other.
Turn differential lock switch to OFF position.
[9] -
CAUTION:
Avoid injury from unexpected machine movement. Ensure that area is clear of bystanders before
operating the machine.
LEGEND:
6 Connecting Link
7 End Plate
8 Cotter Pin (2 used)
Drive Chain Connecting Link

Start machine and slowly rotate wheels to position chain connecting link (6) in a top cover opening.
[10] - Turn machine off.

Section 02 - AXLES AND SUSPENSION SYSTEMS Group 0260: Hydraulic System
[11] - Remove cotter pins (8) and end plate (7) from connecting link through side cover.
[12] - Remove connecting link from drive chain.
[13] - Remove drive chain from tandem housing.
[14] - Clean and inspect parts. Repair or replace parts as 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] -
→NOTE:
Apply a film of grease to the housing side of gaskets to prevent gaskets from sticking to housing. Do not
apply grease to cover side of gaskets.
Install access covers. Apply PM37418 Thread Lock and Sealer (medium strength) to threads of cap screws and tighten to
specification.
Number Name Use

• PM37418 (us)
• PM38621 (canadian) Thread Lock and Sealer (Medium Strength) Apply to tandem housing cover cap screws.
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 Remove and Install . (Group 0110.)
[22] - Fill tandem assembly with oil. See Changing Tandem Oil . (Operator′s Manual.)


6WD Pump Remove and Install
[2] -
CAUTION:
[3] - Turn battery disconnect switch to the OFF position. See Battery Disconnect Switch . (Operator′s Manual.)
[4] - Drain hydraulic oil tank. See Changing Hydraulic Tank Oil . (Operator′s Manual.)
[5] - Drain cooling system. See Drain, Flush, and Refill Cooling System . (Operator’s Manual.)
[6] - Remove right rear engine service door and side shield. See Engine Service Doors and Side Shields Remove and Install .
(Group 1910.)
[7] -
LEGEND:
1 Air Conditioner Condenser
2 Radiator Outlet Formed Hose
3 Radiator Tube
4 Charge Air Tube
5 Left Brace
7 Left Rear Platform Support
Rear Platform Harness-to-Transmission Harness
10
Connector (3 used)
11 Clamp (2 used)
12 Charge Air Tube Coupler
Rear Platform Support

Charge Air Tube and Electrical Connectors

Remove air conditioner condenser (1) and securely place out of working area. See Condenser Remove and Install . (Group
1830.)
[8] - Remove radiator outlet formed hose (2) from radiator tube (3).
[9] - Remove charge air tube coupler (12).
[10] - Remove charge air tube (4).
[11] - Support hydraulic oil tank. Remove left brace (5) and left rear platform support (7). See Hydraulic Oil Tank Remove and
Install . (Group 2160.)
Hydraulic Oil Tank Weight (approximate) 91 kg
200 lb.
[12] - Disconnect rear platform harness-to-transmission harness connectors (10).
[13] -
CAUTION:
pressure.
LEGEND:
Rear Platform Harness-to-Transmission Harness
10
Connector (3 used)
Case Drain-to-Pressure Relief Valve at Hydraulic Oil
13
Tank Hose
14 6WD Right Forward Hose
15 6WD Right Reverse Hose
16 6WD Left Reverse Hose
17 6WD Left Forward Hose
18 Hydraulic Oil Tank-to-Flushing Pump Supply Hose
Flushing Pump Pressure-to-Pressure Relief Valve Return
19
to Hydraulic Oil Tank Hose
20 Flushing Valve Pressure-to-Flushing Valve Hose
21 Case Drain Hose-to-Hydraulic Oil Cooler
22 Hydraulic Filter Outlet-to-Charge Valve Tee Fitting Hose
23 Case Pressure Inlet-to-Charge Valve Tee Fitting Tube
24 Case Drain-to-Charge Valve Tube
6WD Pump Right Side Hoses

6WD Pump Left Side Hoses and Tubes

Tag and disconnect hydraulic oil hoses and tubes (13—24). Close all openings using caps and plugs.
[14] -
CAUTION:
LEGEND:
27 DFT1250 Lifting Bracket
28 DFT1311 Extension
DFT1250 Lifting Bracket and DFT1311 Extension

Supporting 6WD Pump
Support 6WD pump assembly using DFT1250 Lifting Bracket (27), DFT1311 Extension (28), and appropriate lifting equipment.
6WD Pump Assembly Weight (approximate) 160 kg
352 lb.
Lifting Bracket
DFT1250
Lift and balance 6WD pumps.
Extension for DFT1250
DFT1311
Extend the reach of DFT1250.
[15] - Remove support bracket cap screws (25).
[16] -
→NOTE:
Removal of transmission filter will provide additional clearance for the removal of 6WD pump assembly.
[17] - Repair or replace parts, or replace pumps as necessary. See 6WD Pump Disassemble and see 6WD Pump Assemble .
(Group 0260.)
[18] - Replace 6WD pump assembly face O-ring.
[19] - Install 6WD pump assembly using DFT1250 Lifting Bracket, DFT1311 Extension, and appropriate lifting device to
transmission. Install cap screws.
6WD Pump Assembly Weight (approximate) 160 kg
352 lb.
Lifting Bracket
DFT1250
Lift and balance 6WD pumps.
DFT1311
Extend the reach of DFT1250.
[20] - Install 6WD pump support bracket cap screws.
[21] -
IMPORTANT:
Damage to 6WD pump will result if engine is started without hydraulic oil in 6WD pump case.
Fill 6WD pump case with hydraulic oil.
[22] - Connect all hydraulic hoses to pump. See 6WD System Component Location . (Group 9016-15.)
[23] - Connect rear platform harness-to-transmission harness connector.
[24] - Install left rear support and brace.
[25] - Install charge air tube.
[26] - Connect formed hose from radiator-to-radiator tube.
[27] - Install air conditioner condenser. See Condenser Remove and Install . (Group 1830.)
[28] - Install right rear access door and lower door panel.
[29] - Fill cooling system. See Drain, Flush, and Refill Cooling System . (Operator’s Manual.)
[30] - Fill hydraulic oil tank. See Changing Hydraulic Tank Oil . (Operator′s Manual.)
[32] - Turn battery disconnect switch to the ON position.
[33] - Run 6WD pump start-up procedure. See 6WD Start-Up Procedure . (Group 9016-20.)

6WD Pump Disassemble
6WD Pump Housing Assembly

LEGEND:
1 Control Valve-to-Pump Housing Cap Screw (5 used)
2 Solenoid Coil (2 used)
3 Solenoid Tube (2 used)
4 O-Ring (2 used)

5 Solenoid Cap (2 used)

6 Control Valve
7 Control Valve-to-Pump Housing Gasket
8 Upper Clocking Link Retaining Plug
9 Feedback Link
10 Plug (5 used)
11 O-Ring (5 used)
12 Control Piston Cover-to-Pump Housing Cap Screw (8 used)
13 Control Piston Cover (adjustment side)
14 Piston Cover O-Ring (2 used)
15 Backup Ring (2 used)
16 O-Ring (2 used)
17 Orifice (2 used)
18 6WD Pump Housing
19 Pump Housing Seal
20 Seal
21 Snap Ring
22 O-Ring
23 Lower Clocking Link Retaining Plug
24 Pressure Relief Valve
25 Shim (as required)
26 Spring
27 Spool
28 O-Ring
29 Plug
30 O-Ring
31 Control Piston Cover
32 Bearing Cup
33 Bearing
34 Snap Ring
35 Drive Shaft

6WD Pump End Cap Assembly

LEGEND:
36 6WD Motor Flushing Pump Cover-to-End Cap Cap Screw (4 used)
37 Washer (4 used)
38 6WD Motor Flushing Pump Cover
39 O-Ring
40 Pin
41 6WD Motor Flushing Pump Coupling
42 Snap Ring
43 Eccentric Ring
44A Gerotor (star)
44B Gerotor (outer ring)
45 Valve Plate
46 End Cap-to-Pump Housing Cap Screw (8 used)
47 Circuit Relief and Make-Up Valve (2 used)
48 O-Ring (2 used)
49 Plug (2 used)
50 O-Ring (2 used)
51 End Cap
52 Seal (4 used)
53 Fitting (2 used)
54 Dowel (2 used)
55 Plug
56 Ring (2 used)
57 Ring (2 used)
58 End Cap-to-Pump Housing Gasket
59 Valve Plate
60 Bearing
61 Bearing Cup
64 O-Ring (2 used)
65 Plug (2 used)
66 O-Ring (2 used)
67 Spool (2 used)
68 Washer (2 used)
69 Spring (2 used)
71 Pressure Override Valve (2 used)
72 Cap (2 used)

6WD Pump Rotate Group

LEGEND:
73 Bearing Plate
74 Snap Ring
77 Spring
78 Piston Housing

80 Washer (4 used)
81 Plate (2 used)
82 Spacer (4 used)
83 Piston Spacer
84 Piston (9 used)
85 Plate
86 Spring (2 used)
87 Washer (2 used)
88 Swash Plate
89 Control Piston
90 Slide Block
91 Clocking Link (2 used)
92 Locating Pin (2 used)
93 Bearing (2 used)
→NOTE:
6WD pump assembly includes two similar pumps mounted in-line with a 6WD motor flushing pump
mounted at the end of the assembly. Disassemble procedure for one 6WD pump is explained. Procedure
for both pumps is similar.
[1] - Remove 6WD pump assembly from machine. See 6WD Pump Remove and Install . (Group 0260.)
[2] - Remove left 6WD pump from right 6WD pump.
[3] - Remove pressure override valves (71).
[4] - Repair or replace pressure override valve components as needed.
[5] -
LEGEND:
Circuit Relief and Makeup Valves

Remove and inspect circuit relief and make-up valves (47).
[6] - Repair or replace circuit relief and make-up valves as necessary.
[7] - Remove control valve-to-pump housing cap screws (1).
[8] -
LEGEND:
4 O-Ring (2 used)
6 Control Valve
Control Valve Assembly

Remove control valve (6).
[9] - Remove solenoid caps (5).
[10] - Remove O-rings (4) and solenoid coils (2).
[11] - Remove solenoid tubes (3).
[12] - Repair or replace parts as required.
[13] - Install solenoid tubes. Tighten to specification.

Solenoid Tube Torque 27 N·m
240 lb.-in.
[14] - Install solenoid coil and O-ring.
[15] - Install solenoid cap. Tighten to specification.

Solenoid Cap Torque 3 N·m
27 lb.-in.
[16] - Set control valve assembly aside for 6WD pump assembly.
[17] -
LEGEND:
9 Feedback Link
Feedback Link and Upper Clocking Link Retaining Plug

Remove feedback link (9).
[18] - Disassemble 6WD motor flushing pump located on the end of left 6WD pump.
IMPORTANT:
Prevent damage to pump due to misaligned flushing pump. Mark orientation of 6WD flushing pump
cover before disassembly.
Remove 6WD motor flushing pump cover-to-end cap cap screw (36).
b. Remove 6WD motor flushing pump cover (38).

LEGEND:
40 Shear Key
42 Snap Ring
44A Gerotor (star)
c.

6WD Motor Flushing Pump Coupling
6WD Motor Flushing Pump Coupling and Gerotor Star

Remove 6WD motor flushing pump coupling (41) and gerotor star (44A) as an assembly.
LEGEND:
d.
Gerotor Outer Ring
Remove gerotor outer ring (44B).
IMPORTANT:
Prevent damage to pump due to misaligned eccentric ring. Mark orientation of eccentric ring before
disassembly.
LEGEND:
43 Eccentric Ring
Eccentric Ring
Remove eccentric ring (43).
IMPORTANT:
Prevent damage to pump due to misaligned valve plate. Mark orientation of valve plate before
disassembly.

LEGEND:
45 Valve Plate
Valve Plate
Remove valve plate (45).
[19] -
CAUTION:
Prevent possible injury from escaping parts under preload. Evenly loosen cap screws in a criss-cross
pattern to ensure safe removal of end cap.
LEGEND:
51 End Cap
End Cap
Slowly remove cap screws (46).
[20] -
IMPORTANT:
Internal parts are not secure. Internal parts may fall out of pump housing when end cap is removed,
secure internal parts while removing end cap.
Remove end cap (51).
[21] -
LEGEND:
59 Valve Plate
63 Dowel Pin
Valve Plate

[22] -
LEGEND:
61 Bearing Cup
Bearing Cup
Remove bearing cup (61).
[23] -
→NOTE:
Note number and position of shims for ease of assembly.
LEGEND:
Shims
Remove shims (62).
[24] -
LEGEND:
73 Bearing Plate
86 Spring (2 used)
87 Washer (2 used)
Bearing Plate
Remove bearing plate (73).
[25] - Remove springs (86) and washers (87).
[26] -
→NOTE:
Snap ring is located on the right 6WD pump only.

LEGEND:
21 Snap Ring
Right 6WD Pump Snap Ring

Remove snap ring (21) from right 6WD pump.
[27] - Remove rotating group from 6WD pump housing (18).
[28] -
LEGEND:
88 Swash Plate
90 Slide Block
Slide Block
Remove slide block (90) from swash plate (88).
[29] -
LEGEND:
35 Drive Shaft
60 Bearing
100 Rotate Group and Swash Plate
Rotate Group and Bearing

Remove bearing (60) from drive shaft (35).
[30] -
→NOTE:
Rotate group and swash plate are serviced as one assembly.
Remove rotate group and swash plate (100) from drive shaft.
[31] -

LEGEND:
9 Feedback Link
Control Feedback Link and Upper Clocking link Retaining

Plug
Remove upper clocking link retaining plug (8).
[32] -
LEGEND:
18 6WD Pump Housing
Lower Clocking Link Retaining Plug

Remove lower clocking link retaining plug (23) from 6WD pump housing (18).
[33] -
LEGEND:
93A Bearing (2 used)
93B Bearing Race (2 used)
Bearings, Clocking Links, and Bearing Races

Remove bearings (93A), bearing races (93B), and clocking links (91).
[34] -
LEGEND:
18 6WD Pump Housing
32 Bearing Cup

6WD Pump Housing Seal

Remove pump housing seal (19) from 6WD pump housing (18).
[35] - Remove bearing cup (32) from 6WD pump housing.
[36] -
LEGEND:
Control Piston Cover-to-Pump Housing Cap Screw (4
12
used)
Control Piston Cover

Remove control piston cover-to-pump housing cap screws (12) and control piston cover (31).
[37] -
LEGEND:
12
used)
101 Control Piston Adjustment Screw
Control Piston Cover (adjustment side)

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.
[39] -
LEGEND:
14 Control Piston Cover O-Ring (2 used)
Control Piston Cover O-Rings

Remove control piston cover O-rings (14) from control piston covers (13 and 31).
[40] - Remove control piston from 6WD pump housing.
[41] -
IMPORTANT:
Prevent damage to pump. Do not scratch piston bore when removing O-rings and backup rings.

LEGEND:
16 O-Ring (2 used)
102 Control Piston Bore
Control Piston Bore
Control Piston O-Rings and Backup Rings

Remove backup rings (15) and O-rings (16) from control piston bore (102).

6WD Pump Assemble
6WD Pump Housing Assembly

LEGEND:
1 Control Valve-to-Pump Housing Cap Screw (5 used)
4 O-Ring (2 used)


6 Control Valve
7 Control Valve-to-Pump Housing Gasket
9 Feedback Link
10 Plug (5 used)
11 O-Ring (5 used)
12 Control Piston Cover-to-Pump Housing Cap Screw (8 used)
14 Piston Cover O-Ring (2 used)
16 O-Ring (2 used)
17 Orifice (2 used)
18 6WD Pump Housing
20 Seal
21 Snap Ring
22 O-Ring
26 Spring
27 Spool
28 O-Ring
29 Plug
30 O-Ring
32 Bearing Cup
33 Bearing
34 Snap Ring
35 Drive Shaft

6WD Pump End Cap Assembly

LEGEND:
36 6WD Motor Flushing Pump Cover-to-End Cap Cap Screw (4 used)
37 Washer (4 used)
39 O-Ring
40 Pin
42 Snap Ring
43 Eccentric Ring
44A Gerotor (star)
45 Valve Plate
48 O-Ring (2 used)
49 Plug (2 used)
50 O-Ring (2 used)
51 End Cap
52 Seal (4 used)
53 Fitting (2 used)
54 Dowel (2 used)
55 Plug
56 Ring (2 used)
57 Ring (2 used)
59 Valve Plate
60 Bearing
61 Bearing Cup
64 O-Ring (2 used)
65 Plug (2 used)
66 O-Ring (2 used)
67 Spool (2 used)
68 Washer (2 used)
69 Spring (2 used)
71 Pressure Override Valve (2 used)
72 Cap (2 used)

6WD Pump Rotate Group

LEGEND:
73 Bearing Plate
74 Snap Ring
77 Spring
78 Piston Housing

80 Washer (4 used)
81 Plate (2 used)
82 Spacer (4 used)
83 Piston Spacer
84 Piston (9 used)
85 Plate
86 Spring (2 used)
87 Washer (2 used)
88 Swash Plate Assembly
89 Control Piston
90 Slide Block
92 Locating Pin (2 used)
93 Bearing (2 used)
IMPORTANT:
Prevent catastrophic pump damage. Apply clean hydraulic oil to all bearings and finished surfaces.
IMPORTANT:
Prevent damage to pump seals and O-rings. Lubricate all seals and O-rings with petroleum jelly during
assembly.
→NOTE:
6WD pump assembly includes two similar pumps mounted in-line with a 6WD motor flushing pump
mounted at the end of the assembly. Assembly procedure for one 6WD pump is explained. Procedure for
both pumps is similar.
[1] - Inspect and replace damaged parts and assemblies.
[2] - Clean all parts and assemblies before assembly.
[3] -
IMPORTANT:
Prevent damage to pump seals and O-rings. Lubricate all seals and O-rings with petroleum jelly during
assembly.
LEGEND:
16 O-Ring (2 used)
102 Control Piston Bore
Control Piston Bore

Control Piston O-Rings and Backup Rings

Lubricate and install two new O-rings (16) and backup rings (15) into control piston bore (102).
[4] -
LEGEND:
14 Control Piston Cover O-Ring (2 used)
Control Piston Cover O-Rings

Lubricate and install new control piston cover O-rings (14) on control piston covers (13 and 31).
[5] -
LEGEND:
103 Adjustment Screw Lock Nut
104 Beveled Washer
105 Threaded Seal Washer
Control Piston Adjustment Screw

Install control piston cover (13) to the approximate middle of the control piston adjustment screw (101) threads.
[6] -
IMPORTANT:
Prevent a possible leak, the beveled side of the beveled washer must face the threaded seal washer.
Install a new threaded seal washer (105), beveled washer (104), and adjustment screw lock nut (103) on the adjustment screw.
Do not tighten adjustment screw lock nut at this time.
[7] - Lubricate and install control piston assembly into 6WD pump housing.
[8] -

LEGEND:
12
used)
Control Piston Cover
Control Piston Cover (adjustment end)

Install control piston covers (13 and 31) and control piston cover-to-pump housing cap screws (12). Tighten cap screws to
specification.
Control Piston Cover-to-Pump Housing Cap Screw Torque 23 N·m
204 lb.-in.
[9] -
LEGEND:
18 6WD Pump Housing
89 Control Piston
106 Square
Control Piston
Use a square (106) to set the flat side of the control piston (89) perpendicular to the 6WD pump housing (18) face as shown.
[10] -
LEGEND:
18 6WD Pump Housing
32 Bearing Cup

6WD Pump Housing Seal

Install bearing cup (32) to 6WD pump housing (18).
[11] - Install pump housing seal (19) to 6WD pump housing.
[12] -
LEGEND:
93A Bearing (2 used)
93B Bearing Race (2 used)
Bearings, Clocking Links, and Bearing Races

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 links (91) into the 6WD pump housing.
[14] - Lubricate and install bearings (93A) into 6WD pump housing.
[15] - Lubricate and install bearing (33) and snap ring (34) on drive shaft (35).
[16] -
LEGEND:
35 Drive Shaft
100 Rotate Group
Rotate Group and Drive Shaft

Lubricate and install drive shaft (35) into rotate group (100) and swash plate assembly (88).
[17] -
LEGEND:
35 Drive Shaft
60 Bearing
100 Rotate Group
Rotate Group and Bearing

Lubricate and install bearing (60) onto drive shaft (35).
[18] -

LEGEND:
100 Rotate Group
107 Rubber Band (2 used)
Rubber Bands
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.
[19] -
LEGEND:
90 Slide Block
Slide Block
Lubricate and install slide block (90) onto swash plate assembly (88).
[20] - Install rotate group, swash plate, drive shaft assembly into 6WD pump housing.
[21] -
LEGEND:
9 Feedback Link
18 6WD Pump Housing
Feedback Link and Upper Clocking Link Retaining Plug
Lower Clocking Link Retaining Plug

Install upper and lower clocking link retaining plugs (8 and 23). Tighten to specification.
Clocking Link Retaining Plug Torque 169 N·m
125 lb.-ft.
[22] - Remove rubber bands from both arms of the swash plate assembly.
[23] - Adjust control piston to zero position.
LEGEND:
18 6WD Pump Housing
108 Parallel Bar
109 Depth Micrometer
110 Swash Plate Face
a.
Swash Plate Face Measurement Location One
Place parallel bar (108) across face of 6WD pump housing (18).
b. Record swash plate face (110) depth.
LEGEND:
18 6WD Pump Housing
108 Parallel Bar
109 Depth Micrometer
110 Swash Plate Face
c.
Swash Plate Face Measurement Location Two
Move parallel bar (108) to the opposite swash plate face (110).
d. Record swash plate face depth at second location.
LEGEND:
103 Adjustment Screw Lock Nut
e.
Control Piston Adjustment
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 position and tighten adjustment screw lock nut to specification.
Adjustment Screw Lock Nut Torque 61 N·m
45 lb.-ft.

[24] -
LEGEND:
54 Dowel (2 used)
86 Spring (2 used)
87 Washer (2 used)
Dowels, Washers, Springs, and Gasket

Install dowels (54), washers (87), springs (86), and gasket (58) as shown.
[25] -
LEGEND:
51 End Cap
61 Bearing Cup
End Cap
Lubricate and install shims (62) and bearing cup (61) into end cap (51).
[26] -
LEGEND:
18 6WD Pump Housing
51 End Cap
111 Machinist Rule
Swash Plate Alignment

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.
[28] -

LEGEND:
End Cap Cap Screws

Install four cap screws (46) and tighten.
[29] -
LEGEND:
35 Drive Shaft
112 Hammer
Seat Drive Shaft

Seat drive shaft (35) to end cap by gently tapping with a hammer (112) on the input side of the drive shaft.
[30] -
→NOTE:
Snap ring is located on the right 6WD pump only.
LEGEND:
21 Snap Ring
Right 6WD Pump Snap Ring

Install snap ring (21) to right 6WD pump.
[31] -

LEGEND:
35 Drive Shaft
113 Dial Indicator
114 Pliers
Drive Shaft End Play Measurement

Measure drive shaft (35) end play with dial indicator (113) while prying drive shaft up with pliers (114).
[32] - Compare measurements to 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 play to specification.
[34] - Remove end cap.
[35] -
LEGEND:
73 Bearing Plate
Bearing Plate
Lubricate and install bearing plate (73).
[36] -
LEGEND:
51 End Cap
59 Valve Plate
Valve Plate
Apply petroleum jelly to the end cap (51) side of valve plate (59).
[37] - Install valve plate into end cap.
[38] - Install end cap and cap screws (46). Tighten to specification.
End Cap-to-Pump Housing Cap Screw Torque 88 N·m

65 lb.-ft.
[39] - Assemble 6WD motor flushing pump to the end cap of left 6WD pump.
IMPORTANT:
Prevent damage to pump due to misaligned valve plate. Align valve plate with alignment mark
during assembly.
LEGEND:
45 Valve Plate
51 End Cap
115 Alignment Mark
116 Oil Passage
6WD Motor Flushing Pump Valve Plate

Lubricate and install valve plate (45) in end cap (51). Align narrow side of oil passage (116) with alignment mark (115) on
end cap.
IMPORTANT:
Prevent damage to pump due to misaligned eccentric ring. Align eccentric ring with marks made
during disassembly.
LEGEND:
43 Eccentric Ring
Eccentric Ring
Lubricate and install eccentric ring (43).
LEGEND:
c.
Gerotor Outer Ring
Lubricate and install gerotor outer ring (44B).

LEGEND:
40 Shear Key
42 Snap Ring
44A Gerotor (star)
d.
6WD Motor Flushing Pump Coupling
6WD Motor Flushing Pump Coupling and Gerotor Star

Lubricate and install 6WD motor flushing pump coupling (41) and gerotor star (44A).
IMPORTANT:
Prevent damage to pump due to misaligned flushing pump. Align notch on flushing pump cover with
flushing pump inlet during assembly.
LEGEND:
6WD Motor Flushing Pump Cover-to-End Cap Cap
36
Screw (4 used)
51 End Cap
117 Notch
118 6WD Motor Flushing Pump Inlet
6WD Motor Flushing Pump Cover Notch
6WD Motor Flushing Pump Cover

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.

6WD Motor Flushing Pump Cover-to-End Cap Cap Screw Torque 30 N·m
22 lb.-ft.
[40] -
LEGEND:
9 Feedback Link
Feedback Link
Lubricate and install feedback link (9).
[41] - Install control valve gasket (7) and control valve assembly (6) onto 6WD pump housing (18).
[42] - Install control valve-to-6WD pump housing cap screws (1). Tighten to specification.
Control Valve-to-6WD Pump Housing Cap Screws Torque 30 N·m
22 lb.-ft.
[43] -
LEGEND:
Circuit Relief and Makeup Valves

Repair or replace circuit relief and make-up valves (47) as needed.
[44] - Install circuit relief and make-up valves. Tighten to specification.

6WD Circuit Relief and Make-Up Valve Torque 176 N·m
130 lb.-ft.
[45] - Repair or replace pressure override valve (71) components as needed.
[46] - Install pressure override valves. Tighten to 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.)

6WD Charge Pump Remove and Install

See Hydraulic Fan Pump Remove and Install . (Group 2160.)

6WD Engagement Manifold Remove and Install

[1] - Park machine on a hard level surface and lower all attachments.
[3] -
LEGEND:
2 Cap Screw (2 Used)
Side Access Panel

Remove cap screw (2) and side access panel (1).
[4] -
LEGEND:
3 Top Access Panel
Top Access Panel

Remove cap screws (4) and top access panel (3).
[5] - Install vacuum pump on hydraulic oil tank. See Vacuum Pump Installation . (Group 2160.)
[6] -

6WD Engagement Manifold

LEGEND:
5 Drain Line Engagement Valve Hydraulic Line
6 Right Forward Hydraulic Line
7 Left Forward Hydraulic Line
8 Left Motor Drain Line
9 Right Reverse Hydraulic Line
10 Right Motor Drain Line Hydraulic Line
11 Left Reverse Hydraulic Line
12 Right Brake Hydraulic Line
13 Left Brake Hydraulic Line
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
Install identification tags on hydraulic lines (5-18).
[7] - Disconnect hydraulic lines. Close all openings using caps and plugs.
[8] -
CAUTION:
Remove cap screws and 6WD engagement manifold.

6WD Engagement Manifold (approximate) Weight 33 kg
73 lb
[10] - Install 6WD engagement manifold and cap screws.
[11] - Connect hydraulic lines.
[12] - Remove vacuum pump and check for leaks.
[13] - Check hydraulic tank oil level. See Checking Hydraulic Tank Oil Level . (Operator′s Manual.)
[14] - Install top access panel and cap screws.
[15] - Install side access panel and cap screw.

Differential Lock Pump Remove and Install

[2] -
CAUTION:
[4] -
Differential Lock Pump

LEGEND:
1 Differential Oil Filter Hose
3 Differential Lock Pump
4 Differential Housing Hose
Tag and disconnect hoses (1 and 4). Close all openings using caps and plugs.
[5] - Remove cap screws (2) to remove differential pump.
[6] - Replace parts as necessary.
[7] -

IMPORTANT:
Prevent damage to differential pump. Fill pump case with proper oil before startup.
Replace O-ring
[8] - Position pump input shaft into coupling and position into place.
[9] - Install cap screws and tighten to specification.

Cap Screw Torque 61 N·m
45 lb.-ft.
[10] - Connect hydraulic hoses.
[11] - Check differential housing oil level. See Checking Axle Housing Oil Level . (Operator′s Manual.)
[14] - Start machine and check for leaks.

6WD Motor Remove and Install

[2] -
CAUTION:
Manual.)
[5] -
→NOTE:
Remove front hub, spindle, and yoke assembly. See Front Wheel Hub and Spindle Remove and Install—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.)
[7] -
LEGEND:
1 6WD Motor
6WD Motor
[8] -
CAUTION:
Support 6WD motor.

6WD Motor Weight 29 kg
64 lb.
[9] - Remove motor.
[10] - Inspect and repair or replace parts as necessary. See 6WD Motor Disassemble and Assemble . (Group 0260.)
[11] - Install motor.

[12] -
IMPORTANT:
Prevent premature motor failure. Fill motor with oil before installing hydraulic lines.
Fill motor with oil before installing hydraulic lines.
[13] - 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.)
[14] - Install front hub, spindle, and yoke assembly. See Front Wheel Hub and Spindle Remove and Install—6WD . (Group
0240.)

6WD Motor Disassemble and Assemble
6WD Motor
LEGEND:
1 Ring
2 O-Ring
3 Piston
4 Plug (5 used)

5 O-Ring (7 used)
6 6WD Motor Shuttle Valve Plug (2 used)
8 O-Ring
9 O-Ring (5 used)
10 Gasket
11 Plug (2 used)
12 O-Ring (2 used)
13 Spring (2 used)
14 Spool
15 Plug (4 used)
16 O-Ring (4 used)
17 Spring Seat (2 used)
20 End Cap
22 Solenoid Valve Spool
23 Solenoid Valve Coil
24 Nut

6WD Motor
LEGEND:
31 Valve
33 Plug (2 used)
35 O-Ring
37 Valve Plate
TRANSMISSION (g) by Belgreen v2.0
38 Seal
39 Plug (2 used)
40 Retaining Ring (2 used)
41 Speed Ring
42 Gasket
44 Shaft
45 Piston Ring (9 used)
46 Front Motor Speed Sensor
47 O-Ring
48 Cap Screw
[1] - Disassemble parts as shown.
[3] - Assemble parts. Tighten to specifications.

6WD Motor
6WD Motor Shuttle Valve Plug (6) Torque 37 N·m
27 lb.-ft.
6WD High/Low Speed Solenoid Valve Nut (24) Torque 5—7 N·m
44—62 lb-in.
End Cap Cap Screw (18) Torque 110 N·m
81 lb.-ft.
Plug (4) Torque 20 N·m
177 lb.-in.
End Cap Plug (15) Torque 9 N·m
80 lb.-in.
Housing Cap Screw (7) Torque 66 N·m
49 lb.-ft.
Plug (11) Torque 32—44 N·m
24—33 lb.-ft.

Section 03 - TRANSMISSION
Table of contents
Group 0300 - Removal and Installation ................................................................................................ 1
DF180 Transmission ............................................................................................................................. 1
Transmission Remove and Install ......................................................................................................... 3
Group 0360 - Hydraulic System ........................................................................................................... 10
Transmission Charge Pump Remove and Install ................................................................................. 10

Section 03 - TRANSMISSION 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.)
Control Valve Components (DF180)

LEGEND:
A Direction Clutch 2 (High-Forward)
B Direction Clutch 4 (High-Reverse)
C Direction Clutch 3 (Low-Reverse)
D Speed Clutch C (3rd or 4th Gear)
E Speed Clutch D (7th or 8th Gear)
F Pressure Regulating Valve (System Pressure)
G Speed Clutch A (1st or 2nd Gear)
H Speed Clutch B (5th or 6th Gear)
I Direction Clutch 1 (Low-Forward)
Gear Ranges by Clutch
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)

Transmission Remove and Install

SPECIFICATIONS
SPECIFICATIONS
1134 kg
Engine Weight
2500 lb.
771 kg
Transmission Weight
1700 lb.
73 N·m
Transmission-to-Flywheel Housing Cap Screw Torque
51 lb.-ft.
[1] - Park and prepare machine for service. See Park And Prepare For Service Safely . (Group 0001.)
[2] -
CAUTION:
Park brake will not operate when transmission is removed. Chock front wheels before starting this
procedure.
CAUTION:
working in articulation joint area.
Install wheel chocks at front and back of front wheels.
[3] - Install articulation locking pin. See Locking Machine Frame . (Operator′s Manual.)
[5] - Remove batteries. See Removing and Replacing Batteries . (Operator’s Manual.)
[6] -
CAUTION:
Remove engine service doors and side shields on right and left sides of machine. See Engine Service Doors and Side Shields
[7] - Remove adjustable frame. See Adjustable Frame Remove and Install . (Group 0530.)
[8] - Remove rear platform. See Rear Platform Remove and Install . (Group 1740.)
[9] - Drain transmission oil into an appropriate container for storage or disposal. See Changing Transmission Oil and Cleaning
Transmission Pump Inlet Screen . (Operator′s Manual.)
[10] - Remove 6WD pumps (if equipped). See 6WD Pump Remove and Install . (Group 0260.)
[11] - Remove hydraulic oil tank. See Hydraulic Oil Tank Remove and Install .(Group 2160.)
[12] - Remove hydraulic pump. Close all openings using caps and plugs. See Hydraulic Pump Remove and Install . (Group
2160.)
[13] - Remove differential lock pump. Close all openings using caps and plugs. See Differential Lock Pump Remove and Install .
(Group 0260.)
[14] -

CAUTION:
pressure.
Tag and remove hydraulic hoses from transmission charge pump. Close all openings using caps and plugs. See Power Train
Component Location . (Group 9020-15.)
[15] -
Rear of Transmission
LEGEND:
1 Park Brake Manual Release Hose
2 Transmission Cooler-to-Transmission Hose
3 Transmission Filter-to-Transmission Hose (pump)
4 Transmission Filter-to-Transmission Hose (lube)
5 Transmission-to-Transmission Cooler Hose
Tag and remove hydraulic hoses (1—5). Close all openings using caps and plugs.
[16] -

Front of Transmission
LEGEND:
6 Transmission Oil Fill Tube
7 Charge Pump Supply Tube
8 Transmission Quick Service Hose (if equipped)
9 Flywheel Housing Drain Hose
10 Drive Hub
11 Flywheel Housing Cap Screw (12 used)
Disconnect transmission oil fill tube (6). Close all openings using caps and plugs.
[17] - Disconnect transmission quick service hose (8) (if equipped). Close all openings using caps and plugs.
[18] - Disconnect flywheel housing drain hose (9). Close all openings using caps and plugs.
[19] - Remove transmission-to-rear axle drive shaft. See Transmission-to-Rear Axle Drive Shaft Remove and Install . (Group
0225.)
[20] -

→NOTE:
Removing fuel dosing pump-to-fuel dosing injector line (12) and fuel dosing injector (13) will provide
additional clearance when removing and installing transmission.
LEGEND:
12 Fuel Dosing Pump-to-Fuel Dosing Injector Line
13 Fuel Dosing Injector
Fuel Dosing Injector

Remove fuel dosing pump-to-fuel dosing injector line (12) and fuel dosing injector (13). Close all openings using caps and
plugs.
[21] - Disconnect rear platform harness-to-transmission harness connector (X22). See Transmission Harness (W35) Component
Location . (Group 9015-10.)
[22] -
CAUTION:
IMPORTANT:
Rear of engine is supported by the transmission. To avoid damage to engine or engine mounts, make
sure rear of engine is supported before removing transmission.
Support rear of engine using appropriate lifting chains and lifting device.
Engine Weight (approximate) 2500 lb.
1134 kg
[23] -
CAUTION:
LEGEND:
14 7/8-9 Lifting Eyebolt
15 Lifting Chain

Transmission Removal
Install 7/8-9 lifting eyebolt (14) into front threaded hole on top of transmission. Using an appropriate lifting chain (15) and
lifting device, support transmission.
7/8-9 Lifting Eyebolt
To remove transmission from machine.
Transmission Weight (approximate) 771 kg
1700 lb.
[24] - Remove transmission mount-to-engine frame cap screws.
[25] - Remove transmission-to-flywheel housing cap screws.
[26] - Move transmission rearward until drive hub is disengaged from torsional isolator on engine flywheel. Lift transmission
from machine.
[27] -
→NOTE:
After removal of the transmission, the transmission mounts can be removed and installed on the rear of
the engine to support the engine for extended periods.
LEGEND:
16 Transmission Mount (2 used)
17 Rear of Engine
Rear Engine Support Using Transmission Mounts

Remove transmission mounts from each side of transmission. Install transmission mounts (16) to rear of engine (17) using cap
screws (18) as shown.
[28] - Inspect, repair, or replace parts as necessary. For disassembly and assembly of transmission, see Transmission
Identifications and General Procedures list . (CTM308.)
[29] - Install transmission mounts to sides of transmission if used to support engine.
[30] - Clean mating surfaces on flywheel housing and transmission housing.
[31] - Apply PM38655 Flexible Form-In-Place Gasket to flywheel housing and transmission housing.
Number Name Use

• PM38655 (us)
• PM38625 (canadian) Flexible Form-In-Place Gasket Apply to flywheel housing and transmission housing.
[32] -

LEGEND:
19 Flywheel Access Cap
Flywheel Access Cap

Remove flywheel access cap (19).
[33] -
CAUTION:
→NOTE:
Use JDG820 Flywheel Turning Tool to engage splines on transmission drive hub with mating splines in
torsional isolator.
→NOTE:
Use appropriate transmission harness if installing a remanufactured transmission.
Lift transmission into place. Using JDG820 Flywheel Turning Tool, rotate flywheel until torsional isolator and transmission drive
hub splines are aligned. Install flywheel housing cap screws and tighten to specification.
Flywheel Turning Tool
JDG820
To align splines on torsional isolator to transmission drive hub.
Transmission-to-Flywheel Housing Cap Screw Torque 73 N·m
51 lb-ft
[34] - Install transmission mount-to-engine frame cap screws.
[35] - Install fuel dosing injector and fuel dosing pump-to-fuel dosing injector line.
[36] - Connect rear platform harness-to-transmission harness connector (X22). See Transmission Harness (W35) Component
[37] - Install flywheel housing drain hose.
[38] - Install transmission quick service hose if removed.
[39] - Connect transmission oil fill tube at transmission using a new O-ring.
[40] - Install hydraulic hoses to rear of transmission. See Power Train Component Location . (Group 9015-10.)
[41] - Install transmission-to-rear axle drive shaft. See Transmission-to-Rear Axle Drive Shaft Remove and Install . (Group
0225.)
[42] - Install hydraulic hoses to transmission charge pump. See Power Train Component Location . (Group 9015-10.)
[43] - Install differential lock pump. See Differential Lock Pump Remove and Install . (Group 0260.)
[44] - Install hydraulic pump. See Hydraulic Pump Remove and Install . (Group 2160.)

Section 03 - TRANSMISSION Group 0360: Hydraulic System
[45] - Install 6WD pumps (if equipped). See 6WD Pump Remove and Install . (Group 0260.)
[46] - Install hydraulic oil tank. See Hydraulic Oil Tank Remove and Install .(Group 2160.)
[47] - Fill transmission oil to proper level. See Changing Transmission Oil and Cleaning Transmission Pump Inlet Screen and
see Drain and Refill Capacities . (Operator′s Manual.)
[48] - Install rear platform. See Rear Platform Remove and Install . (Group 1740.)
[49] - Install batteries. See Removing and Replacing Batteries . (Operator’s Manual.)
[50] - Install adjustable frame. See Adjustable Frame Remove and Install . (Group 0530.)
[51] - Install engine service doors and side shields. See Engine Service Doors and Side Shields Remove and Install . (Group
1910.)
[52] - Remove wheel chocks. Remove articulation locking pin. See Locking Machine Frame . (Operator′s Manual.)
[54] -
CAUTION:
pressure.
Start and run machine until normal operating temperature is reached. Inspect all lines for leaks.
[55] - Stop machine and check transmission oil level. See Checking Transmission Oil Level . (Operator′s Manual.)
[56] - Calibrate transmission if necessary. See Transmission Control Unit (TCU) Calibration . (Group 9015-20.)


Transmission Charge Pump Remove and Install
[2] -
CAUTION:
[4] -
Transmission Charge Pump

Transmission Suction Tube

LEGEND:
1 Transmission Charge Pump-to-Transmission Filter Hose
3 Transmission Charge Pump
4 Suction Tube
Drain transmission oil and remove suction tube (4). Close all openings using caps and plugs. See Changing Transmission Oil
and Cleaning Transmission Pump Inlet Screen . (Operator′s Manual.)
[5] - Remove hydraulic fan pump and hydraulic pump. See Hydraulic Fan Pump Remove and Install and see Hydraulic Pump
[6] -
CAUTION:
pressure.
Remove transmission charge pump-to-transmission filter hose (1). Close all openings using caps and plugs.
[8] - Remove transmission charge pump (3).
[9] - Inspect, repair, or replace as necessary. For disassembly and assembly of transmission charge pump, see DF180 Series
Powershift Transmission Repair Manual . (CTM308.)

ENGINE (g) by Belgreen v2.0
[10] - Install transmission charge pump using cap screws. Tighten cap screws to specification.
Charge Pump Cap Screw Torque 100 N·m
74 lb.-ft.
[11] - Install transmission charge pump-to-transmission filter hose.
[12] - Install suction tube using cap screws. Tighten to specification.

Suction Tube Cap Screw Torque 25 N·m
221 lb.-ft.
[13] - Fill transmission with oil to correct level. See Changing Transmission Oil and Cleaning Transmission Pump Inlet Screen .
(Operator’s Manual.)
[14] - Install hydraulic pump and hydraulic fan pump. See Hydraulic Pump Remove and Install and see Hydraulic Fan Pump

Section 04 - ENGINE
Table of contents
John Deere Engine ................................................................................................................................ 1
Engine Remove and Install ................................................................................................................... 2
Flywheel Housing Remove and Install .................................................................................................. 9

Section 04 - ENGINE Group 0400: Removal and Installation

John Deere Engine
For additional information on John Deere PowerTech ™ PSX engines and components for engine model 6090HDW16, see the
following component technical manual (CTM).
9.0L OEM Diesel Engines — Interim Tier 4/Stage III B Platform . (CTM104819.)

Engine Remove and Install

[2] - Install articulation locking pin. See Locking Machine Frame . (Operator′s Manual.)
[3] - Drain engine coolant. See Drain, Flush, and Refill Cooling System . (Operator′s Manual.)
[5] -
LEGEND:
1 Electrical Connector
2 Ether Starting Fluid Hose
Ether Starting Fluid System

Disconnect ether starting fluid system electrical connector (1) and ether starting fluid hose (2) at intake pipe (if equipped).
[6] -
CAUTION:
Prevent crushing injury from heavy component. Use appropriate lifting device when lifting component.
LEGEND:
3 Lifting Eyelet (2 used)
4 Front Engine Shield Assembly
Front Engine Shield

Attach appropriate lifting eyelets (3) to front engine shield assembly (4) as shown. Using an appropriate lifting device, support
front engine shield assembly.
Front Engine Shield Assembly Weight (approximate) 68 kg
150 lb.
[7] -

LEGEND:
6 Charge Air Tube Bracket
Front Engine Shield Assembly Left Side of Machine

Remove cap screws (5) securing charge air tube bracket (6) to front engine shield assembly.
[8] -
LEGEND:
7 Nut
8 Washer
9 Cap Screw
10 Spacer
11 Coolant Tube Bracket
Front Engine Shield Assembly Right Side of Machine

Remove nut (7), washer (8), cap screw (9), and spacer (10) securing coolant tube bracket (11) to front engine shield assembly.
[9] - Remove cap screws (12) securing front engine shield assembly to engine frame, and remove front engine shield
assembly.
[10] - Remove serpentine belt. See Inspecting Accessory Belt and Belt Tensioner Spring . (Operator’s Manual.)
[11] - Remove coolant tubes and charge air tubes from right and left sides of machine. See Rear Platform Remove and Install .
(Group 1740.)
[12] -
→NOTE:
It is not necessary to discharge the air conditioning system or disconnect air conditioner lines from the
compressor when removing the engine.
Disconnect electrical harness from air conditioner compressor clutch solenoid (Y10). See Engine Interface Harness (W50)
[13] - Remove air conditioner compressor from engine, leaving all lines attached and set aside.
[14] - Tag and disconnect all electrical connections at alternator.
[15] - Remove fuel supply and return lines. Close all openings using caps and plugs. See Engine Fuel System Component
[16] - Remove auxiliary fuel filter and water separator (if equipped) and set aside. See Engine Fuel System Component
[17] -

LEGEND:
14 Nut
15 Hose Routing Bracket
Hose Bracket at Flywheel Housing

Remove cap screws (13) and nut (14) and remove hose routing bracket (15) from flywheel housing on right side of engine.
[18] - Disconnect heater hoses from engine block. Close all openings using caps and plugs. See Air Conditioner and Heater
[19] - Tag and disconnect all power and ground leads at starter.
[20] -
LEGEND:
16 Remote Grease Line (2 used)
17 ECU Mounting Frame
18 ECU Connector (3 used)
19 Engine Interface Harness Connector
Engine Control Unit (ECU)

Disconnect remote grease lines (16) from engine control unit (ECU) mounting frame (17) and secure to the side.
[21] - Tag and disconnect ECU connectors (18) and secure to the side.
[22] - Disconnect engine interface harness connector (19).
[23] - Remove cap screws (20), and remove ECU and ECU mounting frame as an assembly.
[24] -

LEGEND:
21 Nut
22 Cap Screw
23 Transmission Fill Tube
24 Mounting Bracket
25 Quick Service Panel (if equipped)
Transmission Fill Tube

Remove nut (21) and cap screw (22) to separate transmission fill tube (23) from mounting bracket (24).
[25] - Disconnect engine oil line from quick service fitting located on the back side of quick service panel (25) (if equipped).
Close all openings using caps and plugs.
[26] - Disconnect surge tank-to-exhaust gas recirculation (EGR) cooler hose. Close all openings using caps and plugs. See
Engine Cooling System Component Location . (Group 9010-15.)
[27] -
LEGEND:
28 Surge Tank
29 Mounting Bracket
Surge Tank
Remove cap screws (26 and 27). Remove surge tank (28) and surge tank mounting bracket (29) as an assembly from filter
bracket and set to the side.
[28] - Disconnect flywheel housing drain hose on bottom of flywheel housing.
[29] - Remove engine oil drain tube clamp.
[30] -
→NOTE:
Flywheel housing plug (30) must be removed to allow clearance for lifting block installation.

LEGEND:
30 Flywheel Housing Plug
31 JDG11258P2 Rear Lifting Block
Rear Lifting Block Install

Remove flywheel housing plug (30) and install JDG11258P2 Rear Lifting Block (31) as shown.
Rear Lifting Block
JDG11258P2
To remove engine.
[31] -
LEGEND:
32 JDG11258P1 Rear Lifting Strap
33 Lifting Strap
34 JDG23 Lifting Sling
Engine Removal
Install JDG11258P1 Rear Lifting Strap (32) to lifting block using cap screws as shown. Install front lifting strap (33) to front right
side of engine.
Rear Lifting Strap
JDG11258P1
To remove engine.
[32] -

CAUTION:
Install JDG23 Lifting Sling (34) to lifting straps and support engine using appropriate lifting device.
Engine Weight (approximate) 1134 kg
2500 lb.
[33] - Remove engine flywheel housing-to-transmission cap screws.
[34] - Remove engine isolator-to-frame cap screws.
[35] - Move engine forward until drive hub spline is disengaged from torsional isolator on engine flywheel and remove engine.
[36] - Repair or replace engine as necessary.
[37] - Clean mating surfaces on flywheel housing and transmission housing and apply PM38655 Flexible Form-In-Place Gasket
to flywheel housing and transmission housing.
Number Name Use

• PM38655 (us)
• PM38625 (canadian) Flexible Form-In-Place Gasket Apply to flywheel housing and transmission housing.
[38] - Install engine to transmission and tighten flywheel housing-to-transmission cap screws to specification.
Flywheel Housing-to-Transmission Cap Screw Torque 73 N·m
51 lb.-ft.
[39] - Install engine isolator-to-frame cap screws and tighten to specification.

Engine Isolator-to-Frame Cap Screw Torque 678 N·m
500 lb.-ft.
[40] - Remove all engine lifting brackets. Install flywheel housing plug.
[41] - Install engine oil drain tube clamp.
[42] - Connect flywheel housing drain hose on bottom of flywheel housing.
[43] - Install surge tank and surge tank mounting bracket.
[44] - Connect surge tank-to-exhaust gas recirculation (EGR) cooler hose. See Engine Cooling System Component Location .
(Group 9010-15.)
[45] - Connect engine oil line to quick service fitting (if equipped).
[46] - Connect transmission fill tube to mounting bracket.
[47] - Install ECU and ECU mounting bracket to engine frame, and connect electrical connectors to ECU. See Engine Interface
Harness (W50) Component Location and see Engine Harness (W51) Component Location . (Group 9015-10.)
[48] - Install remote grease lines to ECU mounting bracket.
[49] - Connect engine interface harness connector. See Engine Interface Harness (W50) Component Location . (Group 9015.)
[50] - Install all power and ground leads to starter. See Power and Ground Cables Component Location . (Group 9015.)
[51] - Connect heater hoses to engine block. See Air Conditioner and Heater Component Location . (Group 9031.)
[52] - Install hose routing bracket.

[53] - Install auxiliary fuel filter and water separator, if removed. See Engine Fuel System Component Location . (Group
9010-15.)
[54] - Connect fuel supply and return lines. See Engine Fuel System Component Location . (Group 9010.)
[55] - Connect all electrical connectors at alternator. See Engine Interface Harness (W50) Component Location . (Group
9015-10.)
[56] - Install air conditioner compressor.
[57] - Connect electrical harness to air conditioner compressor clutch solenoid (Y10). See Engine Interface Harness (W50)
[58] - Install engine coolant and charge air tubes. See Rear Platform Remove and Install . (Group 1740.)
[59] - Install serpentine belt. See Inspecting Accessory Belt and Belt Tensioner Spring . (Operator’s Manual.)
[60] - Install front engine shield assembly to engine frame. Install charge air tube and coolant tube brackets.
[61] - Connect ether starting fluid system if removed.
[62] - Fill engine coolant. See Drain, Flush, and Refill Cooling System . (Operator′s Manual.)
[64] - Remove articulation lock pin. See Locking Machine Frame . (Operator′s Manual.)
[66] - Bleed fuel system. See Bleeding the Fuel System . (Operator′s Manual.)
[67] - Check engine oil level. See Checking Engine Oil Level . (Operator′s Manual.)
[68] - Operate machine and verify functions. See Operational Checkout Procedure . (Group 9005-10.)

Flywheel Housing Remove and Install

[1] - Remove engine. See Engine Remove and Install . (Group 0400.)
[2] - Remove torsional isolator. See Torsional Isolator Remove and Install . (Group 0700.)
[3] -
IMPORTANT:
Never reuse flywheel housing-to-engine block or oil pan-to-flywheel housing cap screws. Always replace
with new.
LEGEND:
Flywheel Housing-to-Engine Block Cap Screw and
1
Washer (6 used)
2 Oil Pan-to-Flywheel Housing Cap Screw (6 used)
3 Flywheel Housing
Flywheel Housing Removal

Remove flywheel housing-to-engine block cap screws and washers (1) and discard.
[4] - Remove oil pan-to-flywheel housing cap screws (2) and discard. Remove flywheel housing (3).
[5] -
IMPORTANT:
Avoid oil leaks at flywheel housing. Do not reuse flywheel housing-to-engine block/oil pan gasket. Always
replace with new. Thoroughly clean all gasket mating surfaces of flywheel housing, engine block, and oil
pan before installing new gasket.
Remove and discard old flywheel housing gasket. Thoroughly clean gasket mating surfaces of flywheel housing, engine block,
and oil pan.
[6] -
IMPORTANT:
Avoid oil leaks at flywheel housing. Vertical surface of oil pan and engine block must be within
specification to ensure proper seal of flywheel housing gasket.

LEGEND:
4 Vertical Surface of Oil Pan
5 Vertical Surface of Engine Block
6 Measurement Location
Oil Pan and Engine Block Vertical Surface

Using a straight edge and feeler gauge, verify the distance between vertical surface of oil pan (4) and vertical surface of engine
block (5) does not exceed specification at measurement location (6) as shown. Make adjustments to oil pan if necessary.
Flatness of Vertical Surfaces of Oil Pan and Engine Block Variance (maximum) 0.2 mm
0.008 in.
[7] -
IMPORTANT:
Avoid oil leaks at flywheel housing. Make sure specified amount of flange sealant is applied to gasket
surface that contacts the engine block. Flywheel housing gasket identification tab (8) must be located at
upper right side of engine block when installed.
LEGEND:
7 Flange Sealant Application Location (2 used)
8 Gasket Identification Tab
Flywheel Housing Gasket

Illustration of Sealant Quantity on Flywheel Housing

Gasket
Apply specified amount of LOCTITE 5810A Flange Sealant ™ to flange sealant application locations (7) on flywheel housing
gasket.
Number Name Use

• 5810A (loctite) Flange Sealant To seal flywheel housing-to-engine block/oil pan gasket.
Flange Sealant Quantity 0.3—0.7 cc
[8] - Install gasket to engine with flange sealant contacting the engine block and with gasket identification tab (8) located on
the upper right side of engine block.
[9] - Install flywheel housing and tighten new flywheel housing-to-engine block cap screws and washers to specification.
Flywheel Housing-to-Engine Block Cap Screw and Washer Torque 365 N·m
269 lb-ft.
[10] -
LEGEND:
9 M10 Cap Screw (4 used)
10 M12 Cap Screw (2 used)
Oil Pan-to-Flywheel Housing Cap Screw

ENGINE AUXILIARY SYSTEM (g) by Belgreen v2.0
Torque Sequence
Apply PM37418 Thread Lock and Sealer to threads of new oil pan-to-flywheel housing cap screws (9 and 10). Install and tighten
cap screws to specification in the sequence shown .
Number Name Use

• PM37418 (us)
• PM38621 (canadian) Thread Lock and Sealer (Medium Strength) To seal threads of new cap screws.
M10 Cap Screw Torque 73 N·m
54 lb-ft.
M12 Cap Screw Torque 130 N·m
96 lb-ft.
[11] - Install torsional isolator. See Torsional Isolator Remove and Install . (Group 0700.)
[12] - Install engine. See Engine Remove and Install . (Group 0400.)

Section 05 - ENGINE AUXILIARY SYSTEM

Table of contents
Group 0510 - Cooling System ................................................................................................................. 1
Fan Blade Remove and Install .............................................................................................................. 1
Radiator Remove and Install ................................................................................................................ 3
Hydraulic Oil Cooler Remove and Install ............................................................................................... 9
Transmission and Differential Oil Cooler Remove and Install ............................................................. 13
Fuel Cooler Remove and Install .......................................................................................................... 16
Charge Air Cooler Remove and Install ................................................................................................ 18
Group 0530 - External Exhaust System .............................................................................................. 22
JDG11335 Bellows Alignment Fixture ................................................................................................. 22
Exhaust Tube Remove and Install ...................................................................................................... 26
Exhaust Bellows Alignment Procedure ............................................................................................... 28
Diesel Particulate Filter (DPF) Remove and Install .............................................................................. 35
Exhaust Filter Remove and Install ...................................................................................................... 38
Service Filter Cleaning ........................................................................................................................ 39
Adjustable Frame Remove and Install ................................................................................................ 40
Group 0560 - External Fuel Supply Systems ..................................................................................... 42
Fuel Tank Remove and Install ............................................................................................................. 42
Fast Fill Fuel System Disassemble and Assemble—If Equipped .......................................................... 49

Section 05 - ENGINE AUXILIARY SYSTEM Group 0510: Cooling System
Group 0510 - Cooling System

Fan Blade Remove and Install
[3] -
LEGEND:
2 Washer (8 used)
3 Fan Door Outer Panel
Fan Door Outer Panel Removal

Remove cap screws (1) and washers (2). Remove fan door outer panel (3).
[4] -
LEGEND:
4 Fan Blade Retaining Nut
Fan Blade Retaining Nut

Remove fan blade retaining nut (4).
[5] - Remove two cap screws (5) opposite each other from back side of fan blade.
[6] -

LEGEND:
6 Puller
Remove Fan Blade

Remove fan blade using appropriate puller (6) as shown.
[7] - Inspect and replace fan blade as necessary.
[8] - Install two cap screws on back side of fan blade.
[9] - Install fan blade retaining nut and tighten to specification.

Fan Blade Retaining Nut Torque 81 N·m
60 lb.-ft.
[10] - Install fan door outer panel.

Radiator Remove and Install

[3] -
CAUTION:
Install articulation locking pin. See Locking Machine Frame . (Operator’s Manual.)
[4] - Drain cooling system. See Drain, Flush, and Refill Cooling System . (Operator′s Manual.)
[5] - Remove engine service doors and side shields. See Engine Service Doors and Side Shields Remove and Install . (Group
1910.)
[6] -
IMPORTANT:
Prevent hydraulic tank contamination. Close hydraulic tank opening using appropriate materials.
Rear Compartment Hood Removal

LEGEND:
1 Hydraulic Reservoir Cap

3 Rear Engine Cover

Remove hydraulic reservoir cap (1).
[7] -
CAUTION:
Remove cap screws (2) and remove rear engine cover (3) See Engine Covers Remove and Install . (Group 1910.).
Rear Engine Cover Weight (approximate) 54.5 kg
120 lb.
[8] -
LEGEND:
Air Conditioner Condenser Mounting

Remove cap screws (4) securing air conditioner condenser.
[9] - Pull condenser out from machine until it contacts the stops.
[10] -

Air Conditioner Condenser Removal

Radiator Removal
LEGEND:
6 Upper Air Conditioner Condenser Bracket
8 Hose Clamp (2 used)
9 Radiator Outlet Hose Elbow
11 Hose Clamp
12 Radiator Drain Hose
13 Radiator Vent Hose
15 Radiator Inlet Hose Elbow
16 Cap Screw and Nut (2 used)
18 Lower Air Conditioner Condenser Bracket
Remove cap screws (5). Remove condenser from bracket and set aside.
[11] - Remove cap screws (7) and upper air conditioner condenser bracket (6).
[12] - Loosen hose clamps (8) and remove radiator outlet hose elbow (9). Close all openings using caps and plugs.
[13] - Remove hose clamp (11) and radiator drain hose (12).
[14] - Remove radiator vent hose (13).
[15] - Loosen hose clamps (14) and remove radiator inlet hose elbow (15). Close all openings using caps and plugs.
[16] - Remove cap screws and nuts (16) securing fast fill fuel breather filter to lower air conditioner condenser bracket (18).
Set filter assembly aside.
[17] - Support lower air conditioner condenser bracket (18). Remove cap screws (10 and 17). Remove lower air conditioner

condenser bracket.
[18] -
CAUTION:
Radiator Mounting
LEGEND:
19 Lifting Lug (2 used)
20 Washer (8 used)
22 Radiator
Attach lifting device to lifting lugs (19) and support the radiator (22).
Radiator With Brackets Weight (approximate) 54 kg
120 lb.
[19] - Remove cap screws (21) and washers (20).
[20] -
IMPORTANT:
Use caution while lifting radiator. Damage to radiator cores will require replacement of radiator.
Lift radiator with brackets out of machine.

[22] -
IMPORTANT:
Use caution while lowering radiator. Damage to radiator cores will require replacement of radiator.
CAUTION:
Lower radiator with brackets to machine and install cap screws and washers.
Radiator With Brackets Weight (approximate) 54 kg
120 lb.
[23] - Install lower air conditioner condenser bracket.
[24] - Secure fast fill fuel breather filter to lower air conditioner bracket.
[25] - Install radiator inlet hose elbow.
[26] - Install radiator drain hose.
[27] - Install radiator outlet hose elbow.
[28] - Install air conditioner condenser upper bracket.
[29] - Slide air conditioner condenser into bracket and install cap screws securing it to machine.
[30] -
→NOTE:
Hydraulic tank cap must be removed for rear engine cover installation.
CAUTION:
Install rear engine cover.

Rear Engine Cover Weight (approximate) 54.5 kg
120 lb.
[31] - Install hydraulic tank cap.
1910.)
[35] - Fill cooling system. See Drain, Flush, and Refill Cooling System . (Operator′s Manual.)
[36] - Operate machine and check for leaks.
[37] - Check coolant level. See Checking Engine Coolant Surge Tank Level . (Operator′s Manual.)

Hydraulic Oil Cooler Remove and Install

[4] - Remove rear service doors. See Engine Service Doors and Side Shields Remove and Install . (Group 1910.)
[5] - Remove fan door and grille housing. See Grille Housing Remove and Install . (Group 1921.)
[6] - Install vacuum pump to hydraulic tank. See Vacuum Pump Installation . (Group 2160.)
[7] -
CAUTION:
pressure.
Hydraulic Oil Cooler Upper Hose Connections

LEGEND:
1 6WD Valve-to-Hydraulic Oil Cooler Hose
2 Right 6WD Pump-to-Hydraulic Oil Cooler Hose
3 Hydraulic Oil Cooler
Tag and disconnect 6WD valve-to-hydraulic oil cooler hose (1). Close all openings using caps and plugs.
[8] -
Hydraulic Oil Cooler Lower Hose Connection

LEGEND:
4 Hydraulic Oil Cooler-to-Fan Valve Tee Hose
Tag and disconnect right 6WD pump-to-hydraulic oil cooler hose (2). Close all openings using caps and plugs.
[9] - Tag and disconnect hydraulic oil cooler-to-fan valve tee hose (4). Close all openings using caps and plugs.
[10] -
IMPORTANT:
Take care when supporting/removing cooler to prevent damage to cooler fins.
CAUTION:
Support hydraulic oil cooler (3).

Hydraulic Oil Cooler Weight (approximate) 22.5 kg
50 lb.
[11] -

Hydraulic Oil Cooler Mounting

LEGEND:
6 Rubber Isolator (6 used)
7 Spacer (6 used)
Remove cap screws (5), rubber isolators (6), and spacers (7).
[12] -
Slide hydraulic oil cooler out from machine to remove. Inspect, repair, or replace as necessary.
[13] -
CAUTION:
Install hydraulic oil cooler. Install cap screws, rubber isolators, and spacers.
Hydraulic Oil Cooler Weight (approximate) 22.5 kg
50 lb.

[14] - Connect 6WD valve-to-hydraulic oil cooler hose, right 6WD pump-to-hydraulic oil cooler hose, and hydraulic oil cooler
out-to-fan valve tee hose.
[15] - Install grille housing and fan door. See Grille Housing Remove and Install . (Group 1921.)
[16] - Install rear service doors. See Engine Service Doors and Side Shields Remove and Install . (Group 1910.)

Transmission and Differential Oil Cooler Remove and Install

[4] - Remove rear service doors. See Engine Service Doors and Side Shields Remove and Install . (Group 1910.)
[5] - Remove grille housing. See Grille Housing Remove and Install . (Group 1921.)
[6] -
CAUTION:
pressure.
Transmission and Differential Oil Cooler Hose Connections

Transmission and Differential Oil Cooler Mounting

LEGEND:
1 Differential Oil Cooler-to-Differential Housing Hose
2 Transmission Oil Cooler-to-Transmission Lube Circuit Hose
3 Transmission and Differential Oil Cooler
4 Transmission-to-Transmission Oil Cooler Hose
5 Differential Housing-to-Differential Cooler Hose
6 Axle Filter-to-Differential Cooler Hose
9 Spacer (6 used)
Tag and disconnect hoses (1, 2, and 4—6). Close all openings using caps and plugs.
[7] - Remove cap screws (7), rubber isolators (8), and spacers (9).
[8] - Slide transmission and differential oil cooler (3) out from machine to remove. Inspect, repair or replace as necessary.
[9] - Install transmission and differential oil cooler using cap screws, rubber isolators, and spacers.
[10] - Connect and tighten hoses (1, 2, and 4—6).
[11] - Install grille housing. See Grille Housing Remove and Install . (Group 1921.)

[12] - Install rear service doors. See Engine Service Doors and Side Shields Remove and Install . (Group 1910.)
[16] - Check transmission oil level. See Checking Transmission Oil Level . (Operator′s Manual.)

Fuel Cooler Remove and Install

[3] - Open right rear service door. See Service Doors . (Operator’s Manual.)
[4] -
LEGEND:
1 Fuel Cooler
4 Fuel Return-to-Fuel Cooler Hose
5 Fuel Cooler-to-Fuel Tank Hose
Fuel Cooler Mounting Location

Remove hose clamps (3) from fuel return-to-fuel cooler hose (4) and fuel cooler-to-fuel tank hose (5). Label and disconnect fuel
hoses from fuel cooler. Close all openings using caps and plugs. Dispose of waste properly.
[5] - Remove cap screws (2) and swing fuel cooler away from machine.
[6] - Remove fuel cooler from machine by lifting fuel cooler and bracket assembly straight up and out of hinges.
[7] -

Fuel Cooler and Bracket Assembly

LEGEND:
6 Nut (4 used)
Separate fuel cooler from brackets by removing cap screws (8) and nuts (6).
[8] - Repair or replace as necessary.
[9] - If fuel cooler is replaced, transfer rubber isolators (7) to new fuel cooler.
[10] - Install and tighten cap screws and nuts to mounting brackets.
[11] - Install fuel cooler and bracket assembly to machine hinges. Install and tighten cap screws.
[12] - Connect fuel return-to-fuel cooler hose and fuel cooler-to-fuel tank hose. Install hose clamps.
→NOTE:
Fuel system does not need to be bled after servicing fuel cooler.
[14] - Start engine and check for leaks.

Charge Air Cooler Remove and Install

[4] - Remove radiator. See Radiator Remove and Install . (Group 0510.)
[5] -
Charge Air Cooler Inlet Tube

LEGEND:
1 Hose Clamp
2 Charge Air Cooler Outlet Tube
Loosen hose clamp (1) and disconnect charge air cooler outlet tube (2). Close all openings using caps and plugs.
[6] -

Charge Air Cooler Outlet Tube

LEGEND:
3 Charge Air Cooler Inlet Tube
4 Hose Clamp
6 Cover
Loosen hose clamp (4) and disconnect charge air cooler inlet tube (3). Close all openings using caps and plugs.
[7] - Remove cap screws (5) and cover (6).
[8] -

Charge Air Cooler Removal

LEGEND:
8 Washer (2 used)
9 Spacer (2 used)
10 Lifting Lug (2 used)
11 Nut (3 used)
12 Carriage Bolt (3 used)
13 Charge Air Cooler
Remove cap screws (7), washers (8), and spacers (9).
[9] -
Remove nuts (11) and carriage bolts (12).
[10] -
CAUTION:
Attach appropriate lifting device to lifting lugs (10).

Charge Air Cooler Weight (approximate) 38.5 kg
85 lb.
[11] - Remove charge air cooler (13). Repair or replace as needed.
[12] -

Section 05 - ENGINE AUXILIARY SYSTEM Group 0530: External Exhaust System
CAUTION:
Install charge air cooler.

Charge Air Cooler Weight (approximate) 38.5 kg
85 lb.
[13] - Install and tighten two mounting cap screws, washers, and spacers.
[14] - Install and tighten carriage bolts and nuts.
[15] - Install cover.
[16] - Connect charge air cooler inlet and charge air cooler outlet tubes. Tighten hose clamps.
[17] - Install radiator. See Radiator Remove and Install . (Group 0510.)

Group 0530 - External Exhaust System

JDG11335 Bellows Alignment Fixture
The table below lists the model and series of machine with the required configuration of JDG11335 Bellows Alignment Fixture.
Articulated Dump Truck
Articulated Dump Truck
Model/Series Configuration
250D Series II A
300D Series II A
Crawlers
Crawlers
755K B
850K C
Excavators
Excavators
250G B
290G B
350G B
4WD Loaders
4WD Loaders
624K A
644K A
724K A
744K A
944K A
Motor Graders
Motor Graders
600, 700, and 800 G and GP B
4WD Loaders
Skidders
640L A
648L A
748L A
848L A
948L A

4WD Loaders
Wheeled Feller Buncher
643L A
843L A
JDG11335 Bellows Alignment Fixture Components

LEGEND:
1 JDG11335P5P1 Insert (4 used)
4 JDG11335P7P2 Collar
6 JDG11335P1P1 Bar (2 used)
12 Latch (2 used)
→NOTE:
All tool parts are common except the inserts and bars. Refer to the tables below for configurations and
part numbers for the inserts and bars.
Using the tables below, construct tool with proper configuration.

JDG11335P4P1 Insert Installation
JDG11335P5P1 Insert Installation

Center of Groove-to-Center of Groove Measurement

LEGEND:
15 Groove
18 Center of Groove-to-Center of Groove Measurement
For assembly of all inserts, install inserts with groove (15) closest to the bar.
To verify the tool is built correctly, measure center of groove-to-center of groove (18) for the required configuration.
Configuration A
Configuration A
Insert JDG11335P4P1
Bar 310.0 mm (12.20 in) JDG11335P1P1
284.5 mm
11.20 in
Configuration B
Configuration B
Insert JDG11335P4P1
Bar 269.0 mm (10.60 in) JDG11335P2P1
243.5 mm
9.59 in
Configuration C
Configuration C
Insert JDG11335P5P1
Bar 278.1 mm (10.90 in) JDG11335P3P1
247.5 mm
9.74 in

Exhaust Tube Remove and Install

[4] -
CAUTION:
Prevent possible burning injuries. Allow exhaust components sufficient time to cool before preforming
service.
LEGEND:
1 Exhaust Clamp (2 used)
2 Exhaust Tube
3 JDG11335 Bellows Alignment Fixture
Exhaust Tube
Bellows Alignment Fixture

Remove exhaust clamps (1), exhaust tube (2), and exhaust flange gaskets.
[5] - Inspect and replace components as needed.
[6] -
→NOTE:
To aid with exhaust bellows alignment procedure install exhaust clamp only at turbocharger outlet
flange.
Install exhaust flange gasket, exhaust tube, and exhaust clamp to turbocharger outlet flange. Do not fully tighten exhaust
clamp at this time.
[7] - Assemble JDG11335 Bellows Alignment Fixture (3).

JDG11335
Holds exhaust bellows at nominal alignment for exhaust bellows adjustment and instillation.
See JDG11335 Bellows Alignment Fixture . (Group 0530.)
[8] - Install JDG11335 Bellows Alignment Fixture to exhaust tube.
JDG11335
[9] - Align exhaust tube outlet with exhaust filter inlet accordingly. Tighten exhaust clamp at turbocharger outlet flange to
specification.
Turbocharger-to-Exhaust Tube Clamp Torque 20 N·m
177 lb-in.
[10] - Tap circumference of the turbocharger-to-exhaust tube clamp repeatedly with a dead blow hammer. Tighten exhaust
clamp to specification.
Turbocharger-to-Exhaust Tube Clamp Torque 20 N·m
177 lb-in.
[11] -
IMPORTANT:
The life of the exhaust bellows is dependant on being properly aligned. If not aligned correctly, the life of
the exhaust bellows will significantly decrease and may risk unfiltered exhaust into the atmosphere.
Perform exhaust bellows alignment. See Exhaust Bellows Alignment Procedure . (Group 0530.)

Exhaust Bellows Alignment Procedure

IMPORTANT:
Service life of the exhaust bellows is dependant on being properly aligned. If not aligned correctly, the
life of the exhaust bellows will significantly decrease and may risk unfiltered exhaust into the
atmosphere.
→NOTE:
Graphic is for reference only.
Axial, Angular, and Lateral Specifications

LEGEND:
1 Axial
2 Angular
3 Lateral
This procedure is to be performed whenever the following occurs:
Exhaust tube remove and install.

Rear platform remove and install.
Hydraulic tank remove and install.
Engine remove and install.
Transmission remove and install.
Exhaust filter remove and install.
Service life of exhaust bellows is dependant on how well exhaust bellows is aligned axially (1), angularly (2), and laterally (3).
Exhaust bellows alignment is achieved by using JDG11095 Exhaust Bellows Alignment Tool and adjustment points located at
each corner of adjustable frame. Exhaust bellows are held at nominal alignment by JDG11095 Exhaust Bellows Alignment Tool.
While bellows are held at nominal alignment, the technician can visually see, measure, and verify that exhaust bellows is in
proper alignment. If measurements are not within specification the adjustable frame is used to align exhaust filter inlet to
exhaust bellows.
JDG11335

[2] - Turn battery disconnect switch to the OFF position. See Park And Prepare For Service Safely . (Group 0001.)
[4] - Engine covers and service doors must be removed to access exhaust filter adjustment points. See Engine Service Doors
and Side Shields Remove and Install and see Engine Covers Remove and Install . (Group 1910.)
[5] - Assemble JDG11335 Bellows Alignment Fixture. See JDG11335 Bellows Alignment Fixture . (Group 0530.)

Adjustment Points

LEGEND:
4 Right Front Forward/Back and Left/Right Adjustment Cap Screw
5 Left Rear Forward/Back and Left/Right Adjustment Cap Screw
6 Left Front Left/Right Adjustment Cap Screw
7 Right Rear Left/Right Adjustment Cap Screw
8 Right Front Up/Down Adjustment Cap Screw
9 Right Rear Up/Down Adjustment Cap Screw
10 Left Rear Up/Down Adjustment Cap Screw
11 Left Front Up/Down Adjustment Cap Screw
12 Adjustable Frame Lock Cap Screw (4 used)
13 Up/Down Adjustment Lock Cap Screw (8 used)
[6] -
→NOTE:
To allow adjustable frame to move freely, the engine air intake tube must be removed.
Disconnect engine air intake tube from air cleaner housing. See Engine Intake and Exhaust Component Location . (Group
9010-15.)
[7] -
IMPORTANT:
Prevent damage to exhaust bellows and JDG11335 Bellows Alignment Fixture (15). Exhaust filter inlet-to-
exhaust bellows clamp (14) must be removed prior to installing JDG11335 Bellows Alignment Fixture.
LEGEND:
14 Exhaust Filter Inlet-to-Exhaust Bellows Clamp
15 JDG11335 Bellows Alignment Fixture

Remove exhaust filter inlet-to-exhaust bellows clamp (14) and install JDG11335 Bellows Alignment Fixture (15).
JDG11335
[8] - Visually inspect gap between exhaust bellows and exhaust filter inlet.
LEGEND:
16 Up/Down Angular Gap
17 Left/Right Angular Gap)
Up/Down Angular Gap

Left/Right Angular Gap
[9] -
LEGEND:
18 Axial Gap
19 Lateral Gap
Axial Gap
Lateral Gap
Loosen cap screws (4—7, 12, and 13) to allow adjustable frame to move freely.
→NOTE:
Visually inspect bellows gap before and after making adjustments. Use small increments when adjusting
gap.
a. If up/down angular gap (16) is observed, adjust cap screws (8—11) accordingly to align exhaust filter inlet with exhaust
bellows.
b. If left/right angular gap (17) is observed, loosen cap screws (4—7) and move adjustable frame accordingly to align
exhaust filter inlet with exhaust bellows.
c. If axial gap (18) is observed, loosen cap screws (4—7) and move adjustable frame equally toward rear of machine to align
exhaust filter inlet with exhaust bellows.
d. If lateral gap (19) is observed, equally adjust cap screws (8—11) accordingly to align exhaust filter inlet with exhaust
bellows.

[10] -
→NOTE:
Cap screws (8—11) do not need to be tightened after alignment procedure is performed.
Tighten cap screws in the following order:
1. Up/down adjustment lock cap screws (13)

2. Adjustment cap screws (4—7)
3. Adjustable frame lock cap screw (12)
[11] - Measure gap between exhaust filter inlet and exhaust bellows at four positions. Gap must be within specification.
Exhaust Filter Inlet-to-Exhaust Bellows Gap Length 2.0 mm
0.079 in.
If gap is not within specification repeat steps 8—11.

[12] -
IMPORTANT:
Prevent tool damage. JDG11335 Bellows Alignment Fixture must be removed before exhaust bellows-to-
exhaust filter clamp is tightened.
Remove exhaust bellows alignment fixture and install exhaust filter inlet-to-exhaust bellows clamp . Tighten clamp to
specification.
Exhaust Filter Inlet-to-Exhaust Bellows Clamp Torque 20 N·m
177 lb-in.
[13] - Tap circumference of exhaust filter inlet-to-exhaust bellows clamp repeatedly with a dead blow hammer. Tighten clamp
to specification.
Exhaust Filter Inlet-to-Exhaust Bellows Clamp Torque 20 N·m
177 lb-in.
[14] -

Exhaust Bellows Length

Measure length of exhaust bellows at locations shown. If bellows length is not within specifications use adjustment points to
lengthen or shorten exhaust bellows.
Exhaust Bellows Length 242.5—252.5 mm
9.55—9.95 in.
[15] - Install engine covers and service doors. See Engine Service Doors and Side Shields Remove and Install and see Engine
Covers Remove and Install . (Group 1910.)

Diesel Particulate Filter (DPF) Remove and Install

[1] -
CAUTION:
Prevent burning injuries. Allow sufficient time for exhaust components to cool before performing service.
Park and prepare machine for service. See Park and Prepare for Service Safely . (Group 0001.)
[2] -
CAUTION:
when working in articulation joint area.
1910.)
[6] -
LEGEND:
2 Battery Cover
Battery Cover Removal

Remove cap screws (1) and battery cover (2).
[7] -

Diesel Particulate Filter (DPF) Removal

LEGEND:
3 Diesel Particulate Filter (DPF) Outlet Temperature Sensor
4 Diesel Particulate Filter (DPF) Pressure Sensor Line
5 Clamp
6 Outlet Cone
7 Clamp
8 Mounting Band
9 Diesel Particulate Filter (DPF)
Remove diesel particulate filter (DPF) outlet temperature sensor (3) from outlet cone (6).
[8] - Disconnect diesel particulate filter (DPF) pressure sensor line (4). Close all openings using caps and plugs.
[9] -
→NOTE:
For ease of installation, mark location of outlet cone (6) and diesel particulate filter (DPF) (9) before
removal.
Support outlet cone and remove clamp (5). Remove outlet cone.
[10] - Remove clamp (7) from diesel particulate filter (DPF) (9).
[11] - Support DPF and remove mounting band (8). Remove DPF through battery box.
[12] - Inspect and replace parts as necessary. See Diesel Particulate Filter Maintenance and Service . (CTM104819.)
[13] - Align and install DPF using mounting band. Tighten mounting band to specification.
Diesel Particulate Filter Mounting Band Torque 42 N·m
31 lb.-ft.

[14] - Install clamp (7) and tighten to specification.

Diesel Particulate Filter (DPF) Clamp Torque 20 N·m
177 lb.-in.
[15] - Align outlet cone and install clamp (5). Tighten to specification.
Outlet Cone Clamp Torque 20 N·m
177 lb.-in.
[16] - Apply 41205 Heavy Duty Anti-Seize to threads of diesel particulate filter (DPF) differential pressure sensor line. Connect
sensor line and tighten to specification.
Number Name Use

To prevent corrosion from high temperatures. High temperature anti-seize
• 41205 (us) Loctite ™ Heavy Duty Anti-Seize
lubricant.
Diesel Particulate Filter (DPF) Differential Pressure Sensor Line Torque 35 N·m
310 lb.-in.
[17] - Apply 41205 Heavy Duty Anti-Seize to threads of diesel particulate filter (DPF) outlet temperature sensor. Install sensor
and tighten to specification.
Number Name Use

To prevent corrosion from high temperatures. High temperature anti-seize
• 41205 (us) Loctite ™ Heavy Duty Anti-Seize
lubricant.
Diesel Particulate Filter (DPF) Outlet Temperature Sensor Torque 35 N·m
310 lb.-in.
[18] - Install batteries.
1910.)

Exhaust Filter Remove and Install

[2] -
CAUTION:
1910.)
[5] -
Exhaust Filter Removal

LEGEND:
1 Cap Screw
3 Lifting Point (4 used)
X8 Engine Interface Harness-to-Exhaust Aftertreatment Harness 6-Pin Connector
Disconnect engine interface harness-to-exhaust aftertreatment harness 6-pin connector (X8). See Exhaust Aftertreatment
Harness (W53) Component Location . (Group 9015-10.)
[6] - Remove cap screw (1) and place wire harness aside for removal.
[7] - Disconnect exhaust tube from exhaust filter inlet. See Exhaust Tube Remove and Install . (Group 0530.)
[8] -
CAUTION:
Prevent possible crushing injury. Use appropriate lifting device when lifting component.
Attach appropriate lifting device at lifting points (3) and support exhaust filter.
Exhaust Filter Weight (approximate) 181 kg
400 lb.
[9] - Remove cap screws (2) securing exhaust filter to adjustable frame.
[10] - Remove exhaust filter from machine. Inspect or replace as needed. See Diesel Particulate Filter Maintenance and
Service . (CTM104819.)
[11] -
CAUTION:
Using appropriate lifting device at lifting points install exhaust filter.

Exhaust Filter Weight (approximate) 181 kg
400 lb.
[12] - Install cap screws securing exhaust filter to adjustable frame.
[13] - Install and connect wiring harness (X8).
[14] - Perform exhaust bellows alignment procedure. See Exhaust Bellows Alignment Procedure . (Group 0530.)
[15] - Install engine service doors and side shields.
Service Filter Cleaning

For information on service filter cleaning, see Service Filter Cleaning . (Group 9010-20.)

Adjustable Frame Remove and Install

[4] - Remove engine service doors. See Engine Service Doors and Side Shields Remove and Install . (Group 1910.)
[5] - Remove front and rear engine covers. See Engine Covers Remove and Install . (Group 1910.)
[6] -
Adjustable Frame Removal

LEGEND:
1 Cap Screw
4 Adjustable Frame
X8 Engine Interface Harness-to-Exhaust Aftertreatment Harness 6-Pin Connector
Disconnect engine interface harness-to-exhaust aftertreatment harness 6-pin connector (X8). See Exhaust Aftertreatment
[7] - Remove cap screw (1) and set aside wire harness.
[8] - Disconnect air intake tube from air cleaner housing. See Engine Intake and Exhaust Component Location . (Group
9010-15.)
[9] - Disconnect exhaust tube from exhaust filter inlet. See Exhaust Tube Remove and Install . (Group 0530.)
[10] -
Section 05 - ENGINE AUXILIARY SYSTEM Group 0560: External Fuel Supply Systems
CAUTION:
Attach appropriate lifting device at lifting points (3) and support adjustable frame (4).
Adjustable Frame Weight (approximate) 181 kg
400 lb.
[11] -
IMPORTANT:
To prevent exhaust bellows misalignment, only remove cap screws (2).
To ensure proper bellows alignment during installation, only remove cap screws (2).
[12] - Remove adjustable frame from machine.
[14] -
CAUTION:
Using proper lifting device at lifting points, install adjustable frame to machine.
Adjustable Frame Weight (approximate) 181 kg
400 lb.
[15] - Install cap screws securing adjustable frame to machine.
[16] - Install and connect wiring harness (X8).
[17] - Connect air intake tube to air cleaner housing. See Engine Intake and Exhaust Component Location . (Group 9010-15.)
[18] - Check exhaust bellows alignment and adjust if needed. See Exhaust Bellows Alignment Procedure . (Group 0530.)
[19] - Connect exhaust tube to exhaust filter inlet. See Exhaust Tube Remove and Install . (Group 0530.)
[20] - Install front and rear engine covers. See Engine Covers Remove and Install . (Group 1910.)
[21] - Install engine service doors. See Engine Service Doors and Side Shields Remove and Install . (Group 1910.)

Group 0560 - External Fuel Supply Systems

Fuel Tank Remove and Install
[4] - Drain fuel tank. See Draining Fuel Tank Sump . (Operator′s Manual.)
[5] - Remove ripper (if equipped). See Ripper Remove and Install . (Group 4240.)
[6] - Remove rear engine service doors and side shields. See Engine Service Doors and Side Shields Remove and Install .
(Group 1910.)
[7] -
LEGEND:
Fan Door
Remove cap screws (1) and open fan door.
[8] -
LEGEND:
3 Fuel Level Sending Unit Cover
4 Fuel Cooler-to-Fuel Tank Hose
5 Fuel Level Sending Unit
Fuel Level Sending Unit Panel Location

Fuel Level Sending Unit

Remove cap screws (2) and fuel level sending unit cover (3).
[9] - Tag and disconnect fuel cooler-to-fuel tank hose (4). Close all openings using caps and plugs.
[10] - Disconnect wires from fuel level sending unit (5).
[11] -
LEGEND:
6 Set Screw
7 Lock Ring
8 Fuel Filler Tube
Fuel Filler Tube

Loosen set screw (6).
[12] - Remove lock ring (7) from fuel tank and remove fuel filler tube (8).
IMPORTANT:
Prevent fuel tank contamination. Seal fuel tank openings using appropriate materials.
[13] -

Fast Fill Fuel Tank Vent

LEGEND:
9 Hose Clamp
10 Fast Fill Breather Hose (if equipped)
11 Fuel Supply Hose
Tag and disconnect fuel supply hose (11). Close all openings using caps and plugs.
[14] -
→NOTE:
For standard fuel vent hose removal, see Checking Fuel Tank Vent Hose . (Operator’s Manual.)
Remove hose clamp (9) and disconnect fast fill fuel breather hose (10) (if equipped).
[15] -
LEGEND:
12 Hose Clamp
Engine Oil Drain Hose

Remove hose clamp (12) and disconnect engine oil drain hose from engine.

[16] - Remove cap screws (13) securing hydraulic attenuator (14) to fuel tank bottom guard (20). See Hydraulic Attenuator
Hydraulic Attenuator Location

LEGEND:
14 Hydraulic Attenuator
20 Fuel Tank Bottom Guard
[17] -

Fuel Tank Bottom Guard
Rear Axle Ripper Mount
Fuel Tank Bottom Guard Removal

LEGEND:
16 Hose Clamp
18 Fuel Tank Strap (2 used)
20 Fuel Tank Bottom Guard
22 Rear Axle Ripper Mount (2 used)
Remove cap screws (15) securing fuel hoses to fuel tank bottom guard.
[18] - Remove caps screws (21) and rear axle ripper mounts (22).
[19] -
CAUTION:
Support fuel tank bottom guard.

Fuel Tank (empty) and Bottom Guard Weight (approximate) 200 kg
441 lb.
[20] -
→NOTE:
Fuel tank is mounted to the inside of fuel tank guard.
Remove cap screws (19) securing fuel tank bottom guard (20) to machine frame.
[21] -
IMPORTANT:
Prevent damage to coolant drain hose. Do not fully lower fuel tank bottom guard.
Lower fuel tank and fuel tank bottom guard enough to access coolant drain hose secured inside fuel tank bottom guard.
[22] - Remove hose clamp (16) securing coolant drain hose to fuel tank bottom guard.
[23] - Lower fuel tank and remove from under machine.
[24] - Remove cap screws (17) and fuel tank straps (18) securing fuel tank to fuel tank bottom guard.
[25] -
CAUTION:
Support fuel tank and remove from fuel tank bottom guard.
Fuel Tank (empty) Weight (approximate) 41 kg
90 lb.
[27] -

CAUTION:
Install fuel tank to fuel tank bottom guard.

Fuel Tank (empty) Weight (approximate) 41 kg
90 lb.
[28] - Install straps and cap screws securing fuel tank to fuel tank bottom guard.
[29] - Position fuel tank bottom guard under machine.
[30] -
CAUTION:
Raise fuel tank bottom guard to access coolant drain hose.

Fuel Tank (empty) and Bottom Guard Weight 200 kg
441 lb.
[31] - Install hose clamp securing coolant drain hose to fuel tank bottom guard.
[32] - Install fuel tank, fuel tank guard, and cap screws.
[33] - Install cap screws securing fuel hoses to fuel tank bottom guard.
[34] - Install cap screws securing hydraulic attenuator to fuel tank bottom guard. See Hydraulic Attenuator Remove and Install
. (Group 2160.)
[35] - Connect and secure engine oil drain hose.
[36] - Install fuel breather hose.
[37] - Connect and tighten fuel supply hose.
[38] - Connect wire to fuel level sending unit.
[39] - Connect fuel supply and return hoses.
[40] - Install fuel filler tube and lock ring. Tighten set screw.
[41] - Connect and tighten fuel cooler-to-fuel tank hose.
[42] - Connect wire to fuel level sending unit. Install fuel level sending unit cover and cap screws.
[43] - Close fan door and secure shut with cap screws.
[44] - Install service doors and access panels. See Engine Service Doors and Side Shields Remove and Install . (Group 1910.)
[45] - Fill fuel tank.
[48] - Bleed fuel system. See Bleeding the Fuel System . (Operator′s Manual.)

Fast Fill Fuel System Disassemble and Assemble—If Equipped
Fast Fill Fuel System

LEGEND:
1 Breather Filter
2 Breather Adapter
3 Nut (2 used)
4 Hose Clamp
6 Vent Hose
7 Hose Clamp
8 Fitting
9 Fast Fill Shutoff Float
10 O-Ring
12 Plate
13 Gasket (2 used)
14 O-Ring (2 used)

15 Adapter Fitting
16 O-Ring (2 used)
17 Signal Line
18 Inlet Valve
19 Elbow Fitting
20 Adapter Tube
22 Guard
23 Guard
25 Receiver Valve
26 Cap
[1] -
→NOTE:
During fuel tank removal, fast fill breather assembly can remain on machine.
Remove fuel tank. See Fuel Tank Remove and Install . (Group 0560.)
[2] - Remove cap screws (5) and nuts (3) to remove breather filter (1) assembly from machine.
→NOTE:
For ease of installation, identify position of adapter tube (20) and guard (22).
[3] -
IMPORTANT:
Gaskets are NOT reusable. Always use new gaskets during assembly.
Inspect, repair, or replace as necessary.
[4] - Install O-ring to fast fill shutoff float.
[5] - Apply PM37397 Pipe Sealant to fast fill shutoff float and plate (12). Install fast fill shutoff float to plate. Tighten to
specification.
Number Name Use

• PM37397 (us)
592 Loctite ™ Pipe Sealant with Teflon Seal threads on float assembly.
Fast Fill Shutoff Float-to-Plate Torque 30 N·m
22 lb.-ft.
[6] - Install O-ring to adapter fitting.
[7] - Install and tighten adapter fitting to fast fill shutoff float.
[8] - Install new gasket to fast fill shutoff float and plate assembly.
[9] - Install O-ring to adapter fitting and connect signal line.
[10] -
→NOTE:
Use caution not to kink signal line when inserting into fuel tank.
Route signal line toward hole in left side of fuel tank while inserting fast fill shutoff float into top hole of fuel tank.
[11] - Install twelve cap screws and tighten to specification.

Fast Fill Assembly-to-Fuel Tank Cap Screws Torque 34 N·m
25 lb.-ft.

TORSIONAL ISOLATOR (g) by Belgreen v2.0
[12] - Install new gasket to adapter tube.
[13] -
→NOTE:
Proper orientation of adapter tube is necessary to prevent signal line from becoming kinked.
Install inlet valve assembly to adapter tube. Tighten to specification.

Adapter Tube Torque 30 N·m
22 lb.-ft.
[14] - Install O-ring to elbow fitting. Install and tighten elbow fitting to inlet valve.
[15] -
IMPORTANT:
Use caution when connecting signal line to inlet valve. Fast fill fuel system will not function properly if
signal line becomes kinked.
Connect signal line to inlet valve.
[16] - Position adapter tube to fuel tank as noted on removal.
[17] - Install nine cap screws. Tighten to specification.

Adapter Tube-to-Fuel Tank Cap Screws Torque 34 N·m
25 lb.-ft.
[18] - Install guard and cap screws. Tighten to specification.

Guard-to-Fuel Tank Cap Screws Torque 34 N·m
25 lb.-ft.
[19] - Apply PM37397 Pipe Sealant to hose fitting and install to fast fill shutoff float.
Number Name Use

• PM37397 (us)
592 Loctite ™ Pipe Sealant with Teflon Seal threads on hose fitting.
[20] - Apply PM37397 Pipe Sealant to receiver valve and install. Tighten to specification.
Number Name Use

• PM37397 (us)
592 Loctite ™ Pipe Sealant with Teflon Seal threads on receiver valve.
Receiver Valve Torque 45 N·m
33 lb.-ft.
[21] - Install fuel tank. See Fuel Tank Remove and Install . (Group 0560.)
[22] - Install guard.
[23] - Install breather assembly to cooling system support bracket.
[24] - Connect hose to adapter fitting.

Section 07 - TORSIONAL ISOLATOR

Table of contents
Group 0752 - Elements ............................................................................................................................ 1
Torsional Isolator Remove and Install ................................................................................................... 1

STEERING SYSTEM (g) by Belgreen v2.0
Group 0752 - Elements

Torsional Isolator Remove and Install
[1] - Remove engine. See Engine Remove and Install . (Group 0400.)
[2] -
LEGEND:
1 Torsional Isolator
2 Flywheel
3 Flywheel Housing
4 Cap Screw and Washer (12 used)
Torsional Isolator
Remove cap screws and washers (4).
[3] - Remove torsional isolator (1) from flywheel (2).
[5] - Position torsional isolator on flywheel.
[6] -
→NOTE:
New cap screws are required for torsional isolator.
Lubricate threads of new cap screws with engine oil, install, and tighten to specification.
Torsional Isolator-to-Flywheel Cap Screw Torque 50 N·m
37 lb.-ft.
[7] - Install engine. See Engine Remove and Install . (Group 0400.)

Section 09 - STEERING SYSTEM

Table of contents
Group 0920 - Power Steering ................................................................................................................. 1
Toe-In Check and Adjustment ............................................................................................................... 1
Group 0960 - Hydraulic System ............................................................................................................. 3
Steering Wheel, Column, and Valve Remove and Install—Standard Controls ...................................... 3
Steering Wheel, Column, and Valve Remove and Install—EH Controls ................................................ 6
EH Controls Steering Canceling Valve Remove and Install ................................................................... 9
Steering Valve Disassemble and Assemble ........................................................................................ 11
Steering Cylinder Remove and Install ................................................................................................. 18
Hydraulic Cylinder Disassemble and Assemble .................................................................................. 20
Wheel Lean Cylinder Remove and Install ........................................................................................... 21
Secondary Steering Accumulator Remove and Install—If Equipped ................................................... 24

Section 09 - STEERING SYSTEM Group 0920: Power Steering
Group 0920 - Power Steering

Toe-In Check and Adjustment
Toe-In Check Adjustment Measurements

LEGEND:
1 Left Cylinder Length
2 Right Cylinder Length
3 Right Wheel Axle Center Measurement
4 Left Wheel Axle Center Measurement
5 Floor
6 Axle Center Line
7 Tire Center Line
8 Toe-in Measurement
9 Tie Rod Cap Screws
10 Cylinder Ends
[1] - Position grader on a level surface.
[2] - Raise front of machine and place appropriate supporting device under front axle. See Machine Specifications machine
weight. (Operator′s Manual.)
[3] -
→NOTE:
Cylinder overall length is measured to align front wheels in center position for starting point for
adjustment. Steering cylinders are not adjustable, tie rod ends (10) are locked in place and torqued to
specification. See Steering Cylinder Remove and Install . (Group 0960.)
Straighten wheels. Steering cylinder rod length (1 and 2) must be within specification of each other.
Check and Adjust Toe-In

Cylinder Overall Length (compare left to right) Distance 0—3 mm
0.0—0.12 in.
[4] - Measure distance (3 and 4) from the floor (5) to the center of axle.
Section 09 - STEERING SYSTEM Group 0960: Hydraulic System
[5] - Draw a horizontal (axle center) line (6) on the back side of each tire. Draw a vertical center line (7) on the back side of
each tire.
[6] - Measure distance between center lines (7) to record rear toe-in measurement (8).
[7] - Rotate both tires 180° so marks are at the front.
[8] - Measure distance between center lines (7) to record front toe-in measurement.
Front toe-in measurement must be less than rear toe-in measurement.
Check and Adjust Toe-In

Toe-In (front less than rear ) Distance 3—13 mm
0.12—0.50 in.
If measurement is not to specification:
a. Loosen cylinder hose to both ends of one cylinder so cylinder rod is free to move in or out as required. Place container
under cylinder to catch oil.
b. Loosen tie rod cap screws (9). Rotate tie rod to adjust length.
c. Check measurements. Adjust until within toe-in specification.
d. Tighten tie rod cap screws (9).
e. Tighten steering cylinder hoses. Properly dispose of waste oil.


Steering Wheel, Column, and Valve Remove and Install—Standard
Controls
Standard Controls Steering

LEGEND:
1 Steering Wheel Cover
2 Steering Wheel Retaining Nut
3 Steering Wheel
6 Tilt Console Face Plate
8 Steering Column
9 Mounting Bracket
10 Tilt Console Top Cover
11 Steering Valve

13 Tilt Console Side Cover (2 used)
[2] -
CAUTION:
[4] - Remove steering wheel cover (1).
[5] - Remove steering wheel retaining nut (2).
[6] -
IMPORTANT:
Prevent possible damage to steering wheel. Use shop rag around puller to prevent damaging steering
wheel.
Use bearing pulling attachment D01243AA from 17-1/2 ton capacity puller set D01048AA to remove steering wheel (3).
BEARING PULLING ATTACHMENT

D01243AA
Removes and installs gears, bearings, wheels, couplings, pulleys, etc.
[8] - Remove tilt console top cover (10) from tilt console.
[9] - Disconnect wire harness from tilt console top cover. See Tilt Console Harness (W36) Component Location—Standard
Controls . (Group 9015-10.)
[11] - Remove tilt console face plate (6).
[12] - Disconnect wire harness from tilt console face plate. See Tilt Console Harness (W36) Component Location—Standard
Controls . (Group 9015-10.)
[14] - Remove side covers (13) from tilt console.
[15] -
CAUTION:
pressure.
Stop engine and relieve hydraulic pressure in steering cylinders by moving steering wheel back and forth until front wheels
stop steering.
[16] - Install vacuum pump to hydraulic oil tank to minimize hydraulic oil loss during repair. See Vacuum Pump Installation .
(Group 2160.)

[17] - Tag and disconnect hydraulic hoses from steering valve (11). Close all openings using caps and plugs. See Hydraulic
System Component Location . (Group 9025-15.)
[19] - Remove steering column (8) from mounting bracket (9) and steering valve.
[20] - Repair or replace parts as needed.
[21] - Apply PM37566 Anti-Seize Lubricant (silver grade) to splined joint between steering valve and steering column.
Number Name Use

• PM37566 (us)
NEVER-SEEZ ™ Anti-Seize Lubricant Assist in assembly and disassembly.
[22] - Install steering column to mounting bracket and steering valve.
[23] - Connect hydraulic hoses to steering valve. See Hydraulic System Component Location . (Group 9025-15.)
[24] - Remove vacuum pump from hydraulic oil tank and check for hydraulic oil leaks. See Vacuum Pump Installation . (Group
2160.)
[25] - Connect wire harness to tilt console face plate. See Tilt Console Harness (W36) Component Location—Standard Controls
. (Group 9015-10.)
[26] - Install tilt console face plate.
[27] - Connect wire harness to tilt console top cover. See Tilt Console Harness (W36) Component Location—Standard Controls .
(Group 9015-10.)
[28] - Install tilt console top cover.
[29] - Install tilt console side covers.
[30] - Install steering wheel.
[31] - Tighten steering wheel retaining nut to specification.

Steering Wheel Retaining Nut Torque 44 N·m
32 lb-ft
[32] - Install steering wheel cover.
[33] - Turn battery disconnect switch to the ON position. See Battery Disconnect Switch . (Operator′s Manual.)

Steering Wheel, Column, and Valve Remove and Install—EH Controls
EH Controls Steering
LEGEND:
2 Advanced Display Unit (ADU)
3 Tilt Console Top Cover
5 Steering Valve
6 Tilt Console Side Cover (2 used)

8 Mounting Bracket
9 Steering Column
11 Tilt Console Face Plate
13 Steering Wheel
14 Steering Wheel Retaining Nut
15 O-Ring
16 Steering Wheel Cover
[2] -
CAUTION:
[4] - Remove steering wheel cover (16) and O-ring (15).
[5] - Remove steering wheel retaining nut (14).
[6] -
IMPORTANT:
Prevent possible damage to steering wheel. Use shop rag around puller to prevent damaging steering
wheel.
Use bearing pulling attachment D01243AA from 17-1/2 ton capacity puller set D01048AA to remove steering wheel (13).
BEARING PULLING ATTACHMENT

D01243AA
Removes and installs gears, bearings, wheels, couplings, pulleys, etc.
[8] - Remove tilt console face plate (11).
[9] - Disconnect wire harness from advanced display unit (ADU) (2). See Cab Interior Harness (W15) Component
Location—6WD or see Cab Interior Harness (W16) Component Location—Non 6WD . (Group 9015-10.)
[11] - Remove ADU from tilt console top cover (3).
[13] - Remove tilt console top cover from tilt console.
[14] - Disconnect wire harness from tilt console top cover. See Tilt Console Harness (W36) Component Location . (Group
9015-10.)
[16] - Remove side covers (6) from tilt console.
[17] -

CAUTION:
pressure.
stop steering.
(Group 2160.)
[19] - Tag and disconnect hydraulic hoses from steering valve (5). Close all openings using caps and plugs. See Hydraulic
System Component Location—EH Controls . (Group 9025-15.)
[21] - Remove steering column (9) from mounting bracket (8) and steering valve.
[23] - Apply PM37566 Anti-Seize Lubricant (silver grade) to splined joint between steering valve and steering column.
Number Name Use

• PM37566 (us)
[24] - Install steering column to mounting bracket and steering valve.
[25] - Connect hydraulic hoses. See Hydraulic System Component Location—EH Controls . (Group 9025-15.)
[26] - Remove vacuum pump from hydraulic oil tank and check for hydraulic oil leaks. See Vacuum Pump Installation . (Group
2160.)
[27] - Connect wire harness to tilt console top cover. See Tilt Console Harness (W36) Component Location . (Group 9015-10.)
[28] - Install tilt console top cover.
[29] - Install ADU to tilt console top cover (3).
[30] - Connect wire harness to advanced display unit (ADU) (2). See Cab Interior Harness (W15) Component Location—6WD or
see Cab Interior Harness (W16) Component Location—Non 6WD . (Group 9015-10.)
[31] - Install tilt console face plate.
[32] - Install tilt console side covers.
[33] - Install steering wheel.
[34] - Tighten steering wheel retaining nut to specification.

Steering Wheel Retaining Nut Torque 44 N·m
32 lb-ft
[35] - Install steering wheel cover and O-ring.

EH Controls Steering Canceling Valve Remove and Install

[1] - Lower all attachments to the ground.
[4] -
CAUTION:
pressure.
Relieve pressure in the steering circuit by operating the steering wheel until front wheels stop steering.
(Group 2160.)
[6] -
LEGEND:
1 Nut (2 used)
3 Cover
4 Main Frame
6 EH Controls Steering Canceling Valve
Main Frame Cover
EH Controls Steering Canceling Valve

Remove cap screws (2) and nuts (1).
[7] - Remove cover (3) from main frame (4).
[8] - Disconnect and tag hydraulic hoses (5) from EH controls steering canceling valve (6). Cap and plug all openings.
[10] - Repair or replace components as needed.
[11] - Install cap screws (7).
[12] - Connect hydraulic hoses (5) to EH controls steering canceling valve (6).

2160.)

Steering Valve Disassemble and Assemble

IMPORTANT:
Perform all service on the steering valve in a clean, isolated work area. Use the proper tools, cleaning
material and lubricants.
IMPORTANT:
Clamp steering valve in vise, gerotor meter end up. Clamp lightly on edges of port face sides. Use
Protective material on vise jaws. Housing distortion could result if jaws are overtightened.
IMPORTANT:
To ensure spool, sleeve, and drive pin link does not slip or lock up, secure valve with gerotor end facing
up.
[1] -
Manual Steer Check Valve Location

LEGEND:
1 Cap Screw (0.3125 in x 1.875 in)
2 Cap Screw (0.3125 in x 1.750 in)
Remove cap screw (1).
[2] -

Steering Valve Assembly

LEGEND:
1 Cap Screw
2 Cap Screws (6 used)
3 Manual Steering Steel Ball and Pin
4 Gerotor Cap
5 Gerotor Star
6 Gerotor Meter
7 Spacer Plate
8 Spool and Drive
9 Bearing
11 Housing
Remove manual steering steel ball and pin (3) from cap screw (1) hole.
[3] - Remove remaining cap screws from gerotor meter end.
[4] - Remove gerotor cap (4), gerotor star (5), gerotor meter (6) and spacer plate (7).
[5] -
IMPORTANT:
Spring must be compressed before spool (8) is removed or it may break steering valve housing.

LEGEND:
8 Spool and Sleeve
11 Housing
20 Spline Head
21 20 mm Socket
22 M10 x 120 mm Cap Screw
23 Nuts
Steering Valve Spool Removal
Spool Removal Assemble

Insert a M10 x 120 mm cap screw (22) into the spool so that the head engages into the input spline.
Install two nuts (23) on the other end of the cap screw.
[6] - Hold drive spline head (20) using 20 mm socket (21).
[7] - Rotate cap screw using a wrench to compress spring.

[8] -
IMPORTANT:
Spool is not serviceable. Do not disassemble spool and sleeve.
Push spool (8) down out of housing (11) while spring is compressed.
[9] -
IMPORTANT:
If components are contaminated or damaged replace valve.
Inspect all parts for contamination, nicks and burrs.
[10] -
IMPORTANT:
Lubricate O-rings and seals with Multi-Purpose HD Lithium Complex grease (TY24416). If petroleum jelly
is used for o-ring lubrication use small enough amount to avoid spreading on surfaces of other parts.
Number Name Use

• TY24416 (us) Multi-Purpose HD Lithium Complex O-ring lubrication
→NOTE:
Lubricate spool, sleeve and gerotor star with hydraulic oil before assembling.
Serviceable Seals and O-Rings

LEGEND:
18 O-Ring (3 used)
12 Oil Seal
13 Dust Seal
Place new O-rings (18) in gerotor end of housing (11).
[11] - Install seals in steering input shaft end of housing (11) with dust seal (13) lip facing out and oil seal (12) lip facing inward
toward spool.
[12] - Install thrust washers (10) and bearings (9).
[13] -

Housing and Component Alignment

LEGEND:
5 Gerotor Star
6 Gerotor Meter
7 Spacer Plate
14 Pin
15 Alignment Mark
16 Alignment Mark
17 Alignment Mark
18 O-ring (3 used)
19 Drive Spline
Mark line (16) on top of drive spline (19) parallel to pin (14) in bottom of spool.
[14] -
IMPORTANT:
Spool must rotate freely inside of drive with torque less than specification.
Install spool (8) into housing (11).

Spool Torque 0.11 Nm
1 lb-in
[15] - Install spacer plate (7) on top of valve housing (11).
[16] -
IMPORTANT:
Timing of drive with respect to gerotor star is critical. Line on top of drive spline must be aligned with
valley (inner radius) of gerotor star.
Install gerotor star (5) on to shaft spline.
[17] - Install gerotor meter (6) housing over gerotor star (5).
[18] - Install gerotor cap (4) on to assembly.
[19] - Insert manual steering check ball and pin (3) in cap screw hole (1).
[20] - Apply TY9375 John Deere pipe sealant with teflon on bottom side of cap screw heads.
Number Name Use

• TY9375 (us) John Deere Pipe Sealant With Teflon Used to seal cap screw head.
[21] -
→NOTE:
Cap screw (1) is longer than other six cap screws.
Install cap screw (1).
[22] - Install remaining cap screws.
[23] -
Torque Pattern
Torque all cap screws evenly to initial specification. Then torque in sequence to final specification.
Cap screws Initial Torque 11—17 Nm
100—150 lb-in.
Cap screws Final Torque 25—28 Nm

225—250 lb-in.

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.
[2] -
CAUTION:
[4] -
CAUTION:
pressure.
stop steering.
(Group 2160.)
[6] -
LEGEND:
1 Tie Rod Cotter Pin
2 Tie Rod Nut
3 Wheel Lean Assembly Yoke
4 Tie Rod
5 Steering Cylinder
7 Head End Pin Retaining Cap Screw
8 Head End Pin
9 Nut
Left Steering Cylinder

Tag and disconnect hydraulic hoses (6). Close all openings using caps and plugs.
[7] - Remove tie rod cotter pin (1) and remove tie rod nut (2).
[8] - Use OEM9806 Slide Sledge 11/16" Tie Rod/Ball Joint Separator Fork to remove tie rod (4) from wheel lean assembly yoke
(3).
Tie Rod/Ball Joint Separator Fork
OEM9806

Remove tie rods from wheel lean yoke.
[9] - Remove head end pin retaining cap screw (7) and nut (9).
[10] - Remove head end pin (8).
[11] - Remove steering cylinder (5) from machine.
[12] -
Steering Cylinder Head End

LEGEND:
7 Head End Pin Retaining Cap Screw
8 Head End Pin
9 Nut
10 Steering Cylinder Head End Bore
11 Spacer (2 used)
12 Bushing
13 Snap Ring (2 used)
Remove snap rings (13), spacers (11), and bushings (12) as shown.
[13] - Inspect steering cylinder head end bore, spacers, bushings, and pins for excessive wear or damage.
Steering Cylinder Head End Bore (10) Diameter 30—31 mm
1.18—1.22 in.
Spacer (11) Inside Diameter 30.0—30.2 mm
1.18—1.18
Spacer Outside Diameter 33.8—34.3 mm
1.33—1.35 in.
Bushing (12) Inside Diameter 30 mm
1.18 in.
Bushing Outside Diameter 46.9—47.0 mm
1.84—1.85 in.
Head End Pin (8) Diameter 29.9—30.0 mm
1.17—1.18 in.
[14] - Repair or replace 120 series hydraulic cylinders components as needed. See Cylinder Identification . (CTM120519.)
[15] -

IMPORTANT:
If new cylinder is installed and tie rod end replaced, tie rod must be secured with PM37421 Thread Lock
and Sealer (high strength) on cylinder rod and torqued to specification.
If new cylinder is installed, put PM37421 Thread Lock and Sealer (high strength) to rod threads and tighten tie rod end to
specifications.
Number Name Use

• PM37421 (us)
• PM38623 (canadian) Thread Lock and Sealer (High Strength) Hold tie rod end on cylinder rod
Tie Rod End to Cylinder Rod Torque 270 N·m
200 lb.-ft.
[16] - Install cylinder.
[17] - Install head end pin retaining cap screw and nut. Tighten to specification.
Head End Pin Retaining Cap Screw Torque 171 N·m
126 lb.-ft.
[18] - Install tie rod nut. Tighten to specification.

Tie Rod Nut Torque 171 N·m
126 lb.-ft.
[19] - Install cotter pin.
2160.)
Hydraulic Cylinder Disassemble and Assemble

Repair or replace 120 series hydraulic cylinders components as needed. See Cylinder Identification . (CTM120519.)
IMPORTANT:
If new cylinder is installed and tie rod end replaced, tie rod must be secured with PM37421 Thread Lock
and Sealer (high strength) on cylinder rod and torqued to specification.
[1] - Apply PM37421 Thread Lock and Sealer (high strength) to thread of steering cylinder rod.
Number Name Use

• PM37421 (us)
• PM38623 (canadian) Thread Lock and Sealer (High Strength) Hold tie rod end on cylinder rod
[2] - Install tie rod end onto cylinder rod. Tighten to specification.
Front Steering Cylinder Torque 271 N˙m
200 lb-ft

Wheel Lean Cylinder Remove and Install

[4] -
CAUTION:
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 Install . (Group 0110.)
[6] -
CAUTION:
Support left wheel lean yoke assembly using appropriate lifting device.
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.
[7] -
LEGEND:
1 Wheel Lean Bar Pin
2 Wheel Lean Bar Pin Cap Screw (6 used)
3 Tie Rod Cotter Pin and Nut
4 Tie Rod
5 Steering Cylinder
6 Steering Cylinder Cotter Pin and Nut
7 Wheel Lean Assembly Yoke
Wheel Lean Bar and Yoke Assembly

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).
Tie Rod/Ball Joint Separator Fork
OEM9806
Remove tie rods from wheel lean yoke
[11] -
LEGEND:
8 Wheel Lean Cylinder Rod End Pin
9 Lubrication Line (2 used)
10 Wheel Lean Cylinder
12 Wheel Lean Cylinder Head End Pin
Wheel Lean Cylinder

Disconnect lubrication lines (9).
[12] -
CAUTION:
Support wheel lean cylinder using appropriate lifting device.

Wheel Lean Cylinder Weight (approximate) 25 kg
55 lb
[13] - Remove wheel lean cylinder rod end pin (8) from wheel lean cylinder (10). See NeverGrease™ Pin Joints . (Group 3440.)
[14] - Pivot wheel lean yoke assembly down and support.
[15] -
CAUTION:
pressure.
To relieve pressure in the system, slowly loosen fittings on hydraulic hoses (11) at wheel lean cylinder.
(Group 2160.)
[17] - Disconnect and tag hydraulic hoses from wheel lean cylinder.
[18] - Remove wheel lean cylinder head end pin (12). See NeverGrease™ Pin Joints . (Group 3440.)
[19] - Remove wheel lean cylinder from machine.
[20] - Inspect wheel lean cylinder bushings, and pins for excessive wear or damage.
Wheel Lean Cylinder Bushing Inside Diameter 39.66—39.74 mm

1.561—1.564 in.
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.
[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

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.
Wheel Lean Bar Pin Cap Screw Torque 119—146 N·m
88—108 lb-ft
[29] - Install left front wheel. See Wheel Remove and Install . (Group 0110.)
[30] - Lower machine to the ground

Secondary Steering Accumulator Remove and Install—If Equipped
Secondary Steering Accumulator

LEGEND:
1 Hydraulic Hose
2 Secondary Steering Accumulator
3 Mounting Strap (2 used)
5 Nut (2 used)
[4] -
CAUTION:
pressure. Search for leaks with a piece of cardboard. Protect hands and body from high pressure fluids.
stop steering.
(Group 2160.)
[6] - Disconnect hydraulic hose (1) from secondary steering accumulator (2).
[7] - Remove cap screws (4) and nuts (5).

SERVICE BRAKES (g) by Belgreen v2.0
[8] - Remove mounting straps (3).
[9] -
CAUTION:
Lift secondary steering accumulator using appropriate lifting device.

Secondary Steering Accumulator Weight 31 kg
69 lb.
[10] - Remove secondary steering accumulator from machine.
[12] - Install secondary steering accumulator to machine.
[13] - Install mounting straps.
[14] - Install cap screws and nuts.
[15] - Connect hydraulic hose to secondary steering accumulator.
2160.)

Section 10 - SERVICE BRAKES

Table of contents
Group 1011 - Active Elements ............................................................................................................... 1
Service Brake Repair ............................................................................................................................ 1
Service Brake Valve Remove and Install .............................................................................................. 2
Service Brake Bleeding ......................................................................................................................... 4
Brake Accumulator Remove and Install ................................................................................................ 5

Section 10 - SERVICE BRAKES Group 1060: Hydraulic System

Service Brake Repair
For repair information on service brake components, see Multiple Disk Brake Assembly . (CTM138619.)


Service Brake Valve Remove and Install
CAUTION:
Avoid High-Pressure Fluids

reference a knowledgeable source. Such information is available from Deere & Company Medical
Brake Valve and Pedal

LEGEND:

1 Electrical Connectors (2 used)

2 Brake Valve
4 Spring
5 Pivot
7 U-Bolt
8 Brake Pedal Assembly
[1] -
CAUTION:
[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 60 applications with a full
accumulator), accumulator is discharged.
[3] - Remove lines and seal openings from inner two grader control valves at the right control valve assembly to gain access to
brake valve. Mark lines for ease of assembly.
[4] - Disconnect electrical connectors (1) from the brake valve.
[5] - Attach identification tags on hydraulic lines.
[6] - Disconnect hydraulic lines from the brake valve (2). Close all openings using caps and plugs.
[7] - Remove screws holding floor mat in place.
[8] - Remove floor mat from around the brake valve.
[9] - Remove spring (4) from pivot (5).
[10] - Remove lower link pin from the brake valve pivot.
[11] - Remove hex nuts from U-bolt (7) at the brake valve pivot and remove U-bolt.
[12] - Remove cap screw (3) holding brake pedal assembly (8) to the floor and lift pedal assembly from machine.
[13] - Remove brake valve (2) from the machine.
[14] -
IMPORTANT:
Brake valve is not serviceable.
Repair or replace parts as necessary.
[15] - Install brake pedal assembly (8) and tighten cap screws (3).
[16] - Align brake valve with pedal tube and install U-bolt and install and tighten hex nuts and washers.
[17] - Install all lines to the brake valve.
[18] - Install electrical connectors.
[19] - Install link pin from pedal to brake valve pivot with hardware.
[20] - Install floor mat.
[22] - Bleed service brakes. See Service Brake Bleeding . (Group 1060.)

Service Brake Bleeding

LEGEND:
1 Engine Oil Pan
2 Service Brake Bleed Screw
3 Service Brake Housing
Service Brake Bleed Screw (Right Side Shown)
→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 hydraulic oil into a suitable container.
[2] - Apply hydraulic pressure to the brake system with brake pedal until hydraulic oil starts to flow. Close brake bleed screw
when hydraulic fluid in clear tube is free of air bubbles.

Brake Accumulator Remove and Install
CAUTION:
Escaping Fluid
[1] - Park and prepare machine for service. See Park and Prepare For Service Safely . (Group 0001.)
[2] -
CAUTION:
[4] - 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 60 applications with a full
accumulator), accumulator is discharged.
[5] - Attach identification tags to hydraulic lines.
[6] -

PARK BRAKE (g) by Belgreen v2.0
LEGEND:
1 Brake Accumulator
2 Hydraulic Line (2 used)
4 Clamp (2 used)
Brake Accumulator
Slowly disconnect hydraulic lines (2) from accumulator (1). Close all openings using caps and plugs.
[7] - Remove cap screws (3) and clamps (4). Remove brake accumulator.
[8] - Inspect and replace as necessary.
→NOTE:
Accumulator is not rechargeable or repairable. Replace as necessary.
[9] - Install accumulator using clamps and cap screws.

Section 11 - PARK BRAKE

Table of contents
Group 1111 - Active Elements ............................................................................................................... 1
Park Brake Repair ................................................................................................................................. 1

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

Park Brake Repair
For additional information on DF180 transmission and park brake components, see the following Component Technical
Manuals.
See Park Brake List . (CTM308.)

Section 17 - FRAME, CHASSIS OR SUPPORTING STRUCTURE

Table of contents
Group 1740 - Frame Installation ........................................................................................................... 1
Welding On Machine ............................................................................................................................. 1
Welding Repair of Major Structure ........................................................................................................ 2
Separate Frames at Articulation Joint ................................................................................................... 3
Articulation Bearing Replacement ........................................................................................................ 9
Rear Platform Remove and Install ...................................................................................................... 12

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

Welding On Machine
IMPORTANT:
Disconnect battery ground strap or turn battery disconnect switch to OFF (if applicable).
Disconnect both negative and positive battery cables and microprocessor unit (if applicable).
IMPORTANT:
Have only a qualified welder do this job. Connect welder ground clamp close to each weld area so
electrical current does not pass through any bearings.
Remove or protect all parts that can be damaged by heat or weld splatter.
Weld Metal Specifications
WELD METAL SPECIFICATIONS
Item Specification
Tensile Strength 482.6 MPa (70 000 psi)
Yield Strength 413.7 MPa (60 000 psi)
Elongation 22%
Use one of the following weld processes:

AWS-E-7018 covered electrode with shielded metal arc welding (SMAW) process.
AWS-ER-70S-3f wire electrode with gas metal arc welding (GMAW) process.
AWS-E70T-1 or E71T-1 wire electrode with flux core arc welding (FCAW) process.

Welding Repair of Major Structure

[1] -
CAUTION:
Avoid potentially toxic fumes and dust. Hazardous fumes can be generated when paint is heated by
welding, soldering, or using a torch. Do all work outside or in a well ventilated area. Dispose of paint and
solvent properly.
If you sand or grind paint, avoid breathing the dust. Wear an approved respirator. If you use solvent or
paint stripper, remove stripper with soap and water before welding. Remove solvent or paint stripper
containers and other flammable material from area. Allow fumes to disperse at least 15 minutes before
welding or heating.
Remove paint before welding or heating.
[2] -
IMPORTANT:
Electrical current traveling from the welder through the machine electrical system may damage the
machine electrical system, including battery, machine information center, and pump and valve controller.
Disconnect battery ground cable, machine information center, and pump and valve controller electrical
connectors before welding on the machine.
Have only a qualified welder do this job. Connect welder ground clamp close to each weld area so
electrical current does not pass through any bearings. Remove or protect all parts that can be damaged
by heat or weld splatter.
Use one of the following weld processes:
AWS-E-7018 covered electrode with shielded metal arc welding (SMAW) process.
AWS-ER-70S-3 wire electrode with gas metal arc welding (GMAW) process.
AWS-E70T-1 or E71T-1 wire electrode with flux core arc welding (FCAW) process.

Weld Metal Tensile Strength 482.6 MPa
70,000 psi
Yield Strength 413.7 MPa
60,000 psi
Elongation 22%
[3] -
IMPORTANT:
Area to be repaired must be preheated to allow better weld penetration.
To repair weld metal failure, remove failed weld metal using arc or grinding equipment. Thoroughly clean area to be welded.
Preheat structural assemblies to a minimum of 38°C (100°F). Preheat ground engaging tools (cutting edges, skid shoes, and
teeth shanks) to 177°C (350°F).
To repair base metal failure remove enough material to allow weld to penetrate to the bottom of crack. Preheat structural
assemblies to a minimum of 38°C (100°F). Preheat ground engaging tools (cutting edges, skid shoes, and teeth shanks) to
177°C (350°F).

Structural Assemblies Preheat Temperature 38°C
100°F
Ground Engaging Tools Preheat Temperature 177°C
350°F

Separate Frames at Articulation Joint

Specifications
SPECIFICATIONS
320 N·m
Lower Articulation Joint Cap Screw Torque
235 lb.-ft.
[2] -
→NOTE:
If machine is equipped with a ripper, it must be supported in the up position to allow the engine frame
section to be moved away from equipment frame.
Lower all attachments to the ground except ripper, if equipped.
[3] - Stop engine.
[4] -
CAUTION:
pressure.
→NOTE:
Service brake pedal must be applied and released slowly at least 60 times to discharge service brake
accumulator.
Discharge the service brake accumulator by depressing and releasing service pedal slowly and continuously until service brake
pedal offers no resistance.
[5] - Relieve hydraulic pressure in steering cylinders by moving steering wheel back and forth until front wheels stop steering.
[7] - Drain engine coolant. See Drain, Flush, and Refill Cooling System or see Drain, Flush, and Refill Cooling System (Quick
Service)—If Equipped . (Operator′s Manual.)
[8] - Recover air conditioner refrigerant. See R134a Refrigerant Recovery/Recycling and Charging Station Installation
Procedure . (Group 1830.)
[9] -
CAUTION:
Avoid possible crushing injury or death from heavy component. Use appropriate supporting device.

LEGEND:
1 20-Ton Shop Stand (2 used)
Main Frame Support

Install 20-ton shop stands (1) under front cab mounting gussets as shown.
[10] -
CAUTION:
Avoid possible crushing injury from unexpected movements, support rear of engine frame to keep engine
frame from tipping to the rear when articulation pins are pulled.
LEGEND:
2 Lift Point (2 used)
Lift Point on Rear of Engine Frame

Attach appropriate lifting device to lift points (2) on rear of engine frame.
[11] -
LEGEND:
4 Wire Harness Cover
5 Wire Harness Clamp (2 used)
Cab Wire Harness

Remove wire harness cover cap screws (3) and cover (4) on rear of cab.

[12] - Disconnect wire harness clamps (5).
[13] - Disconnect wire harness connectors from rear of cab. See Cab Interior Harness (W15) Component Location—6WD or see
Cab Interior Harness (W16) Component Location—Non 6WD . (Group 9015-10.)
[14] - Apply vacuum or drain hydraulic oil tank. See Vacuum Pump Installation . (Group 2160.)
If draining hydraulic oil tank, see Changing Hydraulic Tank Oil or see Changing Hydraulic Tank Oil (Quick Service)—If Equipped .
[15] -
CAUTION:
pressure.
Tag and disconnect all hydraulic hoses from bulkhead at main frame. Close all openings using caps and plugs.
[16] - Disconnect 6WD system lines (if equipped) from bulkhead in main frame. See 6WD System Component Location . (Group
9016-15.)
[17] - Disconnect park brake lines from bulkhead in main frame. See Power Train Component Location . (Group 9020-15.)
[18] - Disconnect service brake lines from bulkhead in main frame. See Hydraulic System Component Location or see
Hydraulic System Component Location—EH Controls . (Group 9025-15.)
[19] - Disconnect hydraulic lines from bulkhead in main frame. See Hydraulic System Component Location or see Hydraulic
System Component Location—EH Controls . (Group 9025-15.)
[20] - Disconnect air conditioner and heater lines. See Air Conditioner and Heater Component Location . (Group 9031-15.)
[21] - Remove articulation cylinder rod end pins to disconnect articulation cylinders. See Articulation Cylinders Remove and
[22] -

Engine and Equipment Frames

LEGEND:
6 Cap Screw
7 Washer
8 Upper Pin
9 Bushing (2 used)
10 Equipment Frame
11 Nut (4 used)
12 Lower Pin
13 Seal (2 used)
14 Bushing
15 Bushing
16 Plate
17 Lower Articulation Joint Cap Screw (4 used)
19 Spacer
20 Seal
21 Tapered Bearing Assembly
22 Seal
23 Shim
24 Shim
25 Shim
26 Locking Collar
27 Plate
28 Washer (10 used)
30 Engine Frame
Remove nuts (11) and lower articulation joint cap screws (17).
[23] - Remove cap screws (18), plate (16), and lower pin (12).
[24] - Remove cap screw (6) and upper pin (8).
[25] - Manually release park brake. See Towing Procedure . (Operator’s Manual.)
[26] - Slowly move engine frame back from equipment frame.
[27] - Repair and replace parts as necessary.
[28] - Replace tapered bearing assembly (21), if needed. See Articulation Bearing Replacement . (Group 1740.)
[29] - Assemble engine frame to equipment frame by aligning bushing holes in each frame member.
[30] - Install upper pin through bushing (9) in equipment frame (10) and through upper bushing (14) in engine frame (30).
[31] - Install lower pin (12) through lower bushing in equipment frame, tapered bearing assembly (21), and shims (23—25) in
engine frame.
[32] - Install cap screw (6) and washer (7).
[33] - Install plate (16) and cap screws (18).
[34] - Install lower articulation joint cap screws (17) and nuts (11).
Lower Articulation Joint Cap Screw Torque 320 N·m
235 lb.-ft.
[35] - Connect all hydraulic hoses, electrical harnesses, and linkages.
[36] - Remove vacuum pump or fill hydraulic oil tank.
[37] - Connect heater and air conditioner lines.
[38] - Fill engine coolant. See Drain, Flush, and Refill Cooling System or see Drain, Flush, and Refill Cooling System (Quick
Service)—If Equipped . (Operator′s Manual.)
[39] - Charge air conditioning system. See R134a System Charge . (Group 1830.)
[40] - Connect articulation cylinders. See Articulation Cylinders Remove and Install . (Group 3460.)
[43] - Start machine and check for leaks.


Articulation Bearing Replacement
Articulation Bearing
LEGEND:
1 Engine Frame
2 Seal Spacer
3 Seal
4 Top Bearing Cup

5 Spacer
6 Tapered Bearing (2 used)
7 Lower Bearing Cup
8 Tapered Bearing Assembly
9 Seal
10 Shim
11 Shim
12 Shim
13 Locking Collar
14 Bearing Plate
15 Washers (10 used)
[1] - Park machine on smooth level surface and lower all attachments.
[2] - Separate machine frames at articulation joint. See Separate Frames at Articulation Joint . (Group 1740.)
[3] - Remove cap screws (16) and washers (15).
[4] - Remove bearing plate (14), locking collar (13), and shims (10—12)
[5] - Remove bearing assembly using a 97mm (3.819 in) puller disk under seal spacer (2).
[7] - Apply a light coat of grease to the outside of the rollers or each half of the tapered bearing (6).
[8] -
Seal Spacer and Seal

LEGEND:
2 Seal Spacer
3 Seal
17 Seal Spacer Shoulder
Install seal (3) into seal spacer with lip facing out. Press seal to seal spacer shoulder (17).
[9] - Install seal spacer in top of bore.
[10] -
IMPORTANT:
To prevent bearing damage, do not apply load to new bearing when pressing in top bearing cup.
Press top bearing cup (4) to top of bore using JDG1152 driver disk.
Driver Disk
JDG 1152
For installing bearing cup in articulation joint.
[11] -
IMPORTANT:
To prevent bearing damage, use the same spacer which was removed from the bearing set. Spacers are
not interchangeable with other bearings.
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.
[13] -
Measure Shim Pack

LEGEND:
1 Engine Frame
14 Bearing Plate
18 Distance Between Bearing Plate and Engine Frame
Hold bearing plate in place using four cap screws spaced equally apart. Lightly tighten cap screws but do not tighten to torque
specification. Bearing plate must be in contact with bearing. Measure gap between bearing cover and frame in three places.
Calculate the average of the three readings to determine the shim pack required.
[14] - Subtract bearing preload thickness from averaged measured distance to determine shim pack thickness.
Articulation Bearing Preload 0.03—0.13 mm
0.001—0.005 in.
[15] - Apply grease to top of bearing. Fill cavity above bearing to machined surface to prevent moisture from entering bearing
through shim pack.
[16] - Install cap screws and washers. Torque cap screws to specification. Rotate inner bearing race after tightening.
Cap Screw Torque 140 N•m
103 lb-ft
[17] - Assemble machine frames. See Separate Frames at Articulation Joint . (Group 1740.)

Rear Platform Remove and Install

[3] - Disconnect battery cables at batteries and remove batteries from machine. See Removing and Replacing Batteries .
(Operator’s manual.)
[4] - Drain hydraulic oil tank. See Changing Hydraulic Tank Oil or see Changing Hydraulic Tank Oil (Quick Service)—If Equipped
. (Operator’s Manual.)
[5] - Tag and disconnect all hydraulic hoses from hydraulic oil tank and rear platform. See Hydraulic System Component
Location . (Group 9025-15.) Close all openings using caps and plugs.
[6] - Disconnect soft start valve from rear platform. See Soft Start Valve Remove and Install . (Group 2160.)
[7] - Tag and disconnect all electrical connectors and harnesses from rear platform. See Power and Ground Cables Component
Location , Rear Platform Harness (W26) Component Location and see Midstructure Harness (W34) Component Location . (Group
9015-10.)
[8] - Drain engine cooling system. See Drain, Flush, and Refill Cooling System or see Drain, Flush, and Refill Cooling System
(Quick Service)—If Equipped . (Operator’s Manual.)
[9] -
LEGEND:
Surge Tank-to-Exhaust Gas Recirculation (EGR) Coolant
1
Hose
2 Surge Tank
3 Radiator-to-Coolant Pump Tube
4 Charge Air Cooler-to-Air Throttle Valve Tube
Coolant Hoses and Charge Air Tube Right Side Of

Machine
Disconnect surge tank-to-exhaust gas recirculation (EGR) coolant hose (1) from surge tank (2).
[10] -
→NOTE:
Coolant lines may contain coolant after cooling system has been drained. Use an appropriate container to
collect remaining coolant.
[11] - Remove radiator-to-coolant pump tube (3). Close all openings using caps and plugs.
[12] - Remove charge air cooler-to-air throttle valve tube (4). Close all openings using caps and plugs.

LEGEND:
5 Radiator-to-Surge Tank Hose
6 Radiator-to-Thermostat Housing Tube
Variable Geometry Turbocharger (VGT)-to-Charge Air
7
Cooler Tube
Coolant Hoses and Charge Air Tube Left Side Of Machine
[13] - Disconnect radiator-to-surge tank hose (5).
[14] - Remove radiator-to-thermostat housing tube (6).
[15] - Remove variable geometry turbocharger (VGT)-to-charge air cooler tube (7).
[16] -
LEGEND:
8 Transmission Oil Filter Housing
9 Hydraulic Oil Filter Housing
10 Axle Oil Filter Housing
11 Auxiliary Fuel Filter and Water Separator
12 Lift Point (3 used)
13 Cap Screw and Spacer (6 used)
Rear Platform Remove

Rear Platform Remove

Tag and disconnect oil lines from transmission oil filter housing (8). See Power Train Component Location . (Group 9020.) Close
all openings using caps and plugs.
[17] - Tag and disconnect hydraulic oil lines from hydraulic oil filter housing (9). See Hydraulic System Component Location .
(Group 9025.) Close all openings using caps and plugs.
[18] -
→NOTE:
It is not necessary to disconnect oil hoses from axle filter housing for rear platform removal.
Remove axle oil filter housing (10) from mounting bracket, leaving hoses connected and set aside. See Power Train Component
Location . (Group 9020.)
[19] -
→NOTE:
It is not necessary to disconnect fuel lines from auxiliary fuel filter and water separator for rear platform
removal.
Remove auxiliary fuel filter and water separator (11) (if equipped) from filter mounting bracket, leaving fuel lines connected
and set to the side. See Engine Fuel System Component Location . (Group 9010.)
[20] -
CAUTION:
Avoid possible crushing injury from heavy component. Use appropriate lifting device.
Attach appropriate lifting device to lift points (12) and support rear platform as shown.
Rear Platform Weight (approximate) 227 kg
500 lb.
[21] - Remove cap screws and spacers (13) securing rear platform to engine frame. Lift rear platform from machine.
[22] - Repair or replace rear platform.
[23] -
CAUTION:

OPERATOR’S STATION (g) by Belgreen v2.0
Install rear platform to engine frame using spacers and cap screws.
Rear Platform Weight (approximate) 227 kg
500 lb.
[24] - Install auxiliary fuel filter and water separator if removed. See Engine Fuel System Component Location . (Group 9010.)
[25] - Install axle oil filter housing. See Power Train Component Location . (Group 9020.)
[26] - Install and tighten hydraulic oil lines to hydraulic oil filter housing. See Hydraulic System Component Location . (Group
9025.)
[27] - Install and tighten oil lines to transmission oil filter housing. See Power Train Component Location . (Group 9020.)
[28] - Install variable geometry turbocharger (VGT)-to-charge air cooler tube.
[29] - Install radiator-to-thermostat housing tube.
[30] - Connect radiator-to-surge tank hose.
[31] - Install charge air cooler-to-air throttle valve tube.
[32] - Install radiator-to-coolant pump tube.
[33] - Install surge tank-to-exhaust gas recirculation (EGR) coolant hose.
[34] - Connect all electrical connectors and harnesses to rear platform. See Power and Ground Cables Component Location ,
Rear Platform Harness (W26) Component Location , and see Midstructure Harness (W34) Component Location . (Group
9015-10.)
[35] - Connect soft start valve to rear platform. See Soft Start Valve Remove and Install . (Group 2160.)
[36] - Connect all hydraulic hoses to hydraulic oil tank and rear platform. See Hydraulic System Component Location .
[38] - Install batteries and connect battery cables. See Removing and Replacing Batteries . (Operator’s manual.)
[39] - Fill cooling system. See Drain, Flush, and Refill Cooling System or see Drain, Flush, and Refill Cooling System (Quick
Service)—If Equipped . (Operator’s Manual.)
[40] - Fill hydraulic tank with proper oil. See Changing Hydraulic Tank Oil or see Changing Hydraulic Tank Oil (Quick
[41] - Operate machine and inspect for leaks.

Section 18 - OPERATOR’S STATION

Table of contents
Cab Remove and Install ........................................................................................................................ 1
Cab Remove and Install—GP Machine Only .......................................................................................... 7
Group 1810 - Operator Enclosure ........................................................................................................ 13
Windowpanes Remove and Install ...................................................................................................... 13
Cab Door Handle Remove and Install ................................................................................................. 14
Cab Door Latch Remove and Install .................................................................................................... 16
Rivet Nut Installation .......................................................................................................................... 18
Group 1815 - Pedal Assembly .............................................................................................................. 23
Inching Pedal Remove and Install ....................................................................................................... 23
Group 1816 - Steering Tilt Console ..................................................................................................... 26
Steering Support Console Remove and Install—Standard Controls .................................................... 26
Steering Support Console Remove and Install—EH Controls .............................................................. 29
Console Tilt Remove and Install ......................................................................................................... 32
Steering Tilt Assembly Remove and Install ......................................................................................... 35
Group 1821 - Seat and Seat Belt ......................................................................................................... 36
Seat Remove and Install ..................................................................................................................... 36
Seat Belt Remove and Install .............................................................................................................. 38
Armrest Remove and Install ............................................................................................................... 39
Armrest Remove and Install—EH Controls .......................................................................................... 40
Armrest Disassemble and Assemble—EH Controls ............................................................................. 41
Standard Seat Disassemble and Assemble ......................................................................................... 43
Deluxe Seat Disassemble and Assemble ............................................................................................ 45
Air Suspension Disassemble and Assemble ........................................................................................ 49
Group 1830 - Heating and Air Conditioning ...................................................................................... 51
R134a Refrigerant Cautions and Proper Handling .............................................................................. 51
Flush and Purge Air Conditioner System ............................................................................................ 52
R134a Refrigerant Oil Information ...................................................................................................... 55
R134a Refrigerant Recovery/Recycling and Charging Station Installation Procedure ........................ 57
R134a System Recover ...................................................................................................................... 58
R134a System Evacuate ..................................................................................................................... 60
R134a System Charge ........................................................................................................................ 61
Expansion Valve Remove and Install .................................................................................................. 62
Freeze Control Switch Remove and Install ......................................................................................... 68
High/Low Pressure Switch Remove and Install ................................................................................... 70
Heater Control Valve Remove and Install ........................................................................................... 72
Heater Control Valve Leak Check ....................................................................................................... 74
Blower Motor Assembly Remove and Install ....................................................................................... 74
Compressor Remove and Install ......................................................................................................... 75
Condenser Remove and Install ........................................................................................................... 77
Heater and Air Conditioner Remove and Install .................................................................................. 80
Receiver-Dryer Remove and Install .................................................................................................... 84

Section 18 - OPERATOR’S STATION Group 1800: Removal and Installation

Cab Remove and Install
[1] - Park machine on flat level surface. Lower all attachments to ground.
[2] - Install articulation lock. See Locking Machine Frame . (Operator′s Manual.)
[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 Location—6WD , or
[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.
[11] -
LEGEND:
1 Cab Air Conditioner Outlet Line
2 Cab Air Conditioner Inlet Line
3 Hose Clamp
4 Cap Screw
5 Hose Clamp
6 Hose Clamp
7 Bracket
8 Nut (2 used)
Air Conditioner and Heater Lines

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 engine cooling
system has drained.
[14] - Remove hose clamp (3) from cab drain hose and remove cap screw (4).
[15] - Remove cab floor mat.
[16] - Remove grader control valve. See Grader Control Valve Remove and Install . (Group 3460.)
[17] -

Service Brake Valve

LEGEND:
10 Pin
11 U-Bolt
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.)
[20] - Disconnect heated mirrors (if equipped) from roof harness.
equipped. See Front Platform Harness (W25) Component Location . (Group 9015-10.)
[22] - Remove cap screws holding roof to cab. Note location of spacers and washers.
[23] - Attach lifting straps to cab roof.
[24] -
CAUTION:
Avoid crushing injury. Use appropriate lifting device when removing cab roof.
Using an appropriate lifting device, attach lifting straps to DFT1101

Cab and ROPS Lifting Bracket

DFT1101
Cab and ROPS lifting tool
Cab and ROPS Lifting Bracket and remove cab roof.
Cab Roof Weight 55 kg
121 lb
[25] -
IMPORTANT:
Route chains to prevent chains from making contact with rear and side window.
LEGEND:
15 Lifting Strap
16 Front Cab Hand Rail
17 DFT1101 Cab and ROPS Lifting Bracket
19 Rear Lifting Bracket
20 Chain
Front Cab Lifting Point
Rear Cab Lifting Point

Attach lifting straps (15) to front cab hand rail (16) and attach chains (20) to rear lifting bracket (19).
[26] - Attach lifting straps and chains to DFT1101 Cab and ROPS Lifting Bracket (21).
[27] - Remove cab isolator cap screws.
[28] -
CAUTION:
Avoid crushing injury. Use appropriate lifting device when removing cab.

Using an appropriate lifting device, remove cab with DFT1101 Cab and ROPS Lifting Bracket.
Cab Weight 1035 kg
2280 lb
[30] - Install cab to frame.

Cab Isolators
Front Isolator Torque 500—748 N˙m
368—552 lb-ft
Rear Isolator Torque 857—1285 N˙m
632—948 lb-ft
[31] -
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.
LEGEND:
23 Foam Seal
24 Cab Fresh Air Duct
Cab Fresh Air Duct Seal

Inspect seal (23) around left rear cab corner post. Replace if necessary.
[32] - Align left rear cab corner post with opening in cab roof.
[33] -
IMPORTANT:
Spacers must be installed with cap screws and washers to prevent crushing roof when cap screws are
tightened.
LEGEND:
27 Cap Screw
28 Washer
29 Spacer

Cab Roof Cap Screws and Spacers

Install spacers (29), washers (28), and cap screws (27) to cab roof.
[34] - Connect heated mirrors (if equipped) and cab roof harness connector. See Cab Roof Harness (W14) Component Location
. (Group 9015-10.)
[35] -
Service Brake Valve

LEGEND:
10 Pin
11 U-Bolt
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 Remove and Install . (Group 3460.)
[38] - Install cab floor mat.
[39] -

LEGEND:
3 Hose Clamp
4 Cap Screw
5 Hose Clamp
6 Hose Clamp
7 Bracket
8 Nut (2 used)

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.
[42] - Connect cab air conditioner outlet/inlet lines (1 and 2) under left side of cab.
Cab Air Conditioner Outlet Line (1) Torque 41-47 N·m
30-35 lb.-ft.
Cab Air Conditioner Inlet Line (2) Torque 14-20 N·m
124-177 lb.-in.
[43] - Connect harnesses from front lower wiper, front lower window switches and install harness clamp to cab, if equipped.
See Front Platform Harness (W25) Component Location . (Group 9015-10.)
[44] - Install hydraulic steering lines to front of cab.
[45] - Install cover over frame in front of cab.
[46] - Install harness connectors, harness clamps, and ground strap under right side of cab.
[47] - Connect harness connectors and ground to back of cab. See Cab Interior Harness (W15) Component Location—6WD , or
See Cab Interior Harness (W16) Component Location—Non 6WD . (Group 9015-10.)
[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.)
[53] - Remove articulation lock.
[54] - Operate machine and verify functions. See Operational Checkout . (Group 9005-10.)

Cab Remove and Install—GP Machine Only

[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 Location—6WD , or
See Cab Interior Harness (W16) Component Location—Non 6WD . (Group 9015-10.)
[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 Location—EH Controls . (Group 9025-15.)
[10] - Remove steering supply hose from hydraulic system manifold. See Hydraulic System Component Location—EH Controls .
(Group 9025-15.)
equipped. See Front Platform Harness (W25) Component Location . (Group 9015-10.)
[12] -
LEGEND:
3 Hose Clamp
4 Cap Screw
5 Hose Clamp
6 Hose Clamp
7 Bracket
8 Nut (2 used)

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 engine cooling
system has drained.
[15] - Remove hose clamp (3) from cab drain hose and remove cap screw (4).
[16] - Remove cab floor mat.
[17] -

Service Brake Valve

LEGEND:
10 Pin
11 U-Bolt
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.)
[20] - Disconnect heated mirrors (if equipped) from roof harness. See Cab Roof Harness (W14) Component Location . (Group
9015-10.)
[21] - Remove cap screws holding roof to cab. Note location of spacers and washers.
[22] - Attach lifting straps to cab roof.
[23] -
CAUTION:
Avoid crushing injury. Use appropriate lifting device when removing cab roof.
Using an appropriate lifting device, attach lifting straps to DFT1101

Cab and ROPS Lifting Bracket
DFT1101
Cab and ROPS lifting tool
Cab and ROPS Lifting Bracket and remove cab roof.

Cab Roof Weight 55 kg
121 lb
[24] -
IMPORTANT:
Route chains to prevent chains from making contact with rear and side window.
LEGEND:
15 Lifting Strap
16 Front Cab Hand Rail
19 Rear Lifting Bracket
20 Chain
Front Cab Lifting Point
Rear Cab Lifting Point

Attach lifting straps (15) to front cab hand rail (16) and attach chains (20) to rear lifting bracket (19).
[25] - Attach lifting straps and chains to DFT1101 Cab and ROPS Lifting Bracket (21).
[26] - Remove cab isolator cap screws.
[27] -
CAUTION:
Avoid crushing injury. Use appropriate lifting device when removing cab.
Using an appropriate lifting device, remove cab with DFT1101 Cab and ROPS Lifting Bracket.

Cab Weight 1035 kg
2280 lb
[29] - Install cab to frame.

Cab Isolators
Front Isolator Torque 500—748 N˙m
368—552 lb-ft
Rear Isolator Torque 857—1285 N˙m
632—948 lb-ft
[30] -
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.
LEGEND:
23 Foam Seal
24 Cab Fresh Air Duct
Cab Fresh Air Duct Seal

Inspect seal (23) around left rear cab corner post. Replace if necessary.
[31] - Align left rear cab corner post with opening in cab roof.
[32] -
IMPORTANT:
Spacers must be installed with cap screws and washers to prevent crushing roof when cap screws are
tightened.
LEGEND:
27 Cap Screw
28 Washer
29 Spacer
Cab Roof Cap Screws and Spacers

Install spacers (29), washers (28), and cap screws (27) to cab roof.
[33] - Connect heated mirrors (if equipped) and cab roof harness connector.
[34] -
Service Brake Valve

LEGEND:
10 Pin
11 U-Bolt
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.
[37] -

Section 18 - OPERATOR’S STATION Group 1810: Operator Enclosure
LEGEND:
3 Hose Clamp
4 Cap Screw
5 Hose Clamp
6 Hose Clamp
7 Bracket
8 Nut (2 used)

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.
[40] - Connect cab air conditioner outlet/inlet lines (1 and 2) from under left side of cab.
[41] - Connect harnesses from front lower wiper, front lower window switches and install harness clamp to cab, if equipped.
[42] - Install hydraulic steering lines to steering valve. See Steering Wheel, Column, and Valve Remove and Install—EH
Controls . (Group 0960.)
[43] - Install the one line to hydraulic system manifold. See Hydraulic System Manifold Disassemble and Assemble . (Group
2160.)
[44] - Install cover over frame in front of cab.
[45] - Install harness connectors, harness clamps, and ground strap under right side of cab.
[46] - Connect harness connectors and ground to back of cab. See Cab Interior Harness (W15) Component Location—6WD , or
[47] - Purge the system. See Flush and Purge Air Conditioner System . (Group 1830.)
[48] - Evacuate the system. See R134a System Evacuate . (Group 1830.)
[49] - Charge the system. See R134a System Charge . (Group 1830.)
[53] - Operate machine and verify functions. See Operational Checkout . (Group 9005-10.)

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.
IMPORTANT:
Windowpanes must have an ultra-violet barrier around the edge of the glass since ultra-violet rays will
deteriorate the adhesive. Windowpanes ordered through John Deere Parts have the ultra-violet barrier. If
the windowpane is purchased through a glass dealer, the dealer must put an ultra-violet barrier on the
glass. Do not apply paint to the border of the glass.
If an auto glass dealer is not installing the windowpanes, use the following procedure:
[1] - Purchase urethane adhesive from your local auto glass dealer.
[2] - If window frame is removable, remove frame from cab.
[3] - Scrape broken glass off existing adhesive. Do not remove adhesive from window frame or cab.
[4] -
IMPORTANT:
Adhesive will not stick to bare metal.
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.
[8] - Put a new windowpane into position. Use hand pressure to force windowpane down around the edges until even with
metal frame.
[9] - If windowpane is installed directly on cab, use duct tape to hold it in place while adhesive cures.
[10] - Allow adhesive to cure for 24 hours before operating machine.

Cab Door Handle Remove and Install

[1] -
LEGEND:
1 Bracket
2 Clip
3 Pin
5 Clevis
Cab Door Handle Inside

Remove clip (2) and pin (3) from clevis (5).
[2] - Remove clevis from door handle.
[3] - Remove cap screws (4) and door handle.
[5] -
LEGEND:
5 Clevis
6 Handle
7 Gasket
8 Spacer
Door Handle Parts

Install handle (6), gasket (7) and spacer (8).
[6] -
IMPORTANT:
Do not over torque cap screws. Over torquing cap screws may break cab door glass.
Apply T43512 Thread Lock and Sealer (medium strength) to cap screws and install through bracket into handle.
Number Name Use

• T43512 (us)
• TY9473 (canadian) Thread Lock and Sealer (Medium Strength) Apply to cab door handle cap screws.
Door Handle Cap Screw Torque 5.6—6.7 N·m
49—59 lb-in.
[7] - Install clevis to door handle.

[8] - Install pin and clip to clevis.

Cab Door Latch Remove and Install

[1] -
LEGEND:
2 Cover Plate
3 Door Latch
Door Latch and Cover Assembly

Remove cap screws (1) and cover plate (2).
[2] -
→NOTE:
Cap screw (1) is threaded into door latch (3). Lock nut (9) is also threaded on cap screw.
Door Latch Components

LEGEND:
3 Door Latch
5 Bushing (4 used)
6 Spacer (2 used)
7 Latch Lever
8 Washer (2 used)
9 Nut (2 used)
Remove nut (9) from cap screw (4) and remove washers (8), bushings (5), spacers (6), and latch lever (7).
[3] - Remove cap screws and remove door latch.
[5] - Install latch and cap screws to door.

Cab Door Latch Cap Screw Torque 15.3 N˙m
135 lb-in.
[6] - Install washers, bushings, spacers, and latch lever to door latch.
[7] - Use a wrench to hold cap screw from turning and install nuts.
Cab Door Latch Nut Torque 10.4 N˙m
92 lb-in.
[8] -
→NOTE:
Cap screw may loosen when installing nut.
Verify torque on cap screws.

Cab Door Latch Cap Screw Torque 15.3 N˙m
135 lb-in.
[9] - Install cover plate and cap screws.

Rivet Nut Installation

Remove Rivet Nut
Fastener Removal
Remove flange of rivet nut using a hammer and chisel. Use care not to damage equipment’s surface under the flange or the
hexagonal hole.
Use a punch to remove threaded portion of fastener.
Install Rivet Nut
[1] -
→NOTE:
It is not necessary to drill and broach when replacing a rivet nut.
Locate and mark position for new fastener.
[2] -
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.
Use appropriate drill bit for fastener size being installed and drill hole.
Rivet Nut Drill Bit Size
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.
[3] -
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.
Broach rivet nut hole using appropriate broach for fastener size being installed.
M6 Rivet Nut Broach

JDG1829
Broach hole for M6 rivet nut fastener.
M8 Rivet Nut Broach
JDG1832
M10 Rivet Nut Broach
JDG936
Broach Size
Rivet Nut Size Rivet Nut Broach
M6 JDG1829
M8 JDG1832
M10 JDG936
[4] -
→NOTE:
Hardware fastened to rivet nut fastener must have full thread engagement to rivet nut when installation
is complete.
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 indicates the nominal plate thickness for which the fastener can be used.)
Rivet Nut Length Selection
Material Thickness Flange Stamp Color Code
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
[5] -

IMPORTANT:
Hexagon Hole
LEGEND:
A Hexagon Hole
DO NOT force or drive fastener into hole. Fastener can be damaged and may not hold securely.
Make sure fastener fits easily into hexagon hole (A). If necessary, use a small file to clean edges of hole.
[6] -
IMPORTANT:
Use only specified installation tool for rivet nut. Use of other materials to install rivet nut may result in
fastener failure.
LEGEND:
A Large Threads
B Tool Shoulder
C Rivet Nut Fastener
D Small Threads
Installation Tool
Lubricate large threads (A) of the appropriate installation tool for the fastener size being installed.
M6 Rivet Nut Installation Tool
JDG1830
Install M6 rivet nut.
JDG1295
JDG894

Rivet Nut Installation Tool
Rivet Nut Size Rivet Nut Installation Tool
M6 JDG1830
M8 JDG1295
M10 JDG894
[7] - Install rivet nut fastener (C) on tool:
Small threads (D) of installation tool must extend past fastener.

Flange of fastener must contact tool shoulder (B).
[8] -
LEGEND:
A Socket Head Screw
B Nut
C Flange
Use Crowsfoot Wrench to Tighten Large Nut

Install fastener with installation tool in hexagon hole. Make sure flange (C) is flat against mounting surface.
[9] -
IMPORTANT:
NEVER turn or tighten installation tool socket head screw. Damage to threads of fastener can occur.
While holding socket head screw (A) stationary, tighten large nut (B) to specifications using a crowsfoot wrench.
Rivet Nut Fastener Torque—M6 20—27 N˙m
180—240 lb-in.
Torque—M8 39—46 N˙m
29—34 lb-ft
Torque—M10 68—74 N˙m
50—55 lb-ft
[10] - Loosen large nut to remove tool.
New Rivet Nut Installation
Rivet Nut Size Drill Bit Size Broach Tool Installation Tool
M6 8 mm JDG1829 JDG1830
M6 21/64 in. JDG1829 JDG1830

Section 18 - OPERATOR’S STATION Group 1815: Pedal Assembly
M8 10 mm JDG1832 JDG1295
M8 27/64 in. JDG1832 JDG1295
M10 13 mm JDG936 JDG894
M10 33/64 in. JDG936 JDG894

Group 1815 - Pedal Assembly

Inching Pedal Remove and Install
Inching Pedal Remove and Install (S.N. —630434)
[1] -
Inching Pedal Module

LEGEND:
1 Cap Screw
2 Cover
4 Inching Pedal Module Assembly
S7 Inching Pedal Module
Park machine on flat level surface. Lower all attachments to ground.
[3] - Remove cap screw (1) and cover (2).
[4] - Disconnect harness from inching pedal module (S7).
[5] - Remove cap screws (3) and remove inching pedal module assembly (4).
[7] - Install inching pedal module assembly with cap screws.
[8] - Connect harness to inching pedal module.
[9] - Install cover with cap screw.
[11] - Run machine to verify proper operation. See Operational Checkout . (Group 9005-10.)

Inching Pedal Remove and Install (S.N. 630435— )
[1] - Lower all attachments to ground.
[3] -
LEGEND:
6 Inching Pedal Module Connector
7 Inching Pedal Assembly
8 Inching Pedal (EH controls) Cover
10 Washer (2 used)
11 Inching Pedal (manual controls) Cover
Inching Pedal Cover (EH control machines)
Inching Pedal Cover (manual control machines)

Remove cap screws (9), washers (10) and inching pedal cover (8) or (11).
[4] - Disconnect cab interior harness inching pedal module connector (6) from inching pedal assembly (7)
[5] -

Section 18 - OPERATOR’S STATION Group 1816: Steering Tilt Console
LEGEND:
7 Inching Pedal Assembly
Inching Pedal Assembly

Remove cap screws (5) and inching pedal assembly (7).
[7] - Install inching pedal assembly with cap screws.
[8] - Connect harness to inching pedal module.
[9] - Install cover with cap screws and washers.
[11] - Run machine to verify proper operation. See Operational Checkout . (Group 9005-10.)

Group 1816 - Steering Tilt Console

Steering Support Console Remove and Install—Standard Controls
Steering Support Console—Standard Controls

LEGEND:


7 Flange Nut (9 used)
11 Cap Screw
12 Washer (9 used)
13 Spring Pin
14 Bracket
16 Tilt Console Support Bracket
19 Bottom Console Support
20 Bushing
21 Bracket
22 Bushing (8 used)
24 Front Console Support
29 Washer (20 used)
31 Spacer
32 Rear Console Support
35 Nut (4 used)
36 Nut (4 used)
37 Bracket
39 Nut (4 used)
40 Side Cover
41 Top Console Cover
42 Plate (2 used)
43 Side Cover
44 Plate
[4] - Remove steering wheel, column, and valve. See Steering Wheel, Column, and Valve Remove and Install—Standard
[5] - Remove inching pedal assemble. See Inching Pedal Remove and Install . (Group 1815.)
[6] - Remove control linkage. See Control Linkage Remove and Install . (Group 3415.)
[7] - Disconnect harness connector. See Cab Interior Harness (W15) Component Location—6WD , or See Cab Interior Harness
(W16) Component Location—Non 6WD . (Group 9015-10.)
[8] -
CAUTION:
Avoid crushing injury. Use appropriate lifting device when removing steering support console.
Attach appropriate lifting device to steering support console.

Steering Support Console Weight 32 kg
70 lb
[9] - Remove cap screws (1) from steering support console and remove from cab.
[11] - Install steering support console with cap screws.
[12] - Install control linkage. See Control Linkage Remove and Install . (Group 3415.)
[13] - Install inching pedal assemble. See Inching Pedal Remove and Install . (Group 1815.)
[14] - Install steering wheel, column, and valve. See Steering Wheel, Column, and Valve Remove and Install—Standard

Steering Support Console Remove and Install—EH Controls
Steering Support Console—EH Controls

LEGEND:


10 Flange Nut (9 used)
14 Cap Screw
15 Set Screw
16 Washer (2 used)
17 Washer (9 used)
18 Spring Pin
20 Bracket
21 Bushing (8 used)
22 Bushing (8 used)
25 Bottom Console Support
27 Bracket
28 Front Console Support
30 Rear Console Support
34 Washer (4 used)
35 Spacer
36 Pin Fastener
37 Spacer
40 Bracket
41 Top Console Cover
42 Bracket
43 Nut (4 used)
44 Nut (4 used)
45 Grommet
46 Washer (10 used)
47 Nut (2 used)
48 Side Cover
49 Side Cover
50 Grommet
51 Plate
52 Back Cover
[4] - Remove steering wheel, column, and valve. See Steering Wheel, Column, and Valve Remove and Install—EH Controls .
(Group 0960.)
[5] - Remove inching pedal assemble. See Inching Pedal Remove and Install . (Group 1815.)
[6] - Disconnect harness connector. See Cab Interior Harness (W15) Component Location—6WD , or See Cab Interior Harness
(W16) Component Location—Non 6WD . (Group 9015-10.)
[7] -
CAUTION:
Avoid crushing injury. Use appropriate lifting device when removing steering support console.
Attach appropriate lifting device to steering support console.

Steering Support Console Weight 32 kg
70 lb
[8] - Remove cap screws (2) from steering support console and remove from cab.
[10] - Install steering support console with cap screws (2).

[11] - Install inching pedal assemble. See Inching Pedal Remove and Install . (Group 1815.)
[12] - Install steering wheel, column, and valve. See Steering Wheel, Column, and Valve Remove and Install—EH Controls .
(Group 0960.)

Console Tilt Remove and Install
Console Tilt
LEGEND:
1 Nut (2 used)
2 Bushing (2 used)
3 Console Support Front
4 Cotter Pin

5 Pin Fastener
6 Gas Cylinder
7 Washer
8 Jam Nut
9 Lower Bracket
10 Ball Bearing
11 Spring
12 Pedal
13 Nut (2 used)
14 Washer (2 used)
15 Pin Fastener
16 Cotter Pin
17 Bushing (2 used)
18 Bushing (2 used)
21 Side Panel (2 used)
23 Washer (2 used)
24 Bushing (2 used)
25 Upper Bracket
26 Console Support Rear
[4] - Position steering column forward.
[5] - Remove both side panels (21).
[6] - Position steering column rearward.
[7] - Remove spring (11).
[8] - Remove nuts and cap screws (13 and 19).
[9] - Pull bottom of console support (3) rearward and support.
[10] -
→NOTE:
Position steering column so the gas cylinder is almost in the full retracted position. This will aid in the
assemble of the tilt console.
Remove upper cotter pin (4) and pin fastener (5).
[11] - Remove lower cotter pin (16).
[12] -
→NOTE:
When removing the pedal take note of the small ball bearing (10). It is not retained and can be lost
during disassembly.
Remove pin fastener (15), pedal (12), and gas cylinder (6)
[13] - Remove ball bearing (10) from the end of gas cylinder.
[14] - Remove bracket (9), jam nut (8), and washer (7).
[16] - Install washer and jam nut.
[17] - Install bracket (9) onto gas cylinder rod.

[18] - Install ball bearing (10) to end of rod.
[19] - Install gas cylinder, pedal, and pin fastener (15).
[20] - Install cotter pin.
[21] - Align gas cylinder to upper bracket (25).
[22] - Install pin fastener (5) and retain with cotter pin.
[23] - Install console support and cap screws.
[24] - Install spring.
[25] - Install side panels and cap screws.
[28] - Check function of steering column.

Section 18 - OPERATOR’S STATION Group 1821: Seat and Seat Belt
Steering Tilt Assembly Remove and Install
Steering Tilt Assembly
[1] -
→NOTE:
Standard steering tilt assembly shown EH similar.
Remove console tilt assembly and steering supports to remove steering tilt assembly. See Steering Support Console Remove
and Install—Standard Controls or see Steering Support Console Remove and Install—EH Controls , and see Console Tilt Remove
and Install . (Group 1816.)
[2] - Thoroughly clean and inspect bushing and washers for wear or damage. Replace parts as necessary.

Group 1821 - Seat and Seat Belt

Seat Remove and Install
[3] - Remove armrests. See Armrest Remove and Install , or see Armrest Remove and Install—EH Controls . (Group 1821.)
[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.
[8] -
LEGEND:
1 Nut (2 used)
2 Nut (2 used)
3 Cap Screw and Nut (2 used)
Seat Pan
Remove nuts (1 and 2).
[9] - Remove cap screws and nuts (3).

Seat Back Weight 19 kg
42 lb
[10] - Remove seat pan with back from machine.
[11] -

LEGEND:
4 Screw
5 Cab Air Filter Assembly Cover
Cab Air Filter Assembly Cover

Remove cab air filter assembly cover.
[12] -
→NOTE:
Access Plug
LEGEND:
6 Seat Suspension
7 Access Plug
Access to one of the cap screws is through a plug (7) in the cab air filter assembly box.
Remove access plug (7).
[13] - Remove cap screws from under seat suspension.
[14] -
CAUTION:
Avoid crushing injury. Use appropriate lifting device when removing seat suspension.

Use appropriate lifting device to remove seat suspension.

Seat Suspension Weight 31 kg
68 lb
[16] - Install seat suspension and connect harness.
[17] - Install seat pan with back tighten cap screws and nuts.
[18] - Install seat cushion.
[19] - Install armrests. See Armrest Remove and Install , or see Armrest Remove and Install—EH Controls . (Group 1821.)
[20] -
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.
Install access plug and cab air filter assembly cover.
Seat Belt Remove and Install

[2] -
LEGEND:
1 Cap Screw
2 Seat Belt Buckle
Seat Belt Buckle

Remove cap screw (1) and seat belt buckle (2).
[3] -

LEGEND:
4 Seat Belt
5 Cap Screw
Seat Belt
Remove cap screw (5) and seat belt (4).
[5] - Install seat belt and cap screw (1).

Seat Belt Torque 32—46 N˙m
24—34 lb-ft
[6] - Install seat belt buckle and cap screws (5).

Seat Belt Buckle Torque 32—46 N˙m
24—34 lb-ft
Armrest Remove and Install

→NOTE:
Left side shown, right side is similar.
LEGEND:
1 Nut (4 used)
Armrest
[2] - Remove nuts (1).

[4] - Install armrest and nuts.
[5] - Adjust armrest height and tighten nuts. See Adjusting Premium Seat—Grade Pro Machines Only . (Operator′s Manual.)
Armrest Remove and Install—EH Controls

LEGEND:
Armrest Mount With Seat Back Tilted Forward
[3] - Tilt seat back forward.
[4] - Disconnect wiring harnesses from seat. See Electrohydraulic (EH) Main Cab Harness (W38) Component Location . (Group
9015-10.)
[6] - Remove right side armrest.
[8] - Remove left side armrest.
[9] - Repair or replace parts as necessary. For disassembly, see Armrest Disassemble and Assemble—EH 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.)

Armrest Disassemble and Assemble—EH Controls
Left Side Armrest Disassemble and Assemble

LEGEND:
2 Armrest
3 Armrest Bracket
4 Washer (4 used)

5 Arm Pad Adjustment Handle (2 used)

6 Cover
7 Bushing
8 Screw
9 Armrest Interlock Switch
11 Armrest Assembly
12 Lower Console
14 Control Pod Adjustment Handle
15 Bushing
16 Plate
18 Arm Kit
19 Controller (4 used)
20 Boot (4 used)
21 Knob (4 used)
22 Upper Console
23 Cap Screw (4 per controller)
26 Horn Button
27 Nut
28 Switch
29 Washer (3 used)
30 Push Nut (3 used)
→NOTE:
Left side shown, right side is similar.
[1] -
→NOTE:
When removing controller note location and orientation for install.
Disassemble armrest.
[3] - Adjust armrest. See Adjusting Premium Seat—Grade Pro Machines Only . (Operator′s Manual.)

Standard Seat Disassemble and Assemble
Standard Seat
LEGEND:
1 Headrest
2 Seat Back Cushion
3 Holder
4 Rivet (6 used)
5 Roll Pin (2 used)

6 Cap Screw
7 Handle
8 Rod
9 Back Support
10 Seat Pan
11 Nut (3 used)
12 Tilt Assemble
14 Knob
15 Track Slide (4 used)
16 Spring
17 Snap Ring
18 Seat Lock (2 used)
19 Seat Cushion
20 Spring
21 Torsion Spring
22 Seat Slide Control
23 Snap Ring

Deluxe Seat Disassemble and Assemble
Deluxe Seat (S.N. —641721)

LEGEND:
1 Headrest
2 Seat Back Cushion
3 Head Restraint Holder (2 used)
4 Seat Pan
5 Tilt Assemble
6 Nut (3 used)
8 Knob
9 Snap Ring
10 Spring
11 Spring
12 Torsion Spring
14 Seat Cushion
17 Snap Ring
18 Spring
19 Back Support

Deluxe Seat (S.N. 641722— )

LEGEND:
1 Headrest
2 Seat Back Cushion
3 Head Restraint Holder (2 used)
4 Seat Pan
5 Tilt Assemble
6 Nut (3 used)

8 Knob
9 Snap Ring
10 Spring
11 Spring
12 Torsion Spring
14 Seat Cushion
17 Snap Ring
18 Spring
19 Back Support

Air Suspension Disassemble and Assemble
Seat Air Suspension

LEGEND:
1 Upper Seat Pan
2 Lever Kit (2 used)
3 Frame
Section 18 - OPERATOR’S STATION Group 1830: Heating and Air Conditioning
5 Cover
6 Bottom Seat Pan
9 Shaft (2 used)
10 Lock Nut (2 used)
11 Washer (2 used)
12 Bearing (4 used)
13 Rod
15 Arm
16 Housing
19 Shock Absorber
20 Bracket
21 Lock Nut 3
22 Bolt (2 used)
23 Knob
24 Bearing
25 Spring
26 Cap Screw
27 Lock Nut
28 Cap Screw
29 Tie Band (2 used)
30 Lock Nut
31 Washer
32 Bearing (2 used)
33 Washer (2 used)
34 Cap Screw
35 Cap Screw
36 Bumper
37 Bumper (2 used)
38 Screw (2 used)
39 Nut
41 Washer (5 used)
42 Valve
43 Fitting
44 Air Spring Seat Kit
45 Elbow Fitting
46 Cap Screw
47 Cap Screw
48 Compressor
49 Clamp

Group 1830 - Heating and Air Conditioning

R134a Refrigerant Cautions and Proper Handling
JT02167A Prism Pro Refrigerant Identification Instrument
CAUTION:
DO NOT allow liquid refrigerant to contact eyes or skin. Liquid refrigerant will freeze eyes or skin on
contact. Wear goggles, gloves and protective clothing.
If liquid refrigerant contacts eyes or skin, DO NOT rub the area. Splash large amounts of COOL water on
affected area. Go to a physician or hospital immediately for treatment.
DO NOT allow refrigerant to contact open flames or very hot surfaces such as electric welding arc,
electric heating element and lighted smoking materials.
DO NOT heat refrigerant over 52 °C (125 °F) in a closed container. Heated refrigerant will develop high
pressure, which can burst the container.
Keep refrigerant containers away from heat sources. Store refrigerant in a cool place.
DO NOT handle damp refrigerant container with your bare hands. Skin may freeze to container. Wear
gloves.
If skin freezes to container, pour COOL water over container to free the skin. Go to a physician or
hospital immediately for treatment.
IMPORTANT:
To meet government standards relating to the use of refrigerants, R134a is used in the air conditioning
system. Because it does not contain chlorine, R134a is not detrimental to the ozone in the atmosphere.
However, it is illegal to discharge any refrigerant into the atmosphere. It must be recovered using the
appropriate recovery stations.
Use correct refrigerant recovery/recycling and charging stations. Never mix refrigerants, hoses, fittings,
components or refrigerant oils.
IMPORTANT:
Use only John Deere approved R134a refrigerant products. Mixing of products not compatible will cause
system damage and contaminate recovery/recycling and charging station equipment. Care must be taken
to identify and use equipment, refrigerant oil and refrigerant designed only for R134a refrigerant
systems. Refrigerant should be tested for type and purity before recovery, recycling or charging of
system. JT02167A Prism Pro Refrigerant Identification Instrument should be used before any testing or
repair to system is performed.
Prism Pro Refrigerant Identification Instrument

JT02167A
To safely identify type and check purity of refrigerant prior to recovery, recycling and recharging of A/C systems.

Flush and Purge Air Conditioner System

This procedure should only be performed on machines that have had a catastrophic air conditioner compressor malfunction.
Cleanup procedure must be performed prior to returning machine air conditioning system back into service.
CAUTION:
Liquid refrigerant will freeze eyes or skin on contact. Wear goggles, gloves, and protective clothing. See
Refrigerant Cautions and Proper Handling . (Group 1830.)
→NOTE:
Anytime air conditioning system is discharged, a new receiver-dryer and accumulator (if equipped) must
be installed.
[1] - Recover R134a refrigerant. See R134a System Recover . (Group 1830.)
[2] -
IMPORTANT:
DO NOT attempt to flush through compressor or receiver-dryer. Flushing solution may not be completely
removed from these components and could cause system malfunction.
Remove air conditioner compressor. See Compressor Remove and Install . (Group 1830.)
[3] -
→NOTE:
be installed.
Remove and discard receiver-dryer. See Receiver-Dryer Remove and Install . (Group 1830.)
[4] - Remove and discard expansion valve. See Expansion Valve Remove and Install . (Group 1830.)
[5] -
→NOTE:
Determine if the condenser is continuous loop or parallel flow style. Continuous loop style has either
multiple round tubes or an extruded serpentine construction. Use an adapter and connect hoses at a
continuous loop condenser.
If condenser is parallel flow style construction, do not flush, it should be replaced. A parallel flow
condenser with potential blockages probably will not flush completely and could result in system
malfunction.
Divide system into evaporator or condenser circuits, including hoses. Flush and purge procedure is the same for both circuits.
[6] - Flush and purge air conditioner continuous loop condenser circuit:
Connect flusher outlet hose to inlet end of air conditioner compressor discharge line using adapter from JT02098 Air
Conditioning Fitting Kit.
Air Conditioning Flushing Kit
JT02098
Adapter to connect flusher outlet hose to inlet end of compressor discharge line.
Connect hoses at continuos loop condenser with an adapter from JT02098 Air Conditioning Fitting Kit.
JT02098
Adapter to connect hoses at continuos loop condenser.
Attach a return hose and aerator nozzle to end of receiver-dryer inlet hose using JT03197 Reducer. Put nozzle in
container to collect flushing solvent.

Reducer
JT03197
Attach a return hose and aerator nozzle to outlet end of receiver-dryer inlet hose.
Add TY25601 ACC-Flush-II Flushing Solution to system with JT02075 Air Conditioning Flusher using fittings from
JT02098 Air Conditioning Fitting Kit.
Number Name Use
▪ TY25601 (us) ACC-Flush-II Flushing Solution Used to flush R134a air conditioning system.
Air Conditioning Flusher
JT02075
To be used with air conditioning flushing kit.
JT02098
Flush air conditioning system and adjust expansion valve.
Fill air conditioning system flusher tank with 4 L (1 gal) of solvent and tighten all connections.
Air Conditioning System Flusher Tank Capacity 4L
1 gal
→NOTE: Air pressure must be at least 620 kPa (6.2 bar) (90 psi) for flushing and purging.
Air Conditioning System Air Pressure (minimum for flushing and purging) 620 kPa
6.2 bar
90 psi
Connect supply line of moisture-free compressed air or dry nitrogen to flusher air valve.
Open air valve to force flushing solvent into air conditioner circuit. Flusher tank is empty when hose pulsing stops.
Disconnect flusher tank and connect to flushed circuit discharge hose end.
IMPORTANT: Additional flushing cycles are required if system is heavily contaminated with
burned oil or metal particles.
Fill flusher tank and repeat flushing procedure in reverse direction.
→NOTE: Purging takes 10—12 minutes to thoroughly remove solvent.
Disconnect hose from aeration nozzle to check circuit for solvent. Hold discharge hose close to a piece of cardboard.
Continue purging until cardboard is dry, and proceed to next step.
Flush and purge air conditioner evaporator:
a. Remove evaporator. See Heater and Air Conditioner Remove and Install . (Group 1830.)
b. Follow the same flush and purge procedure used on condenser, using adapters from JT02098 Air Conditioning Fitting Kit.
JT02098
Adapter to connect flusher outlet hose to inlet end of compressor discharge line.
c. Install evaporator and proceed to next step. See Heater and Air Conditioner Remove and Install . (Group 1830.)
[7] -
→NOTE:
be installed.
Install new receiver-dryer. See Receiver-Dryer Remove and Install . (Group 1830.)
[8] - Install new expansion valve. See Expansion Valve Remove and Install . (Group 1830.)
[9] -

→NOTE:
Determine if the condenser is continuous loop or parallel flow style. Continuous loop style has either
multiple round tubes or an extruded serpentine construction. Use an adapter and connect hoses at a
continuous loop condenser.
If condenser is parallel flow style construction, do not flush, it should be replaced. A parallel flow
condenser with potential blockages probably will not flush completely and could result in system
malfunction.
Install new condenser, if needed. See Condenser Remove and Install . (Group 1830.)
[10] - Install new compressor. See Compressor Remove and Install . (Group 1830.)
[11] - Add required R134a refrigerant oil to air conditioning system. See R134a Refrigerant Oil Information . (Group 1830.)
[12] - Evacuate and charge air conditioning system. See R134a System Evacuate and see R134a System Charge . (Group
1830.)

R134a Refrigerant Oil Information
CAUTION:
CAUTION:
All new compressors are charged with a mixture of nitrogen and TY22101 (R134a) Refrigerant Oil. Wear
safety goggles and discharge the compressor slowly to avoid possible injury.
IMPORTANT:
DO NOT leave system or R134a compressor oil containers open. Refrigerant oil easily absorbs moisture.
DO NOT spill R134a compressor oil on acrylic or ABS plastic. This oil will deteriorate these materials
rapidly. Identify R134a oil containers to eliminate accidental mixing of different oils.
IMPORTANT:
Avoid adding more oil than required, or maximum cooling will be reduced.
A compressor with threaded ports from parts depot contains 230 mL (7.77 fl. oz.) of new oil.
A compressor without threaded ports from parts depot contains 160 mL (5.41 fl. oz.) of new oil.
1. Determine if R134a leakage was detected. Remove and repair, or replace component. See Refrigerant Leak Test . (Group
9031-25.)
→NOTE: Anytime air conditioning system is discharged, a new receiver-dryer and accumulator (if
equipped) must be installed.
Remove and discard receiver-dryer. See Receiver-Dryer Remove and Install . (Group 1830.)
→NOTE: Flush and purge air conditioning system only if machine had a catastrophic air conditioner
compressor malfunction.
→NOTE: Air conditioner compressor is not to be flushed and purged.
→NOTE: Determine if the condenser is continuous loop or parallel flow style. Continuous loop style
has either multiple round tubes or an extruded serpentine construction. Use an adapter and connect
hoses at a continuous loop condenser. If condenser is parallel flow style construction, do not flush, it
should be replaced. A parallel flow condenser with potential blockages probably will not flush
completely and could result in system malfunction.
Flush and purge air conditioning system, only if needed. See Flush and Purge Air Conditioner System . (Group 1830.)
→NOTE: Anytime air conditioning system is discharged, a new receiver-dryer and accumulator (if
equipped) must be installed.
Install new receiver-dryer. See Receiver-Dryer Remove and Install . (Group 1830.)
5. Add required amount of TY22101 Refrigerant Oil to air conditioning system according to vehicle platform requirements
and type of service performed. Determine vehicle platform requirements by engine code and serial number.
Motor Grader—Total System Oil (using compressor without threaded ports) Volume 350.8 mL
11.86 fl. oz.
Motor Grader—Total System Oil (using compressor with threaded ports) Volume 307 mL
10.4 fl. oz.
Number Name Use

⚬ TY22101 (us) Low Viscosity (ISO 40) R134a PAG Oil Lubricate R134a air conditioning system.
6. Type of service to perform:
Oil charge required for acceptable circuit flushing. Compressor type total system oil charge minus compressor oil
volume.
Measure any oil captured during system recovery and add this quantity of new oil back to the system along with oil
quantities for particular replacement components.
Compressor replacement, other than catastrophic malfunction, measure oil volume drained from old compressor.
Drain oil from new compressor and add back to the new compressor new oil of same volume as old oil.
Condenser replacement oil charge. Use formula 1.5 percent of specified system total oil charge to add.
Evaporator replacement oil charge. Use formula 56 percent of specified system total oil charge to add.
Receiver-dryer replacement oil charge. Use formula 4.5 percent of specified system total oil charge to add.
→NOTE: Hoses = 3 mL per 30 cm (0.1 fl. oz. per ft.)
Hose replacement oil charge. If any section of hose is removed and flushed or replaced, measure length of hose and
use the formula 3 ml per 30 cm (0.1 fl. oz. per ft.) to determine correct amount of oil to add.
7. Evacuate and charge system. See R134a System Evacuate and see R134a System Charge . (Group 1830.)

R134a Refrigerant Recovery/Recycling and Charging Station Installation

Procedure
CAUTION:
IMPORTANT:
Use only John Deere approved R134a refrigerant products. Mixing of products not compatible will cause
system damage and contaminate recovery/recycling and charging station equipment. Care must be taken
to identify and use equipment, refrigerant oil, and refrigerant designed only for R134a refrigerant
systems. Refrigerant should be tested for type and purity before recovery/recycling or charging of
system. JT02167A Prism Pro Refrigerant Identification Instrument should be used before any testing or
repair to system is performed.
JT02167A
To safely identify type and check purity of refrigerant prior to recovery, recycling and recharging of air
conditioning systems.
IMPORTANT:
Use only John Deere approved refrigerant recovery/recycling and charging stations. DO NOT mix
refrigerant, hoses, fittings, components, or refrigerant oils.
[2] -
CAUTION:
[3] -

LEGEND:
1 High Pressure Charge Port Cap
2 Red Hose
3 Blue Hose
4 High Pressure Relief Valve
5 Refrigerant Recovery/Recycling and Charging Station
Charging Station Installation

Close both high-side and low-side valves on refrigerant recovery/recycling and charging station (5).
HFC134a Deluxe Recovery/Recycling and Charging Station
JT02045
Used to remove refrigerant from system.
Charging Station
JT02046
[ Used with JT02050 Recovery and Recycling Station. ]
Servicing air conditioning system using R134a refrigerant.

Recovery and Recycling Station
JT02050
[ Used with JT02046 Charging Station. ]
Servicing air conditioning system using R134a refrigerant.
[4] - Remove cap from low pressure charge port and connect blue hose (3) from refrigerant recovery/recycling and charging
station (5).
[5] - Remove high pressure charge port cap (1) and connect red hose (2).
[6] - Follow manufacturer′s instructions when using the refrigerant recovery/recycling and charging station.
R134a System Recover

CAUTION:
Liquid refrigerant will freeze eyes or skin on contact. Wear goggles, gloves, and protective clothing.
See Refrigerant Cautions and Proper Handling . (Group 1830.)
IMPORTANT:
Use correct refrigerant recovery/recycling and charging stations. DO NOT mix refrigerant, hoses, fittings,
components, or refrigerant oils.
[1] - Run air conditioning system for 3 minutes to help in recovery process. Turn air conditioning system off before proceeding
with recovery steps.
[2] - With engine OFF, identify refrigerant type using JT02167A Refrigerant Identification Instrument.
JT02167A
To safely identify type and check purity of refrigerant prior to recovery, recycling, and recharging of air conditioning systems.
[3] - Connect refrigerant recovery system. See R134a Refrigerant Recovery/Recycling and Charging Station Installation
[4] - Follow manufacturer’s instructions when using refrigerant recovery/recycling and charging station.

R134a System Evacuate
CAUTION:
[1] - Connect refrigerant recovery system. See R134a Refrigerant Recovery/Recycling and Charging Station Installation
[2] - Open low-side and high-side valves on refrigerant recovery/recycling and charging station.
[3] - Follow manufacturer’s instructions and evacuate system.
[4] -
→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.
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
Evacuate system until low-side gauge registers 98 kPa (980 mbar) (29 in. Hg) vacuum.
Evacuate System Vacuum 98 kPa
980 kPa
29 in. Hg
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 minutes, there is a leak in system.
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] - Recharge the air conditioning system. See R134a System Charge . (Group 1830.)

R134a System Charge
CAUTION:
IMPORTANT:
Use only John Deere approved refrigerant recovery/recycling and charging stations. DO NOT mix
refrigerant, hoses, fittings, components, or refrigerant oils.
[1] - Identify refrigerant type using JT02167A Refrigerant Identification Instrument.

JT02167A
To safely identify type and check purity of refrigerant prior to recovery, recycling and recharging of air conditioning systems.
[2] - Connect R134a Refrigerant Recovery/Recycling and Charging Station. See R134a Refrigerant Recovery/Recycling and
Charging Station Installation Procedure . (Group 1830.)
[3] - Evacuate system. See R134a System Evacuate . (Group 1830.)
[4] -
→NOTE:
Before beginning to charge air conditioning system, the following conditions must exist: Engine
STOPPED, the pump must be capable of pulling at least 97 kPa (967 mbar) (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.
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
Follow manufacturer’s instructions and charge system.
[5] - Add refrigerant to air conditioning system.

Air Conditioning System Refrigerant Capacity 2.38 kg
5.25 lb.
[6] - Check air conditioning system operation. See Diagnose Air Conditioning System Malfunctions . (Group 9031-25.)

Expansion Valve Remove and Install

Specifications
SPECIFICATIONS
6 N·m
Rear Retaining Plate Cap Screw Torque
53 lb.-in.
10 N·m
Front Retaining Plate Cap Screw Torque (S.N. —671137)
89 lb.-in.
21 N·m
Front Retaining Plate Nut Torque (S.N. 671138— )
186 lb.-in.
CAUTION:
→NOTE:
be installed.
[3] - Recover refrigerant from air conditioning system. See R134a System Recover . (Group 1830.)
[4] -
LEGEND:
1 Knob
4 Rear Panel

Rear Panel Removal

Remove knob (1) and cab air filter assembly cover (2).
[5] - Remove cap screws (3) and rear panel (4).
[6] -
Refrigerant Line Removal (S.N. —671137)

Refrigerant Line Removal (S.N. 671138— )

LEGEND:
5 Front Retaining Plate Cap Screw
6 Front Retaining Plate
7 Expansion Valve-to-Compressor Low-Pressure Line
8 Receiver Dryer-to Expansion Valve High-Pressure Line
14 Front Retaining Plate Nut (S.N. 671138— )
Remove front retaining plate cap screw (5) and front retaining plate (6).
[7] - Machines with (S.N. 671138— ): Remove front retaining plate nut (14) and front retaining plate (6).
[8] - Disconnect refrigerant lines (7, 8). To prevent contamination of air conditioning system, close all openings using caps and
plugs.
[9] -
→NOTE:
With front retaining plate removed, access is gained to rear retaining plate cap screws (9) threaded into
rear retaining plate (10).

Rear Retaining Plate Removal (S.N. —671137)

Rear Retaining Plate Removal (S.N. 671138— )

LEGEND:
9 Rear Retaining Plate Cap Screw (2 used)
10 Rear Retaining Plate
Remove rear retaining plate cap screws (9) and rear retaining plate (10).
[10] -
LEGEND:
10 Rear Retaining Plate
11 Evaporator High-Pressure Line
12 Evaporator Low-Pressure Line
13 Expansion Valve
Expansion Valve Removal

Disconnect refrigerant lines (11, 12) and remove expansion valve (13). To prevent contamination of air conditioning system,
close all openings using caps and plugs.
[12] -
IMPORTANT:
Install expansion valve (13) using new O-rings and rear retaining plate (10). Install rear retaining plate cap screws (9).Tighten
cap screws to specification.
Rear Retaining Plate Cap Screw Torque 6 N·m
53 lb.-in.
[13] -
→NOTE:
be installed.
Remove and install a new receiver-dryer. See Receiver-Dryer Remove and Install . (Group 1830.)
[14] - Connect air conditioner lines and retaining plates to expansion valve. Check for leaks. See Refrigerant Leak Test . (Group
9031-25.)
[15] - Install front retaining plate (6) and front retaining plate cap screw (5). Tighten cap screw to specification.
Front Retaining Plate Cap Screw Torque 10 N·m
89 lb.-in.
[16] - Machines with (S.N. 671138— ): Install front retaining plate (6) and front retaining plate nut (14). Tighten nut to
specification.
Front Retaining Plate Nut Torque 21 N·m
186 lb.-in.
[17] - Install rear panel (4) and cap screws (3).
[18] - Install cab air filter assembly cover (2) and secure with knob (1).
[19] - Evacuate and charge the air conditioning system. See R134a System Evacuate and see R134a System Charge . (Group
1830.)
[21] - Before returning machine to service, operate machine and verify heating and air conditioning systems operate correctly.
See Operational Checkout . (Group 9005-10.)

Freeze Control Switch Remove and Install

[3] -
LEGEND:
1 Knob

[4] - Remove access panel inside rear of cab, behind seat.
[5] -
Freeze Control Switch

LEGEND:

5 Probe
B34 Air Conditioner Freeze Control Switch
Disconnect wire harness from air conditioner freeze control switch (B34).
[6] - Remove probe (5) of freeze control switch from evaporator coil.
[7] - Remove cap screws (4) from heater/evaporator coil top cover to remove freeze control switch (B34).
[8] - Test freeze control switch. See Air Conditioner Freeze Control Switch Test . (Group 9031-25.)
[9] - Attach freeze control switch (B34) to heater/evaporator coil top cover.
[10] - Connect wire harness to freeze control switch connector.
[11] - Insert freeze control switch probe into evaporator coil.
[12] - Install access panel behind seat.
[13] - Install cab air filter assembly cover and secure with knob.

High/Low Pressure Switch Remove and Install
CAUTION:
[3] -
LEGEND:
1 Knob
4 Rear Panel
Rear Panel Removal

Remove knob (1).
[4] - Remove cab air filter assembly cover (2).
[6] -

LEGEND:
B35 High/Low Pressure Switch
High/Low Pressure Switch Location

Disconnect electrical connector (5) from high/low pressure switch (B35).
[7] -
→NOTE:
It is not necessary to recover the system. A valve prevents the system from discharging when high/low
pressure switch is removed.
Remove high/low pressure switch.
[9] - Install high/low pressure switch. Check for leaks. See Refrigerant Leak Test . (Group 9031-25.)
[10] - Connect electrical connector to high/low pressure switch.
[11] - Install rear panel.
[12] - Install cab air filter assembly cover and secure.
[14] - Before returning machine to service, operate machine and verify heating and air conditioning systems operate correctly.
See Operational Checkout Procedure . (Group 9005-10.)

Heater Control Valve Remove and Install

[3] -
LEGEND:
1 Knob
4 Rear Panel
Rear Panel Removal

[5] -

LEGEND:
M15 Heater Control Valve
Water Valve Actuator Electrical Connector
Water Valve Actuator Removal

Disconnect electrical connector (5) from heater control valve (M15).
[6] - Clamp heater hoses near water valve actuator to prevent coolant loss.
[7] - Remove hose clamps (6) and disconnect heater hoses from heater control valve (M15).
[8] -
→NOTE:
Water valve actuator is not serviceable and must be replaced as an assembly.
Remove heater control valve. Inspect or replace as needed.
[9] - Inspect heater hoses and replace as necessary.
[10] - Install heater control valve.
[11] - Connect hoses and install hose clamps.
[12] - Remove clamps from heater hoses.
[13] - Connect electrical connector to water valve actuator.
[14] - Install rear panel behind seat.
[15] - Install cab air filter assembly cover and secure with screw.
[16] - Add coolant to the surge tank to account for any coolant loss in the heater circuit. See Drain, Flush, and Refill Cooling
System . (Operator′s Manual.)
[18] - Operate machine and verify heating and air conditioning systems operate correctly. See Operational Checkout
Procedure . (Group 9005-10.)
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 Valve Remove and Install . (Group 1830.)
[3] - After removal, perform a visual inspection of valve for cracks, debris, and free movement of the valve.
[4] -
→NOTE:
The heater control valve is serviced as an assembly.
Replace heater control valve if valve leaks or is damaged.
[5] - Install heater control valve. See Heater Control Valve Remove and Install . (Group 1830.)
Blower Motor Assembly Remove and Install

[3] -
LEGEND:
1 Heater and Air Conditioner Assembly
M2 Blower Motor Assembly
R6 Blower Resistor
Blower Motor
Remove heater and air conditioner assembly (1). See Heater and Air Conditioner Remove and Install . (Group 1800.)
[4] - Remove cap screws (2) and blower motor assembly (M2).
[6] - Install blower motor assembly into heater and air conditioner assembly with cap screws.
[7] - Install heater and air conditioner assembly. See Heater and Air Conditioner Remove and Install . (Group 1800.)

Compressor Remove and Install

→NOTE:
be installed.
[2] -
CAUTION:
[3] -
CAUTION:
Recover refrigerant from air conditioning system. See R134a System Recover . (Group 1830.)
[5] -
LEGEND:
1 Air Conditioner Compressor
3 Connector
4 Compressor-to-Condenser High Pressure Refrigerant Line
5 Evaporator-to-Compressor Low Pressure Refrigerant Line
6 Compressor Relief Valve
7 Accessory Belt
Air Conditioner Compressor

Disconnect connector (3) from air conditioner compressor (1).
[6] - Remove refrigerant lines (4 and 5) from compressor. To prevent contamination of air conditioning system, close all
openings using caps and plugs.
[7] - Remove engine accessory belt (7). See Inspecting Accessory Belt and Belt Tensioner Spring . (Operator′s Manual.)
[8] - Remove cap screws (2) and compressor.
[9] - Replace air conditioner compressor as necessary.
[10] - Install compressor and cap screws.

[11] - Install refrigerant lines to air conditioner compressor.
[12] - Install engine accessory belt and connect harness. See Inspecting Accessory Belt and Belt Tensioner Spring . (Operator′s
Manual.)
[13] -
→NOTE:
be installed.
Remove and install a new receiver-dryer. See Receiver-Dryer Remove and Install . (Group 1830.)
1830.)
[17] - Before returning machine to service, verify heating and air conditioning systems operate correctly. See Operational
Checkout Procedure . (Group 9005-10.)

Condenser Remove and Install

→NOTE:
be installed.
[2] -
CAUTION:
[3] -
CAUTION:
[5] - Open right rear service door. See Service Doors . (Operator’s Manual.)
[6] -
LEGEND:
Air Conditioner Condenser Mounting

[7] - Pull air conditioner condenser out from machine until it contacts the stops.
[8] -

Air Conditioner Condenser Removal

LEGEND:
2 Compressor-to-Condenser High Pressure Refrigerant Line
3 Condenser-to-Receiver-Dryer High Pressure Refrigerant Line
4 Cap Screw
Disconnect compressor-to-condenser high pressure refrigerant line (2) and condenser-to-receiver-dryer high pressure
refrigerant line (3). To prevent contamination of air conditioning system, close all openings using caps and plugs.
[9] - Remove cap screw (4) securing refrigerant lines to condenser bracket. Set lines aside.
[10] - Support air conditioner condenser and remove cap screws (5).
[11] - Remove condenser from slide-out bracket. Repair or replace parts as necessary.
[12] - To install condenser, support condenser and install cap screws.
[13] - Route and connect refrigerant lines. Tighten to specification.

Compressor-to-Condenser High Pressure Refrigerant Line Torque 24 N·m
212 lb.-in.
Condenser-to-Receiver-Dryer High Pressure Refrigerant Line Torque 17 N·m
150 lb.-in.
[14] - Install cap screw and clamp securing refrigerant lines to condenser bracket.
[15] - Push air conditioner condenser into normal operating location. Install cap screws.
[16] -

→NOTE:
be installed.
Remove, discard, and install a new receiver-dryer. See Receiver-Dryer Remove and Install . (Group 1830.)
1830.)
[19] - Close service door. See Service Doors . (Operator’s Manual.)

Heater and Air Conditioner Remove and Install

→NOTE:
be installed.
[2] -
CAUTION:
[4] -
CAUTION:
[6] - Remove seat. See Seat Remove and Install . (Group 1821.)
[7] - Remove floor mat.
[8] -
LEGEND:
1 Knob

[9] -

LEGEND:
3 Rear Panel
4 Cab Air Filter Assembly
5 Cab Air Filter Plate
7 Rear Lower Panel
9 Seat Base
Cab Floor Without Seat

Remove rear panel (3).
[10] - Remove cap screws (6) from cab air filter plate (5).
[11] - Remove cap screws (8) and remove rear lower panel (7).
[12] - Remove cap screws (10) and remove seat base (9).
[13] -
Cab Air Filter Assembly Housing

LEGEND:
11 Cab Air Filter Assembly
12 Cap Screw
15 Cap Screw
17 Cap Screw
Remove cap screws (12—17) and remove cab air filter assembly (11).
[14] -
LEGEND:
18 Expansion Valve
19 Heater Hose (2 used)
Heater Hoses and Expansion Valve

Disconnect refrigerant lines from expansion valve (18). Close all openings using caps and plugs. See Expansion Valve Remove
[15] - Disconnect heater hoses (19) connected to heater core. Close all openings using caps and plugs.
[16] - Disconnect harness from blower motor, blower motor resistor, and air conditioner freeze switch. See Heater and Air
Conditioner Harness (W12) Component Location . (Group 9015-10.)
[17] -
LEGEND:
21 Cap Screw
Heater and Air Conditioner Assembly

Remove cap screws (20 and 21).
[18] - Remove heater and air conditioner assembly.
[20] - Install heater and air conditioner assembly.
[21] - Connect heater hoses to heater core.
[22] - Install heater and air conditioner.
[23] -

IMPORTANT:
Install expansion valve. See Expansion Valve Remove and Install . (Group 1830.)
[24] - Install cab air filter assembly.
[25] - Install seat base.
[26] - Install both rear panels.
[27] - Install seat. See Seat Remove and Install . (Group 1821.)
[28] - Install floor mat.
[29] - Install cab air filter assembly cover.
1830.)

Receiver-Dryer Remove and Install

→NOTE:
be installed.
[2] -
CAUTION:
[4] -
CAUTION:
[5] -
LEGEND:
1 Condenser-to-Receiver-Dryer High Pressure Line
2 Receiver-Dryer-to-Expansion Valve High Pressure Line
3 Receiver-Dryer
Reviever-Dryer Mounting Location

Remove high pressure refrigerant lines (1 and 2) from receiver-dryer (3). To prevent contamination of air conditioning system,
close all openings using caps and plugs.
[6] - Loosen cap screws (4) and slide receiver-dryer up out of clamps.
[7] - Install new receiver-dryer. Tighten cap screws.
[8] -

SHEET METAL AND STYLING (g) by Belgreen v2.0
IMPORTANT:
Using new O-rings, connect high pressure refrigerant lines. Tighten to specification.
Condenser-to-Receiver-Dryer High Pressure Line Torque 17 N·m
150 lb.-in.
Receiver-Dryer-to-Expansion Valve High Pressure Line Torque 17 N·m
150 lb.-in.
[9] - Evacuate and charge air conditioning system. See R134a System Evacuate and see R134a System Charge . (Group 1830.)

Section 19 - SHEET METAL AND STYLING

Table of contents
Group 1910 - Engine Enclosure ............................................................................................................. 1
Engine Service Doors and Side Shields Remove and Install ................................................................. 1
Engine Covers Remove and Install ....................................................................................................... 2
Group 1921 - Grille and Grille Housing ................................................................................................. 5
Grille Housing Remove and Install ........................................................................................................ 5

Section 19 - SHEET METAL AND STYLING Group 1910: Engine Enclosure
Group 1910 - Engine Enclosure

Engine Service Doors and Side Shields Remove and Install
Engine Service Doors and Side Shields

LEGEND:
1 Rear Engine Service Door (2 used)
2 Front Engine Service Door (2 used)
3 Front Side Shield (2 used)
4 Rear Side Shield (2 used)
CAUTION:
Remove engine service doors or side shields as necessary.

Rear Engine Service Door Weight 45 kg
100 lb.
Front Engine Service Door Weight 36 kg
80 lb.

Engine Covers Remove and Install

Front Engine Cover Remove and Install
[3] - Open engine service doors. See Service Doors . (Operator’s Manual.)
[4] -
LEGEND:
2 JDG19 Lifting Bracket (4 used)
3 Lifting Strap (4 used)
4 Front Engine Cover
Front Engine Cover

Remove front engine cover cap screws (1).
[5] -
→NOTE:
It is not necessary to remove precleaner for engine cover removal.
Attach JDG19 Lifting Brackets (2) and lifting straps (3) to engine cover as shown.
Lifting Brackets
JDG19
To aid in removal of engine covers.
[6] -
CAUTION:
Avoid crushing injury. Use appropriate lifting device when lifting component.
Attach appropriate lifting device to lifting straps and remove engine cover.
Front Engine Cover Weight 45 kg
100 lb.
[7] - Repair or replace cover as necessary.
[8] -
CAUTION:

Lift engine cover and set in place.

Front Engine Cover Weight 45 kg
100 lb.
[9] - Remove lifting straps and brackets from cover.
[10] - Align engine cover and install cap screws.
[11] - Close engine service doors.
Rear Engine Cover Remove and Install
[3] - Open engine service doors. See Service Doors . (Operator’s Manual.)
[4] -
IMPORTANT:
Make sure hydraulic oil tank cap is installed after rear engine cover is removed to avoid contaminants
entering hydraulic oil system.
LEGEND:
1 Hydraulic Oil Tank Cap
Rear Engine Cover

Remove hydraulic oil tank cap (1) and rear engine cover mounting cap screws (2).
[5] -
LEGEND:
3 JDG19 Lifting Bracket (2 used)
4 Lifting Strap (4 used)
5 Rear Engine Cover Tab (4 used)
6 Grille Housing
Rear Engine Cover Removal

Section 19 - SHEET METAL AND STYLING Group 1921: Grille and Grille Housing
Attach JDG19 Lifting Brackets (3) and lifting straps (4) to rear engine cover as shown.
Lifting Bracket
JDG19
To aid in removal of rear engine cover.
[6] -
CAUTION:
→NOTE:
Rear engine cover must be raised slightly and moved forward to allow rear engine cover tabs (5) to clear
grille housing (6).
Attach appropriate lifting device to lifting straps. Raise rear engine cover slightly and move toward front of machine until rear
engine cover tabs (5) clear grille housing (6). Remove rear engine cover.
Rear Engine Cover Weight 54 kg
120 lb.
[7] - Install hydraulic oil tank cap.
[8] - Repair or replace cover as necessary.
[9] -
CAUTION:
Remove hydraulic oil tank cap. Lift engine cover and set in place.
Rear Engine Cover Weight 54 kg
120 lb.
[10] - Remove lifting straps and brackets from cover.
[11] - Align engine cover and install cap screws. Install hydraulic oil tank cap.
[12] - Close engine service doors.

Group 1921 - Grille and Grille Housing

Grille Housing Remove and Install
[4] - Remove left rear and right rear engine service doors. See Engine Service Doors and Side Shields Remove and Install .
(Group 1910.)
[5] - Remove fuel cooler. See Fuel Cooler Remove and Install . (Group 0510.)
[6] -
LEGEND:
Fan Door
[7] -
CAUTION:
pressure.
Disconnect hydraulic fan motor hoses and hydraulic fan speed sensor (B58) electrical connector. See Hydraulic Fan Motor
[8] - Disconnect rear turn lights, rear stop and marker lights, and rear backup lights. See Rear Platform Harness (W26)
[9] -
CAUTION:

Fan Door Support

Support fan door using an appropriate lifting device.
Fan Door Weight (approximate) 136 kg
300 lb.
[10] -
LEGEND:
2 Nut (2 used)
3 Washer (8 used)
Fan Door Hinge Cap Screws

Remove nuts (2), washers (3), and cap screws (4). Remove fan door.
[11] - Disconnect rear camera harness (if equipped). See Rear Camera Harness (W27) Component Location—If Equipped .
(Group 9015-10.)
[12] -
LEGEND:
5 Backup Alarm Electrical Connector (2 used)

Backup Alarm
Tag and disconnect backup alarm electrical connectors (5). Set harness aside.
[13] -
LEGEND:
6 Nut (2 used)
7 Washer (6 used)
9 Bracket (2 used)
Grille Housing Bracket (left side shown)

Remove nuts (6), washers (7), cap screws (8), and brackets (9) from upper left and upper right side of grille housing.
[14] -
IMPORTANT:
Prevent fuel tank contamination. Close fuel tank opening using appropriate materials.
Remove fuel tank cap. Close opening using appropriate materials.
[15] -
CAUTION:
Grille Housing Support

Support grille housing using an appropriate lifting device.
Grille Housing Weight (approximate) 136 kg
300 lb.
[16] -

LEGEND:
Engine Frame-to-Grille Housing Cap Screws

Remove cap screws (10) and remove grille housing.
[17] - Repair or replace grille housing as needed.
[18] -
CAUTION:
Install grille housing using appropriate lifting device.

Grille Housing Weight (approximate) 136 kg
300 lb.
[19] - Install cap screws securing grille housing to engine frame.
[20] - Install fuel tank cap.
[21] - Install brackets, washers, and nuts to grille housing.
[22] - Connect electrical harness to backup alarm.
[23] - Connect rear camera electrical connector (if equipped). See Rear Camera Harness (W27) Component Location—If
Equipped . (Group 9015-10.)
[24] -
CAUTION:
Install fan door.

Fan Door Weight (approximate) 136 kg
300 lb.
[25] - Connect rear turn lights, rear stop and marker lights, and rear backup lights. See Rear Platform Harness (W26)
[26] - Connect hoses and harness to hydraulic fan motor. See Hydraulic Fan Motor Remove and Install . (Group 2160.)
[27] - Install fuel cooler. See Fuel Cooler Remove and Install . (Group 0510.)
[28] - Install left rear and right rear engine service doors. See Engine Service Doors and Side Shields Remove and Install .
MAIN HYDRAULIC SYSTEM (g) by Belgreen v2.0
(Group 1910.)

Section 21 - MAIN HYDRAULIC SYSTEM

Table of contents
Vacuum Pump Installation .................................................................................................................... 1
Hydraulic Pump Remove and Install ..................................................................................................... 2
Hydraulic Pump Disassemble and Assemble ........................................................................................ 5
Hydraulic System Manifold Remove and Install .................................................................................. 10
Hydraulic System Manifold Disassemble and Assemble ..................................................................... 12
Soft Start Valve Remove and Install ................................................................................................... 13
Soft Start Valve Disassemble and Assemble ...................................................................................... 15
Hydraulic Fan Pump Remove and Install ............................................................................................ 17
Hydraulic Fan Motor Remove and Install ............................................................................................ 22
Hydraulic Fan Valve Remove and Install ............................................................................................ 24
Hydraulic Attenuator Remove and Install ........................................................................................... 27
Hydraulic Oil Tank Remove and Install ............................................................................................... 29
General Oil Cleanup Procedure ........................................................................................................... 32
Hydraulic/Hydrostatic Component Failure Cleanup Procedure ........................................................... 34

Section 21 - MAIN HYDRAULIC SYSTEM Group 2160: Hydraulic System

Vacuum Pump Installation
Vacuum Pump Installation

LEGEND:
1 Hydraulic Oil Tank Breather Hose
2 Hydraulic Oil Tank Breather Filter
JT05510 Vacuum Pump (air operated)
→NOTE:
This installation will minimize hydraulic oil leakage when disconnecting hydraulic lines.
Attach JT05510 Vacuum Pump to open end of hydraulic oil tank breather hose (1) and apply a vacuum to the tank.
Vacuum Pump (air operated)
JT05510
Place vacuum on main hydraulic oil tank

Hydraulic Pump Remove and Install

[2] -
CAUTION:
[5] - Remove hydraulic fan pump. See Hydraulic Fan Pump Remove and Install . (Group 2160.)
[6] -
Hydraulic Pump Remove and Install

LEGEND:
1 Hydraulic Pump

3 Hydraulic Pump Case Drain-to-Hydraulic Oil Tank Hose

4 Split Flange (2 used)
5 Hydraulic Pump Supply Hose
6 Hydraulic Fan Pump-to-Hydraulic Pump Case Drain Tube
7 Hydraulic Pump Load Sense-to-Left Control Valve Hose
8 Hydraulic System Manifold-to-Hydraulic Oil Tank Return Hose
9 Transmission Charge Pump
Tag and disconnect hydraulic system manifold-to-hydraulic oil tank return hose (8). Close all openings using caps and plugs.
[7] -
CAUTION:
pressure.
Tag and disconnect hydraulic hoses (3, 5, and 7) and hydraulic fan pump-to-hydraulic pump case drain tube (6) from hydraulic
pump (1). Close all openings using caps and plugs.
[8] -
CAUTION:
Support hydraulic pump using DFT1250 Lifting Bracket, DFT1311 Extension, and appropriate lifting device. Remove cap screws
(4).
Hydraulic Pump Weight 35 kg
77 lb.
Lifting Bracket
DFT1250
Lift and balance hydraulic fan pump.
DFT1311
Extend reach of DFT1250.
[9] -
→NOTE:
The coupler connecting the transmission charge pump (9) and hydraulic pump splines may stay with the
transmission charge pump during removal of hydraulic pump.
Slide hydraulic pump rearward to separate coupler from spline of transmission charge pump.
[10] - Inspect, repair, or replace parts as necessary. If hydraulic pump repair is needed, see Hydraulic Pump Disassemble and
Assemble . (Group 2160.)
[11] -
CAUTION:
→NOTE:
Install coupler on transmission charge pump spline during hydraulic pump install.

Install hydraulic pump using DFT1250 Lifting Bracket, DFT1311 Extension, and appropriate lifting device.
Hydraulic Pump Weight 35 kg
77 lb.
Lifting Bracket
DFT1250
DFT1311
[12] - Connect hydraulic hoses and case drain tube to hydraulic pump. See Hydraulic System Component Location or see
[13] - Install fan pump. See Hydraulic Fan Pump Remove and Install . (Group 2160.)
[17] - Operate machine, verify functions, and check for leaks.
[18] - Check hydraulic pump pressure and relief settings. Hydraulic Pump Standby Pressure & Load Sense Standby Pressure
Test and see Load Sense Relief Valve & Pump Relief Test . (Group 9025-25.)

Hydraulic Pump Disassemble and Assemble
Hydraulic Pump Assembly

LEGEND:
2 Washer (4 used)
3 O-Ring (used with auxiliary drive)
4 Cap Screw (4 used with auxiliary drive)

5 Adapter Plate (auxiliary drive)

6 Coupler (4 used with auxiliary drive)
7 Plug (3 used)
8 Screw (4 used with auxiliary drive)
10 Fitting Plug (2 used)
11 O-Ring
12 Bearing Kit
13 Valve Plate
14 Rotate Group
15 Drive Shaft
16 Swashplate
17 Bearing Kit
18 Bias Piston Assembly
19 Swashplate Bearing (2 used)
20 Plug
21 O-Ring
22 O-Ring (6 used)
23 Sleeve (used with auxiliary drive)
24 Seal
25 Snap Ring
26 Snap Ring (used with auxiliary drive)
30 O-Ring
31 Control Piston Cap
32 Control Piston
33 Piston (10 used)
40 Backup Ring
41 O-Ring
42 O-Ring
48 Load Sense Control Assembly
49 Cap Screw
52 Spool
53 O-Ring
54 O-Ring (4 used)
55 Screw (4 used)
57 O-Ring (2 used)
58 Plug Fitting (2 used)
59 O-Ring (2 used)
60 Plug (2 used)
61 Spring
62 O-Ring
63 O-Ring
[1] -
LEGEND:
9 Pump End Cover
31 Control Piston Cap
34 Pump Housing
48 Load Sense Control Valve
Locating Marks on Pump

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 replace parts as necessary.
[3] - Position pump upright on table. Remove pump end cover.
[4] -

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.
LEGEND:
13 Valve Plate
32 Dowel Pin
Valve Plate and Timing Pin

[5] - Inspect valve plate for cracks or scratches. Valve plate thickness must be no less than specification.
Valve Plate Thickness (minimum) 4.950 mm
0.195 in
[6] - Remove bias piston assembly (18). Inspect and replace parts as necessary.
[7] - Remove control piston (32). Inspect for damage in the bore and on the piston. If it is damaged. Replace pump assembly.
[8] -
→NOTE:
Rotate group consists of cylinder block and pistons.
LEGEND:
14 Cylinder Block
15 Drive Shaft
33 Pistons
Rotate Group and Drive Shaft

Position pump on its side. Remove drive shaft (15) and rotate group so that pistons (33) do not come out of cylinder block (14).
[9] - Remove drive shaft from rotate group. Inspect splines for wear or damage.
[10] - Inspect rotate group. Check slippers on end of pistons for wear and excessive end play. Check cylinder block height.
Piston Slipper Thickness Thickness (minimum) 2.23 mm
0.127 in.
Slipper End Play Thickness (minimum) 0.102 mm

0.004 in.
Cylinder Block Height Thickness (minimum) 62.23 mm
2.450 in.
[11] -
→NOTE:
Mark swash plate orientation before disassembly.
Position pump upright. Remove swash plate (16).
[12] -
IMPORTANT:
Mark orientation and location of swash plate bearings before disassembly.
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).
[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.

Control Piston Plug Torque 230 N·m
170 lb-ft
[21] - Install bias piston assembly (18). Torque plug to specification.

Bias Piston Assembly Plug Torque 230 N·m
170 lb-ft
[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.
Main Hydraulic Pump End Cap-to-Pump Housing Cap Screw Torque 96 N·m
71 lb-ft
[26] -

Pump Shaft Seal

LEGEND:
1 Retaining Ring
2 Oil Seal
3 Pump Shaft
4 Pump Housing
Inspect sealing area of pump shaft and polish if required.
[27] - Apply grease to pump shaft and oil seal lips.
[28] - Install shaft seal (24) with cupped side toward shaft bearing just far enough to install retaining ring (25).
[29] - Install load sense control valve assembly (48).

Hydraulic System Manifold Remove and Install
Hydraulic System Manifold

LEGEND:
2 Washer (3 used)
3 Hydraulic System Manifold
4 Mounting Bracket
5 Mounting Stud
[4] -
CAUTION:
If equipped with secondary steering, operate steering function until front wheels stop steering to relieve the secondary steering
accumulator of stored hydraulic oil.
[5] -

CAUTION:
pressure.
To relieve pressure in the system, slowly loosen all fittings on hoses at hydraulic system manifold (3).
(Group 2160.)
[7] - Disconnect and tag all hydraulic hoses from hydraulic system manifold. See Hydraulic System Component Location or see
[8] - Remove cap screws (1) and washers (2) from mounting studs (5).
[9] - Remove hydraulic system manifold (3) and mounting bracket (4) from main frame.
[10] - Repair or replace components as needed. See Hydraulic System Manifold Disassemble and Assemble . (Group 2160.)
[11] - Install hydraulic system manifold and mounting bracket to the main frame.
[12] - Install cap screws and washers to the mounting studs.
[13] - Connect all hydraulic hoses. See Hydraulic System Component Location or see Hydraulic System Component
Location—EH Controls . (Group 9025-15.)
2160.)

Hydraulic System Manifold Disassemble and Assemble
Hydraulic System Manifold

LEGEND:
1 Plug
3 Mounting Bracket
4 Washer (4 used)
5 Isolator (3 used)
7 Saddle Lock Solenoid
8 Pressure Reducing Valve
9 Check Valve
10 Plug
11 System Relief Valve
12 Plug (2 used)
13 Plug (2 used)
[1] - Remove hydraulic system manifold (2) from machine. See Hydraulic System Manifold Remove and Install . (Group 2160.)
[2] - Remove cap screws (6) and washers (4) from hydraulic system manifold.
[3] - Remove mounting bracket (3) and isolators (5) from hydraulic system manifold.
[4] - Remove plugs (1, 10, 12, and 13), saddle lock solenoid (7), pressure reducing valve (8), check valve (9), and system relief
valve (11) as shown.
[6] - Install plugs, saddle lock solenoid, pressure reducing valve, check valve, and system relief valve as shown.
[7] - Install mounting bracket and isolators to hydraulic system manifold.
[8] - Install cap screws and washers to hydraulic system manifold.
[9] - Install hydraulic system manifold to machine. See Hydraulic System Manifold Remove and Install . (Group 2160.)

Soft Start Valve Remove and Install

→NOTE:
Soft start valve is located near the main hydraulic pump accessed through the left rear service door.
[2] -
CAUTION:
(Group 2160.)
[5] -
CAUTION:
pressure.
LEGEND:
3 Soft Start Valve
Y2 Soft Start Solenoid
Soft Start Valve

Tag and disconnect hydraulic hoses (2) at soft start valve (3). Close all openings using caps and plugs. See Hydraulic System
Component Location or see Hydraulic System Component Location—EH Controls . (Group 9025-15.)
[6] - Disconnect soft start solenoid (Y2) electrical connector (1) from midstructure harness. See Midstructure Harness (W34)
[7] - Remove cap screws (4) and remove soft start valve.
[8] - Repair or replace components as needed. See Soft Start Valve Disassemble and Assemble . (Group 2160.)
[9] - Install soft start valve to machine using cap screws.
[10] - Connect soft start solenoid.
[11] - Connect hydraulic hoses to soft start valve. See Hydraulic System Component Location or see Hydraulic System

Component Location—EH Controls . (Group 9025-15.)
[12] - Remove vacuum pump from hydraulic oil tank breather hose. See Vacuum Pump Installation . (Group 2160.)

Soft Start Valve Disassemble and Assemble
Soft Start Valve

LEGEND:
1 Solenoid Valve
2 Solenoid Coil
3 Solenoid Retaining Nut
4 Seal Kit

5 Soft Start Valve

6 Solenoid Valve Assembly
7 Solenoid Kit
8 Housing
[1] - Remove soft start valve from machine. See Soft Start Valve Remove and Install . (Group 2160.)
[2] - Remove solenoid retaining nut (3) from soft start valve (5).
[3] - Remove solenoid coil (2) from solenoid valve (1).
[4] - Remove solenoid valve from housing (8).
[5] - Inspect solenoid valve for damage, replace if scratched or damaged.
[6] - Replace seal kit (4) and install solenoid valve into housing.
[7] - Install solenoid coil over solenoid valve and install solenoid retaining nut.
[8] - Install soft start valve to machine. See Soft Start Valve Remove and Install . (Group 2160.)

Hydraulic Fan Pump Remove and Install

[2] -
CAUTION:
[5] - Remove left rear engine service door and side shield. See Engine Service Doors and Side Shields Remove and Install .
(Group 1910.)
[6] -
CAUTION:
pressure.

Rear Platform Support Remove and Install

LEGEND:
1 Steering Valve Return-to-Tank Hose
2 Park Brake Valve Return-to-Tank Hose
3 Rear Handle
5 Soft Start Valve
7 Cross Support
9 Rear Platform Left Support
Tag and disconnect steering valve return hose (1) and park brake valve return hose (2) connected to hydraulic tank. Close all
[7] - Remove rear handle (3) and cross support (7).
[8] - Remove soft start valve (5). See Soft Start Valve Remove and Install . (Group 2160.)
[9] - Support hydraulic tank and rear platform left support (9).
[10] -
Charge Air Tube and Fuel Tank Vent Remove and Install
LEGEND:
12 Fuel Tank Breather
14 Fuel Tank Breather Hose
15 Clamp

16 Clamp (4 used)
17 Coupler (2 used)
18 Charge Air Tube
19 Hydraulic Pump-to-Attenuator Hose
20 Quick Service-to-Hydraulic Oil Tank Hose
Remove fuel tank breather (12) and fuel tank breather hose (14).
[11] - Tag and disconnect hydraulic pump-to-attenuator hose (19) at hydraulic pump and quick service-to-hydraulic oil tank
hose (20) and oil tank to provide additional clearance.
[12] - Disconnect or remove charge air tube (18). If disconnected, position securely out of work area.
[13] -
Fan Pump Hoses Remove and Install

LEGEND:
21 Hydraulic Fan Pump
22 Supply Hose from Hydraulic Oil Tank
24 Split Flange (2 used)
25 Hydraulic Fan Pump-to-Hydraulic Fan Valve Load Sense Hose
26 Hydraulic Fan Pump-to-Hydraulic Fan Valve Pressure Supply Hose
27 Hydraulic Fan Pump Case Drain-to-Hydraulic Pump Case Drain Tube
Remove hydraulic hoses (22, 25, and 26) and case drain tube (27) from hydraulic fan pump (21). Close all openings using caps
and plugs.
[14] -
CAUTION:

Support hydraulic fan pump using DFT1250 Lifting Bracket, DFT1311 Extension, and appropriate lifting device. Remove cap
screws (28).
Hydraulic Fan Pump Weight 22.0 kg
48.5 lb.
Lifting Bracket
DFT1250
DFT1311
[15] -
→NOTE:
The coupler connecting the hydraulic pump and hydraulic fan pump may stay with the hydraulic pump
during removal of hydraulic fan pump.
Slide hydraulic fan pump rearward to separate spline coupler from hydraulic pump.
[16] - Replace hydraulic fan pump as necessary.
[17] - Replace hydraulic fan pump mounting face O-ring.
[18] -
CAUTION:
Install hydraulic fan pump using DFT1250 Lifting Bracket, DFT1311 Extension, and appropriate lifting device.
Hydraulic Fan Pump Weight 22.0 kg
48.5 lb.
Lifting Bracket
DFT1250
DFT1311
[19] - Connect hydraulic hoses to hydraulic fan pump. See Hydraulic System Component Location or see Hydraulic System
[20] - Install hydraulic tank support and cross supports.
[21] - Install soft start valve. See Soft Start Valve Remove and Install . (Group 2160.)
[22] - Connect steering and park brake hydraulic hoses to hydraulic tank. See Hydraulic System Component Location or see
[23] - Connect charge air tube, if removed, reinstall between cooler and turbocharger.
[24] - Install left rear engine service door and side shield. See Engine Service Doors and Side Shields Remove and Install .
(Group 1910.)

[29] - Check hydraulic fan pump pressure settings. See Hydraulic Fan Pump Pressure Test . (Group 9025-25.)

Hydraulic Fan Motor Remove and Install

[3] - Remove fan blade. See Fan Blade Remove and Install . (Group 0510.)
(Group 2160.)
[5] -
LEGEND:
1 Hydraulic Fan Motor
2 Nut (2 used)
3 Reversing Hydraulic Fan Motor Work Port Hose
4 Hydraulic Fan Motor Case Drain Hose
5 Forward Hydraulic Fan Motor Work Port Hose
B58 Hydraulic Fan Speed Electrical Sensor
Hydraulic Fan Motor Remove and Install

Tag and disconnect hydraulic fan speed electrical sensor (B58) connector.
[6] -
CAUTION:
pressure.
Tag and disconnect hydraulic fan motor work port hoses (3 and 5) and hydraulic fan motor case drain hose (4). Close all
[7] - Remove nuts (2).
[8] - Remove hydraulic fan motor (1).
[9] - Inspect and replace hydraulic fan motor as necessary.
[10] - Install hydraulic fan motor using nuts.
[11] - Connect hydraulic fan motor case drain hose and hydraulic fan motor work port hoses. See Hydraulic System

[12] - Remove vacuum pump to hydraulic oil tank to minimize hydraulic oil loss during repair. See Vacuum Pump Installation .
(Group 2160.)
[13] - Connect hydraulic fan speed electrical sensor connector. See Fan Door Harness (W31) Component Location . (Group
9015-10.)
[14] - Install fan blade. See Fan Blade Remove and Install . (Group 0510.)
[17] - Operate machine, verify hydraulic fan functions and check for leaks. See Advanced Display Unit (ADU)—Fan Speed .
(Group 9015-16.)

Hydraulic Fan Valve Remove and Install

[2] -
CAUTION:
[4] -
Fan Door
JDG1385 Snap-to-Connect® Tool

Snap-to-Connect® Tool Use on Valve Hoses

LEGEND:
2 Release Sleeve
3 Shoulder
4 JDG1385 Snap-to-Connect® (STC) Tool
(Group 2160.)
[6] -
→NOTE:
The hydraulic fan valve uses Snap-to-Connect ™ (STC) fittings. An STC tool is supplied with the vehicle
and is located on the left side of the rear platform.
To prevent damage to STC fittings, use the following steps to disconnect and connect.
a. Clean around the STC fittings.

IMPORTANT:
Do not pry against release sleeve (2) or damage to fitting could result. Do not force release sleeve
beyond normal range of travel, otherwise release sleeve could fall off when hose is disconnected. If
damaged fitting is connected without the release sleeve installed, fitting will not disconnect.
Tag hydraulic hose(s). Insert JDG1385 Snap-to-Connect (STC) Tool (4) between release sleeve (2) and shoulder (3) of
fitting.
Snap-to-Connect ™ (STC)
JDG1385
Disconnect Snap-to-Connect® Fittings.
c. Gently push, do not pry, release sleeve away from shoulder to disengage the STC fitting.
d. Pull hydraulic hose to disconnect.
e. Close all openings using caps and plugs.
[7] -
CAUTION:
pressure.
LEGEND:
5 Hydraulic Fan Valve-to-Cooler Hose
Hydraulic Fan Valve-to-Hydraulic Fan Motor Case Drain
6
Hose
Hydraulic Fan Valve-to-Hydraulic Fan Motor Reversing
7
Work Port Hose
Hydraulic Fan Valve-to-Hydraulic Fan Motor Forward
8
Work Port Hose
Hydraulic Fan Valve-to-Hydraulic Fan Pump Load Sense
9
Hose
Hydraulic Fan Valve-to-Hydraulic Fan Pump Pressure
10
Supply Hose
Y4 Hydraulic Fan Speed Solenoid Electrical Connector
Y5 Hydraulic Fan Direction Solenoid Electrical Connector
Hydraulic Fan Valve
Tag and disconnect hydraulic hoses (5—10). Close all openings using caps and plugs.
[8] - Disconnect electrical connectors for hydraulic fan speed solenoid (Y4) and hydraulic fan direction solenoid (Y5).
[10] - Remove hydraulic fan valve.
[12] - Install hydraulic fan valve using cap screws.
[13] - Connect hydraulic STC fitting hoses by pushing into fitting. Connect remaining hydraulic hose(s). See Hydraulic System
[14] - Remove vacuum pump from hydraulic oil tank. See Vacuum Pump Installation . (Group 2160.)
[15] - Connect hydraulic fan speed solenoid (Y4) and hydraulic fan direction solenoid (Y5) connectors. See Midstructure
[18] - Operate machine and verify hydraulic fan functions. Check for leaks. Perform Hydraulic Fan Motor Speed Test . (Group
9025-25.)

Hydraulic Attenuator Remove and Install

[2] -
CAUTION:
(Group 2160.)
[5] -
LEGEND:
1 Rear Access Panel
2 Front Access Panel
4 Attenuator-to-Hydraulic System Manifold Hose
5 Clamp (2 used)
6 Hydraulic Pump-to-Attenuator Hose
Bottom Access Panels
Attenuator Through Front Panel

Attenuator Through Rear Panel

Remove front access panel (2) and rear access panel (1).
[6] -
CAUTION:
pressure.
Tag and disconnect hydraulic hoses (4 and 6). Close all openings using caps and plugs.
[7] - Loosen clamps (5) and remove attenuator through front access.
[8] - Install attenuator and snug clamps to allow positioning of attenuator.
[9] - Connect hydraulic hoses, tighten clamps, and tighten hose fittings.
[10] - Install front and rear bottom access panels.
[11] - Remove vacuum pump. See Vacuum Pump Installation . (Group 2160.)

Hydraulic Oil Tank Remove and Install

[3] - Drain hydraulic oil tank. See Changing Hydraulic Tank Oil or see Changing Hydraulic Tank Oil (Quick Service)—If Equipped
. (Operator’s Manual.)
[4] - Drain cooling system. See Drain, Flush, and Refill Cooling System or see Drain, Flush, and Refill Cooling System (Quick
[5] -
LEGEND:
2 Battery Cover
Battery Cover Removal

Remove cap screws (1) and remove battery cover (2).
[7] -
→NOTE:
Coolant lines may contain coolant after cooling system has been drained. Use an appropriate container to
collect remaining coolant.
LEGEND:
Surge Tank-to-Exhaust Gas Recirculation (EGR) Coolant
3
Hose
4 Surge Tank
5 Radiator-to-Coolant Pump Tube
6 Charge Air Cooler-to-Air Throttle Valve Tube
Coolant Hoses and Charge Air Tube on Right Side of

Machine
Disconnect surge tank-to-exhaust gas recirculation (EGR) coolant hose (3) from surge tank (4). Close all openings using caps
and plugs.
[8] - Remove radiator-to-coolant pump tube (5) and charge air cooler-to-air throttle valve tube (6). Close all openings using
caps and plugs.

[9] -
LEGEND:
8 Battery Box
Battery Box Removal

Remove cap screws (7) and remove battery box (8).
[10] -
LEGEND:
9 Hydraulic Breather Hose
10 Radiator-to-Surge Tank Hose
11 Hydraulic Oil Tank
13 Surge Tank Platform
14 Hydraulic Oil Tank Bracket
16 Filter Platform
Hydraulic Oil Tank

Remove hydraulic breather hose (9) and radiator-to-surge tank hose (10) from top of hydraulic oil tank (11).
[11] - Remove cap screws (12) securing surge tank platform (13) to hydraulic oil tank bracket (14).
[12] - Remove cap screws (15) securing filter platform (16) to hydraulic oil tank bracket.
[13] - Tag and disconnect all hydraulic oil hoses from hydraulic oil tank. Close all openings using caps and plugs. See Hydraulic
System Component Location . (Group 9025-15.)
[14] -
CAUTION:

LEGEND:
17 Lifting Chain
19 Cap Screw and Spacer (6 used)
Hydraulic Oil Tank Removal

Attach lifting chains (17) and appropriate lifting device to hydraulic oil tank lifting points (18) and support as shown.
Hydraulic Oil Tank Weight (approximate) 91 kg
200 lb.
[15] - Remove cap screws and spacers (19). Remove hydraulic oil tank from rear platform.
[16] - Repair or replace hydraulic oil tank as necessary.
[17] -
CAUTION:
Install hydraulic oil tank to rear platform using spacers and cap screws.
[18] - Connect all hydraulic oil hoses to hydraulic oil tank. See Hydraulic System Component Location . (Group 9025-15.)
[19] - Install cap screws securing filter platform to hydraulic oil tank bracket.
[20] - Install cap screws securing surge tank platform to hydraulic oil tank bracket.
[21] - Install hydraulic breather hose and radiator-to-surge tank hose to top of hydraulic oil tank.
[22] - Install battery box.
[23] - Install radiator-to-coolant pump tube and charge air cooler-to-air throttle valve tube.
[24] - Connect surge tank-to-exhaust gas recirculation (EGR) coolant hose at surge tank.
[25] - Install batteries. See Removing and Replacing Batteries . (Operator’s Manual.)
[26] - Install battery cover.
[27] - Fill cooling system. See Drain, Flush, and Refill Cooling System or see Drain, Flush, and Refill Cooling System (Quick
[28] - Fill hydraulic oil tank. See Changing Hydraulic Tank Oil or see Changing Hydraulic Tank Oil (Quick Service)—If Equipped .
(Operator’s Manual.)
[30] - Start machine and inspect for leaks.

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 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.
[6] -
→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.
LEGEND:
1 Discharge Wand
2 Suction Wand
3 Oil Fill Tube
Super Caddy Installation

Install suction and discharge wands (1 and 2) from Super Caddy JDG10712 into the hydraulic oil tank through the oil fill tube
(3).
Super Caddy
JDG10712
Used to clean hydraulic oil
[7] - Seal suction and discharge wands to oil fill tube to secure wands to hydraulic oil tank and prevent contamination.
[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 ADVISOR ™ for operating procedure.
[9] - Remove super caddy wands from machine.
[10] - Install new hydraulic oil filter for cleanup procedure. See Replacing Hydraulic Oil Filter . (Operator′s Manual.)
[11] -
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.
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.)
[13] -
IMPORTANT:
Avoid additional oil contamination. Do not force the hydraulic system over system relief or over the
hydraulic oil cooler bypass.
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, install new hydraulic oil filter. See Replacing Hydraulic Oil Filter .
[17] -
→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.
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 Hydraulic Tank Oil Level . (Operator′s Manual.)

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 increases 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 of 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 filtering oil.
→NOTE:
Filter oil at 27°C (80°F) or above for best Super Caddy performance. Reduce flow rate to filter oil below
27°C (80°F).
Super Caddy requires a 20 amp electric circuit. Use of electrical extension cord is not recommended.
[2] -
CAUTION:
[4] - Remove hydraulic reservoir. See Hydraulic Oil Tank Remove and Install . (Group 2160.)
[5] -
IMPORTANT:
To prevent hydraulic system contamination, after cleaning, disassembling, and assembling each
hydraulic component, store component in a dry, dust-free area until installation.
Clean hydraulic reservoir completely.
[6] - Remove each hydraulic component from the machine. Disassemble, clean, inspect, and assemble each component,
working one circuit at a time. Repair or replace damaged components.
Hydraulic Oil Cooler— See Hydraulic Oil Cooler Remove and Install . (Group 0510.)
Hydraulic Oil Cooler Bypass Valve
Steering Valve— See Steering Wheel, Column, and Valve Remove and Install—Standard Controls or see Steering Wheel,
Column, and Valve Remove and Install—EH Controls . (Group 0960.)
Steering Cylinder— See Steering Cylinder Remove and Install . (Group 0960.)
Wheel Lean Cylinder— See Wheel Lean Cylinder Remove and Install . (Group 0960.)
Hydraulic Cylinder Repair— See Hydraulic Cylinder Disassemble and Assemble . (Group 0960.)
Service Brake Valve— See Service Brake Valve Remove and Install . (Group 1060.)
Brake Accumulator— See Brake Accumulator Remove and Install . (Group 1060.)
Hydraulic Fan Pump— See Hydraulic Fan Pump Remove and Install . (Group 2160.)
Hydraulic Pump— See Hydraulic Pump Remove and Install . (Group 2160.)
Soft Start Valve— See Soft Start Valve Remove and Install . (Group 2160.)
Hydraulic System Manifold— See Hydraulic System Manifold Remove and Install . (Group 2160.)
Hydraulic Oil Filter Bypass Valve
Hydraulic Fan Valve— See Hydraulic Fan Valve Remove and Install . (Group 2160.)
Hydraulic Fan Motor— See Hydraulic Fan Motor Remove and Install . (Group 2160.)
Hydraulic Attenuator— See Hydraulic Attenuator Remove and Install . (Group 2160.)
Saddle Locking Cylinder— See Saddle Locking Cylinder Remove and Install . (Group 3440.)
Circle Rotate Motor— See Circle Drive Gearbox Remove and Install and see Circle Rotate Motor Disassemble and
Rotary Manifold— See Rotary Manifold Remove and Install . (Group 3460.)
Grader Control Valve— See Grader Control Valve Remove and Install . (Group 3460.)
Blade Lift, Blade Pitch, and Circle Side Shift Cylinders— See Blade Lift, Blade Pitch, and Circle Side Shift Cylinders Remove
Blade Side Shift Cylinder— See Blade Side Shift Cylinder Remove and Install . (Group 3460.)
Articulation Cylinders— See Articulation Cylinders Remove and Install . (Group 3460.)
Optional Equipment
Left and Right 6WD Pump (if equipped)— See 6WD Pump Remove and Install . (Group 0260.)
6WD Charge Pump— See 6WD Charge Pump Remove and Install . (Group 0260.)
6WD Engagement Manifold (if equipped)— See 6WD Engagement Manifold Remove and Install . (Group 0260.)
Left and Right 6WD Motor (if equipped)— See 6WD Motor Remove and Install and see 6WD Motor Disassemble and
EH Controls Steering Canceling Valve (if equipped)— See EH Controls Steering Canceling Valve Remove and Install .
(Group 0960.)
Secondary Steering Accumulator (if equipped)— See Secondary Steering Accumulator Remove and Install—If Equipped .
(Group 0960.)
EH Grader Control Valve (if equipped)— 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.)
Midmount Scarifier Cylinder (if equipped)— See Midmount Scarifier Cylinder Remove and Install . (Group 4240.)
Ripper Cylinders (if equipped)— See Ripper Cylinders Remove and Install . (Group 4240.)
Auxiliary Hydraulic Attachments (if equipped)
[7] -
IMPORTANT:
Debris trapped and then later dislodged from oil coolers can cause premature hydraulic/hydrostatic
component failure. If system contains a large amount of debris, oil cooler cannot be completely cleaned
of contamination and must be replaced.
Replace hydraulic oil cooler when required. See Hydraulic Oil Cooler Remove and Install . (Group 0510.)
[8] -
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.
Disconnect and tag all hydraulic/hydrostatic hoses and lines. Close all openings using caps and plugs. See Hydraulic System
[9] - Clean all hydraulic lines and hoses using JDG1770 Ultra Clean Hose Kit.
Ultra Clean Hose Kit
JDG1770
For use in cleaning Hydraulic hoses.
IMPORTANT:
Airborne debris can cause premature hydraulic/hydrostatic component failure. Close all openings with
caps and plugs to minimize additional contamination.
[10] -
→NOTE:
During installation, fill hydraulic components, hoses, and lines with clean hydraulic oil where possible to
prevent a dry start-up.
Install a new hydraulic oil filter. See Replacing Hydraulic Oil Filter . (Operator′s Manual.)

GRADING DEVICE (g) by Belgreen v2.0
[11] - Install new hydraulic tank breather filter. See Replacing Rear Axle Breather Filter and Hydraulic Tank Breather Filter .
[12] -
IMPORTANT:
Damage to 6WD pump will result if engine is started without oil in 6WD pump case.
Fill 6WD pump case with oil (if equipped). See 6WD Start-Up Procedure . (Group 9016-20.)
[13] - With all components installed, fill hydraulic oil tank to proper operating level. See Changing Hydraulic Tank Oil .
[14] -
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.
Remove remaining air from hydraulic system. Slowly operate all hydraulic functions without holding over relief valves.
[15] -
CAUTION:
Escaping fluid under pressure can penetrate the skin causing serious injury. Tighten all connections
before applying pressure. Search for leaks with a piece of cardboard. Protect hands and body from high
pressure fluids.
Inspect for leaks.
[16] - Stop machine and remove residual oil contaminants from hydraulic oil tank using JDG10712 Super Caddy III. See General
Oil Cleanup Procedure . (Group 2160.)
Super Caddy III
JDG10712
Used to clean hydraulic oil.

Section 34 - GRADING DEVICE

Table of contents
Group 3415 - Controls Linkage .............................................................................................................. 1
Control Linkage Remove and Install ..................................................................................................... 1
Group 3440 - Frames ............................................................................................................................... 3
NeverGrease™ Pin Joints ...................................................................................................................... 3
Lift Arms Remove and Install ................................................................................................................ 7
Saddle Locking Cylinder Remove and Install ...................................................................................... 11
Saddle Lock Cylinder Disassemble and Assemble .............................................................................. 14
Saddle Frame Remove and Install ...................................................................................................... 16
Blade Pitch Frame Remove and Install ............................................................................................... 18
Draft and Circle Frame Remove and Install ........................................................................................ 22
Circle Adjustment ............................................................................................................................... 26
Blade Side Shift Wear Inserts Remove and Install .............................................................................. 32
Group 3450 - Circle Gearbox ................................................................................................................ 34
Circle Drive Gearbox Remove and Install ........................................................................................... 34
Dual Input Circle Drive Gearbox Remove and Install—If Equipped ..................................................... 36
Circle Drive Gearbox Disassemble and Assemble .............................................................................. 39
Circle Drive Gearbox (With Slip Clutch) Disassemble and Assemble .................................................. 44
Dual Input Circle Drive Gearbox Disassemble and Assemble—If Equipped ........................................ 59
Dual Input Circle Drive Gearbox (With Slip Clutch) Disassemble and Assemble—If Equipped ............ 64
Circle Rotate Motor Disassemble and Assemble ................................................................................. 69
Circle Rotate Sensor Remove and Install ............................................................................................ 84
Group 3460 - Hydraulic System ........................................................................................................... 88
Grader Control Valve Remove and Install ........................................................................................... 88
Draft Frame Mount Grader Control Valve Remove and Install—EH Controls ...................................... 92
Cab Mount Grader Control Valve Remove and Install—EH Controls ................................................... 95
Grader Control Valve Disassemble and Assemble .............................................................................. 97
Midmount Scarifier Valve Section Disassemble and Assemble ......................................................... 101
Midmount Scarifier Valve Section Disassemble and Assemble—EH Controls ................................... 103
Blade Lift Valve Section Disassemble and Assemble ........................................................................ 105
Blade Lift Valve Section Disassemble and Assemble—EH Controls .................................................. 107
Auxiliary (With Float) Valve Section Disassemble and Assemble ..................................................... 109
Auxiliary (Without Float) Valve Section Disassemble and Assemble ................................................ 111
Auxiliary Valve Section Disassemble and Assemble—EH Controls ................................................... 113
Wheel Lean, Articulation, Circle Side Shift, Blade Pitch, and Blade Side Shift Valve Section Disassemble
and Assemble ............................................................................................................................ 115
Wheel Lean, Articulation, Circle Side Shift, Blade Pitch, Blade Side Shift, and Steering Valve Section
Disassemble and Assemble—EH Controls ................................................................................. 117
Circle Rotate Valve Section Disassemble and Assemble .................................................................. 119
Circle Rotate Valve Section Disassemble and Assemble—EH Controls ............................................. 121
Return Check Poppets Disassemble and Assemble .......................................................................... 122
Rotary Manifold Remove and Install ................................................................................................. 124
Rotary Manifold Disassemble and Assemble .................................................................................... 127
Blade Lift, Blade Pitch, and Circle Side Shift Cylinders Remove and Install ...................................... 130
Blade Side Shift Cylinder Remove and Install ................................................................................... 132
Articulation Cylinders Remove and Install ........................................................................................ 134

Section 34 - GRADING DEVICE Group 3415: Controls Linkage
Group 3415 - Controls Linkage

Control Linkage Remove and Install
Control Linkage Exploded View

LEGEND:
1 Linkage Rod Cap Screw (8 used)
2 Control Lever Retaining Cap Screw (2 used)
3 Washer (2 used)
4 Bushing (16 used)
5 Control Lever (8 used)
6 Control Lever Mounting Rod
7 Control Linkage Rod
→NOTE:
Standard control levers shown. Auxiliary control levers will be mounted to the outside of the standard
control levers. Removal and installation of auxiliary control levers is the same.
[4] - Remove linkage rod cap screws (1) from control levers (5) and linkage rods (7) being removed.
[5] - For removal of linkage rods from control valve, see Grader Control Valve Remove and Install . (Group 3460.)
[6] - Remove control lever retaining cap screw (2) and washer (3).
[7] - Remove bushings (4) and control levers from control lever mounting rod (6).
[9] - Install control levers and bushings as shown.
[10] - Install control lever cap screw and washer on control lever mounting rod.

Section 34 - GRADING DEVICE Group 3440: Frames
[11] - Connect linkage rods to control levers with linkage rod cap screws.
[12] - If removed, connect linkage rods to control valve. See Grader Control Valve Remove and Install . (Group 3460.)
[13] - Remove frame articulation lock pin.

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 such as “bearing type” it will be called out specifically.
Cleanliness
Cleanliness is very critical. The bushing must be kept clean at all times. Nothing should come in contact 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
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.
Installing Bushing

Bushing Type Joint
Bushing Type Joint with External Split Seal (optional type seals shown)
LEGEND:
1 Boss
2 Bushing
3 Disk
4 Hydraulic Puller Rod
6 Frame
7 Clearance
8 Split Seal (as required)
9 Pin
10 Internal Bushing Seal
Removal and Replacement of Bushings
IMPORTANT:
Only use a hydraulic puller for removal and installing bushing. Never use slide hammer or impact type
puller.
Shimming is required where specified. Some joints are more critical and will be specified when required.
Alignment in the joint is important to prevent premature wear.

[1] - Remove the old bushing from bore with Hydraulic Puller Set D01047AA or Hydraulic Press D01013AA for larger bushings.
Hydraulic Puller Set
D01047AA (17 1/2 and 30 Ton)
To remove and install steering cylinder bushings.
Hydraulic Press
D01013AA (100 Ton)
To remove and install larger bushings if required
[2] - Clean up bores thoroughly.
[3] - Check to make sure bore and bushing are perfectly clean and dry. Do not apply lubrication to any components in joint.
[4] - Measure bore I.D. for size to determine what disk (3) size will be required for installation of bushing. It must pass through
the bore I.D. for proper centering in frame bore with a hydraulic puller.
[5] -
IMPORTANT:
No lubrication should be used on any components of joint including pin. This may decrease life of joint.
Assemble Hydraulic Puller Set D01047AA and rod (4) through center of bushing and bore and attach proper size disk (3).
Support tooling to not come in contact with bushing surfaces.
[6] -
IMPORTANT:
Must have the bushing aligned square to the bore while installing. This will keep from having
misalignment in bore and damage to bushing.
Make sure the bushing (2) is square to the bore. With hydraulic puller install bushing into bore or frame. Keep perfectly square
and aligned to bore while installing. Center bushing in bore by pulling slightly past face of boss. Check each side to make sure
bushing is centered in bore.
[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.
Bearing Type Joint (roller bearing) Clearance (maximum total of both sides) 1 mm
.040 in
[10] -
IMPORTANT:
No lubrication should be used on any parts of joint including pin. This may decrease life of joint.
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.

Lift Arms Remove and Install
Lift Arms
LEGEND:
1 Saddle Locking Bar Cap Screw (4 used)
2 Saddle Locking Bar Washer (4 used)
3 Left Lift Arm
4 Yoke Retainer Cap Screw (4 used)
5 Yoke Retainer Washer (4 used)
6 Yoke Retainer (2 used)
8 O-Ring (2 used)
9 Seal (4 used)
10 Rear Yoke Bushing (2 used)
11 Front Yoke Bushing (2 used)
12 O-Ring (2 used)
14 Blade Lift Yoke (2 used)

15 Saddle-to-Lift Arm Pin (2 used)

16 Saddle-to-Lift Arm Pin Cap Screw (2 used)
17 Saddle-to-Lift Arm Pin Washer (4 used)
18 Saddle Mounting Pin
19 Saddle-to-Lift Arm Pin Nut (2 used)
20 Saddle Bushing (4 used)
21 Saddle-to-Lift Arm Seal (4 used)
22 Saddle
23 Saddle Locking Bar Ball
24 Saddle Locking Bar Seal (4 used)
25 Saddle Locking Bar Bushing (2 used)
26 Saddle Locking Bar Pin
27 Saddle Locking Bar
28 Right Lift Arm
29 Saddle Position Indicator
30 Saddle Position Indicator Nut
[3] - Retract saddle locking pin.
[5] - Remove circle side shift cylinder. See Blade Lift, Blade Pitch, and Circle Side Shift Cylinders Remove and Install . (Group
3460.)
[6] -
CAUTION:
Use an appropriate lifting device to support saddle locking bar (27) during removal.
Saddle Locking Bar Weight (approximate) 50 kg
110 lb.
[7] - Remove saddle locking bar cap screws (1), saddle locking bar ball (23), saddle locking bar pin (26) and saddle locking bar
(27). See NeverGrease™ Pin Joints . (Group 3440.)
[8] -
CAUTION:
Use an appropriate lifting device to support left and right lift arms (3 and 28).
Left or Right Lift Arm Weight (approximate) 132 kg
291 lb.
[9] - Remove blade lift cylinders. See Blade Lift, Blade Pitch, and Circle Side Shift Cylinders Remove and Install . (Group 3460.)
[10] -
CAUTION:

Use an appropriate lifting device to support yokes (14) during removal.

Blade Lift Yoke Weight (approximate) 26 kg
57 lb.
[11] - Remove yoke retainer cap screws (4), yoke retainer (6) and yoke (14) as shown. See NeverGrease™ Pin Joints . (Group
3440.)
[12] -
CAUTION:
Use an appropriate lifting device to support saddle-to-lift arm pins (15) during removal.
Saddle Arm Pin Weight (approximate) 32 kg
70 lb.
[13] - Remove saddle-to-lift arm pin cap screws (16) and saddle-to-lift arm pin nuts (19).
[14] - Remove saddle-to-lift arm pins (15), and lift arms (3 and 28). See NeverGrease™ Pin Joints . (Group 3440.)
[16] - If removed, install front and rear yoke bushings (11 and 10) to specified depth on both lift arms. See NeverGrease™ Pin
Joints . (Group 3440.)
Front Yoke Bushing Installation Depth 8.4—10.4 mm
0.33—0.41 in.
Rear Yoke Bushing Installation Depth 8.4—10.4 mm
0.33—0.41 in.
[17] - If removed, install saddle bushings (20) to specified depth on both saddle arms. See NeverGrease™ Pin Joints . (Group
3440.)
Saddle Bushing Installation Depth 7.5—9.5 mm
0.30—0.37 in.
[18] - Install lift arms (3 and 28), saddle-to-lift arm seals (21), and saddle-to-lift arm pins (15). See NeverGrease™ Pin Joints .
(Group 3440.)
[19] - Install saddle-to-lift arm pin cap screws (16), saddle-to-lift arm pin washers (17), and saddle-to-lift arm pin nuts (19) as
shown.
[20] - Install thrust washers (13), O-rings (12), and seals (9) on both yokes (14).
[21] - Install yokes (14) in saddle arms (3 and 28). See NeverGrease™ Pin Joints . (Group 3440.)
[22] - Install seals (9), thrust washers (7), O-rings (8), retainers (6), washers (5) and cap screws (4) to yoke (14), as shown. See
NeverGrease™ Pin Joints . (Group 3440.)
[23] - Install blade lift cylinders. See Blade Lift, Blade Pitch, and Circle Side Shift Cylinders Remove and Install . (Group 3460.)
[24] - If removed, install saddle locking bar bushings (25) to specified depth. See NeverGrease™ Pin Joints . (Group 3440.)
Saddle Locking Bar Bushing Installation Depth 10.5—12.5 mm
0.41—0.49 in.
[25] - Install saddle locking bar seals (24) into saddle locking bar (25) bushing holes.

[26] - Apply a heavy coat of PM37566 Anti-Seize Lubricant (silver grade) or an equivalent to saddle locking bar holes.
Number Name Use

• PM37566 (us)
[27] - Install saddle locking bar ball (23), saddle locking bar pin (26) and saddle locking bar (27) to lift arms as shown. See
NeverGrease™ Pin Joints . (Group 3440.)
[28] - Install saddle locking bar cap screws (1) and saddle locking bar washers (2).
[29] - Install circle side shift cylinders. See Blade Lift, Blade Pitch, and Circle Side Shift Cylinders Remove and Install . (Group
3460.)
[32] - Lock saddle locking bar pin in center hole of saddle locking bar.
[33] - Install saddle position indicator (29) on right lift arm (28). Point indicator to middle drill point on saddle (22). Adjust
saddle position indicator nut (30) to specified clearance.
Rear Face of Saddle-to-Indicator Clearance 6.4—9.5 mm
0.25—.0375 in.
[34] - Calibrate machine sensors (GP machines only). See Display Unit—Main Menu—Machine Configuration (Grade Pro
Machines Only) . (Operator′s Manual.)

Saddle Locking Cylinder Remove and Install
Saddle Locking Cylinder

LEGEND:
1 Saddle
2 Saddle Locking Cylinder Bracket
4 Saddle Locking Cylinder
5 Saddle Locking Cylinder Cap Screws (6 used)
6 Saddle Locking Cylinder Bracket Washers (6 used)
7 Saddle Locking Cylinder Bracket Cap Screws (6 used)
[3] - Retract saddle locking pin.

[5] -
CAUTION:
pressure.
To relieve pressure in the system, slowly loosen fittings on hoses at saddle locking cylinder (4).
(Group 2160.)
[7] - Label and disconnect hydraulic hoses at saddle locking cylinder. Cap and plug all openings. See Hydraulic System
Component Location or see Hydraulic System Component Location—EH Controls for hydraulic line location. (Group 9025-15.)
[8] - Disconnect saddle locking pin indicator switch (S11). See Front Platform Harness (W25) Component Location for switch
location. (Group 9015-10.)
[9] -
CAUTION:
Use an appropriate lifting device to support saddle locking cylinder bracket (2) and saddle locking cylinder assembly during
removal.
Saddle Locking Cylinder Bracket Weight (approximate) 50 kg
110 lb.
Saddle Locking Cylinder (approximate) Weight 12 kg
26 lb.
Saddle Locking Cylinder and Bracket Combined Weight (approximate) 72 kg
136 lb.
[10] - Remove saddle locking cylinder bracket cap screws (7) and washers (6).
[11] - Remove saddle locking cylinder bracket and cylinder from machine.
[12] - Remove saddle locking cylinder cap screws (5).
[13] -
→NOTE:
Note number and position of shims for ease of assembly.
Remove saddle locking cylinder and shims (3) from saddle locking cylinder bracket.
[15] - Install saddle locking pin cylinder and shims to saddle locking cylinder bracket.
[16] - Install saddle locking cylinder cap screws.
[17] - Connect hydraulic lines and electrical connector to saddle lock pin cylinder. See Hydraulic System Component Location
or see Hydraulic System Component Location—EH Controls for hydraulic line location. (Group 9025-15.) See Front Platform
Harness (W25) Component Location for switch location. (Group 9015-10.)
[18] - Tighten rear then front saddle locking bracket cap screws to initial torque specification. Repeat sequence and tighten to
final torque specification.

Saddle Locking Bracket Cap Screws Initial Torque 28 N·m
21 lb-ft
Final Torque 229 N·m
169 lb-ft
[19] -
Saddle Locking Pin Gap

LEGEND:
4 Saddle Locking Cylinder
8 Saddle Locking Bar Pad
9 Saddle Locking Cylinder-to-Saddle Locking Bar Pad Gap
Measure distance between saddle locking cylinder (4) and saddle locking bar pad (8). Add or remove shims (3) as required.
Saddle Locking Cylinder-to-Saddle Locking Bar Pad Gap (9) Distance 0.3—2 mm
0.01—0.08 in.
9025-25.)

Saddle Lock Cylinder Disassemble and Assemble

Specifications
SPECIFICATIONS
O-Ring Port From Center of Saddle Lock Cylinder Indicator Switch Distance 58—78°
14—54 N·m
Saddle Lock Cylinder Indicator Switch Torque
10—40 lb.-ft.
Other Material
OTHER MATERIAL
PM37418 Loctite ™ U.S. Thread Lock and Sealer (medium strength)
[1] -
Saddle Lock Cylinder Components

LEGEND:
1 Barrel
2 Lubrication Fitting
3 Pin
4 Wear Ring (2 used)
5 Piston Seal
6 O-Ring
7 O-Ring
9 Locking Pin Housing
10 Washer (6 used)
12 Saddle Lock Cylinder Indicator Switch
Remove saddle lock cylinder indicator switch (12) from locking pin housing (9).
[2] - Remove locking pin housing (9) from barrel (1).
[3] - Remove pin (3) from barrel (1).
[4] - Remove wear rings (4), piston seal (5), and O-rings (6 and 7).
[5] - Clean parts in a suitable solvent. Dry parts.

[6] - Apply clean hydraulic oil and install wear ring, piston seal, and O-rings.
[7] - Install pin into barrel with large chamfer on pin towards outside of barrel.
[8] - Apply PM37418 Thread Lock and Sealer (medium strength) to threads of barrel and locking pin housing.
Number Name Use

• PM37418 Loctite ™ (us) Thread Lock and Sealer (medium strength) Apply to threads of lock pin housing and barrel.
[9] - Install and tighten barrel against housing.
[10] -
LEGEND:
12 Saddle Lock Cylinder Indicator Switch
14 O-Ring Port
15 O-Ring Port Alternate Location
O-Ring Port and Saddle Lock Cylinder Indicator Switch

Loosen barrel the minimum amount so O-ring port (14) is 58—78° from center of saddle lock cylinder indicator switch (12).
O-Ring Port From Center of Saddle Lock Cylinder Indicator Switch Angle 58—78°
[11] - Adjust shims for saddle lock cylinder indicator switch so saddle lock indicator will light when pin is disengaged and not
light when pin is engaged.
[12] - Tighten switch to specification so terminals are parallel to flange on locking pin housing.
Saddle Lock Cylinder Indicator Switch Torque 14—54 N·m
10—40 lb.-ft.

Saddle Frame Remove and Install
Saddle Frame
LEGEND:
1 Saddle Frame
3 Washer (2 used)
4 Saddle Pin
[1] - Remove lift arms. See Lift Arms Remove and Install . (Group 3440.)
[2] - Remove saddle locking cylinder. See Saddle Locking Cylinder Remove and Install . (Group 3440.)
[3] -
CAUTION:

Use an appropriate lifting device to support saddle frame (1) during removal.
Saddle Frame Weight (approximate) 109 kg
240 lb.
[4] - Remove caps screws (2) and washers (3) from saddle pin (4) and saddle frame.
[5] - Remove saddle frame from machine.
[6] -
CAUTION:
Use an appropriate lifting device to support saddle pin during removal.

Saddle Pin Weight (approximate) 44 kg
97 lb.
[7] - Remove saddle pin from main frame.
[9] - Install saddle pin to main frame.
[10] - Lift saddle frame onto machine. Mate saddle frame to saddle pin.
[11] - Install cap screws and washers. Tighten to specification.

Saddle Pin Cap Screw Torque 1700 N·m
1255 lb.-ft.
[12] - Install saddle locking cylinder. See Saddle Locking Cylinder Remove and Install . (Group 3440.)
[13] - Install lift arms. See Lift Arms Remove and Install . (Group 3440.)

Blade Pitch Frame Remove and Install
Blade Pitch Frame

LEGEND:
2 Washer (2 used)
3 Spacer (2 used)

4 Pin (2 used)
5 Bushing (6 used)
6 Circle Frame
7 Spacer (6 used)
8 Spacer (8 used)
9 Spacer (2 used)
10 Washer (2 used)
11 Nut (2 used)
12 Pin
13 Spacer
14 Washer
15 Cap Screw
16 Blade Pitch Cylinder
18 Washer (12 used)
19 Wear Insert Retaining Plate (4 used)
20 Wear Insert
22 Washers (6 used)
23 Blade Retainer (2 used)
24 Pin
25 Spacer
26 Washer
27 Cap Screw
28 Shims (as required)
30 Pin
31 Moldboard
32 Blade Pitch Frame
33 Pin
34 Spacer
35 Washer
36 Cap Screw
37 Blade Side Shift Cylinder
[1] - Move draft frame and moldboard (31) to one side to allow for easier access to blade pitch frame. Lower all attachments to
ground.
[4] -
CAUTION:
Use an appropriate lifting device to support moldboard (31) during removal.

Moldboard Weight (approximate) 953 kg
2100 lb.
[5] - Remove blade side shift cylinder (37) from machine. See Blade Side Shift Cylinder Remove and Install . (Group 3460.)
[6] -
→NOTE:
Note the number and position of shims (28) to aid in assembly.
Remove retainers (23) and shims (28) from blade pitch frame (32).
[7] - Remove moldboard (31) from pitch frame (32).
[8] - Remove blade pitch cylinder (16) from machine. See Blade Lift, Blade Pitch, and Circle Side Shift Cylinders Remove and

[9] -
CAUTION:
Avoid crushing injury. Use lifting device.
Use an appropriate lifting device to support blade pitch frame (32) during removal.
Blade Pitch Frame Weight (approximate) 245 kg
540 lb
[10] -
→NOTE:
Note the number and position of washers (2 and 10) and spacers (3, 7, 8, and 9) to aid in assembly.
Remove cap screws (1), lock nuts (11), washers (2 and 10), spacers (3, 7, 8, and 9), and pin (4) holding blade pitch frame (32)
to circle frame (6). See NeverGrease™ Pin Joints . (Group 3440.)
[11] - Remove blade pitch frame (32) from circle frame (6).
[12] - Repair or replace components as required.
[13] - Install bushing to specified depth. See NeverGrease™ Pin Joints . (Group 3440.)
Bushing Depth Flush—1.5 mm
Flush—0.06 in.
[14] -
→NOTE:
Spacers (7) are used to center the tilt frame between the circle frame. Spacers (8) are used to reduce the
excess play in the pins (4). Shims and washers should be able to rotate freely.
Install pin (4) through circle frame, spacers (7), tilt frame and spacers (8). See NeverGrease™ Pin Joints . (Group 3440.)
[15] - Install cap screws (1), washers (2), spacers (3), spacers (9), washers (10), and nuts (11). Tighten to specification.
Blade Pitch Frame-to-Circle Frame Cap Screw Nut Torque 800 Nm
590 lb-ft
[16] - Install blade pitch cylinder. See Blade Lift, Blade Pitch, and Circle Side Shift Cylinders Remove and Install . (Group 3460.)
[17] - Place moldboard onto tilt frame and install retainer and cap screws.
[18] -
CAUTION:
Use an appropriate lifting device to support moldboard (31) during installation.

Moldboard Weight (approximate) 953 kg
2100 lb.
[19] - Place moldboard on lower wear inserts.

[20] - Install retainers (23) and shims (28) on to blade pitch frame (32).
[21] - Install cap screws (21).
[22] - Install blade side shift wear inserts. See Blade Side Shift Wear Inserts Remove and Install . (Group 3440.)

Draft and Circle Frame Remove and Install
Draft and Circle Frame Removed

LEGEND:
2 Bushing (18 used)
5 Draft Frame Retainer

6 Washer (6 used)
9 Draft Frame Retainer
10 Draft Frame
11 Circle Frame
12 Shims (as required)
13 Vertical Wear Strip (15 used)
14 Circle Support
15 Horizontal Wear Strip (6 used)
16 Wear Strip Retainer (6 used)
17 Wear Strip Retainer Washer (12 used)
18 Wear Strip Retainer Cap Screw (12 used)
19 Support-to-Draft Frame Cap Screw (12 used)
20 Support-to-Draft Frame Washer (12 used)
[1] - Remove moldboard and blade pitch frame. See Blade Pitch Frame Remove and Install . (Group 3440.)
[2] -
CAUTION:
Use an appropriate lifting device to support circle frame (11) during removal.
Circle Frame Weight (approximate) 990 kg
2183 lb.
[3] - Remove support-to-draft frame cap screws (19) and circle supports (14).
[4] - Remove circle frame (11) from machine.
[5] -
CAUTION:
pressure.
To relieve pressure in the system, slowly loosen fittings all hydraulic lines on the draft frame.
(Group 2160.)
[7] - Disconnect and tag all hydraulic lines from draft frame. Cap and plug all openings. See Hydraulic System Component
Location or see Hydraulic System Component Location—EH Controls . (Group 9025-15.)
[8] - If equipped—disconnect electrohydraulic (EH) draft frame harness (W40) from main frame harness (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 Control Valve Remove and
Install—EH Controls . (Group 3460.)
[10] - Remove rotary manifold. See Rotary Manifold Remove and Install . (Group 3460.)
[11] - Remove circle drive gearbox and rotate motor. See Circle Drive Gearbox Remove and Install . (Group 3450.)
[12] -

CAUTION:
Use an appropriate lifting device to support draft frame (10) during removal.
Draft Frame Weight (approximate) 1155 kg
2550 lb.
[13] - Remove blade lift and blade side shift cylinders. See Blade Lift, Blade Pitch, and Circle Side Shift Cylinders Remove and
[14] -
→NOTE:
Note the number and position of shims (8) for ease of assembly.
Remove cap screws (3) from draft frame retainer (9).
[15] - Remove draft frame from machine.
[17] - Install shims (8) and retainer (9) to draft frame ball assembly to permit turning by hand. Lubricate assembly. Apply
PM37566 Anti-Seize Lubricant (silver grade) or an equivalent to retainer (5).
Number Name Use

• PM37566 (us)
[18] - Adjust ball assembly end play to specification. Add or remove shims (8) as required.
Draft Frame Ball Assembly Maximum End Play 1.5 mm
0.059 in.
[19] - Connect blade lift and blade side shift cylinders to draft frame. See Blade Lift, Blade Pitch, and Circle Side Shift Cylinders
Remove and Install and see Blade Side Shift Cylinder Remove and Install . (Group 3460.)
[20] - Install circle drive gearbox and rotate motor. See Circle Drive Gearbox Remove and Install . (Group 3450.)
[21] - Install rotary manifold. See Rotary Manifold Remove and Install . (Group 3460.)
[22] - If equipped—install draft frame mount grader control valve. See Draft Frame Mount Grader Control Valve Remove and
[23] - If equipped—connect electrohydraulic (EH) draft frame harness (W40). See Electrohydraulic (EH) Main Frame Harness
(W39) Component Location . (Group 9015-10.)
[24] - Connect all hydraulic lines to draft frame. See Hydraulic System Component Location or see Hydraulic System
2160.)
[26] -
CAUTION:
Use an appropriate lifting device to lift circle frame (11) into place under draft frame (10).

Circle Frame Weight (approximate) 990 kg
2183 lb.
[27] - Install circle supports (14), support-to-draft frame washers (20), and support-to-draft frame cap screws (19).
[28] -
IMPORTANT:
Prevent possible machine damage due to a misaligned circle frame. If cap screws (20) are overtightened,
support will not move when support is adjusted. If cap screws are too loose, support will move
excessively when final torque is applied.
Tighten support-to-draft frame cap screws to initial torque specification.

Support-to-Draft Frame Cap Screw (initial adjustment) Torque 41 N·m
30 lb-ft
[29] - Adjust circle position on draft frame. See Circle Adjustment . (Group 3440.)
[30] - Install moldboard and blade pitch frame. See Blade Pitch Frame Remove and Install . (Group 3440.)

Circle Adjustment
Circle Support Cross Section
Circle Drive Pinion-to-Circle Frame Distance

LEGEND:
2 Vertical Clearance
3 Circle Frame
4 Horizontal Clearance
7 Circle Support (6 used)
8 Jam Nut
9 Adjustment Cap Screw
11 Draft Frame
12 Circle Drive Pinion-to-Circle Frame Distance
13 Circle Drive Pinion
→NOTE:
It may be easier and less time consuming to replace wear strips than adjust circle. If circle adjustment is
at factory setting, replacing wear strips should adjust circle back to original specifications.

[1] - Measure the thickness of all wear strips (1 and 5) before adjusting circle clearance. If wear strips are worn to less than
minimum thickness, replace wear strips. Apply PM37421 Thread Lock and Sealer (high strength) to wear strip cap screws and
tighten to specification.
Number Name Use

• PM37421 (us)
• PM38623 (canadian) Thread Lock and Sealer (high strength) Enter the part use here.
Vertical Wear Strips (1) New Thickness 16 mm
0.63 in.
Minimum Thickness 11 mm
0.433 in.
Horizontal Wear Strips (5) New Thickness 8 mm
0.31 in.
Minimum Thickness 2 mm
0.08 in.
Vertical and Horizontal Wear Strips Torque 42 N·m
31 lb.-ft.
[2] - If all wear strips are within specification, raise blade and rotate 90° to main frame. Turn circle drive pinion (13) until a
tooth is pointed directly forward and into the root of the circle gear as shown on the drawing illustrating pinion-to-circle
distance (12).
[3] - Ensure that the circle frame (3) is rearward as far as it will go in the draft frame (11).
[4] - Measure the distance between circle drive pinion-to-circle frame (12).
[5] - Compare distance to specifications.

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).

b. Tighten support-to-draft frame cap screws (6) to initial adjustment torque.
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).
e. Tighten support-to-draft frame cap screws (6).
f. Hold adjustment cap screws (9) in place and tighten jam nuts (8).
[7] -

→NOTE:
Circle frame must be centered within the draft frame to ensure an accurate horizontal clearance
measurement.
Rear Support Location (1 of 2)

LEGEND:
3 Circle Frame
14 Locating Hole-to-Circle Dimension
15 Locating Hole
Center the circle frame (3) within the draft frame using a pry bar or C-clamps. Distance (14) from locating hole (15) to the circle
frame (3) must be within 3 mm (0.12 in.) of each other at both rear support locations.
[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:
Horizontal Clearance (4) 0.25—0.76 mm
0.010—0.030 in.
a. Loosen support-to-draft frame cap screws (6).

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.
Tighten support-to-draft frame cap screws to initial adjustment torque.

Support-to-Draft Frame Cap 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).
f. Hold adjustment cap screws (9) in place and tighten jam nuts (8).
[9] -
→NOTE:
All of the vertical clearance at the lower vertical wear strips allows for an accurate measurement of
vertical clearance (2).
Place all of the vertical clearance at the lower vertical wear strips:
a.
Circle Support Cross Section

Circle Drive Pinion-to-Circle Frame Distance
Vertical Clearance Measurement Position

LEGEND:
2 Vertical Clearance
3 Circle Frame
4 Horizontal Clearance
7 Circle Support (6 used)
8 Jam Nut
9 Adjustment Cap Screw
11 Draft Frame
12 Circle Drive Pinion-to-Circle Frame Distance
13 Circle Drive Pinion
16 Blade
Raise front of machine off of the ground using the blade lift functions. Install appropriate support device under machine to
secure front of circle frame (3) against upper vertical wear strips. See Machine Specifications for machine weight.
b. Tilt the top of the blade (16) forward. Lower the blade to push rear of circle up against upper vertical wear strips.
[10] - Measure and adjust each support individually. Add or remove shims (10) to adjust vertical clearance (2) to specification.
Vertical Clearance (2) 0.2—1.0 mm
0.01—0.04 in.
[11] -

IMPORTANT:
Prevent possible machine damage. Ensure that shims will clear circle teeth while circle is being rotated.
Check for adequate clearance between shims and circle teeth. Tighten the support-to-draft frame cap screws to specification.
Support-to-Draft Frame Cap 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 binding. If circle
binds, stop circle at the tight spot.
[13] - Adjust any supports that are binding until circle rotates freely.

Blade Side Shift Wear Inserts Remove and Install
Blade Side Shift Wear Inserts

LEGEND:
1 Blade Pitch Frame
2 Top Wear Insert Cap Screws (12 used)
3 Top Wear Insert Retaining Plate (4 used)
4 Wear Insert Adjustment Cap Screws (4 used)
5 Jam Nut (4 used)
6 Top Wear Insert (2 used)
7 Bottom Wear Insert Retaining Cap Screws (12 used)
8 Bottom Wear Insert (4 used)
→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 moldboard is too loose and there is no adjustment left in the
system.
[1] -
LEGEND:
9 Moldboard
10 Support Block (2 used)
11 Bottom Moldboard Slide Bar
12 Top Moldboard Slide Bar
Blade Side Shift Remove and Install Position

Section 34 - GRADING DEVICE Group 3450: Circle Gearbox
Rotate circle until moldboard is approximately 90° to main frame.
[2] - Slide the moldboard (9) to the approximate center of the blade pitch frame.
[3] - Center the circle side shift so the blade lift cylinders are approximately vertical with the cutting edge on the ground.
[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.
[6] - Loosen jam nut (5) and turn adjusting cap screws (4) 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 PM37566 Anti-Seize Lubricant (silver grade) to threads of cap screws (2).
Number Name Use

• PM37566 (us)
[14] - Install cap screws (2) and tighten to 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 PM37566 Anti-Seize Lubricant (silver grade) to threads of cap screws (7).
Number Name Use

• PM37566 (us)

Bottom Wear Insert Cap Screws Torque 59 N·m
43 lb-ft
[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.)

Group 3450 - Circle Gearbox

Circle Drive Gearbox Remove and Install
[4] -
LEGEND:
1 Circle Rotate Motor
3 Nut (2 used)
4 Fill Plug
5 Circle Drive Gearbox
6 Mounting Cap Screw (3 used)
7 Oil Level Plug
8 Oil Drain Plug
9 Draft Frame
10 Nut
11 Hydraulic Hoses (2 used)
Circle Drive Gearbox

Remove plugs (4, 7, and 8). Drain circle drive gearbox (5). See Drain and Refill Capacities . (Operator′s Manual.)
(Group 2160.)
[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
[7] - Remove circle rotate motor (1) from motor flange.
[8] - Remove cap screws (6) and nut (10) holding circle drive gearbox (5) to draft frame (9).
[9] -
CAUTION:
Prevent crushing injury. Use appropriate lifting device.

Circle Drive Gearbox Weight (approximate) 150 kg
330 lb
Use appropriate lifting device to remove circle drive gearbox (5) from machine.
[10] - Inspect and replace parts as necessary. See Circle Drive Gearbox Disassemble and Assemble or See Circle Drive
Gearbox (With Slip Clutch) Disassemble and Assemble . (Group 3450.)
[11] -

CAUTION:

Circle Drive Gearbox Weight (approximate) 150 kg
330 lb
Use appropriate lifting device to install circle drive gearbox (5) to machine.
[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 or see Hydraulic System
Component Location—EH Controls for circle rotate motor location. (Group 9025-15.)
2160.)

Dual Input Circle Drive Gearbox Remove and Install—If Equipped

[1] - Park machine on flat level surface, and lower all attachments to ground.
[3] - Turn battery disconnect switch to the OFF position.
[4] -
Dual Input Circle Drive Gearbox

Dual Input Circle Drive Gearbox (top view)

LEGEND:
1 Circle Rotate Motor
3 Nut (2 used)
4 Fill Plug
5 Circle Drive Gearbox
6 Mounting Cap Screw (3 used)
7 Oil Level Plug
8 Oil Drain Plug
9 Draft Frame
10 Nut
Remove plugs (4, 7, and 8). Drain circle drive gearbox (5). See Drain and Refill Capacities . (Operator′s Manual.)
(Group 2160.)
[6] - Disconnect and tag hydraulic hoses (11) from circle rotate motors (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
[7] - Remove circle rotate motors (1) from motor flanges.
[8] - Remove cap screws (6) and nut (10) holding circle drive gearbox (5) to draft frame (9).
[9] -

CAUTION:

Dual Input Circle Drive Gearbox—With Slip Clutch Weight (approximate) 173 kg
382 lb.
Dual Input Circle Drive Gearbox Weight (approximate) 164 kg
362 lb.
Use appropriate lifting device to remove circle drive gearbox (5) from machine.
[10] - Inspect and replace parts as necessary. See Dual Input Circle Drive Gearbox (With Slip Clutch) Disassemble and
Assemble—If Equipped or see Dual Input Circle Drive Gearbox Disassemble and Assemble—If Equipped . (Group 3450.)
[11] -
CAUTION:

Dual Input Circle Drive Gearbox—With Slip Clutch Weight (approximate) 173 kg
382 lb.
Dual Input Circle Drive Gearbox Weight (approximate) 164 kg
362 lb.
Use appropriate lifting device to install circle drive gearbox (5) to machine.
[12] - Secure circle drive gearbox to draft frame with cap screws (6) and 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 or see Hydraulic System
Component Location—EH Controls for circle rotate motor location. (Group 9025-15.)
2160.)

Circle Drive Gearbox Disassemble and Assemble
Circle Drive Gearbox

LEGEND:
1 Bearing Cone
2 Seal
3 Pressure Relief Fitting
4 Bearing Cone

5 Bearing Cone (2 used)

6 Bearing Cup (2 used)
7 Bearing Cup
8 Bearing Cup
9 O-Ring
10 Gear Case
11 Pinion Shaft
12 Cover
13 Worm Gear
14 Motor Flange
15 Circle Gear
22 Plug
23 Retaining Plate
25 O-Ring
26 Cap
27 Fill Plug
28 O-Ring (2 used)
29 Plug (2 used)
30 Washer (4 used)
33 Adapter
34 O-Ring
36 Circle Drive Gear Box
37 Cap Screw
39 Nut
[4] - Remove circle drive gearbox from the draft frame. See Circle Drive Gearbox Remove and Install . (Group 3450.)
[5] - Remove cap (26).
[6] -
→NOTE:
Note number and position of shims (19) to aid in assembly.
Remove cap screws (32), retaining plate (23) and shims (19) from pinion shaft (11).
[7] - Remove cap screws (32) from cover (12).
[8] -
IMPORTANT:
Prevent possible component damage. Make sure the pinion shaft does not fall out of the bottom of the
gearbox when removing the cover and bearing cone.
Install three cap screws in tapped holes in cover (12) and pull bearing cone (4) and bearing cup (7) with cover (12) from pinion
shaft (11).
[9] - Remove O-ring (9), thrust washers (24), circle gear (15) and shaft (11) with bearing cone (1).
[10] - Pull bearing cone (1) from pinion shaft (11).
[11] - Pull bearing cup (7) from cover (12) and bearing cup (8) from gear case (10).
[12] - Remove seal (2) from gear case (10).

[13] - Remove cap screws (31) and motor flange (14) from gear case (10).
[14] -
→NOTE:
Remove shims (16) and O-ring (25).
[15] - Remove worm gear (13) with bearing cones (5).
[16] - Pull bearing cones (5) from worm gear (13).
[17] - If inner bearing cups (6) are replaced, plug (22) must be tapped out of gear case (10) to drive bearing cup out.
[18] - Pull bearing cups (6) from gear case (10) and motor flange (14).
[20] - Determine worm gear (13) preload as follows:
a. Install bearing cups (6) in gear case (10) and motor flange (14).
LEGEND:
10 Housing
13 Worm Gear
b.
Install Bearing Cones on Worm Gear
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.
→NOTE:
Shims come in 0.1 mm (0.004 in.) 0.2 mm (0.008 in.) and 0.5 mm (0.020 in.) thickness.
Add or remove shims (16) to obtain specified worm gear end play.
Worm Gear End Play 0—0.125 mm
0—0.005 in.
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.

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).
[29] - Apply pipe sealant to threads of cap screws that protrude through the cover into the oil cavity of gear case.
Number Name Use

• TY9375 (us)
• TY9480 (canadian) Pipe Sealant Apply to threads of cover-to-housing cap screws.
[30] - Install O-ring (9) and cover (12) with cap screws (32). Tighten cap screws to 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.
Shaft (worn) Bearing Preload End Play 0.0675 mm
0.0025 in.
[36] - Install retaining washer (23) and cap screws (32). Tighten cap screws to 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.
Number Name Use

• TY16135 (us)
Apply to mating surfaces of cap and
• NA (canadian) ULTRA BLUE ™ RTV Silicone Form-In-Place Gasket
gearbox.
[38] -
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.
Circle Gearbox, Pinion Shaft Seal Installer
JDG1009
To install pinion shaft seal.

Install seal (2) in gear case (10) around shaft (11) from bottom of gearbox using JDG1009 Seal Installer.
JDG1009
[39] - Install circle drive gearbox to draft frame. See Circle Drive Gearbox Remove and Install . (Group 3450.)

Circle Drive Gearbox (With Slip Clutch) Disassemble and Assemble
Circle Drive Gearbox (with slip clutch)

LEGEND:
1 Bearing Cone
2 Seal
4 Bearing Cone


7 Bearing Cup
8 Bearing Cup
9 O-Ring
10 Gear Case
11 Pinion Shaft
12 Cover
13 Worm Gear
14 Motor Flange
15 Circle Gear
17 Washer (4 used)
18 Nut
22 Plug
23 Retaining Plate
25 O-Ring
26 Cover
27 Fill Plug
28 O-Ring (2 used)
29 Plug (2 used)
33 Adapter
34 O-Ring
35 Splined Hub
36 Backing Plate
37 Pressure Plate
38 Bearing Quill
42 O-Ring
44 Belleville Spring
45 Separator Plate (13 used)
46 Clutch Disk (14 used)
48 O-Ring
50 Circle Drive Gear Box
52 Cap Screw
[4] - Remove circle drive gearbox from draft frame. See Circle Drive Gearbox Remove and Install . (Group 3450.)
[5] - Remove cap screws (43) and cover (26).
[6] - Remove cap screws (32), retaining plate (23) and shims (39) from bearing quill (38).
[7] -
→NOTE:
Remove cap screws (47), bearing (4), bearing quill (38), and shims (19) from pinion shaft (11).
[9] -

IMPORTANT:
Install three cap screws (30) in tapped holes in cover (12) and pull bearing cup (7) with cover (12) from shaft (11).
[10] - Remove O-ring (9), Belleville spring (44), thrust washer (24), and pressure plate (37).
[11] - Remove separator plates (45), clutch disks (46), splined hub (35), circle gear (15), thrust washer (24), backing plate
(36), and shaft (11) with bearing cone (1).
[12] - Pull bearing cone (1) from shaft (11).
[13] - Pull bearing cup (7) from cover (12) and bearing cup (8) from gear case (10).
[14] - Remove seal (2) from gear case (10).
[15] - Remove cap screws (31) and motor flange (14) from gear case (10).
[16] -
→NOTE:
Remove shims (16) and O-ring (25).
[18] - Pull bearing cones (5) from worm gear (13).
[19] - If bearing cups (6) are replaced, plug (22) must be tapped out of gear case (10) to drive bearing cup out.
[20] - Pull bearing cups (6) from gear case (10) and motor flange (14).
a. Install bearing cups (6) in gear case (10) and motor flange (14).
LEGEND:
10 Housing
13 Worm Gear
b.
Install Bearing Cones on Worm Gear
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.
→NOTE:
Shims come in 0.1 mm (0.004 in.) 0.2 mm (0.008 in.) and 0.5 mm (0.020 in.) thickness.
Add or remove shims (16) to obtain specified worm end play.

Worm End Play 0—0.125 mm
0—0.005 in.
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).
[26] -
LEGEND:
36 Backing Plate
Install Backing Plate

Install backing plate (36).
[27] -
→NOTE:
Make sure thrust washer (24) is centered and seated on lower surface of backing plate.

LEGEND:
24 Thrust Washer
Thrust Washer
Install thrust washer (24).
[28] - Manually rotate circle gear (15) and worm gear (13) to allow circle gear to fall into position.
[29] -
LEGEND:
15 Circle Gear
Install Circle Gear

Install circle gear (15).

Motor Mounting Flange Cap Screw Torque 130 N·m
96 lb-ft
[31] -

LEGEND:
35 Splined Hub
Install Splined Hub

Install splined hub (35) with inside recessed section towards gear end of circle pinion shaft (11).
[32] -
LEGEND:
45 Plate (13 used)
Install Clutch Disks

Install Separator Plates

Install 14 clutch disks (46) and 13 separator plates (45). Starting with a clutch disk, alternate clutch disks and separator plates
during installation.
[33] -
LEGEND:
37 Pressure Plate
Install Pressure Plate

Install pressure plate (37).
[34] -
→NOTE:
Make sure thrust washer is centered and seated on lower surface of pressure plate.

LEGEND:
24 Thrust Washer
Install Thrust Washer

[35] -
LEGEND:
44 Belleville Spring
Belleville Spring
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.
Number Name Use

• TY9375 (us)
[38] - Install O-ring (9) and cover (12) with cap screws (30). Tighten cap screws to specification.
51 lb-ft
[39] -

LEGEND:
4 Bearing Cone
38 Bearing Quill
Install Bearing Cone on Bearing Quill

Determine Belleville spring (44) preload and circle pinion shaft (11) end play as follows:
a. Install bearing cone (4) on bearing quill (38).

LEGEND:
4 Bearing Cone
38 Bearing Quill
b.
Tap Quill into Position
Install bearing cone (4) and quill (38). Tap quill into position.
c. Install cap screws (47) and tighten to specification.
Quill-to-Circle Pinion Shaft Cap Screw Torque 36 N·m
27 lb-ft

d.
Measure Distance
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.
[40] -
LEGEND:
Bearing Quill Shims

Remove cap screws (47), install shim pack (19) determined in previous step under bearing quill (38).
[41] -

Tighten Cap Screws in Circular Pattern

Install cap screws (47). Tighten to specification in a circular pattern.
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

Retaining Plate-to-Circle Pinion Shaft Cap Screw Torque 70 N·m
52 lb-ft
.
[44] -
LEGEND:
4 Bearing Cone
38 Bearing Quill
Measure Bearing-to-Quill Distance

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.
[45] -

LEGEND:
39 Shim Pack (as required)
Retaining Plate Shims

Remove cap screws (32) and retaining plate (23). Install shim pack (39).
[46] -
LEGEND:
23 Retaining Plate
Retaining Plate
Install retaining plate (23).
[47] -

LEGEND:
Install Cap Screws

Install cap screws (32) and tighten to specification.
Retaining Plate-to-Circle Pinion Shaft Cap Screw Torque 70 N·m
52 lb-ft
[48] -
LEGEND:
42 O-Ring
Install O-Ring
Install O-ring (42).
[49] -

LEGEND:
26 Cover
Install Cover
Position cover (26) on gear case as shown.

Cover-to-Cover Cap Screw Torque 40 N·m
30 lb-ft
[51] -
LEGEND:
2 Oil Seal
10 Gear Case
Install Seal in Housing

Install seal (2) in gear case (10) with JDG1009 seal installer until seal is seated flush with edge of gear case.
JDG1009
[52] - Install circle drive gearbox to draft frame. See Circle Drive Gearbox Remove and Install . (Group 3450.)


Dual Input Circle Drive Gearbox Disassemble and Assemble—If Equipped
Dual Input Circle Drive Gearbox

LEGEND:
1 Dual Input Circle Drive Gearbox
2 Gear Case
3 Bearing Cup
4 Bearing Cone

5 Pinion Shaft
6 Seal
8 Driven Gear
9 Cover
10 O-Ring
11 Shim
12 Shim
13 Shim
14 Bearing Cup
15 Bearing Cone
16 Retaining Washer
18 Cap
19 O-Ring
20 Fitting
21 Adapter Fitting
23 Bearing Housing (2 used)
24 O-Ring (4 used)
28 Worm Gear (2 used)
29 Shim (2 used)
30 Shim (2 used)
31 Shim (2 used)
32 Flange (2 used)
33 O-Ring (2 used)
35 Serial Number Plate
36 Pin Fastener (2 used)
37 Washer (4 used)
39 Cap Screw
40 Nut
Disassemble
[4] - Remove circle drive gearbox from the draft frame. See Dual Input Circle Drive Gearbox Remove and Install—If Equipped .
(Group 3450.)
[5] - Remove cap (18).
[6] - Remove cap screws (17) from cover (9) and retaining washer (16), and remove retaining washer from pinion shaft (5).
[7] -
IMPORTANT:
Install three cap screws in tapped holes in cover and pull bearing cone (15) and bearing cup (14) with cover from pinion shaft.
[8] -
→NOTE:
Note number and position of shims (11—13) to aid in assembly.
Remove shims (11—13), thrust washers (7), worm gear (28), and shaft (5) with bearing cone (4).

[9] - Pull bearing cone (4) from pinion shaft.
[10] - Pull bearing cup (14) from cover and pull bearing cup (3) from gear case (2).
[11] - Remove seal (6) from gear case.
[12] - Remove cap screws (25) and motor flanges (32) from gear case.
[13] -
→NOTE:
Remove cap screws (25) and flange (32).
[14] - Remove shims (29—31) and O-rings (24).
[16] - Pull bearing cones from worm gears.
[17] - Remove bearing housing (23) and O-ring (24).
Assemble
a. Install bearing cups (26) in bearing housing (23).

b. Install bearing cones (27) on worm gear (28).
c. Install bearing housing with O-ring (24) to gear case (2).
d. Install worm gear with bearing cones in gear case.
e. Position shims (29—31) removed during disassembly between bearing cup (26) and motor flange (32).
f. Install O-ring (24) on motor flange.
g. Install motor mounting flange to gear case.
h. Tighten cap screws (25) finger tight.
→NOTE:
Shims come in 0.1 mm (0.004 in.), 0.2 mm (0.008 in.), and 0.5 mm (0.020 in.) thicknesses.
Add or remove shims (29—31) to obtain specified worm gear end play.
0—0.005 in.
j. Install bearing cup (3) in gear case.
[2] - Press bearing cone (4) on pinion shaft (5).
[3] - Install pinion shaft in gear case.
[4] - Install lower thrust washer (7).
[5] - Install driven gear (8) while manually rotating driven gear and worm gear, allowing driven gear to fall into position
aligning with worm gear.

Motor Flange-to-Gear Case Cap Screw Torque 130 N·m

95 lb.-ft.
[7] - Install upper thrust washer (7) and align shims (11—13) into position.
[8] - Install bearing cup (14) into cover (9).
[9] - Apply pipe sealant to threads of cap screws that protrude through cover into oil cavity of gear case.
Number Name Use

• TY9375 (us)
• TY9480 (canadian) Pipe Sealant Apply to threads of cover-to-gear case cap screws.
[10] - Install O-ring (10) and cover with cap screws (17). Tighten cap screws to specification.
51 lb.-ft.
[11] - Place bearing cone (15) and retaining washer (16) onto shaft (5).
[12] - Pull bearing cone (15) onto pinion shaft (5) using cap screws (17) and retaining washer (16) while aligning retaining
washer holes with shims holes.
[13] - Remove cap screws (17) and retaining washer.
[14] - Check for end play with dial indicator.
[15] - Add and subtract shims as required to set bearing preload to specification.
Pinion Shaft (worn) Bearing Preload End Play 0.0675 mm
0.0025 in.
[16] - Install retaining washer and cap screws. Tighten cap screws to specification.
Retaining Washer-to-Pinion Shaft Cap Screw Torque 70 N·m
51 lb.-ft.
[17] - Apply PM37465 RTV Silicone Form-In-Place Gasket to cap (18). Install cap.
Number Name Use

• TY16135 (us)
Apply to mating surfaces of cap and
• NA (canadian) ULTRA BLUE ™ RTV Silicone Form-In-Place Gasket
gearbox.
[18] -
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.
JDG1009
Install seal (6) in gear case (2) around pinion shaft (5) from bottom of gearbox using JDG1009 Seal Installer.
JDG1009
[19] - Install dual input circle drive gearbox to draft frame. See Dual Input Circle Drive Gearbox Remove and Install—If
Equipped . (Group 3450.)


Dual Input Circle Drive Gearbox (With Slip Clutch) Disassemble and
Assemble—If Equipped
Dual Input Circle Drive Gearbox (with slip clutch)

LEGEND:
1 Dual Input Circle Drive Gearbox (with slip clutch)
2 Gear Case

3 Bearing Cup
4 Bearing Cone
5 Backing Plate
7 Driven Gear
8 Pinion Shaft
9 Seal
10 Splined Hub
12 Separator Plate (13 used)
13 Pressue Plate
14 Disk Spring
15 Cover
16 O-Ring
17 Bearing Cup
18 Bearing Cone
19 Shim
20 Shim
21 Shim
22 Bearing Quill
23 Shim
24 Shim
25 Shim
26 Retaining Plate
29 O-Ring
30 Cap
32 O-Ring
33 Fitting
34 Adapter Fitting
37 Bearing Housing (2 used)
38 O-Ring (4 used)
42 Worm Gear (2 used)
43 Shim (2 used)
44 Shim (2 used)
45 Shim (2 used)
46 Motor Mounting Flange (2 used)
47 O-Ring (2 used)
49 Serial Number Plate
50 Pin Fastener (2 used)
51 Washer (4 used)
53 Cap Screw
54 Nut
Disassemble
[4] - Remove circle drive gearbox from draft frame. See Dual Input Circle Drive Gearbox Remove and Install—If Equipped .
(Group 3450.)
[5] - Remove cap screws (31) and cap (30).
[6] - Remove cap screws (28), retaining plate (26), shims (23—25), from bearing quill (22).

[7] -
→NOTE:
Remove cap screws (27), bearing cone (18), bearing quill (22), and shims (19—21) from pinion shaft (8).
[9] -
IMPORTANT:
Install three cap screws (35) in tapped holes in cover, and pull bearing cup (17) with cover from pinion shaft.
[10] - Remove O-ring (16), disk spring (14), thrust washer (6), and pressure plate (13).
[11] - Remove separator plates (12), clutch disks (11), splined hub (10), driven gear (7), thrust washer (6), backing plate (5),
and pinion shaft (8) with bearing cone (4).
[12] - Pull bearing cone from pinion shaft.
[13] - Pull bearing cup (17) from cover and pull bearing cup (3) from gear case (2).
[14] - Remove seal (9) from gear case.
[15] - Remove cap screws (39) and motor mounting flanges (46) from gear case.
[16] -
→NOTE:
Remove shims (43—45) and O-ring (35).
[18] - Pull bearing cones from worm gear.
[19] - Remove bearing housings (37) and O-rings (38) with bearing cups (40).
[20] - Pull bearing cups from bearing housings and motor flanges.
Assemble
[1] - Determine worm gear preload as follows:
a. Install bearing cups in bearing housings and motor flanges.

b. Install bearing cones (41) on worm gear.
c. Install O-rings (38) with bearing housings to gear case (2).
d. Install worm gear with bearing cones (41) in gear case.
e. Position shims (43—45) removed during disassembly between bearing cups (40) and motor flanges.
f. Install O-rings (38) on motor flanges.
g. Install motor flanges.
h. Tighten cap screws (39) finger tight.
→NOTE:
Shims come in 0.1 mm (0.004 in.), 0.2 mm (0.008 in.), and 0.5 mm (0.020 in.) thicknesses.

Add or remove shims (43—45) to obtain specified worm gear end play.
0—0.005 in.
[2] - Install bearing cup (3) in gear case.
[3] - Press bearing cone (4) on pinion shaft (8).
[4] - Install pinion shaft in gear case.
[5] - Install backing plate (5).
[6] -
→NOTE:
Make sure thrust washer (6) is centered and seated on lower surface of backing plate.
[7] - Install driven gear (7) while manually rotating driven gear and worm gear, allowing driven gear to fall into position
aligning with worm gear.

Motor Mounting Flange Cap Screw Torque 130 N·m
96 lb.-ft.
[9] - Install splined hub (10) with inside recessed section towards gear end of pinion shaft.
[10] - Install clutch disks (11) and separator plates (12). Starting with a clutch disk, alternate clutch disks and separator plates
during installation.
[11] - Install pressure plate (13).
[12] -
→NOTE:
Make sure thrust washer is centered and seated on lower surface of pressure plate.
[13] - Install disk spring (14), concave side down.
[14] - Install bearing cup (17) in cover (15).
[15] - Apply pipe sealant to threads of cap screws that protrude through cover into oil cavity of gear case.
Number Name Use

• TY9375 (us)
[16] - Install O-ring (16) and cover with cap screws (35). Tighten cap screws to specification.
Cap-to-Gear Case Cap Screw Torque 70 N·m
51 lb.-ft.
[17] - Determine disk spring preload and pinion shaft end play as follows:
a. Install bearing cone (18) on bearing quill (22).

b. Install bearing cone and quill. Tap quill into position.
c. Install cap screws (27) and tighten to specification.

Bearing Quill-to-Pinion Shaft Cap Screw Torque 36 N·m
27 lb.-ft.
d. Measure distance from top of bearing quill to top of pinion shaft through hole in center of bearing quill.
e. Subtract 10 mm (0.394 in.) from measurement made in previous step to obtain shim pack thickness. Build shim pack
using shims (19—21).
[18] - Remove cap screws (27) and install shim pack determined in previous step under bearing quill.
[19] - Install cap screws (27). Tighten to specification in a circular pattern.

Bearing Quill-to-Pinion Shaft Cap Screw Final Torque 240 N·m
177 lb.-ft.
[20] - Install retaining plate (26).

Retaining Plate-to-Pinion Shaft Cap Screw Torque 70 N·m
52 lb.-ft.
[22] - Measure distance from top of bearing cone (18) to top of bearing quill. Subtract 0.1 mm (0.004 in.) from measurement
and build shim pack using shims (23—25).
[23] - Remove cap screws (28) and retaining plate. Install shim pack.
[24] - Install retaining plate.

Retaining Plate-to-Pinion Shaft Cap Screw Torque 70 N·m
52 lb.-ft.
[26] - Install O-ring (16).
[27] - Position cap (30) on gear case.

Cap-to-Cover Cap Screw Torque 40 N·m
30 lb.-ft.
[29] - Install seal (9) in gear case with JDG1009 Seal Installer until seal is seated flush with edge of gear case.
JDG1009
[30] - Install dual input circle drive gearbox to draft frame. See Dual Input Circle Drive Gearbox Remove and Install—If
Equipped . (Group 3450.)

Circle Rotate Motor Disassemble and Assemble

Specifications
SPECIFICATIONS
50 N·m
Cap Screw Torque
37 lb.-ft.
[1] -
Circle Drive Motor

LEGEND:
1 Circle Drive Motor
[2] -
→NOTE:
Use care lifting valve housing assembly. This will help ensure pins, springs, balance ring assembly, and
valve remain on the valve plate.

Valve Housing Assembly

LEGEND:
3 Valve Housing Assembly
Remove valve housing assembly (3).
[3] -

Plug and O-ring Removal

LEGEND:
4 Seal
5 O-Ring
6 Plug
Remove seal (4).
[4] - Remove plug (6) and O-ring (5).
[5] -
Valve and Balance Ring Assembly

LEGEND:
7 Valve
8 Balance Ring Assembly
9 Outer Face Seal
10 Pin (2 used)
11 Spring (2 used)
12 Inner Face Seal
Remove springs (11) and pins (10).
[6] - Remove balance ring assembly (8).
[7] - Remove inner face seal (12) and outer face seal (9) from balance ring assembly.
[8] - Remove valve (7).
[9] -

Valve Plate
LEGEND:
13 Valve Drive
14 Seal
15 Valve Plate
Remove valve plate (15), seal (14), and valve drive (13).
[10] -
→NOTE:
When removing gerotor, be sure to retain rollers in outer ring if they are loose.

Gerotor and Shaft

LEGEND:
16 Seal
17 Shaft
18 Gerotor
Remove gerotor (18).
[11] - Remove shaft (17).
[12] - Remove seal (16).
[13] -

Wear Plate
LEGEND:
19 Bearing Housing
20 Seal
21 Shaft Face Seal
22 Wear Plate
23 Key
Remove wear plate (22).
[14] - Remove shaft face seal (21) from wear plate.
[16] - Remove key (23).
[17] -
→NOTE:
A press maybe needed to remove shaft and bearing assembly from bearing housing.
→NOTE:
Individual parts from shaft and bearing assembly are not serviceable. If damaged, replace shaft and
bearing assembly.

Shaft and Bearing Assembly

LEGEND:
19 Bearing Housing
24 Shaft and Bearing Assembly
Remove shaft and bearing assembly (24).
[18] -
IMPORTANT:
Using a small screw driver to remove seals can help prevent damage to housing bore. Internal damage to
circle drive motor can occur if housing bore is damaged.

Bearing Housing
LEGEND:
19 Bearing Housing
25 Seal
26 Backup Ring
27 Seal
Remove seal (27) and backup ring (26).
[21] -
→NOTE:
Lip of seal must face outward.
→NOTE:
Use a press to install seal in outer bore of bearing housing. If press is not available, use a plastic or
rubber hammer.


LEGEND:
17 Shaft
19 Bearing Housing
20 Seal
21 Shaft Face Seal
22 Wear Plate
23 Key
24 Shaft and Bearing Assembly
25 Seal
26 Backup Ring
27 Seal
28 Alignment Stud (2 used)
29 Notch (on wear plate)
Apply clean hydraulic oil to seal (25). Install seal and backup ring (26).
[22] - Apply clean hydraulic oil and install seal (27), shaft face seal (21), and seal (20).
[23] -
→NOTE:
Alignment studs can be very helpful in assembly of circle drive motor. If alignment studs are used, install
two alignment studs diagonally in bearing housing.
Install alignment studs (28) into bearing housing (19).
[24] - Install wear plate (22) and key (23).
[25] -
→NOTE:
When installing the gerotor, be sure to retain rollers in outer ring if they are loose.
Timing Alignment
LEGEND:
7 Valve
13 Valve Drive
14 Seal
15 Valve Plate
16 Seal
17 Shaft
18 Gerotor
30 Notch (on gerotor)
31 Notch (on valve plate)
Install shaft (17).
[26] - Apply clean hydraulic oil and install seal (16).
[27] - Install gerotor (18) and valve drive (13).
[28] - Locate the largest open pocket in the gerotor and apply alignment marks on the outside edge.
[30] - Install valve plate (15).
[31] - Align notch (30) on gerotor with notch (31) on valve plate.
[32] - Install valve (7) and align an opening with an open spot on valve plate that is aligned with marking on gerotor.
[33] -
IMPORTANT:
Rotation of valve should only be moved about 1/2 spline tooth. If moved any farther, internal damage
may occur.
Circle Drive Motor Rotation

LEGEND:
32 Clockwise Rotation
33 Counter Clockwise Rotation
Rotate valve clockwise until spline teeth engage. This will provide proper rotation when pressurized.
[34] -

Circle Drive Motor Valve Housing

LEGEND:
4 Seal
10 Pin (2 used)
11 Spring (2 used)
Install springs (11) and pins (10).
[36] -
IMPORTANT:
Avoid bending or damaging face seals. Any damage to face seals will affect operation of motor and may
cause internal damage.

Face Seals
LEGEND:
9 Outer Face Seal
12 Inner Face Seal
34 Pin Notch
Install inner face seal (12) and outer face seal (9).
[37] -


LEGEND:
8 Balance Ring Assembly
Align pin notches in balance ring assembly (8) with pins in valve housing assembly (3).
[38] -


LEGEND:
15 Valve Plate
28 Alignment Stud (2 used)
Insert finger through port of valve housing assembly (3) and apply pressure to side of balance ring assembly.
[39] -
→NOTE:
After installing valve housing assembly, check for proper placement. Push down on the valve housing
assembly; a slight spring action should be felt through port.
Hold balance ring assembly in position until valve housing assembly is placed against valve plate (15).
[40] -
→NOTE:
If alignment studs were used during assembly, install cap screws opposite from alignment studs and
tighten until finger tight. Then remove alignment studs and install remaining cap screws.
Circle Drive Motor

LEGEND:
5 O-Ring
6 Plug
Install cap screws (2) and tighten to specification.
Cap Screw Torque 50 N·m
37 lb.-ft.
[41] - Install O-ring (5) and plug (6).

Circle Rotate Sensor Remove and Install

[1] -
Circle Rotate Sensor Cover

LEGEND:
2 Circle Rotate Sensor Cover
6 Rotary Manifold Cover
Remove cap screws (1) and circle rotate sensor cover (2).
[2] -
→NOTE:
Note the Orientation of circle rotate sensor electrical connector to outer screw holes.

Circle Rotate Sensor

LEGEND:
4 Circle Rotate Sensor Electrical Connector
B39 Circle Rotate Sensor
Disconnect circle rotate sensor electrical connector (4).
[3] -

Circle Rotate Sensor, Coupler and Adapter

LEGEND:
5 Coupler
7 Adapter
B39 Circle Rotate Sensor
Remove cap screws (3) and circle rotate sensor (B39).
[4] - Remove coupler (5) from shaft on circle rotate sensor.
[6] -
IMPORTANT:
When installing coupler to circle rotate sensor shaft, align D shape on shaft to D shape on coupler. Key
shape on outer side of coupler lines up with key shape on adapter (7). Incorrect installation will cause
inaccurate circle rotate sensor readings.
Install coupler to circle rotate sensor shaft.
[7] - Align coupler with adapter to install circle rotate sensor and tighten cap screws.
[8] - Connect circle rotate sensor electrical connector.
[9] - Install circle rotate sensor cover and cap screws.
[10] - Calibrate circle rotate sensor. See Display Unit—Main Menu—Machine Configuration—Cross Slope Sensor Cal—Circle
Section 34 - GRADING DEVICE Group 3460: Hydraulic System
Rotate Cal (Grade Pro Machines Only) . (Operator′s Manual.)


Grader Control Valve Remove and Install
Hydraulic System Manifold and Control Valves

LEGEND:
1 Left Control Valve Assembly
2 Left Control Valve End Cap
3 Left Auxiliary Valve Section (without float)
4 Left Auxiliary Valve Section (with float)
5 Left Auxiliary Valve Section (with float)
6 Left Control Valve Assembly Mid-inlet Section
7 Left Blade Lift Valve Section
8 Blade Side Shift Valve Section
9 Circle Rotate Valve Section
10 Blade Pitch Valve Section
11 Left Control Valve End Cap
12 Left Blade Lift Relief Valve
13 Load Sense Relief Valve
14 Right Control Valve Assembly
16 Articulation Valve Section
17 Circle rotate Valve Section
18 Wheel Lean Valve Section
19 Blade Lift Valve Section
20 Right Control Valve Assembly Mid-inlet
21 Right Auxiliary Valve Section (midmount scarifier valve section—if equipped)
22 Right Auxiliary Valve Section (with float)
23 Right Auxiliary Valve Section (without float)
25 Circuit Relief—Midmount Scarifier Only
26 Right Blade Lift Relief Valve
[1] - Rotate blade away from control valve assembly being removed.
[2] - Tilt blade all the way forward. Lower all attachments to the ground.

[6] -
CAUTION:
pressure.
To release pressure in the system, slowly loosen fittings on lines at control valve.
[7] - Remove all hydraulic lines from control valve 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.
[9] - Tilt steering console back towards the seat.
[10] -
LEGEND:
30 Air Duct Cap Screw
31 Linkage Rod
32 Air Duct
33 Linkage Boots (2 used)
34 Linkage Boot Cap Screw (8 used)
35 Cover Plate
Control Valve Linkage Boots (right control valve shown)

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).
[12] -
LEGEND:
31 Linkage Rod
35 Cover Plate
36 Cover Plate Cap Screw (4 used)
37 Linkage Rod Cap Screw
38 Valve Lever
Control Valve Cover Plate (right control valve shown)

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.
[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.
[16] -

CAUTION:
Avoid crushing injury. Use a lifting device.
LEGEND:
39 Lifting Strap
40 Valve Assembly
Lifting Strap
Connect hoist to valve assembly (40) using lifting strap (39).
Control Valve Assembly Weight (approximate) 50 kg
110 lb.
[17] -
LEGEND:
39 Lifting Strap
40 Valve Assembly
41 Cab
42 Mounting Bracket Cap Screws (3 used)
43 Mounting Bracket
Control valve Mounting Bracket (front view)
Control Valve Mounting Bracket (rear view)

Remove control valve mounting bracket cap screws (42) and lower control valve assembly (40) from cab.
[18] - Repair grader control valve as needed. See Grader Control Valve Disassemble and Assemble . (Group 3460.)
[19] -
CAUTION:

Lift assembly into machine and install control valve mounting hardware.
Control Valve Assembly Weight (approximate) 50 kg
110 lb.
[20] - Connect linkage rods to the control valve assembly.
[21] - Install cover plate over control valve assembly.
[22] -
→NOTE:
When installing floor mat, make sure floor mat does not interfere with control levers, boots or pedal.
Install floor mat and cap screws.
[23] - Move steering console to forward position.
[24] -
→NOTE:
When linkage boot is out of specification lever effort complaints can result. Position linkage boots to
specification to reduce lever effort variations.
LEGEND:
44 Boot Neck
45 Floor Plate
Linkage Boot
Adjust linkage boots so neck (44) is above floor plate (45) to specification.
Floor Plate to Top of Linkage Boots Length 50 mm
2 in.
[25] - Connect all lines.
9025-25.)
[27] - Check hydraulic oil level in tank. See Drain and Refill Capacities . (Operator′s Manual.)

Draft Frame Mount Grader Control Valve Remove and Install—EH

Controls
Draft Frame Control Valve

LEGEND:
1 Toolbox
3 Draft Frame Cover
4 Nut (2 used)
5 Clamp (7 used)
6 Stud (2 used)
7 Solenoid
8 Draft Frame Mount Control Valve
9 Draft Frame
14 Washer (4 used)
[1] - Tilt blade forward. Lower all attachments to the ground.

[4] - Remove cap screws (2) and washers (14) from draft frame cover (3).
[5] - Remove draft frame cover from draft frame (9).
[6] - Remove toolbox (1) from draft frame.
[7] - Remove nuts (4) and clamps (5) from studs (6) to allow for removal of hydraulic lines.
[8] -
CAUTION:
pressure.
[10] -
LEGEND:
7 Solenoid
8 Draft Frame Mount Control Valve
11 Hydraulic Hoses
12 Hydraulic Lines
13 Wire Harness
Hydraulic Lines Wire Harness

Remove and tag all hydraulic hoses (11) and lines (12) from draft frame mount control valve (8). Cap and plug all openings.
[11] - Remove wire harness (13) from solenoids (7).
[12] - Remove cap screws (10) from draft frame.
[13] -
CAUTION:
Using an appropriate lifting device, lift draft frame mount control valve away from draft frame.
Draft Frame Mount Control Valve Weight (approximate) 82 kg
180 lb.

[15] -
CAUTION:
Lift draft frame mount control valve into machine and install control valve mounting hardware.
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).
[22] - Install washers (14) and cap screws (2) to draft frame cover (3).
[23] - Remove vacuum pump from hydraulic oil tank. See Vacuum Pump Installation . (Group 9025-25.)
[27] - Calibrate valve (GP machines only). See Display Unit—Main Menu—Machine Configuration—Valve Cals (Grade Pro

Cab Mount Grader Control Valve Remove and Install—EH Controls
Cab Mount Control Valve

LEGEND:
2 Cab Mount Control Valve
3 Hydraulic Hoses
4 Solenoid
5 DFT1310 Cab Mount Control Valve Support Bracket
6 Cab Mount Control Valve Mounting Bracket
[1] - Rotate the blade away from the cab mount control valve.
[2] - Tilt blade forward. Lower all attachments to the ground.
[5] -
CAUTION:
pressure.
[7] - Remove and tag all hydraulic hoses (3) from cab mount control valve. Cap and plug all openings.
[8] - Remove wire harness from all solenoids (4). See Electrohydraulic (EH) Main Frame Harness (W39) Component Location for
[9] - Install DFT1310 Cab Mount Control Valve Support Bracket (5) to cab mount control valve mounting bracket.
[10] -

CAUTION:
Secure DFT1310 Cab Mount Control Valve Support Bracket to an appropriate lifting device.
Cab Mount Control Valve Weight (approximate) 73 kg
160 lb.
[12] - Using an appropriate lifting device, remove cab mount control valve away from under the cab.
[14] -
CAUTION:
Using DFT1310 Cab Mount Control Valve Support Bracket and an appropriate lifting device place cab mount control valve in
place under cab.
Cab Mount Control Valve Weight (approximate) 73 kg
160 lb.
[15] - Install caps screws (1).
[16] - Connect wire harness to solenoids (4). See Electrohydraulic (EH) Main Frame Harness (W39) Component Location for
[17] - Connect all hydraulic hoses. See Hydraulic System Component Location—EH Controls for correct hydraulic hose
placement. (Group 9025-15.)
9025-25.)
[22] - Calibrate valve (GP machines only). See Display Unit—Main Menu—Machine Configuration—Valve Cals (Grade Pro

Grader Control Valve Disassemble and Assemble
Control Valve
LEGEND:
1 Small Cap Screw (2 used)
2 Large Cap Screw
3 Small Stud (2 used)
4 Large Stud
5 Large Stud
6 Small Stud (2 used)
7 Large Nut (2 used)
8 Small Nut (4 used)
→NOTE:
Standard control valve is shown. Disassemble and assemble procedure of EH controls control valves are
the same as standard control valve.
[4] - Remove control valve to be disassembled from 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 Grader Control Valve Remove
and Install—EH Controls for EH control machines. (Group 3460.)
[5] -

Control Valve Mounting Bracket (left control valve shown)

LEGEND:
9 Mounting Bracket
11 Control Valve
[6] - Remove mounting bracket (9) from control valve (11).
[7] - Mark the valve sections configuration to aid assembly. See Control Valve Operation—Standard Controls or see Control
Valve Operation—EH Controls . (Group 9025-05.)
[8] -
→NOTE:
Depending on the number of valve sections, cap screws (1 and 2) might be used in place of the studs and
nuts (5, 6, 7 and 8).
Remove nuts from each side of control valve.
[9] - Separate valve sections.

For disassemble and assemble procedures of individual valve sections:
See Midmount Scarifier Valve Section Disassemble and Assemble . (Group 3460.)
See Midmount Scarifier Valve Section Disassemble and Assemble—EH Controls . (Group 3460.)
See Blade Lift Valve Section Disassemble and Assemble . (Group 3460.)
See Blade Lift Valve Section Disassemble and Assemble—EH Controls . (Group 3460.)
See Auxiliary (With Float) Valve Section Disassemble and Assemble . (Group 3460.)
See Auxiliary (Without Float) Valve Section Disassemble and Assemble . (Group 3460.)
See Auxiliary Valve Section Disassemble and Assemble—EH Controls . (Group 3460.)
See Wheel Lean, Articulation, Circle Side Shift, Blade Pitch, and Blade Side Shift Valve Section Disassemble and Assemble
. (Group 3460.)
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 Assemble . (Group 3460.)
See Circle Rotate Valve Section Disassemble and Assemble—EH Controls . (Group 3460.)
[11] -
→NOTE:
Calibration data from new valve sections is necessary when performing calibration procedure.

Blade Lift Valve Section Shown
Sample Calibration Data Decal

LEGEND:
12 Calibration Data Decal
Record 6-digit calibration data numbers A and B from calibration data decal (12) on solenoids of valve sections that are being
replaced.
Valve Section Calibration Data
Valve Section Calibration Data
Left Blade Lift Valve Section Right Blade Lift Valve Section
A— A—
B— B—
[12] - The calibration data on valves is needed for calibration.
[13] - Assemble valve sections in order removed.

[14] - Tighten control valve nuts (cap screws) accordingly.
Control Valve Nut (small) Torque 19 N·m
168 lb-in
Control Valve Nut (large) Torque 45 N·m
33 lb-ft
[15] - 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 Grader Control Valve Remove
and Install—EH Controls for EH control machines. (Group 3460.)
[16] - Calibrate value. See Electrohydraulic Valve Calibration Procedure . (Group 9015-20.)

Midmount Scarifier Valve Section Disassemble and Assemble
Midmount Scarifier Valve Section

LEGEND:
2 Detent Housing
4 Seal
5 O-Ring (3 used)
6 Float Detent
7 Spring Housing
9 Spring
10 Check Valve (2 used)
11 Check Valve Spool (2 used)
12 Midmount Scarifier Valve Section
13 Shuttle Valve Disk
14 Compensator Spool
15 Compensator Spring
16 O-Ring
17 O-Ring (2 used)
18 Actuator Spring
19 Actuator Housing
20 O-Ring (2 used)
21 Actuator Arm
23 Spool
24 Plug
25 Seal
[1] - Remove control valve containing midmount scarifier control valve section. See Grader Control Valve Remove and Install .
(Group 3460.)
[2] - Remove midmount scarifier control valve section from control valve. See Grader Control Valve Disassemble and Assemble
. (Group 3460.)
[3] - Remove check valves (10) and spools (11).
[4] - Remove shuttle valve disk (13).
[5] - Remove compensator spring (15) and compensator spool (14).
[6] - Remove actuator arm (21) from actuator housing (19).
[8] - Remove actuator housing (19) and actuator spring (18).
[10] - Remove detent housing (2), float detent (6), and spring housing (7).
[11] - Remove spring seats (8) and spring (9).
[12] - Slide spool (23) out of valve section (12).
[13] - Remove pressure relief valve (3).
[14] - Remove plug (24).
[16] - Replace all O-rings (5, 16, 17, and 20) and seals (4 and 25).
[17] - Assemble valve.
[18] - Tighten parts to specification.

Check Valve-to-Valve Body Torque 45 N·m
33 lb-ft
Pressure Relief Valve-to-Valve Body Torque 45 N·m
33 lb-ft
Plug-to-Valve Body Torque 45 N·m
33 lb-ft
Detent Housing-to-Spring Housing-to-Valve Body Torque 9.5 N·m
84 lb-in.
Actuator Housing-to-Valve Body Torque 9.5 N·m
84 lb-in.
[19] - Assemble midmount scarifier control valve section to control valve. See Grader Control Valve Disassemble and Assemble
. (Group 3460.)
[20] - Install control valve containing midmount scarifier control valve section to the machine. See Grader Control Valve
Midmount Scarifier Valve Section Disassemble and Assemble—EH

Controls
Midmount Scarifier Valve Section (EH controls)

LEGEND:
2 Seal
3 Seal
4 Plug
8 Solenoid Valve (2 used)
10 Solenoid Valve Housing (2 used)
11 Actuator Spring (2 used)

13 O-Ring (2 used)
14 O-Ring (4 used)
15 Spool
16 Midmount Scarifier Valve Section
18 O-Ring (2 used)
21 O-Ring
[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 Assemble .
(Group 3460.)
[7] - Remove solenoid valves (8).
[9] - Remove solenoid valve housings (10).
[10] - Remove actuator springs (11) and spring seats (12).

33 lb-ft
33 lb-ft
33 lb-ft
Solenoid Valve-to-Solenoid Valve Housing Torque 2 N·m
18 lb-in
Solenoid Valve Housing-to-Valve Body Torque 9.5 N·m
84 lb-in
[18] - Assemble midmount scarifier valve section to control valve. See Grader Control Valve Disassemble and Assemble .
(Group 3460.)
[19] - Install control valve containing midmount scarifier valve section to the machine. See Draft Frame Mount Grader Control
Valve Remove and Install—EH Controls . (Group 3460.)

Blade Lift Valve Section Disassemble and Assemble
Blade Lift Valve Section

LEGEND:
2 Detent Housing
4 Seal
5 O-Ring (3 used)
6 Float Detent
7 Spring Housing
9 Spring
16 O-Ring
17 O-Ring (2 used)
18 Actuator Spring
19 Actuator Housing
20 O-Ring (2 used)
21 Actuator Arm
23 Spool
24 Plug
25 Seal
[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.)

33 lb-ft
33 lb-ft
33 lb-ft
84 lb-in
84 lb-in
[19] - Assemble blade lift valve section to control valve. See Grader Control Valve Disassemble and Assemble . (Group 3460.)
[20] - Install control valve containing blade lift valve section to the machine. See Grader Control Valve Remove and Install .
(Group 3460.)

Blade Lift Valve Section Disassemble and Assemble—EH Controls
Blade Lift Valve Section (EH controls)

LEGEND:
2 Seal
3 Seal
4 Plug
13 O-Ring (2 used)
14 O-Ring (4 used)

15 Spool
18 O-Ring (2 used)
21 O-Ring
[1] - Remove control valve containing blade lift valve section. See Cab Mount Grader Control Valve Remove and Install—EH
[2] - Remove blade lift valve section from control valve. See Grader Control Valve Disassemble and Assemble . (Group 3460.)

33 lb-ft
33 lb-ft
Plug-to-Valve Body Torque 45.0 N·m
33 lb-ft
18 lb-in
84 lb-in
[18] - Assemble blade lift valve section to control valve. See Grader Control Valve Disassemble and Assemble . (Group 3460.)
[19] - Install control valve containing blade lift valve section to the machine. See Cab Mount Grader Control Valve Remove and

Auxiliary (With Float) Valve Section Disassemble and Assemble
Auxiliary (with float) Valve Section

LEGEND:
2 Detent Housing
4 Seal
5 O-Ring (3 used)
6 Float Detent
7 Spring Housing
9 Spring
12 Auxiliary (with float) Control Valve Section
16 O-Ring
17 O-Ring (2 used)
18 Actuator Spring
19 Actuator Housing
20 O-Ring (2 used)
21 Actuator Arm
23 Spool
24 Plug
25 Seal
[1] - Remove control valve containing auxiliary valve section. See Grader Control Valve Remove and Install . (Group 3460.)
[2] - Remove auxiliary valve section from control valve. See Grader Control Valve Disassemble and Assemble . (Group 3460.)

33 lb-ft
33 lb-ft
33 lb-ft
84 lb-in
84 lb-in
[19] - Assemble auxiliary valve section to control valve. See Grader Control Valve Disassemble and Assemble . (Group 3460.)
[20] - Install control valve containing auxiliary valve section to the machine. See Grader Control Valve Remove and Install .
(Group 3460.)

Auxiliary (Without Float) Valve Section Disassemble and Assemble
Auxiliary (with float) Valve Section

LEGEND:
3 Plug (2 used)
4 Seal (2 used)
6 Spring Housing
8 Spring
9 O-Ring (2 used)
10 Auxiliary (without float) Valve Section
14 O-Ring

15 O-Ring (2 used)
16 Actuator Spring
17 Actuator Housing
18 O-Ring (2 used)
19 Actuator Arm
21 Spool
[1] - Remove control valve containing auxiliary valve section. See Grader Control Valve Remove and Install . (Group 3460.)
[10] - Remove spring housing (6).
[13] - Remove plugs (3).
[15] - Replace all O-rings (9, 14, 15, and 18) and seals (4).

33 lb-ft
33 lb-ft
Spring Housing-to-Valve Body Torque 9.5 N·m
84 lb-in
84 lb-in
[19] - Install control valve containing auxiliary valve section to the machine. See Grader Control Valve Remove and Install .
(Group 3460.)

Auxiliary Valve Section Disassemble and Assemble—EH Controls
Auxiliary Valve Section—EH Controls

LEGEND:
1 Plug (2 used)
2 Seal (2 used)
11 O-Ring (2 used)
12 O-Ring (4 used)
13 Spool
14 Auxiliary Valve Section—EH Controls


16 O-Ring (2 used)
19 O-Ring
[1] - Remove control valve containing auxiliary valve section. See Draft Frame Mount Grader Control Valve Remove and
Install—EH Controls or see Cab Mount Grader Control Valve Remove and Install—EH Controls . (Group 3460.)
[12] - Remove plugs (1).
[14] - Replace all O-rings (11, 12, 16, and 19) and seals (2).

33 lb-ft
33 lb-ft
18 lb-in
84 lb-in
[18] - Install control valve containing auxiliary valve section to the machine. See Draft Frame Mount Grader Control Valve
Remove and Install—EH Controls or see Cab Mount Grader Control Valve Remove and Install—EH Controls . (Group 3460.)

Wheel Lean, Articulation, Circle Side Shift, Blade Pitch, and Blade Side
Shift Valve Section Disassemble and Assemble
Wheel Lean Valve Section

LEGEND:
4 Actuator Housing
5 O-Ring (2 used)
6 Actuator Arm
7 Actuator Spring
8 O-Ring (2 used)
9 Wheel Lean Valve Section

13 O-Ring
14 O-Ring (2 used)
16 Spring
17 Spring Housing
19 Spool
[1] - Remove control valve containing valve section to be disassembled. See Grader Control Valve Remove and Install . (Group
3460.)
[2] - Remove valve section to be disassembled from control valve. See Grader Control Valve Disassemble and Assemble .
(Group 3460.)
[3] -
→NOTE:
Wheel lean valve section is shown. Articulation, circle side shift, blade pitch, and blade side shift valve
section disassemble and assemble procedure is the same.
Remove check valves (1) and spools (2).
[14] - Replace all O-rings (5, 8, 13, and 14).

33 lb-ft
84 lb-in
84 lb-in
[17] - Assemble valve section to be disassembled to control valve. See Grader Control Valve Disassemble and Assemble .
(Group 3460.)
[18] - Install control valve containing valve section to the machine. See Grader Control Valve Remove and Install . (Group
3460.)

Wheel Lean, Articulation, Circle Side Shift, Blade Pitch, Blade Side Shift,
and Steering Valve Section Disassemble and Assemble—EH Controls
Wheel Lean Valve Section—EH Controls

LEGEND:
9 O-Ring (2 used)
10 O-Ring (4 used)
11 Spool
12 Wheel Lean Valve Section—EH Controls


14 O-Ring (2 used)
17 O-Ring
[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 Controls . (Group 3460.)
[2] - Remove valve section to be disassembled from control valve. See Grader Control Valve Disassemble and Assemble .
(Group 3460.)
[3] -
→NOTE:
Wheel lean valve section is shown. Articulation, circle side shift, blade pitch, and blade side shift valve
section disassemble and assemble procedure is the same.
Remove check valves (1) and spools (2).
[13] - Replace all O-rings (9, 10, 14, and 17).

33 lb-ft
18 lb-in
84 lb-in
[16] - Assemble valve section to be disassembled to control valve. See Grader Control Valve Disassemble and Assemble .
(Group 3460.)
[17] - Install control valve containing valve section to the machine. See Draft Frame Mount Grader Control Valve Remove and
Install—EH Controls or see Cab Mount Grader Control Valve Remove and Install—EH Controls . (Group 3460.)

Circle Rotate Valve Section Disassemble and Assemble
Circle Rotate Valve Section

LEGEND:
1 Plug (2 used)
2 O-Ring (2 used)
3 Spool (2 used)
5 Actuator Housing
6 O-Ring (2 used)
7 Actuator Arm
8 Actuator Spring
9 O-Ring (2 used)
10 Circle Rotate Valve Section
14 O-Ring

15 O-Ring (2 used)
17 Spring
18 Spring Housing
20 Spool
[1] - Remove control valve containing circle rotate valve section. See Grader Control Valve Remove and Install . (Group 3460.)
[2] - Remove circle rotate valve section from control valve. See Grader Control Valve Disassemble and Assemble . (Group
3460.)
[3] - Remove plugs (1) and spools (3).
[8] - Remove actuator housing and actuator spring (8).
[14] - Replace all O-rings (2, 6, 9, 14, and 15).

33 lb-ft
84 lb-in
84 lb-in
[17] - Assemble circle rotate valve section to control valve. See Grader Control Valve Disassemble and Assemble . (Group
3460.)
[18] - Install control valve containing circle rotate valve section to the machine. See Grader Control Valve Remove and Install .
(Group 3460.)

Circle Rotate Valve Section Disassemble and Assemble—EH Controls
Circle Rotate valve Section—EH Controls

LEGEND:
1 Plug (2 used)
2 O-Ring (2 used)
3 Spool (2 used)
10 O-Ring (2 used)
11 O-Ring (4 used)
12 Spool
13 Circle Rotate Valve Section—EH Controls

15 O-Ring (2 used)
18 O-Ring
[1] - Remove control valve containing circle rotate valve section. See Draft Frame Mount Grader Control Valve Remove and
[2] - Remove circle rotate valve section from control valve. See Grader Control Valve Disassemble and Assemble . (Group
3460.)
[3] - Remove plugs (1) and O-rings (2).
[13] - Replace all O-rings (2, 10, 11, 15, and 18).

33 lb-ft
18 lb-in
84 lb-in
[16] - Assemble circle rotate valve section to control valve. See Grader Control Valve Disassemble and Assemble . (Group
3460.)
[17] - Install control valve containing circle rotate valve section to the machine. See Draft Frame Mount Grader Control Valve
Remove and Install—EH Controls . (Group 3460.)
Return Check Poppets Disassemble and Assemble

LEGEND:
1 Check Valve Spool
2 Backup Ring
3 O-Ring
4 Poppet Body
5 O-Ring
6 Check Poppet
7 Spring
8 O-Ring
9 Plug
Disassemble and Assemble Return Poppets
→NOTE:
Poppets are serviced as an assembly except O-rings and backup rings.

Rotary Manifold Remove and Install

[4] - If equipped, remove circle rotate sensor (B39). See Electrohydraulic (EH) Main Frame Harness (W39) Component Location
. (Group 9015-10.)
[5] -
LEGEND:
2 Rotary Manifold
4 Cover
5 Draft Frame
7 Washer (4 used)
8 Spacers (2 used)
Rotary Manifold (bottom view)
Rotary Manifold (top view)

Remove cap screws (3) and spacers (8).
[6] - Remove cover (4) to allow for access to hydraulic hoses (6).
[7] -
CAUTION:
pressure.
To release pressure in the system, slowly loosen fittings on lines at rotary manifold (2).

[9] -
→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.
Label and remove hydraulic hoses (6) from rotary manifold. Cap and plug all openings.
[10] - Remove cap screws (1) and washers (7) from rotary manifold (2).
[11] -
CAUTION:
Remove rotary manifold (2) from draft frame (5).

Rotary Manifold Weight (approximate) 38 kg
84 lb.
[12] - Repair or replace as necessary. See Rotary Manifold Disassemble and Assemble . (Group 3460.)
[13] -
CAUTION:
Install rotary manifold (2) on draft frame (5).

Rotary Manifold Weight (approximate) 38 kg
84 lb.
[14] - Install washers (7) and cap screws (1) in rotary manifold (2).
[15] -
→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.
Connect hydraulic hoses (6) to rotary manifold. See Hydraulic System Component Location or see Hydraulic System Component
Location—EH Controls . (Group 9025-15.)
9025-25.)
[17] - Install cover (4), spacers (8) and cap screws (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) . (Operator′s Manual.)


Rotary Manifold Disassemble and Assemble

Early Design
Rotary Manifold (exploded view)

LEGEND:
3 Plate
4 Thrust Washer
5 Ring
6 Wear Ring (2 used)
8 Washer (4 used)
9 Housing
10 Seal (5 used)
12 Seal
13 Spool
[1] - Apply alignment marks on housing (9) and spool (13).
[2] - Remove cap screws (1), lock washers (2), and plate (3).
[3] - Press spool from housing.
[5] - Soak seals (10 and 12) and wear rings (6) in clean hydraulic oil.
[6] - Install parts (5, 6, 10, and 12) on spool (13).
[7] - Align alignment marks on spool and housing (9).
[8] - Install plate, lock washers, and cap screws (1).

Later Design
Rotary Manifold (exploded view)

LEGEND:
2 Cover Plate
3 O-ring (6 used)
5 Cover
6 Seal
8 Thrust Washer
9 O-ring
10 O-ring and Seal (5 used)
11 O-ring
12 Temp Label
13 Housing
14 Seal
15 O-ring
16 Lock Ring
17 Oil Seal
18 Spool
19 Set Screw (3 used)
[1] - Apply alignment marks on housing (13) and spool (18).
[2] - Remove set screw (19).

[3] - Remove cap screw (1), cover plate (2), and O-ring (3).
[4] - Remove cap screw (4), cover (5), and seal (6).
[5] - Remove cap screw (7), thrust washer (8), and O-ring (9).
[6] - Press spool from housing (13).
[8] - Install oil seal (17) on spool.
[9] -
→NOTE:
Apply black seal silicon on lock ring.
Install lock ring (16). Fill grease between spool and lock ring.
[10] - Install parts (10, 14, and 15) on spool.
[11] - Align alignment mark on housing and spool.
[12] - Install parts (11 and 12) on housing.
[13] - Install O-ring (9), thrust washer, and cap screw (7).
[14] - Install seal (6), cover, and cap screw (4).
[15] - Install O-ring (3), cover plate, and cap screw (1).
[16] - Install set screw.

Blade Lift, Blade Pitch, and Circle Side Shift Cylinders Remove and
Install
[4] -
CAUTION:
pressure.
To relieve pressure in the system, slowly loosen fittings on hoses at cylinders.
(Group 2160.)
[6] -
CAUTION:

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.
Blade Lift Cylinder:

Blade Lift Cylinder Weight (approximate) 70 kg
155 lb.
Blade Pitch Cylinder:

Blade Pitch Cylinder Weight (approximate) 23 kg
51 lb.
Circle Side Shift Cylinder:

Circle Side Shift Cylinder Weight (approximate) 47 kg
104 lb.
Disconnect and tag hydraulic lines.
[7] - Remove cylinder from machine.
[9] - Install cylinder and connect lines.
2160.)
[12] - The ball and socket assemblies on the lift cylinder rod 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.

Ball and Socket, Lift Cylinder Rod End and Circle Side Shift Cylinder Rod and Head End Shimmed 1.1 mm
0.045 in.

Blade Side Shift Cylinder Remove and Install

[4] -
LEGEND:
1 Moldboard
2 Cap Screw
3 Pin
4 Blade Side Shift Cylinder
5 Blade Pitch Frame
7 Pin
Blade Side Shift Cylinder (left side shown)
Blade Side Shift Cylinder (right side shown)

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
[6] - Remove moldboard (1) from blade pitch frame (5). See Blade Pitch Frame Remove and Install . (Group 3440.)
[7] -
CAUTION:
pressure.
To relieve pressure in the system, slowly loosen fittings on hoses at blade side shift cylinder (4).
(Group 2160.)
[9] - Label and disconnect hydraulic hoses (6). Cap and plug all openings.
[10] - Remove pin (7) from blade pitch frame (5). See NeverGrease™ Pin Joints . (Group 3440.)
[11] -

CAUTION:
Remove blade side shift cylinder (4) from machine.

Blade Side Shift Cylinder. Weight (approximate) 58 kg
128 lb.
[12] - Inspect blade side shift cylinder, bushings, and pins for excessive wear or damage.
Blade Side Shift Cylinder End Bushing Bore Diameter 44.62—44.74 mm
1.757—1.761 in.
Blade Side Shift Cylinder Pin Diameter 44.45 mm
1.75 in.
[14] -
CAUTION:
Install blade side shift cylinder (4) to machine.

Blade Side Shift Cylinder. Weight (approximate) 58 kg
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).
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 Joints . (Group
3440.)

Articulation Cylinders Remove and Install

→NOTE:
Right articulation cylinder is shown. Remove and install procedure for left articulation cylinder is the
similar.
[4] -
CAUTION:
pressure.
To relieve pressure in the system, slowly loosen fittings on hoses at articulation cylinder (4).
(Group 2160.)
[6] -
LEGEND:
1 Pin (rod end)
2 Cap Screw
3 Hydraulic Hoses (3 used)
4 Articulation Cylinder
5 Cap Screw
6 Pin (head end)
7 Nut
Articulation Cylinder (right side shown)

Disconnect and tag hydraulic hoses. Cap and plug all openings.
[7] - Remove cap screw (5) and nut (7).
[8] - Remove pin (6). See NeverGrease™ Pin Joints . (Group 3440.)
[9] - Remove cap screw (2).
[10] - Remove pin (1). See NeverGrease™ Pin Joints . (Group 3440.)
[11] -
CAUTION:
Remove articulation cylinder (4) from machine.

Articulation Cylinder Weight (approximate) 31 kg
69 lb.

GROUND CONDITIONING TOOL (g) by Belgreen v2.0
[12] - Inspect articulation cylinder, bushings, and pins for excessive wear or damage.
Blade Side Shift Cylinder Boss Bushing Diameter 49.67—49.77 mm
1.955—1.959 in.
Articulation Pin (head end) Diameter 49.5—49.45 mm
1.949—1.947 in.
Blade Side Shift Cylinder Bushing Bore (rod end) Diameter 49.67—49.77 mm
1.955—1.959 in.
Articulation Pin (rod end) Diameter 49.475 mm
1.948 in.
[14] -
CAUTION:
Install articulation cylinder (4) to machine.

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).
2160.)

Section 42 - GROUND CONDITIONING TOOL

Table of contents
Group 4240 - Frames ............................................................................................................................... 1
NeverGrease™ Pin Joints ...................................................................................................................... 1
Scarifier/Blade Remove and Install ....................................................................................................... 5
Midmount Scarifier Remove and Install ................................................................................................ 8
Midmount Scarifier Cylinder Remove and Install ................................................................................ 14
Ripper Remove and Install .................................................................................................................. 16
Ripper Cylinders Remove and Install .................................................................................................. 19
Balderson™ Style Front Lift Group Remove and Install ...................................................................... 21

Section 42 - GROUND CONDITIONING TOOL Group 4240: Frames
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 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
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.
Installing Bushing

Bushing Type Joint
Bushing Type Joint with External Split Seal (optional type seals shown)
LEGEND:
1 Boss
2 Bushing
3 Disk
4 Hydraulic Puller Rod
6 Frame
7 Clearance
8 Split Seal (as required)
9 Pin
10 Internal Bushing Seal
Removal and Replacement of Bushings
IMPORTANT:
Only use a hydraulic puller for removal and installing bushing. Never use slide hammer or impact type
puller.
Shimming is required where specified. Some joints are more critical and will be specified when required.
Alignment in the joint is important to prevent premature wear.

[1] - Remove the old bushing from bore with Hydraulic Puller Set D01047AA or Hydraulic Press D01013AA for larger bushings.
Hydraulic Puller Set
D01047AA (17 1/2 and 30 Ton)
To remove and install steering cylinder bushings.
Hydraulic Press
D01013AA (100 Ton)
To remove and install larger bushings if required
[2] - Clean up bores thoroughly.
[3] - Check to make sure bore, bushing is perfectly clean and dry. Do not apply any lubrication to any components in joint.
[4] - Measure bore I.D. for size to determine what disk (3) size will be required for installation of bushing. It must pass through
the bore I.D. for proper centering in frame bore with a hydraulic puller.
[5] -
IMPORTANT:
No lubrication should be used on any components of joint including pin. This may decrease life of joint.
Assemble Hydraulic Puller Set D01047AA and rod (4) through center of bushing and bore and attach proper size disk. Support
tooling to not come in contact with bushing surfaces.
[6] -
IMPORTANT:
Must have the bushing aligned square to the bore while installing. This will keep from having
misalignment in bore and damage to bushing.
Make sure the bushing (2) is square to the bore. With hydraulic puller install bushing into bore or frame. Keep perfectly square
and aligned to bore while installing. Center bushing in bore by pulling slightly past face of boss. Check each side to make sure
bushing is centered in bore.
[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.
Bearing Type Joint (roller bearing) Clearance (maximum total of both sides) 1 mm
.040 in
[10] -
IMPORTANT:
No lubrication should be used on any parts of joint including pin. This may decrease life of joint.
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 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.

Scarifier/Blade Remove and Install

[1] - Park machine on flat level surface.
[2] - Remove scarifier shanks (5) if equipped and lower all attachments to ground.
Scarifier

Blade
LEGEND:
1 Scarifier/Blade
3 Pin (4 used)
4 Link (2 used)
5 Shank
7 Nut (4 used)
[4] - Support links (4).
[5] -
CAUTION:
Use an appropriate lifting device to support scarifier/blade (1) during removal.

Scarifier (if equipped) Weight (approximate) 1797 kg
815 lb.
Blade (if equipped) Weight (approximate) 2944 kg
1334 lb.
[6] - If equipped, remove snap rings (2).

[7] - If equipped, remove cap screws and nuts (6 and 7).
[8] - Remove pins (3) from scarifier/blade to remove.
[10] -
CAUTION:
Install scarifier/blade and pins.

Scarifier (if equipped) Weight (approximate) 1797 kg
815 lb.
Blade (if equipped) Weight (approximate) 2944 kg
1334 lb.
[11] - If equipped, install snap rings.
[12] - If equipped, install cap screws and nuts.
[14] - Operate scarifier/blade up and down to check function.

Midmount Scarifier Remove and Install

[2] -
LEGEND:
1 Wood Block
2 Midmount Scarifier Tool Bar
Midmount Scarifier Resting on Blocks

Place wood blocks (1) under midmount scarifier tool bar (2) as shown.
[3] - Lower midmount scarifier onto wood blocks.
[4] -
CAUTION:
pressure.
To relieve pressure in the system, slowly loosen fittings on hoses for scarifier fittings.
[6] - Remove midmount scarifier cylinder. See Midmount Scarifier Cylinder Remove and Install . (Group 4240.)
[7] -
CAUTION:

LEGEND:
3 Support Rod (2 used)
Midmount Scarifier Support Rods

Support support rods (3).
Support Rod Weight (approximate) 29 kg
64 lb.
[8] -
→NOTE:
Record position of shims on support rod ends to aid in assembly.
Remove cap screws (4) and remove support rod (3). Repeat procedure for opposite side.
[9] -
CAUTION:
LEGEND:
5 Midmount Scarifier Arm (2 used)
Midmount Scarifier Tool Bar Arms

Support midmount scarifier tool bar (2).

Midmount Scarifier Tool Bar Weight (approximate) 203 kg
448 lb.
[10] -
CAUTION:
Support midmount scarifier arms (5).

Midmount Scarifier Arm Weight (approximate) 149 kg
329 lb.
[12] - Remove midmount scarifier tool bar.
[13] -
LEGEND:
8 Collar (2 used)
9 Pin
10 Nut (2 used)
12 Midmount Scarifier Mount/Push Block
Front of Midmount Scarifier

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.
[16] -
CAUTION:
Support midmount scarifier mount/push block (12).

Midmount Scarifier Mount/Push block Weight (approximate) 609 kg
1342 lb.

[18] -
IMPORTANT:
To prevent damage to hydraulic lines, watch that hydraulic lines are free of midmount scarifier
mount/push block.
Remove midmount scarifier mount/push block.
[19] -
CAUTION:
LEGEND:
14 Bellcrank
16 Nut (4 used)
17 Bellcrank Bearing Housing (4 used)
Midmount Scarifier Bellcrank

Support bellcrank (14).
Bellcrank Weight (approximate) 172 kg
379 lb.
[20] - Remove nuts (16), cap screws (15).
[21] - Remove bellcrank bearing housings (17) from bellcrank (14).
[22] - Remove bellcrank.
[23] - Inspect and repair or replace parts as necessary.
[24] -
CAUTION:
Install bellcrank bearing housings and bellcrank.

Bellcrank Weight (approximate) 172 kg

379 lb.
[25] - Install cap screws and nuts.
[26] -
CAUTION:
IMPORTANT:
To prevent damage to hydraulic lines, watch that hydraulic lines are free of midmount scarifier
mount/push block.
LEGEND:
8 Collar (2 used)
9 Pin
10 Nut (2 used)
12 Midmount Scarifier Mount/Push Block
Front of Midmount Scarifier

Install midmount scarifier mount/push block (12).
Midmount Scarifier Mount/Push block Weight (approximate) 609 kg
1342 lb.
[27] -
CAUTION:
Install midmount scarifier arms (5).

Midmount Scarifier Arm Weight (approximate) 149 kg
329 lb.
[28] -
CAUTION:

LEGEND:
Midmount Scarifier Tool Bar Arms

Install midmount scarifier tool bar (2).
Midmount Scarifier Tool Bar Weight (approximate) 203 kg
448 lb.
[29] -
CAUTION:
IMPORTANT:
Install shims in previously noted location.
Install support rods (3).

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.

Midmount Scarifier Cylinder Remove and Install

[3] -
CAUTION:
pressure.
To relieve pressure in the system, slowly loosen fittings on hoses for scarifier cylinders.
[4] -
LEGEND:
1 Scarifier Cylinder
2 Scarifier Raise Hydraulic Line
3 Scarifier Lower Hydraulic Line
5 Pin (2 used)
Scarifier Cylinder
Attach identification tags to scarifier raise hydraulic line (2) and scarifier lower hydraulic line (3).
[5] - Disconnect hydraulic lines. Close all openings using caps and plugs.
[6] -
CAUTION:
Support scarifier cylinder (1).

Scarifier Cylinder Weight (approximate) 37 kg
81 lb.
[7] - Remove cap screws (4), pins (5) and scarifier cylinder.
[9] -

CAUTION:
Install scarifier cylinder, pins and cap screws.

Scarifier Cylinder Weight (approximate) 37 kg
81 lb.
[10] - Connect hydraulic lines to scarifier cylinder.
[11] - Operate midmount scarifier to bleed air from scarifier cylinder.

Ripper Remove and Install

[2] - Shut machine off and operate ripper control lever to relieve hydraulic pressure.
[4] -
CAUTION:
pressure.
LEGEND:
1 Left Cylinder Down Hydraulic Line
2 Right Cylinder Up Hydraulic Line
3 Right Cylinder Down Hydraulic Line
4 Left Cylinder Up Hydraulic Line
Ripper Hydraulic Lines

Tag hydraulic lines (1—4). Slowly loosen fittings and disconnect hydraulic lines. Close all openings using caps and plugs.
[5] -
CAUTION:
LEGEND:
5 Ripper Support Arm (2 used)
6 Pin (2 used)
Ripper Support Arm (right side shown)

Support ripper support arm (5).
Ripper Support Arm Weight (approximate) 34 kg
75 lb.
[6] - Remove pins (6) from support arms.

[7] - Lower support arms to ground.
[8] -
CAUTION:
LEGEND:
7 Ripper
Ripper Assembly
Support ripper (7) and remove cap screws (8).
Ripper Weight (approximate) 1790 kg
3946 lb.
[9] - Remove ripper.
[10] - Inspect and repair parts as necessary.
[11] -
CAUTION:
Install ripper using cap screws.

Ripper Weight (approximate) 1790 kg
3946 lb.
[12] -
CAUTION:
Install ripper support arms and pins.

Ripper Support Arm Weight (approximate) 34 kg
75 lb.

[15] - Slowly operate ripper up and down to bleed air from ripper cylinders.

Ripper Cylinders Remove and Install

[1] - Park and prepare machine for service. See Park and Prepare for Service Safely .
[2] - Shut machine off and operate ripper control lever to relieve hydraulic pressure.
[4] -
CAUTION:
pressure.
LEGEND:
2 Right Cylinder Up Hydraulic Line
3 Right Cylinder Down Hydraulic Line
Ripper Hydraulic Lines

Tag hydraulic lines (1—4). Slowly loosen fittings and disconnect hydraulic lines. Close all openings using caps and plugs.
[5] -
CAUTION:
LEGEND:
5 Ripper Cylinder
6 Nut (4 used)
8 Collar (4 used)
9 Pin (4 used)

Left Ripper Cylinder Head End
Left Ripper Cylinder Rod End

Support ripper cylinders and remove cap screws (7), nuts (6), and collars (8). Slide ripper cylinder off pin (9).
Ripper Cylinder Weight (approximate) 40 kg
88 lb.
[6] - Repeat for opposite ripper cylinder.
[7] - Inspect and repair 120 series ripper cylinders as necessary. See Cylinder Identification . (CTM120519.)
[8] -
CAUTION:
Install ripper cylinders using collars, cap screws, and nuts.

Ripper Cylinder Weight (approximate) 40 kg
88 lb.
[9] - Connect hydraulic lines to ripper cylinders.
[11] - Slowly operate ripper up and down to bleed air from ripper cylinders.

Balderson™ Style Front Lift Group Remove and Install

[3] -
CAUTION:
pressure.
To relieve pressure slowly loosen fittings on hoses at hydraulic lift cylinder (6).
[4] -
LEGEND:
1 Balderson Style Front Lift Group Frame
2 Attachment Raise Hydraulic Line
3 Attachment Lower Hydraulic Line
5 Balderson Style Front Lift Group Mount
6 Hydraulic Cylinder
Balderson Style Front Lift Group

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.
[6] -
CAUTION:
Support Balderson ™ Style Front Lift Group.

Balderson Style Front Lift Group Weight (approximate) 1100 kg
2425 lb.
[8] - Remove Balderson style front lift group mount (5).
[9] - Inspect and repair as necessary.
[10] -

DEALER FABRICATED TOOLS (g) by Belgreen v2.0
CAUTION:
Install Balderson style front lift group and cap screws.
[13] - Operate Balderson style front lift group to bleed hydraulic cylinder.

Section 99 - DEALER FABRICATED TOOLS

Table of contents
Group 9900 - Dealer Fabricated Tools .................................................................................................. 1
DF1057—Axle Adjusting Tool ................................................................................................................ 1
DFT1101 Cab and ROPS Lift Bracket .................................................................................................... 3
DFT1151—Outboard Bearing Driver ..................................................................................................... 4
DFT1152—Inboard Bearing Driver ........................................................................................................ 5
DFT1225—Rolling Torque Measurement Tool ....................................................................................... 6
DFT1250 Lifting Bracket ....................................................................................................................... 7
DFT1282—King Pin Torque Adapter ...................................................................................................... 9
DFT1310—Cab Mount Control Valve Support Bracket ........................................................................ 10
DFT1311—Extension for DFT1250 ...................................................................................................... 11

Section 99 - DEALER FABRICATED TOOLS Group 9900: Dealer Fabricated Tools
Group 9900 - Dealer Fabricated Tools

DF1057—Axle Adjusting Tool
DF1057—Axle Adjusting Tool

LEGEND:
A 660.4 mm (26 in.)
B 225.4 mm (8.87 in.)
C 1/2 in. Drilled Hole (2 places)
D Welded Nut (Centered)
E 300 mm (11.81 in.)
F 274.1 mm (10.79 in.)
G 250.8 mm (9.87 in.)
H 223.8 mm (8.81 in.)
I 25.4 mm (1 in.)
J 0.25 x 1 x 1.38 in. Each Chain Link
K 3/4 in. Drilled Hole (8 Places)
L 0.1875 x 2 x 2 in. Tube
M 25.4 mm (1 in.)
N 25.4 mm (1 in.)
O 11/16 in. Drilled Hole
P 104.7 mm (4.13 in.)

Q 50.8 mm (2 in.)
R 307.9 mm (12.12 in.)
S 355.6 mm (14 in.)
T 425.2 mm (16.74 in.)
U 25.4 mm (1 in.)
V 3/4 in. Drilled Hole (2 places)
W 25.4 mm (1 in.)
X 88.9 mm (3.5 in.)
Material Required:
2 x 2 in. Steel Tube

2 x 1/2 in. Flat Steel
Use an odd number of links in the section of chain.

Tool is used to remove axle shaft and adjust axle bearings.

DFT1101 Cab and ROPS Lift Bracket
DFT1101 Cab and ROPS Lift Bracket

LEGEND:
A Drill Six Holes (0.625 in.)
B Weld
C U46161 Lift Eyes Welded to Tube with 0.25 in. Fillet Weld
Used to remove and install cab or ROPS.
Material:
2.0 in. x 2.0 in. x 0.250 in. Square Tube

U46161 U-Bolts (4 used)
JT01748 Lift Brackets (2 used)
0.625 in. x 3.00 in. "F" Grade Cap Screws (2 used)

DFT1151—Outboard Bearing Driver
DFT1151—Outboard Bearing Driver
Material Required:
114.4 mm OD x 9.5 mm wall (4.50 in. OD x 0.375 in. wall)

Steel tubing or equivalent

DFT1152—Inboard Bearing Driver
DFT1152—Inboard Bearing Driver

LEGEND:
1 Weld All Around
2 1 1/16 in. Drill
3 98.00 mm (3.858 in.) Minimum 98.5 mm (3.878 in.) Maximum
Material Required:
Cap—20 mm (0.75 in.) mild steel plate

Barrel—114.4 mm OD x 9.5 mm wall (4.50 in. OD x 0.375 in. wall)
Steel tubing or equivalent

DFT1225—Rolling Torque Measurement Tool
DFT1225—Rolling Torque Measurement Tool

LEGEND:
A 580 mm (23 in) (minimum)
B 523 mm (20.6 in)
C 10 mm (3/8 in) flat steel bar
D 262 mm (10.3 in)
E 10 mm (3/8 in) nut and washer (8 used)
F 10 mm (3/8 in) threaded rod
G 230 mm (9 in)
H 10 mm (3/8 in) cap screw
Material Required:
10 mm (3/8 in) flat steel bar (C)

10 mm (3/8 in) threaded rod (F)
10 mm (3/8 in) nuts and washers (E) (8 used)
10 mm (3/8 in) cap screw (H)
Tool is used to measure rolling torque on HFWD wheel drive hubs.

DFT1250 Lifting Bracket
DFT1250 Lifting Bracket
Lifting bracket is used to remove and install final drives and other heavy components with limited access.
Material required:
50 x 50 mm (2 x 2 in.) 1020 Steel Bar Stock

20 x 50 mm (0.75 x 2 in.) 1020 Steel Plate

7018 Electrodes for welding

DFT1282—King Pin Torque Adapter
DFT1282—King Pin Torque Adapter

LEGEND:
A 173 mm (6.8 in.)
B 70.5 mm (2.78 in.)
C 86.5 mm (3.41 in.)
D 70.5 mm (2.78 in.)
E Weld
F 6 mm (0.25 in.)
G 24 mm Nut
H 13 mm (0.5 in.)
J 19 mm (0.750 in.)
K 38 mm (1.5 in.)
Material Required:
6 mm (1/4 in.) flat steel bar

24 mm Nut
Tool is used to measure rolling torque of lean yoke on lower king pin of front hubs.

DFT1310—Cab Mount Control Valve Support Bracket
DFT1310—Cab Mount Control Valve Support Bracket

LEGEND:
1 3.81 cm (1-1/2 in.) x 30.5 cm (12 in.) x 0.635 cm (1/4 in.) angle iron (2 used)
2 5.08 cm (2 in.) x 30.5 cm (12 in.) x 0.635 cm (1/4 in.) angle iron
3 Weld Joints
Material Required:
3.81 cm (1-1/2 in.) x 30.5 cm (12 in.) x 0.635 cm (1/4 in.) angle iron (2 used)
5.08 cm (2 in.) x 30.5 cm (12 in.) x 0.635 cm (1/4 in.) angle iron
Tool is used to support cab mount control valve during removal and installation procedure.

DFT1311—Extension for DFT1250

LEGEND:
1 457.2 mm (18 in.) x 63.5 mm (2.5 in.) x 9.53 mm (0.375 in.) Flat Steel (2 used)
2 50.2 mm (2 in.) x 76.2 mm (2 in.) x 152.4 mm (6 in.) Squared Tube
3 Weld Joints (4 used)
Material Required
457.2 mm (18.0 in.) x 63.5 mm (2.5 in.) x 9.53 mm (0.375 in.) Flat Steel (2 used)
50.2 mm (2 in.) x 76.2 mm (2 in.) x 152.4 mm (6 in.) Squared Tube
18 mm (0.706 in.) x 100 mm (3.937 in.) Cap Screw (2 used)
18 mm (0.706 in.) Nut (2 used)
18 mm (0.706 in.) Washer (4 used)
Tool is mounted to DFT1250 with cap screws and nuts to allow for removal and installation of transmission.

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770G, 770GP, 772G, and

772GP Motor Grader (SN.

REPAIR TECHNICAL MANUAL

Graders (SN. 634380—656507) models 770G, 770GP, 772G, 772GP w.Engines

For complete service information also see:

John Deere Construction and Forestry

Group 4240 - Frames

<- Go to Global Table of contents TM12141-REPAIR TECHNICAL MANUAL

<- Go to Global Table of contents TM12141-REPAIR TECHNICAL MANUAL

Manual Identiﬁcation—READ THIS FIRST!

Choosing the Correct Supporting Manuals

PIN Plate Location

PIN Plate (13 Digit)

<- Go to Global Table of contents TM12141-REPAIR TECHNICAL MANUAL

PIN Plate (17 Digit)

Engine Serial Number Plate

<- Go to Global Table of contents TM12141-REPAIR TECHNICAL MANUAL

Engine Serial Nuimber Plate Location—6090HDW04

Engine Serial Number Plate Location—6090HDW01

Engine Serial Number Plate Location—6090HDW11 and 6090HDW16

<- Go to Global Table of contents TM12141-REPAIR TECHNICAL MANUAL

Engine Model Number

Engine Model Number Engine Emission Level

6090HDW11 and 6090HDW16 Interim Tier 4/Stage III B

6090HDW01 Tier 3/Stage III A

xxxxxxxxxx E xxxxxx Interim Tier 4/Stage III B

xxxxxxxxxx D xxxxxx Tier 3/Stage III A

xxxxxxxxxx C xxxxxx Stage II

<- Go to Section TOC Section 00 page 4 TM12141-REPAIR TECHNICAL MANUAL

Section 00 - GENERAL INFORMATION

<- Go to Global Table of contents TM12141-REPAIR TECHNICAL MANUAL

<- Go to Global Table of contents TM12141-REPAIR TECHNICAL MANUAL

Group 001 - Safety

Safety alert Symbols

Safety Alert Symbols

Follow Safety Instructions

<- Go to Section TOC Section 00 page 1 TM12141-REPAIR TECHNICAL MANUAL

Operate Only If Qualiﬁed

<- Go to Section TOC Section 00 page 2 TM12141-REPAIR TECHNICAL MANUAL

Wear Protective Equipment

Avoid Unauthorized Machine Modiﬁcations

<- Go to Section TOC Section 00 page 3 TM12141-REPAIR TECHNICAL MANUAL

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

Stay Clear of Moving Parts

Stay Clear Of Moving Parts

Entanglements in moving parts can cause serious injury.

Avoid High-Pressure Fluids

<- Go to Section TOC Section 00 page 4 TM12141-REPAIR TECHNICAL MANUAL

Avoid High-Pressure Oils

Avoid High Pressure Oils

Avoid High-Pressure Oils

Work In Ventilated Area

<- Go to Section TOC Section 00 page 5 TM12141-REPAIR TECHNICAL MANUAL

Engine exhaust fumes

Handle Fuel Safely

Clean Machine Regularly

Carry A Fire Extinguisher

Prevent Battery Explosions

Handle Chemical Products Safely

Material Safety Data Sheet

Decommissioning: Proper Recycling and Disposal of Fluids and

<- Go to Section TOC Section 00 page 7 TM12141-REPAIR TECHNICAL MANUAL

Exhaust Filter Ash Handling and Disposal

Prepare for Emergencies