244K, 244K-II, and 324K Compact 4WD Loader Repair

244K, 244K-II, and 324K
Compact 4WD Loader

Repair
(PIN: 1LU244K_ _ _B034088—044118)
(PIN: 1LU244KT_ _B042870— )
(PIN: 1LU324K_ _ _B034182— )
REPAIR TECHNICAL MANUAL

244K, 244K-II, and 324K Compact
4WD Loader
TM13279X19 09FEB21 (ENGLISH)
sable marco
Jean-Francois Langlais
26 chemin de la pêche
PONT-ROUGE QC G3H 1C3
Canada
Email address:
jflanglais@sablemarco.com
Phone:
4185580378
Worldwide Construction
And Forestry Division
PRINTED IN U.S.A.
Introduction
Foreword
This manual is written for an experienced technician. Information is organized in groups for the various
Essential tools required in performing certain service work components requiring service instruction. At the
are identified in this manual and are recommended for use. beginning of each group are summary listings of all
Live with safety: Read the safety messages in the applicable essential tools, service equipment and tools,
introduction of this manual and the cautions presented other materials needed to do the job, service parts kits,
throughout the text of the manual. specifications, wear tolerances, and torque values.
Technical manuals are concise guides for specific
This is the safety-alert symbol. When this symbol is machines. They are on-the-job guides containing only the
seen on the machine or in this manual, be alert for the vital information needed for diagnosis, analysis, testing,
potential of personal injury. and repair.
Technical manuals are divided in two parts: repair and Fundamental service information is available from other
operation and tests. Repair sections tell how to repair the sources covering basic theory of operation, fundamentals
components. Operation and test sections help to quickly of troubleshooting, general maintenance, and basic type
identify the majority of routine failures quickly. of failures and their causes.
MM16284,00026ED -19-19JAN21-1/1
TM13279X19 (09FEB21) 244K, 244K-II, and 324K Compact 4WD Loader

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Introduction
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
TX1170842A —UN—03SEP14
(PIN) when choosing the correct manual.
Choosing the Correct Supporting Manuals

John Deere loaders are available in different machine
configurations based on the various markets into which
they are sold. Different supporting manuals exist for
different machine configurations. PIN Plate Location
When necessary, product identification numbers (PINs)
are listed on the front covers of loader manuals. These JOHN DEERE
numbers are used to identify the correct supporting
manual for your machine.
Product Identification Number
Product Serial Number Identification * 1LU244KXEZB123456 *
TX1170844 —UN—03SEP14
The product identification number (PIN) plate (1) is located
on the left side of the machine on the loader frame. Each LOADER
machine has a 17-character PIN (2) shown on PIN plate. DEERE & COMPANY MOLINE, ILLINOIS MADE IN AUSTRIA
2
Example of PIN Plate
1— PIN Plate 2— 17-Character PIN
The PIN identifies the producing factory, machine model

number, machine option, year of manufacture, and
machine serial number.
Continued on next page WC20922,0004FB6 -19-24JUN16-1/2

020921
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Introduction
17-Character PIN Example

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17
1 L U 2 4 4 K _ _ _ B 1 2 3 4 5 6
• (1—3) World Code: Identifies location where machine _ .................... Manufacturing Year Code (variable)
is manufactured. D ................ 2013
1LU ................ World Code (manufacturing location) E ................. 2014
1DW ............ Davenport Works F ................. 2015
1T8 .............. Thibodaux Works G ................ 2016
1T0 .............. Dubuque Works H ................. 2017
1FF .............. Deere—Hitachi J .................. 2018
1LU .............. Liebherr Z.................. Not used for calendar year of manufacture.
• (4—7) Machine Model Identifier: Identifies model • (10) Check Letter: This is a random character assigned
number. by the factory. This is not used in machine identification.
244K ............... Machine Model Identifier _ .................... Check Letter (variable)
324K ............... • (11) Liebherr Factory Code: Identifies factory of
• (8) Model Identifier Suffix, Machine Configuration manufacture.
Code, or Additional Machine Information: Contains B .................... Bischofshofen
additional machine information for overall machine
identification. • (12—17) Machine Serial Number: Identifies machine
serial number. This character will change from one
_ .................... Machine Option Code machine to another.
X ................. Base Machine 123456 ............ Machine Serial Number
T.................. 244K II with Turbocharger
H ................. 324K High Lift
• (9) Manufacturing Year Code: Identifies year of

machine manufacture.
WC20922,0004FB6 -19-24JUN16-2/2

020921
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Contents
Section 00—General Information Group 1810—Operator Enclosure
Group 0001—Safety Information Group 1830—Heating and Air Conditioning System
Group 0003—Torque Values
Section 19—Sheet Metal and Styling
Section 01—Wheels Group 1910—Hood or Engine Enclosure
Group 0110—Wheels and Fasteners Group 1913—Miscellaneous Shields
Section 02—Axles and Suspension System Section 21—Main Hydraulic System

Group 0200—Removal and Installation Group 2160—Hydraulic System
Group 0225—Axle Shafts and U-Joints
Group 0250—Axle Shaft, Bearings, and Rear Axle Section 31—Loader
Reduction Gears Group 3102—Bucket
Group 3104—Attachment Coupler
Section 03—Transmission Group 3140—Frames
Group 0300—Hydrostatic Components Removal and Group 3160—Hydraulic System
Installation
Group 0360—Hydrostatic Components Repair Section 99—Dealer Fabricated Tools
Group 9900—Dealer Fabricated Tools
Section 04—Engine
Group 0400—Removal and Installation
Section 05—Engine Auxiliary Systems

Group 0510—Cooling System
Group 0530—External Exhaust Systems
Group 0560—External Fuel Supply Systems
Section 07—Damper Drive

Section 09—Steering System

Group 0960—Hydraulic System
Section 10—Service Brakes

Group 1011—Active Elements
Section 11—Park Brake

Section 16—Electrical System

Section 17—Frame or Supporting Structure

Group 1740—Frame Installation
Group 1749—Chassis Weights
Section 18—Operator's Station

Original Instructions. All information, illustrations and specifications in this

manual are based on the latest information available at the time of publication.
The right is reserved to make changes at any time without notice.
COPYRIGHT © 2021
DEERE & COMPANY
Moline, Illinois
All rights reserved.
A John Deere ILLUSTRUCTION ™ Manual
Previous Editions
Copyright © 2015, 2016, 2017, 2018, 2019
TM13279X19 (09FEB21) i 244K, 244K-II, and 324K Compact 4WD Loader

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Contents
TM13279X19 (09FEB21) ii 244K, 244K-II, and 324K Compact 4WD Loader

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Section 00
General Information
Contents
Page
Page
Group 0001—Safety Information
Recognize Safety Information ................... 00-0001-1 Service Tires Safely................................. 00-0001-16
Follow Safety Instructions.......................... 00-0001-1 Clean Exhaust Filter Safely ..................... 00-0001-17
Operate Only If Qualified ........................... 00-0001-1
Wear Protective Equipment....................... 00-0001-2 Group 0003—Torque Values
Avoid Unauthorized Machine Torque Value
Modifications.......................................... 00-0001-2 Metric Bolt and Cap Screw....................00-0003-1
Add Cab Guarding for Special Additional Metric Cap Screw
Uses ...................................................... 00-0001-2 Torque Values ........................................ 00-0003-2
Inspect Machine ........................................ 00-0001-3 Unified Inch Bolt and Cap Screw ..........00-0003-3
Stay Clear of Moving Parts........................ 00-0001-3 Service Recommendation
Avoid High-Pressure Oils .......................... 00-0001-3 Metric 24 O-Ring Seal DIN 20078.........00-0003-4
Avoid High-Pressure Fluids ....................... 00-0001-4 Service Recommendations
Work In Ventilated Area............................. 00-0001-4 For Non-Restricted Banjo
Prevent Fires ............................................. 00-0001-5 (Adjustable) Fittings............................... 00-0003-5
Avoid Static Electricity Risk When Service Recommendations For
Refueling ............................................... 00-0001-6 O-Ring Boss Fittings With
Clean Debris from Machine ....................... 00-0001-6 Shoulder ................................................ 00-0003-6
Prevent Battery Explosions ....................... 00-0001-6 Service Recommendations for
Handle Chemical Products Safely.............. 00-0001-7 Metric Series Four Bolt Flange
Decommissioning — Proper Fitting..................................................... 00-0003-8
Recycling and Disposal of Fluids Service Recommendations For
and Components ................................... 00-0001-7 Inch Series Four Bolt Flange
Exhaust Filter Ash Handling and Fittings ................................................... 00-0003-9
Disposal................................................. 00-0001-7 Inch Series Four Bolt Flange Fitting
Prepare for Emergencies........................... 00-0001-8 For High Pressure Service
Use Steps and Handholds Recommendations............................... 00-0003-10
Correctly ................................................ 00-0001-8
Start Only From Operator's Seat ............... 00-0001-8
Use and Maintain Seat Belt ....................... 00-0001-8
Prevent Unintended Machine
Movement.............................................. 00-0001-9
Avoid Work Site Hazards......................... 00-0001-10
Use Special Care When Operating
Loader ................................................. 00-0001-11
Keep Riders Off Machine ........................ 00-0001-11
Avoid Backover Accidents ....................... 00-0001-11
Avoid Machine Tip Over and
Machine Damage ................................ 00-0001-12
Operating on Slopes................................ 00-0001-12
Operating or Traveling On Public
Roads .................................................. 00-0001-13
Inspect and Maintain ROPS .................... 00-0001-13
Travel Safely............................................ 00-0001-13
Add and Operate Attachments
Safely................................................... 00-0001-13
Park and Prepare for Service
Safely................................................... 00-0001-14
Service Cooling System Safely ............... 00-0001-14
Remove Paint Before Welding or
Heating ................................................ 00-0001-15
Make Welding Repairs Safely ................. 00-0001-15
Drive Metal Pins Safely ........................... 00-0001-15
Follow Tire Recommendations ................ 00-0001-16
TM13279X19 (09FEB21) 00-1 244K, 244K-II, and 324K Compact 4WD Loader
020921
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Contents
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Group 0001
Safety Information
Recognize Safety Information
This is the safety alert symbol. When you see this
T133555 —UN—15APR13
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
T133588 —19—28AUG00
yellow. DANGER and WARNING signs are located near
specific hazards. General precautions are on CAUTION
labels.
TX,RECOGNIZE -19-28JUN10-1/1
Follow Safety Instructions

Carefully read all safety messages in this manual and on
your machine safety signs. Keep safety signs in good
condition. Replace missing or damaged safety signs. Use
this operator’s manual for correct safety sign placement.
Be sure that new equipment components and repair parts
TS201 —UN—15APR13
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.
If you do not understand any part of this manual and need
Keep your machine in proper working condition.
assistance, contact your John Deere dealer.
Unauthorized modifications to the machine could impair
the function or safety and affect machine life.
TX,FOLLOW -19-20JAN11-1/1
Operate Only If Qualified machine functions with the machine in an open area
before starting to work.
Do not operate this machine unless the operator's manual
has been read carefully, and you have been qualified by Know and observe all safety rules that may apply to every
supervised training and instruction. work situation and work site.
Operator should be familiar with the job site and
surroundings before operating. Try all controls and
TX,QUALIFIED -19-18JAN11-1/1
TM13279X19 (09FEB21) 00-0001-1 244K, 244K-II, and 324K Compact 4WD Loader
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Safety Information
Wear Protective Equipment

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.
TX,WEAR,PE -19-22SEP10-1/1
Avoid Unauthorized Machine Modifications

John Deere recommends using only genuine John Deere reliability, and may create a hazard for the operator or
replacement parts to ensure machine performance. others near the machine. The installer of any modification
Never substitute genuine John Deere parts with alternate which may affect the electronic controls of this machine is
parts not intended for the application as these can responsible for establishing that the modification does not
create hazardous situations or hazardous performance. adversely affect the machine or its performance.
Non-John Deere Parts, or any damage or failures
resulting from their use, are not covered by any John Always contact an authorized John Deere dealer before
Deere warranty. making machine modifications that change the intended
use, weight, or balance of the machine, or that alter
Modifications of this machine, or addition of unapproved machine controls, performance, or reliability.
products or attachments, may affect machine stability or
AM40430,00000A9 -19-02JUN15-1/1
Add Cab Guarding for Special Uses screens or guarding should be installed when falling
or flying objects could enter or damage the machine.
Special work situations or machine attachments could A rear screen should always be used with a winch to
create an environment with falling or flying objects. protect against a snapping cable. Before operating in any
Working near an overhead bank, demolition work, using special work environments, follow the operator protection
a hydraulic hammer or winch, working in a forestry recommendations of the manufacturer of any specialized
application or wooded area, or working in a waste attachment or equipment. Contact your authorized John
management application, for example, could require Deere dealer for information on protective guarding.
added guarding to protect the operator.
Additional level II FOPS (falling object protective
structure), forestry protection packages, and special
TX,CABGUARD -19-12FEB13-1/1
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Safety Information
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
T6607AQ —UN—15APR13
immediately. Pay special attention to hydraulic hoses and
electrical wiring.
TX,INSPECT -19-08SEP10-1/1
Stay Clear of Moving Parts
T133592 —UN—15APR13
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.
TX,MOVING,PARTS -19-20JAN11-1/1
Avoid High-Pressure Oils

This machine uses a high-pressure hydraulic system.
Escaping oil under pressure can penetrate the skin
causing serious injury.
Never search for leaks with your hands. Protect hands.
T133509 —UN—15APR13
Use a piece of cardboard to find location of escaping oil.
Stop engine and relieve pressure before disconnecting
lines or working on hydraulic system.
If hydraulic oil penetrates your skin, see a doctor
immediately. Injected oil must be removed surgically
within hours or gangrene could result. Contact a
knowledgeable medical source or the Deere & Company
Medical Department in Moline, Illinois, U.S.A.
T133840 —UN—20SEP00
TX,HPOILS -19-20JAN11-1/1
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Safety Information
Avoid High-Pressure Fluids

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.
X9811 —UN—23AUG88
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.
a few hours or gangrene may result. Doctors unfamiliar
Search for leaks with a piece of cardboard. Protect hands with this type of injury should reference a knowledgeable
and body from high-pressure fluids. medical source. Such information is available in English
from Deere & Company Medical Department in Moline,
If an accident occurs, see a doctor immediately. Any fluid Illinois, U.S.A.
injected into the skin must be surgically removed within
KR46761,00007FD -19-18DEC12-1/1
Work In Ventilated Area

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.
DX,AIR -19-17FEB99-1/1
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Safety Information
Prevent Fires
T133552 —UN—15APR13
Handle Fluids Safely: All fuels, most lubricants, and
some coolant mixtures are flammable. Store flammable
fluids away from fire hazards. Never refuel machine while
smoking or when near sparks or flame.
Clean Machine Regularly: Keep flammable debris
(trash, leaves, twigs, straw, and other debris) and grease
and oil from accumulating in engine compartment and Handle Fuel Safely
away from fuel lines, hydraulic lines, exhaust components, T133553 —UN—07SEP00
and electrical wiring. Never store oily rags or flammable
materials inside a machine compartment.
Maintain Hoses, Tubes, and Wiring: Replace hoses
and tubes immediately if they begin to leak. 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. Clean Machine Regularly
T133554 —UN—07SEP00
Know how to use an extinguisher properly.
Be Aware of the Operating Environment: Airborne
debris may contain sparks or embers. Do not operate
near any flame.
Lithium-Ion Battery Safety:
• To reduce the risk of fire or burns, do not attempt to
open, disassemble, or service the display unit. Servicing
of this unit is to be performed only by an authorized Carry a Fire Extinguisher
dealer. There are no user-serviceable parts inside the
display unit. Accessing the inside of the equipment will
void the warranty.
T133555 —UN—15APR13
• Do not remove or handle a damaged or leaking
Lithium-Ion Polymer battery.
• Do not crush or puncture battery, short battery contacts,
or dispose of battery in fire or water.
• Do not expose to temperatures above 60°C (140°F).
Caution
TX,PREVENT,FIRE -19-28APR20-1/1
020921
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Safety Information
Avoid Static Electricity Risk When Refueling

The removal of sulfur and other compounds in Ultra-Low
Sulfur Diesel (ULSD) fuel decreases its conductivity and
increases its ability to store a static charge.
Refineries may have treated the fuel with a static
RG22142 —UN—17MAR14
dissipating additive. However, there are many factors that
can reduce the effectiveness of the additive over time.
Static charges can build up in ULSD fuel while it is flowing
through fuel delivery systems. Static electricity discharge
when combustible vapors are present could result in a
fire or explosion.
Therefore, it is important to ensure that the entire system
used to refuel your machine (fuel supply tank, transfer
pump, transfer hose, nozzle, and others) is properly
grounded and bonded. Consult with your fuel or fuel
system supplier to ensure that the delivery system is in
compliance with fueling standards for proper grounding
RG21992 —UN—21AUG13
and bonding practices.
DX,FUEL,STATIC,ELEC -19-12JUL13-1/1
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.
T6669AG —UN—15APR13
Temperature in engine compartment could go up
immediately after engine is stopped. BE ON GUARD
FOR FIRES DURING THIS PERIOD.
Open access door(s) to cool the engine faster, and clean
engine compartment.
TX,DEBRIS -19-20JAN11-1/1
Prevent 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).
DX,SPARKS -19-03MAR93-1/1
020921
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Safety Information
Handle Chemical Products Safely

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.
TS1132 —UN—15APR13
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.)
DX,MSDS,NA -19-03MAR93-1/1
Decommissioning — Proper Recycling and

Disposal of Fluids and Components
Safety and environmental stewardship measures must
be taken into account when decommissioning a machine
and/or component. These measures include the following:
TS1133 —UN—15APR13
• 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 filters; batteries; and, other substances or parts.
systems. Burning of flammable fluids or components in other than
• Minimize exposure to components which may have specially designed incinerators may be prohibited by law
residue from agricultural chemicals, such as fertilizers and could result in exposure to harmful fumes or ashes.
and pesticides. Handle and dispose of these • Service and dispose of air conditioning systems
components appropriately. appropriately. Government regulations may require
• Carefully drain engines, fuel tanks, radiators, hydraulic a certified service center to recover and recycle air
cylinders, reservoirs, and lines before recycling conditioning refrigerants which could damage the
components. Use leak-proof containers when draining atmosphere if allowed to escape.
fluids. Do not use food or beverage containers. • Evaluate recycling options for tires, metal, plastic,
• Do not pour waste fluids onto the ground, down a drain, glass, rubber, and electronic components which may be
or into any water source. recyclable, in part or completely.
• Observe all national, state, and local laws, regulations, • Contact your local environmental or recycling center, or
or ordinances governing the handling or disposal of your John Deere dealer for information on the proper
waste fluids (example: oil, fuel, coolant, brake fluid); way to recycle or dispose of waste.
DX,DRAIN -19-01JUN15-1/1
Exhaust Filter Ash Handling and Disposal governing hazardous waste disposal. Only a
qualified service provider should remove ash from
CAUTION: Under federal, state, and local laws or the exhaust filter. Personal protective equipment
regulations, exhaust filter ash can be classified and clothing, maintained in a sanitary and reliable
as a hazardous waste. Hazardous waste must condition, should be used when handling and
be disposed of in accordance with all applicable cleaning exhaust filter. See your authorized dealer
federal, state, and local laws or regulations for exhaust filter ash handling and disposal.
TX,ASH,DISP -19-20JAN11-1/1
020921
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Safety Information
Prepare for Emergencies

Be prepared if a fire starts.
Keep a first aid kit and fire extinguisher handy.
Keep emergency numbers for doctors, ambulance service,
hospital, and fire department near your telephone.
DX,FIRE2 -19-03MAR93-1/1
Use Steps and Handholds Correctly

Prevent falls by facing the machine when you get on and
T133468 —UN—15APR13
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.
TX,STEPS -19-09FEB11-1/1
Start Only From Operator's Seat
T133715 —UN—15APR13
Avoid unexpected machine movement. Start engine only
while sitting in operator's seat. Ensure that all controls and
working tools are in proper position for a parked machine.
Never attempt to start engine from the ground. Do not
attempt to start engine by shorting across the starter
solenoid terminals.
TX,SOFOS -19-20JAN11-1/1
Use and Maintain Seat Belt

Use seat belt when operating machine. Remember to
TX1165594 —19—23JUL14
fasten seat belt when loading and unloading from trucks
and during other uses.
CAUTION: Prevent personal injury. Check

condition of seat belt and mounting hardware
before operating machine. Replace if worn,
frayed, or damaged.
Replace seat belt at least every 3 years,
regardless of condition.
TX,SEAT,BELT -19-27JUL20-1/1
020921
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Safety Information
Prevent Unintended Machine Movement

When coworkers are present, disable hydraulics.
Lower all equipment to the ground during work
T142001 —UN—15MAY01
interruptions. Lock transmission control in neutral, engage
park brake and stop engine before allowing anyone to
approach the machine.
Follow these same precautions before standing up,
leaving the operator's seat, or exiting the machine.
TX03679,00017C7 -19-08MAR07-1/1
020921
PN=17
Safety Information
Avoid Work Site Hazards

Before digging, check local requirements and call
utility line location services to identify and mark all
T141894 —UN—15APR13
underground utilities in digging area before starting
work. Avoid contact with gas lines, buried cables and
water lines.
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 Avoid Contact With Gas Line
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
TX1286211 —UN—03OCT19
loads. Avoid swinging or raising booms, attachments, or (USA only)
loads over or near personnel. Use barricades or a signal
person to keep vehicles and pedestrians away. Use a 1-888-258-0808
signal person if moving machine in congested areas or
where visibility is restricted. Always keep signal person in
(USA & Canada)
view. Coordinate hand signals before starting machine.
Operate only on solid footing with strength sufficient
811 Call Before You Dig
to support machine. Be especially alert working near
embankments or excavations.
Avoid working under overhanging embankments or
stockpiles that could collapse under or on machine.
T141670 —UN—24APR01
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.
Avoid Contact With Overhead Electrical Lines
T141672 —UN—04MAY01
Operate Only on Solid Footing
DP99999,0000113 -19-07OCT19-1/1
020921
PN=18
Safety Information
Use Special Care When Operating Loader

Never use the loader to lift people. Do not allow
anyone to ride in the bucket or use the bucket as a
T141957 —UN—15APR13
work platform.
Operate carefully with raised loads. Raising the load
reduces machine stability, especially on side slopes or an
unstable surface. Drive and turn slowly with a raised load.
Ensure that objects in the bucket are secure. Do not
attempt to lift or carry objects that are too big or too long to
fit inside the bucket unless secured with an adequate chain
or other device. Keep bystanders away from raised loads.
Be careful when lifting objects. Never attempt to lift
objects too heavy for your machine. Assure machine
T141902 —UN—07MAY01
stability and hydraulic capability with a test lift before
attempting other maneuvers. Use an adequate chain or
sling and proper rigging techniques to attach and stabilize
loads. Never lift an object above or near another person.
TX,LOADER,OP -19-17DEC20-1/1
Keep Riders Off Machine

Always use seat belt.
Only allow operator on machine.
T141671 —UN—15APR13
The instructional seat, if equipped, is used to
accommodate trainers, persons that need to observe
machine operation, and for coworkers to provide further
operational instructions.
Riders are subject to injury due to fall from machine, being
caught between machine parts, or being struck by foreign Keep Riders Off Machine
objects. Riders may obstruct the operator's view or impair
the operator's ability to operate machine safely.
TX,NO,RIDERS,4WD -19-23APR20-1/1
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 PC10857XW —UN—15APR13
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, if equipped, to determine if personnel are
behind the machine. The system has limitations due to
maintenance practices, environmental conditions, and
operating range.
TX,AVOID,BACKOVER -19-04MAR16-1/1
020921
PN=19
Safety Information
Avoid Machine Tip Over and Machine Damage

Use seat belt at all times.
T133716 —19—17APR13
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.
Use Seat Belt
Be careful on slopes. Avoid sharp turns. Balance loads
so weight is evenly distributed and load is stable. Carry
tools and loads close to the ground to aid visibility and
lower center of gravity. Use extra care on soft, rocky, or
frozen ground.
Know the capacity of the machine. Do not overload. Be
T141676 —UN—04MAY01
careful with heavy loads. Using oversize buckets or lifting
heavy objects reduces machine stability.
Ensure solid footing. Use extra care in soft ground
conditions that may not uniformly support the wheels,
especially when raising the boom. Do not operate close to
banks or open excavations that may cave in and cause
machine to tip or fall. Do Not Jump
T141672 —UN—04MAY01
Ensure solid footing
TX03679,000179D -19-05MAR20-1/1
Operating on Slopes
Avoid side slope travel whenever possible. Drive up steep
slope in forward and down in reverse.
T141681 —UN—15APR13
Select low gear speed before starting down slope. The
grade of the slope will be limited by ground condition and
load being handled.
Use service brakes to control speed. Sudden brake
application with a loaded bucket on downhill side could
cause machine to tip forward.
Operating on Slopes
TX03679,000179E -19-24FEB15-1/1
020921
PN=20
Safety Information
Operating or Traveling On Public Roads

Machines that work near vehicle traffic or travel slower
than normal highway speeds must have proper lighting
T141891 —UN—15APR13
and markings to assure they are visible to other drivers.
Install additional lights, beacon lights, 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.
TX,ROADS -19-20JAN11-1/1
Inspect and Maintain ROPS To maintain the ROPS:

A damaged rollover protective structure (ROPS) should
be replaced, not reused.
• Replace missing hardware using correct grade
hardware.
The protection offered by ROPS could be impaired if • Check hardware torque.
ROPS is subjected to structural damage, is involved in • Check isolation mounts for damage, looseness, or
an overturn incident, or is in any way altered by welding, wear; replace them if necessary.
bending, drilling, or cutting. • Check ROPS for cracks or physical damage.
If ROPS was loosened or removed for any reason, inspect
it carefully before operating the machine again.
TX,ROPS -19-20JAN11-1/1
Travel Safely
When working on steep slopes, travel as straight up and
down as possible to prevent roll-over.
DO NOT PARK ON A HILLSIDE OR AN INCLINE.
T6964AD —UN—20DEC88
Always park the machine on level ground.
Know the location of bystanders before moving the
machine.
Always keep the reverse warning alarm in working
condition. The alarm warns bystanders when the machine
starts to move in reverse.
Travel Safely
Use a signal person when moving the machine in
congested areas. Coordinate hand signals before starting
the machine.
CN93077,00000B3 -19-01JUL15-1/1
Add and Operate Attachments Safely is required or recommended. Verify that all connections
are secure and attachment responds properly to controls.
Always verify compatibility of attachments by contacting
your authorized dealer. Adding unapproved attachments Carefully read attachment manual and follow all
could affect machine stability or reliability and could create instructions and warnings. In an area free of bystanders
a hazard for others near the machine. and obstructions, carefully operate attachment to learn its
characteristics and range of motion.
Ensure that a qualified person is involved in attachment
installation. Add guards to machine if operator protection
TX,ATTACH -19-20JAN11-1/1
020921
PN=21
Safety Information
Park and Prepare for Service Safely

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.
T133332 —19—17APR13
• Engage park brake.
• Stop engine.
• Install frame locking bar.
• Attach a DO NOT OPERATE tag in an obvious place in
the operator's station.
• Do not support machine with boom, bucket, or other
hydraulically actuated equipment.
• Do not support machine with cinder blocks or wooden
pieces that can crumble or crush.
• Do not support machine with a single jack or other
devices that could slip out of place.
Securely support machine or attachment before working
under it.
TS229 —UN—23AUG88
Install wheel chocks to ensure that machine cannot move
backward or forward during service.
Understand service procedures before beginning repairs.
Keep service area clean and dry. Use two people
whenever the engine must be running for service work.
When performing above-ground maintenance, use
appropriate support devices such as ladders, lifts, or
platforms. If equipped, use the machine anchorage points
and approved fall arrest harnesses and lanyards
TX,PARK,4WD -19-23SEP20-1/1
Service Cooling System Safely

Explosive release of fluids from pressurized cooling
system can cause serious burns.
Shut off engine. Only remove filler cap when cool enough
to touch with bare hands. Slowly loosen cap to first stop
to relieve pressure before removing completely.
DX,RCAP -19-04JUN90-1/1
020921
PN=22
Safety Information
Remove Paint Before Welding or Heating

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
Do all work in an area that is well ventilated to carry toxic
from area. Allow fumes to disperse at least 15 minutes
fumes and dust away.
before welding or heating.
Do not use a chlorinated solvent in areas where welding Dispose of paint and solvent properly.
will take place.
DX,PAINT -19-24JUL02-1/1
Make Welding Repairs Safely

IMPORTANT: Disable electrical power before welding.
T133547 —UN—15APR13
Turn off main battery switch and disconnect
positive (+) and negative (-) battery cables.
Do not weld or apply heat on any part of a reservoir or

tank that has contained oil or fuel. Heat from welding and
cutting can cause oil, fuel, or cleaning solution to create
gases which are explosive, flammable, or toxic.
Heating Near Pressurized Fluid Lines
Avoid welding or heating near pressurized fluid lines.
Flammable spray may result and cause severe burns if
pressurized lines malfunction as a result of heating. Do not Make sure there is good ventilation. Wear eye protection
let heat go beyond work area to nearby pressurized lines. and protective equipment when welding.
Remove paint properly. Do not inhale paint dust or fumes.

Use a qualified welding technician for structural repairs.
MB60223,0000212 -19-02JUL15-1/1
Drive Metal Pins Safely
T133738 —UN—15APR13
Always wear protective goggles or safety glasses and
other protective equipment before striking hardened
parts. Hammering hardened metal parts such as pins and
bucket teeth could dislodge chips at high velocity.
Use a soft hammer or a brass bar between hammer and
object to prevent chipping.
TX,PINS -19-20JAN11-1/1
020921
PN=23
Safety Information
Follow Tire Recommendations

Keep your machine in proper working order.
Use only prescribed tire sizes with correct ratings and
inflate to the pressure specified in this manual.
H111235 —UN—13MAY14
Use of other than prescribed tires may decrease stability,
affect steering, result in premature tire failure, or cause
other durability or safety issues.
DX,TIRE,INFO -19-19MAY14-1/1
Service Tires Safely

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.
DX,RIM -19-24AUG90-1/1
020921
PN=24
Safety Information
Clean Exhaust Filter Safely

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 that 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
TS1693 —UN—09DEC09
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 engine and remove key (if equipped) before
leaving the machine unattended.
TS1695 —UN—07DEC09
DX,EXHAUST,FILTER -19-12JAN11-1/1
020921
PN=25
Safety Information
020921
PN=26
Group 0003
Torque Values
Metric Bolt and Cap Screw Torque Values
METRIC BOLT AND CAP SCREW TORQUE VALUES—Tolerance is ±10% unless otherwise specified
TORQ2 —UN—15APR13
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
Thread Lubricateda Dryb Lubricateda Dryb Lubricateda Dryb Lubricateda Dryb
Size Nm (lb-ft) Nm (lb-ft) Nm (lb-ft) Nm (lb-ft) Nm (lb-ft) Nm (lb-ft) Nm (lb-ft) Nm (lb-ft)
M6 4.7 (3.5) 6 (4.4) 9 (6.6) 11.5 (8.5) 13 (9.5) 16.5 (12.2) 15.5 (11.5) 19.5 (14.5)
M8 11.5 (8.5) 14.5 (10.7) 22 (16) 28 (20.5) 32 (23.5) 40 (29.5) 37 (27.5) 47 (35)
M10 23 (17) 29 (21) 43 (32) 55 (40) 63 (46) 80 (59) 75 (55) 95 (70)
M12 40 (29.5) 50 (37) 75 (55) 95 (70) 110 (80) 140 (105) 130 (95) 165 (120)
M14 63 (46) 80 (59) 120 (88) 150 (110) 175 (130) 220 (165) 205 (150) 260 (190)
M16 100 (74) 125 (92) 190 (140) 240 (175) 275 (200) 350 (255) 320 (235) 400 (300)
M18 135 (100) 170 (125) 265 (195) 330 (245) 375 (275) 475 (350) 440 (325) 560 (410)
M20 190 (140) 245 (180) 375 (275) 475 (350) 530 (390) 675 (500) 625 (460) 790 (580)
M22 265 (195) 330 (245) 510 (375) 650 (480) 725 (535) 920 (680) 850 (625) 1080 (800)
M24 330 (245) 425 (315) 650 (480) 820 (600) 920 (680) 1150 (850) 1080 (800) 1350 (1000)
M27 490 (360) 625 (460) 950 (700) 1200 (885) 1350 (1000) 1700 (1250) 1580 (1160) 2000 (1475)
M30 660 (490) 850 (625) 1290 (950) 1630 (1200) 1850 (1350) 2300 (1700) 2140 (1580) 2700 (2000)
M33 900 (665) 1150 (850) 1750 (1300) 2200 (1625) 2500 (1850) 3150 (2325) 2900 (2150) 3700 (2730)
M36 1150 (850) 1450 (1075) 2250 (1650) 2850 (2100) 3200 (2350) 4050 (3000) 3750 (2770) 4750 (3500)
a
"Lubricated" means coated with a lubricant such as engine oil, or fasteners with phosphate and oil coatings.
b
"Dry" means plain or zinc plated without any lubrication.
Fasteners should be replaced with the same or higher property class. If

CAUTION: Use only metric tools on metric hardware. Other higher property class fasteners are used, these should only be tightened
tools may not fit properly. Tool may slip and cause injury. to the strength of the original.
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
general use only. Check tightness of fasteners periodically. Tighten plastic insert or crimped steel-type lock nuts to approximately
50 percent of the dry torque shown in the chart, applied to the nut, not
Shear bolts are designed to fail under predetermined loads. Always to the bolt head. Tighten toothed or serrated-type lock nuts to the full
replace shear bolts with identical property class. torque value.
OUT3035,TORQUE2 -19-22MAR04-1/1
020921
PN=27
Torque Values
Additional Metric Cap Screw Torque Values
T6873AA —UN—15APR13
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
T-Bolt
for a specific application.
Shear bolts are designed to fail under predetermined
T6873AB —UN—18OCT88
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 that the
thread engagement is properly started. This will prevent
fasteners from failing when tightening. H-Bolt
Tighten cap screws having lock nuts to approximately 50
T6873AC —UN—18OCT88
percent of amount shown in chart.
METRIC CAP SCREW TORQUE VALUESa
T-Bolt H-Bolt M-Bolt
Nomi-
nal Di-
ameter N·m lb·ft N·m lb·ft N·m lb·ft
8 29 21 20 15 10 7 M-Bolt
10 63 46 45 33 20 15
12 108 80 88 65 34 25
14 176 130 137 101 54 40
16 265 195 206 152 78 58
18 392 289 294 217 118 87
20 539 398 392 289 167 125
22 735 542 539 398 216 159
24 931 687 686 506 274 202
27 1372 1012 1029 759 392 289
30 1911 1410 1421 1049 539 398
33 2548 1890 1911 1410 735 542
36 3136 2314 2401 1772 931 687
a
Torque tolerance is ±10%.
04T,90,M170 -19-09JUL19-1/1
020921
PN=28
Torque Values
Unified Inch Bolt and Cap Screw Torque

Values
UNIFIED INCH BOLT AND CAP SCREW TORQUE VALUES—Tolerance is ±10% unless otherwise specified
TORQ1A —UN—15APR13
Top—SAE Grade and Head Markings; Bottom—SAE Grade and Nut Markings
Grade 1 (No Mark) Grade 2a (No Mark) Grade 5, 5.1 or 5.2 Grade 8 or 8.2
b c
Thread Lubricated Dry Lubricatedb Dryc Lubricatedb Dryc Lubricatedb Dryc
Size N·m (lb-ft) N·m (lb-ft) N·m (lb-ft) N·m (lb-ft) N·m (lb-ft) N·m (lb-ft) N·m (lb-ft) N·m (lb-ft)
1/4 3.8 (2.8) 4.7 (3.5) 6 (4.4) 7.5 (5.5) 9.5 (7) 12 (9) 13.5 (10) 17 (12.5)
5/16 7.7 (5.7) 9.8 (7.2) 12 (9) 15.5 (11.5) 19.5 (14.5) 25 (18.5) 28 (20.5) 35 (26)
3/8 13.5 (10) 17.5 (13) 22 (16) 27.5 (20) 35 (26) 44 (32.5) 49 (36) 63 (46)
7/16 22 (16) 28 (20.5) 35 (26) 44 (32.5) 56 (41) 70 (52) 80 (59) 100 (74)
1/2 34 (25) 42 (31) 53 (39) 67 (49) 85 (63) 110 (80) 120 (88) 155 (115)
9/16 48 (35.5) 60 (45) 76 (56) 95 (70) 125 (92) 155 (115) 175 (130) 220 (165)
5/8 67 (49) 85 (63) 105 (77) 135 (100) 170 (125) 215 (160) 240 (175) 305 (225)
3/4 120 (88) 150 (110) 190 (140) 240 (175) 300 (220) 380 (280) 425 (315) 540 (400)
7/8 190 (140) 240 (175) 190 (140) 240 (175) 490 (360) 615 (455) 690 (510) 870 (640)
1 285 (210) 360 (265) 285 (210) 360 (265) 730 (540) 920 (680) 1030 (760) 1300 (960)
1-1/8 400 (300) 510 (375) 400 (300) 510 (375) 910 (670) 1150 (850) 1450 (1075) 1850 (1350)
1-1/4 570 (420) 725 (535) 570 (420) 725 (535) 1280 (945) 1630 (1200) 2050 (1500) 2600 (1920)
1-3/8 750 (550) 950 (700) 750 (550) 950 (700) 1700 (1250) 2140 (1580) 2700 (2000) 3400 (2500)
1-1/2 990 (730) 1250 (930) 990 (730) 1250 (930) 2250 (1650) 2850 (2100) 3600 (2650) 4550 (3350)
a
Grade 2 applies for hex cap screws (not hex bolts) up to 6 in. (152 mm) long. Grade 1 applies for hex cap screws over 6 in. (152 mm) long, and
for all other types of bolts and screws of any length.
b
"Lubricated" means coated with a lubricant such as engine oil, or fasteners with phosphate and oil coatings.
c
"Dry" means plain or zinc plated without any lubrication.
DO NOT use these values if a different torque value or tightening Make sure fastener threads are clean and that you properly start thread
procedure is given for a specific application. Torque values listed are for engagement. This will prevent them from failing when tightening.
general use only. Check tightness of fasteners periodically.
Tighten plastic insert or crimped steel-type lock nuts to approximately
Shear bolts are designed to fail under predetermined loads. Always 50 percent of the dry torque shown in the chart, applied to the nut, not
replace shear bolts with identical grade. to the bolt head. Tighten toothed or serrated-type lock nuts to the full
torque value.
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.
OUT3035,TORQUE1 -19-14JAN04-1/1
020921
PN=29
Torque Values
Metric 24° O-Ring Seal DIN 20078 Service

Recommendations
METRIC 24° O-RING SEAL DIN 20078 TORQUE VALUES
Fitting Heavy Fitting Light Fitting Torque
Tube OD Size Size
Size
mm mm mm Turns
6 — M12 x 1.5
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 — Hand tighten so
O-ring contacts seat
18 — M26 x 1.5 plus an additional
— 1/4—1/3 turn using
20 M30 x 2 a wrench
22 — M30 x 2
25 M36 x 2 —
28 — M36 x 2
30 M42 x 2 —
35 — M45 x 2
38 M52 x 2 —
T113889 —UN—15APR13
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.
4. Align an adjustable fitting with the tube.
1. Inspect the fitting sealing surfaces. They must be free Hold connections together while tightening nut to
of dirt scratches, nicks, and burrs. ensure proper seal.
2. Inspect the O-ring. It must be free dirt, cuts, cracks, 5. Tighten nut (A) hand tight so O-ring contacts seat and
swelling or flatten condition. then an additional 1/4—1/3 turn using a wrench.
3. Lubricate O-rings using a thin film of clean hydraulic oil.
CED,OUO1002,517 -19-14JAN04-1/1
020921
PN=30
Torque Values
Service Recommendations For

Non-Restricted Banjo (Adjustable) Fittings
1. Inspect all fitting sealing surfaces. They must be free
of dirt and defects.
2. Inspect O-ring (A). It must be free of damage or defects.
3. Inspect sealing ring (B) for damage or defects.
4. Hold body in desired position while tightening stud by
hand.
5. Tighten stud (C) to torque value shown on the chart.
Do not allow body to twist when tightening stud.
NOTE: The L in the Tube Fitting OD Size column
T113948 —UN—06MAR98
indicates “light” designed fitting and the S
indicates “heavy” designed fitting.
Torque Value
Tube Fitting Metric Thread N·m lb-ft
O.D. Size
6 L M 10 x 1 30 22
8 L M 12 x 1.5 40 30 Torque Value
10 L M 14 x 1.5 60 44 Tube Fitting Inch Size N·m lb-ft
O.D. Size
12 L M 16 x 1.5 100 74
6 L 1/8 25 18
15 L M 18 x 1.5 130 96
18 L M 22 x 1.5 160 118 8 L 1/4 50 37
22 L M 26 x 1.5 250 184 10 L 1/4 50 37
28 L M 33 x 2 400 295 12 L 3/8 90 66
35 L M 42 x 2 600 443 15 L 1/2 130 96
42 L M48 x 2 800 590 18 L 1/2 150 111
6 S M 12 x 1.5 40 30 22 L 3/4 250 184
8 S M 14 x 1.5 60 44 28 L 1 400 295
10 S M 16 x 1.5 100 74 35 L 1-1/4 600 443
12 S M 18 x 1.5 130 96 42 L 1-1/2 800 590
14 S M 20 x 1.5 160 118 6 S 1/4 50 37
16 S M 22 x 1.5 160 118 8 S 1/4 50 37
20 S M 27 x 2 250 184 10 S 3/8 90 66
25 S M 33 x 2 400 295 12 S 3/8 100 74
30 S M 42 x 2 600 443 14 S 1/2 130 96
38 S M 48 x 2 800 590 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
CS33148,0002C88 -19-18MAR09-1/1
020921
PN=31
Torque Values
Service Recommendations For O-Ring Boss

Fittings 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.
T113957 —UN—06MAR98
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 O-Ring Boss Fitting With Shoulder
tightening fittings.
Torque Value
NOTE: The L in the Tube Fitting OD Size column
indicates “light” designed fitting and the S Tube Fitting Inch Size N·m lb·ft
indicates “heavy” designed fitting. O.D. Size
6 L 1/8 20 15
Torque Value
8 L 1/4 40 30
Tube Fitting Metric Thread N·m lb·ft
10 L 1/4 40 30
O.D. Size
12 L 3/8 80 59
6 L M10 x 1 20 15
15 L 1/2 140 103
8 L M12 x 1.5 30 22
18 L 1/2 100 74
10 L M14 x 1.5 45 33
22 L 3/4 180 133
12 L M16 x 1.5 60 44
28 L 1 300 221
15 L M18 x 1.5 80 59
35 L 1-1/4 600 443
18 L M22 x 1.5 130 96
42 L 1-1/2 800 590
22 L M26 x 1.5 190 140
6 S 1/4 50 37
28 L M33 x 2 300 221
35 L M42 x 2 600 443 8 S 1/4 50 37
42 L M48 x 2 800 590 10 S 3/8 90 66
6 S M12 x 1.5 40 30 12 S 3/8 90 66
8 S M14 x 1.5 60 44 14 S 1/2 160 118
10 S M16 x 1.5 80 59 16 S 1/2 140 103
12 S M18 x 1.5 110 81 20 S 3/4 250 184
14 S M20 x 1.5 140 103 25 S 1 400 295
16 S M22 x 1.5 170 125 30 S 1-1/4 650 479
20 S M27 x 2 250 184 38 S 1-1/2 800 590
25 S M33 x 2 450 332

30 S M42 x 2 600 443
38 S M48 x 2 800 590
Continued on next page CED,OUO1002,563 -19-09MAR98-1/2
020921
PN=32
Torque Values
Hex Socket Head Plugs Only

Torque Value
Thread Size N·m lb·ft
M10 x 1 13 10
M12 x 1.5 30 22
M14 x 1.5 40 30
M16 x 1.5 60 44
M18 x 1.5 70 52
M20 x 1.5 90 66
M22 x 1.5 100 74
M26 x 1.5 120 89
M27 x 2 150 111
M33 x 2 250 184
M42 x 2 400 295
M48 x 2 500 369
1/8 15 11
1/4 33 24
3/8 70 52
1/2 90 66
3/4 150 111
1 220 162
1-1/4 600 443
1-1/2 800 590
CED,OUO1002,563 -19-09MAR98-2/2
020921
PN=33
Torque Values
Service Recommendations for Metric Series Four Bolt Flange Fitting
T6890BB —UN—15APR13
Metric Series Four Bolt Flange Fitting
A—Sealing Surface C—Pinched O-Ring
B—Split Flange D—Single Piece Flange
1. Clean sealing surfaces (A). Inspect. Scratches cause

DO NOT use air wrenches. DO NOT tighten one cap
leaks. Roughness causes seal wear. Out-of-flat
screw fully before tightening the others. DO NOT over
causes seal extrusion. If defects cannot be polished
tighten.
out, replace component.
TORQUE CHARTa
2. Install the correct O-ring (and backup washer if
b
required) into groove using petroleum jelly to hold it Thread N·m lb·ft
in place. M6 12 9
3. Split flange: Loosely assemble split flange (B) halves. M8 30 22

Make sure split is centrally located and perpendicular M10 57 42
to the port. Hand tighten cap screws to hold parts in
M12 95 70
place. Do not pinch O-ring (C).
M14 157 116
4. Single piece flange (D): Place hydraulic line in center
M16 217 160
of flange and install four cap screws. Flange must be
centrally located on port. Hand tighten cap screws to M18 334 246
hold flange in place. Do not pinch O-ring. M20 421 318
a
5. After components are properly positioned and cap Tolerance ± 10%. The torques given are enough for the given size
connection with the recommended working pressure. Increasing
screws are hand tightened, tighten one cap screw, cap screw torque beyond these amounts will result in flange and
then tighten the diagonally opposite cap screw. cap screw bending and connection failures.
Tighten two remaining cap screws. Tighten all cap b
Metric standard thread.
screws as specified in the chart below.
04T,90,K175 -19-29SEP99-1/1
020921
PN=34
Torque Values
Service Recommendations For Inch Series Four Bolt Flange Fittings
Flange Fittings
1. Clean sealing surfaces (A). Inspect. Scratches cause TORQUE CHART

leaks. Roughness causes seal wear. Out-of-flat N·m lb·ft
causes seal extrusion. If defects cannot be polished
out, replace component. Nominal Cap Screw
Flange Size
2. Install O-ring (and backup washer if required) into Size Min Max Min Max
groove using petroleum jelly to hold it in place. 1/2 5/16-18 UNC 20 31 15 23
3. Split flange: Loosely assemble split flange (B) halves. 3/4 3/8-16 UNC 28 54 21 40
Make sure split is centrally located and perpendicular 1 3/8-16 UNC 37 54 27 40
to port. Hand tighten cap screws to hold parts in place. 1-1/4 7/16-14 UNC 47 85 35 63
Do not pinch O-ring (C).
1-1/2 1/2-13 UNC 62 131 46 97
4. Single piece flange (D): Place hydraulic line in center
2 1/2-13 UNC 73 131 54 97
of flange and install cap screws. Flange must be
centrally located on port. Hand tighten cap screws to 2-1/2 1/2-13 UNC 107 131 79 97
hold flange in place. Do not pinch O-ring. 3 5/8-11 UNC 158 264 117 195
5. Tighten one cap screw, then tighten the diagonally 3-1/2 5/8-11 UNC 158 264 117 195
opposite cap screw. Tighten two remaining cap screws. 4 5/8-11 UNC 158 264 117 195
Tighten all cap screws as specified in the chart below.
5 5/8-11 UNC 158 264 117 195
DO NOT use air wrenches. DO NOT tighten one cap
screw fully before tightening the others. DO NOT over
tighten.
04T,90,K174 -19-01AUG94-1/1
020921
PN=35
Torque Values
Inch Series Four Bolt Flange Fitting For High Pressure Service Recommendations
INCH SERIES FOUR BOLT FLANGE FITTING FOR 41 400 kPa (414 O-ring wear. Out-of-flat causes O-ring extrusion.
bar) (6000 psi) PRESSURE SERIES TORQUE VALUES—Tolerance If imperfection cannot be polished out, replace
is ± 10% unless otherwise specified component.
Nominal Cap Screw Sizea Min—Max Torque
Flange Size 2. Install the O-ring (and backup ring, if used) into
b groove. Use petroleum jelly to hold it in place.
in. in. Nm (lb-ft)
1/2 5/16-18 UNC 20—31 (15—23) IMPORTANT: DO NOT use air wrenches. DO NOT
tighten one cap screw fully before tightening
3/4 3/8-16 UNC 34—54 (25—40) the others. DO NOT over tighten.
1 7/16-14 UNC 57—85 (42—63)
1-1/4 1/2-13 UNC 85—131 (63—97) 3. Split flange: Loosely assemble split flange (B) halves.
Make sure split is centrally located and perpendicular
1-1/2 5/8-11 UNC 159—264 (117—195) to port. Hand tighten cap screws to hold flange halves
2 3/4-10 UNC 271—468 (200—345) and line in place. Do not pinch O-ring (C).
a
JDM A17D, SAE Grade 5 or better cap screws with plated hardware. Single piece flange (D): Make sure flange is centrally
Lock washers are permissible but not recommended.
located on port and line is centered in flange. Install
b
Minimum torques given are enough for the given size connection the cap screws. Hand tighten cap screws to hold
with the recommended working pressure. Torques can be increased flange and line in place. Do not pinch O-ring.
to the maximum shown for each cap screw size if desired. Increasing
cap screw torque beyond the maximum will result in flange and cap 4. Tighten one cap screw and then the diagonally
screw bending and connection failures.
opposite cap screw. Tighten the two remaining cap
screws. Tighten cap screws within the specified torque
1. Clean sealing surfaces (A). Inspect. Scratches, values.
nicks, and burrs cause leaks. Roughness causes
OUT3035,0000422 -19-05MAR09-1/1
020921
PN=36
Section 01
Wheels
Contents
Page
Group 0110—Wheels and Fasteners

Wheel Remove and Install......................... 01-0110-1
Tire Remove and Install............................. 01-0110-1
020921
PN=1
Contents
020921
PN=2
Group 0110
Wheels and Fasteners
Wheel Remove and Install
1. Raise machine and install 10-ton floor stands under
axle.
CAUTION: Prevent possible crushing injury from

heavy component. Use appropriate lifting device.
Specification
Wheel—Approximate
T204465A —UN—26OCT04
Weight............................................................................................110 kg
243 lb
2. Position wheel lift under wheel. Fasten safety chain

around upper part of tire.
3. Remove lug nuts (1) and wheel.
4. Clean mounting surface on wheel and axle flange. 1— Lug Nuts (8 used)
Install wheel and tighten lug nuts to specification.
Specification
Wheel-to-Axle Lug
Nuts—Torque..............................................................................450 N·m
332 lb-ft
OUO1010,00006C0 -19-25OCT04-1/1
Tire Remove and Install

CAUTION: Explosive separation of a tire and rim
parts can cause serious injury or death.
DO NOT attempt to mount a tire unless you
have 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 tire
pressure resulting in a tire explosion. Welding
can also 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.
Inspect tires and wheels for low pressure,
cuts, bubbles, damaged rims or missing
lug bolts and nuts.
NOTE: Tire can be removed and installed without

removing wheel from machine.
Continued on next page SP66632,0004ABF -19-12DEC14-1/2
020921
PN=39
Wheels and Fasteners
1. Before attempting any demounting operation,

completely deflate the tire by removing the valve core
(A).
2. Inspect all parts for wear or damage. Replace where
necessary.
T115662B —UN—03JUN98
3. Make sure all parts are clean and free from rust or
grease before assembly.
A—Valve Core
SP66632,0004ABF -19-12DEC14-2/2
020921
PN=40
Section 02
Axles and Suspension System
Contents
Page

Front Axle Remove and Install .................. 02-0200-1
Rear Axle Remove and Install ................... 02-0200-3
Group 0225—Axle Shafts and U-Joints

Drive Shaft Remove and Install ................. 02-0225-1
Group 0250—Axle Shaft, Bearings, and

Rear Axle Reduction Gears
Axle Shaft, Bearings, and Rear
Axle Reduction Gears............................ 02-0250-1
020921
PN=1
Contents
020921
PN=2
Group 0200
Removal and Installation
Front Axle Remove and Install
TX1180746 —UN—09JAN15
4
5
TX1180746
Front Axle
1— Front Axle 3— Mounting Plate (2 used) 4— Washer (4 used)
2— Lug Nut (16 used) 5— Cap Screw (4 used)
CAUTION: Prevent possible crushing

injury from heavy component. Use
SPECIFICATIONS appropriate floor stands.
244K and 244K- II Machine 5591 kg
Weight (approximate) 12 325 lb. • Raise front of machine. Install D01182AA 20-Ton Floor
Stands under front frame.
324K Machine Weight 6396 kg
(approximate) 14 100 lb. Removal
Front Axle Weight (approximate) 270 kg
595 lb. 1. Remove front wheels. See Wheel Remove and Install.
(Group 0110.)
Axle Mounting Cap Screw Torque 1150 N·m
850 lb.-ft. 2. Remove drive shaft. See Drive Shaft Remove and
Lug Nut Torque 450 N·m Install. (Group 0225.)
332 lb.-ft.
3. Tag and disconnect hydraulic lines from axle and drum
SERVICE EQUIPMENT AND TOOLS brake.
D01182AA 20-Ton Floor Stand
JT01642A Low-Lift Transmission Jack heavy component. Use appropriate lifting device.
Machine Preparation 4. Position JT01642A Low-Lift Transmission Jack under

axle and secure axle to jack.
• Prepare machine for service. See Park and Prepare for
Service Safely. (Group 0001.) 5. Remove cap screws (5), washers (4), and mounting
• Raise boom and install boom lock. See Loader Boom plates (3). Lower axle (1) and remove from machine.
Lock. (Operator’s Manual.)
• Stop engine. 6. Repair or replace axle. See Axle Shaft, Bearings, and
Rear Axle Reduction Gears. (Group 0250.)
Continued on next page SP66632,0004ABD -19-23AUG16-1/2
020921
PN=43
Installation
• Bleed service brake. See Drum Brake Bleed. (Group
Installation is reverse of removal procedure. 1060.)
• Check differential and wheel hub oil levels. See Check
• Tighten axle mounting cap screws to specification. Final Drives Oil Level and see Check Front Differential
Specification Oil Level. (Operator's Manual.)
Axle Mounting Cap • Check drum service brake reservoir oil level. See Check
Screw—Torque.......................................................................... 1150 N·m Service (Drum) Brake Oil Level. (Operator's Manual.)
850 lb.-ft. • Check hydraulic reservoir fluid level. See Hydraulic Oil.
(Operator's Manual.)
• Tighten lug nuts (2) to specification. See Wheel

Remove and Install. (Group 0110.)
Specification
Lug Nut—Torque.........................................................................450 N·m
332 lb.-ft.
SP66632,0004ABD -19-23AUG16-2/2
020921
PN=44
Rear Axle Remove and Install
TX1050496 —UN—27OCT08
Rear Axle
1— Steering Arm (2 used) 3— O-Ring (2 used) 5— Pivot Pin 7— Nut (2 used)
2— O-Ring 4— Bumper (2 used) 6— Washer (2 used)
CAUTION: Prevent possible crushing

injury from heavy component. Use
SPECIFICATIONS appropriate floor stands.
244K and 244K-II Machine Weight 5591 kg
(approximate) 12 325 lb. • Raise rear of machine. Install D01182AA 20-Ton Floor
Stands under front frame.
324K Machine Weight 6396 kg
(approximate) 14 100 lb. Removal
Rear Axle Weight (approximate) 380 kg
838 lb. 1. Remove hydrostatic motor. See Hydrostatic Motor
Rear Axle Pivot Pin End Play Zero
Steering Link Tie Rod End Nut 475 N·m 2. Remove rear wheels. See Wheel Remove and Install.
Torque 350 lb.-ft. (Group 0110.)
Lug Nut Torque 450 N·m 3. Disconnect tie rod end from left and right steering
332 lb.-ft.
arms (1).
SERVICE EQUIPMENT AND TOOLS 4. Tag and disconnect front and rear lubrication lines
D01182AA 20-Ton Floor Stand from pivot pin housing.
JT01642A Low-Lift Transmission Jack NOTE: It may be necessary to compress bumper
on opposite side of frame from bumper that
Machine Preparation is being removed.
• Prepare machine for service. See Park and Prepare for 5. Remove left and right bumpers (4).
Service Safely. (Group 0001.)
• Install frame lock bar.
• Stop engine.
Continued on next page SP66632,0004ABE -19-23AUG16-1/2
020921
PN=45
6. Position JT01642A Low-Lift Transmission Jack under

axle. Raise jack until axle just starts to move upward. Installation
Secure axle to low-lift jack. Installation is reverse of removal procedure.
NOTE: It may be necessary to move axle up or down • Tighten tie rod end nuts to specification.
slightly to remove pivot pin.
Specification
7. Remove pivot pin cover and shim. Install an M16 cap Steering Link Tie Rod
screw or eyebolt into end of pivot pin (5) and remove End Nut—Torque.........................................................................475 N·m
pin and O-rings (3). Lower axle and remove from 350 lb.-ft.
machine. • Tighten lug nuts to specification. See Wheel Remove
8. Repair or replace axle as needed. See Axle Shaft, and Install. (Group 0110.)
Bearings, and Rear Axle Reduction Gears. (Group Specification
0250.) Lug Nut—Torque.........................................................................450 N·m
332 lb.-ft.
9. If removed, install new pivot pin bushings.
10. Position axle under machine. Install pivot pin, with • Check differential and wheel hub oil levels. See Check
O-rings installed on each end of pin between axle and Final Drives Oil Level and see Check Rear Differential
axle carrier. and Gear Case Oil Levels. (Operator's Manual.)
11. Install rear cover without shim. Evenly snug cap • Check hydraulic reservoir fluid level. See Hydraulic Oil.
screws to make sure pivot pin is against front of axle. (Operator's Manual.)
• Add grease to all axle and pivot grease fittings. See
12. Using a feeler gauge, measure gap between cover Grease. (Operator's Manual.)
and axle in three places, 120° apart. Average the • Perform Hydrostatic Start-Up Procedure. (Group 0300.)
three measurements. Install shim of same thickness
to get zero end play of pivot pin. Tighten cap screws.
Specification
Rear Axle Pivot Pin—End
Play...................................................................................................Zero
SP66632,0004ABE -19-23AUG16-2/2
020921
PN=46
Group 0225
Axle Shafts and U-Joints
Drive Shaft Remove and Install
T204462 —UN—26OCT04
1— Drive Shaft 3— Lock Nut (8 used) 4— Cap Screw (8 used)
2— Lock Nut (8 used)
2. Install drive shaft. Tighten lock nuts (2 and 3) to

CAUTION: Prevent possible injury from specification.
unexpected machine movement. Place
blocks at front and rear of tires to prevent Specification
machine from rolling. Drive Shaft Lock
Nuts—Torque................................................................. 60 N·m (44 lb-ft)
1. Remove drive shaft (1).
IMPORTANT: Use new lock nuts for drive shaft
installation. DO NOT use nylon-type lock nuts to
install drive shaft. Use only specified hardware.
SP66632,0004ABC -19-11DEC14-1/1
020921
PN=47
Axle Shafts and U-Joints
020921
PN=48
Group 0250
Axle Shaft, Bearings, and Rear Axle Reduction Gears
Axle Shaft, Bearings, and Rear Axle
324K Axles
Reduction Gears
For service and repair of axle shaft, bearings, and rear
• 112F20 Front Axle Service Manual
axle reduction gears, see supporting manuals section in
• 212S20 Rear Axle Service Manual
Service ADVISOR™. For special tool T14 in 212S20 Rear Axle Service Manual,
use DFT1254 Differential Bevel Gear Holding Tool.
Reference the following DANA service manuals: (Group 9900.)
244K and 244K-II Axles For special tool T15 in 212S20 Rear Axle Service Manual,
• 111F40 Front Axle Service Manual use DFT1255 Differential Bevel Gear Pin Installation Tool.
• 211S40 Rear Axle Service Manual (Group 9900.)
Service ADVISOR is a trademark of Deere & Company
SP66632,0004ABB -19-23AUG16-1/1
020921
PN=49
Axle Shaft, Bearings, and Rear Axle Reduction Gears
020921
PN=50
Section 03
Transmission
Contents
Page
Group 0300—Hydrostatic Components

Hydrostatic Pump Valves Remove
and Install .............................................. 03-0300-1
Directional Control Valve Remove
and Install .............................................. 03-0300-1
Charge Pump Remove and Install.............. 03-0300-1
Hydrostatic Pump Remove and
Install ..................................................... 03-0300-2
Hydrostatic Motor Remove and
Install ..................................................... 03-0300-3
Inching Valve Remove and Install.............. 03-0300-5
Hydrostatic Start-Up Procedure................. 03-0300-5
Group 0360—Hydrostatic Components Repair

Directional Control Valve
Disassemble and Assemble .................. 03-0360-1
Hydrostatic Pump Disassemble................. 03-0360-1
Hydrostatic Pump Assemble ..................... 03-0360-1
Hydrostatic Motor Control Valve
O-Rings and Seals Remove and
Install ..................................................... 03-0360-1
Hydrostatic Motor Flushing Valve
O-Rings and Servo Piston Seals
Remove and Install................................ 03-0360-2
Hydrostatic Motor Disassemble................. 03-0360-4
Hydrostatic Motor Rotating Group
Inspect and Recondition ........................ 03-0360-5
Hydrostatic Motor Assemble...................... 03-0360-8
020921
PN=1
Contents
020921
PN=2
Group 0300
Hydrostatic Components Removal and Installation
Hydrostatic Pump Valves Remove and Install
For detailed service information on John Deere 244K,
244K-II, and 324K hydrostatic pump, see Hydrostatic
Pump Repair Manual. (CTM10078X19.)
SP66632,0004AD6 -19-03FEB15-1/1
Directional Control Valve Remove and Install

SP66632,0004AD7 -19-03FEB15-1/1
Charge Pump Remove and Install NOTE: The hydraulic and charge pumps are removed
John Deere model 244K, 244K-II, and 324K Compact and serviced as an assembly.
Loaders use a tandem hydraulic-charge pump assembly.
For more information, see Hydraulic Pump/Priority Valve
SP66632,0004AD8 -19-09JAN15-1/1
020921
PN=53
Hydrostatic Pump Remove and Install

SPECIFICATIONS
Hydrostatic Pump Weight 44 kg
(approximate) 97 lb.
Hydrostatic Pump Mounting Cap 230 N·m
Screw Torque 170 lb.-ft.
Machine Preparation
• Park and prepare machine for service. See Park and
TX1183213A —UN—26JAN15
Prepare for Service Safely. (Group 0001.)
• Turn battery disconnect switch to OFF position. See
Battery Disconnect Switch. (Operator’s Manual.)
CAUTION: Avoid personal injury from

high-pressure fluid. High-pressure release of
oil from pressurized system can cause serious
burns or penetrating injury. Relieve pressure Hydrostatic Pump
from hydraulic system before servicing.
1— Hydraulic Pump 3— Cap Screw (2 used)
• Relieve pressure from hydraulic system.Perform 2— Hydrostatic Pump
Hydraulic System Pressure and Accumulators
Discharge Procedure. (Group 2160.)
NOTE: A special reservoir drain hose is stored in
operator's station. As drain hose is tightened CAUTION: Prevent possible crushing injury from
on reservoir drain fitting, the drain fitting heavy component. Use appropriate lifting device.
valve will automatically open, allowing oil
to drain from reservoir. 4. Remove cap screws (3), washers, and hydrostatic
pump, using an appropriate lifting device.
• Apply a vacuum to hydraulic reservoir or drain hydraulic 5. Repair or replace hydrostatic pump as necessary. See
system. See Change Hydraulic Oil. (Operator’s Hydrostatic Pump Disassemble and see Hydrostatic
Manual.) Pump Assemble. (Group 0360.)
Removal Installation
CAUTION: Prevent possible crushing injury from Installation is reverse of removal procedure.
• Tighten hydrostatic pump mounting cap screws to
specification.
1. Remove left side counterweight. See Counterweights
Remove and Install. (Group 1749.) • Fill hydraulic reservoir to proper level.
See Change
Hydraulic Oil. (Operator's Manual.)
2. Remove hydraulic pump (1). See Hydraulic • Perform Hydrostatic Start-Up Procedure. (Group 0300.)
Pump/Priority Valve Remove and Install. (Group • Perform Hydrostatic Pump Performance (Timing) Test
2160.) and Adjustment. (Group 9020-25.)
NOTE: Close all openings using caps and plugs to
prevent contamination of hydraulic system.
3. Tag and disconnect all hydraulic lines and electrical

harness connectors from hydrostatic pump (2).
SP66632,0004ADF -19-16FEB15-1/1
020921
PN=54
Hydrostatic Motor Remove and Install

1. Remove drive shaft (4).
2. Drain hydraulic reservoir or apply a vacuum to retain
oil in reservoir. See Drain and Refill Capacities.
1— Socket Head Cap Screw 3— Hydraulic Line

2— Hydrostatic Motor 4— Drive Shaft
T203332A —UN—23SEP04
Continued on next page DE88008,0000219 -19-13MAR09-1/2
020921
PN=55
IMPORTANT: A 1.5 mm orifice disk is located in

the fitting of hydraulic line (3). If this line is
disconnected from the hydrostatic motor, the
orifice disk must be removed and saved, to
be installed when line is connected.
T129105B —UN—13MAR00
NOTE: Close all hose and fitting openings using
caps and plugs to prevent contamination
of hydrostatic system.
3. Mark and disconnect all hydraulic lines and electrical

harness connectors from hydrostatic motor (2). When
hydraulic line (3) is disconnected, remove the 1.5 mm
orifice disk located in fitting. Save orifice disk and 1.5 mm Orifice Disk
install in fitting before hydraulic line (3) is connected.
Specification
CAUTION: Prevent possible crushing injury from Hydrostatic Motor
heavy component. Use appropriate lifting device. Socket Head Cap
Screw—Torque............................................................................230 N·m
4. Support motor with an appropriate lifting device, then 170 lb-ft
remove socket head cap screws (1), washers, and
hydrostatic motor. IMPORTANT: A 1.5 mm orifice disk is located in
the fitting of line (3). The orifice disk must be
Specification
installed before line is connected.
Hydrostatic
Motor—Weight
9. Connect all hydraulic lines and harness connectors as
(approximate).................................................................................. 60 kg
marked. Make sure the 1.5 mm orifice disk is installed
132 lb.
in fitting before line (3) is connected.
5. Repair or replace hydrostatic motor as necessary. See 10. Install drive shaft (4) using new lock nuts. Tighten
Hydrostatic Motor Disassemble and see Hydrostatic lock nuts to specification.
Motor Assemble. (Group 0360.)
Specification
6. Replace mounting flange O-ring. Drive Shaft Flange Lock
Nut—Torque..................................................................................60 N·m
7. Install hydrostatic motor. Apply PM37509 Cure Primer,
44 lb-ft
then PM37418 Thread Lock and Sealer (medium
strength) to threads of socket head cap screws (1).
8. Install and tighten socket head cap screws to 11. Perform Hydrostatic Start-Up Procedure. (Group
specification. 0300.)
12. Perform Hydrostatic Motor Minimum Displacement
Adjustment. (Group 9020-20.)
DE88008,0000219 -19-13MAR09-2/2
020921
PN=56
Inching Valve Remove and Install
CAUTION: 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.
1. Tag and disconnect hydraulic lines (1 and 4). Close all

openings using caps and plugs.
TX1051179A —UN—10NOV08
2. Remove spring (2), pin (3), and inching valve (5).
NOTE: Inching valve is not serviceable. Replace
valve if necessary.
3. Replace inching valve as necessary.

4. Install inching valve, pin, and springs. Inching Valve
5. Connect hydraulic lines.
1— Hydraulic Line 4— Hydraulic Line
6. Perform Brake/Inching Pedal Linkage Adjustment. 2— Spring (2 used) 5— Inching Valve
(Group 9020-20.) 3— Pin
CS33148,0002BC2 -19-09FEB09-1/1
Hydrostatic Start-Up Procedure

SPECIFICATIONS
Engine Speed Slow Idle
Hydrostatic Pump Pressure 1000 kPa
(minimum) 10 bar
145 psi
SERVICE EQUIPMENT AND TOOLS
TX1182186 —UN—12JAN15
JT02162 Transducer 34 000 kPa (350 bar) (5000 psi)
JT02158 Digital Pressure and Temperature Analyzer
This procedure is to ensure the hydrostatic system has

the needed oil for initial start-up after a system component
is replaced or repaired.
1. Fill hydraulic system. See Change Hydraulic Oil and Hydrostatic Pump
see Check Hydraulic Oil Level. (Operator’s Manual.)
2. Install JT02160 Transducers at test port MH (1). 1— Test Port MH
3. Connect JT02158 Digital Pressure and Temperature

Analyzer. See JT02156A Digital Pressure and
Temperature Analyzer Kit Installation. (Group 6. If pressure is below minimum specification after 30
9025-25.) seconds, stop engine immediately.
IMPORTANT: To avoid hydraulic system damage, 7. Check for oil leaks or possible mechanical problem.
operate machine at slow idle for 2 to 3 minutes 8. If no oil leaks or mechanical problems are found,
before increasing engine speed. repeat procedure.
4. Start engine and operate at specification. 9. Check oil level in reservoir; add recommended
oil if necessary. See Check Hydraulic Oil Level.
5. Cycle forward, neutral, reverse (FNR) switch between (Operator's Manual.)
forward and reverse directions.
SP66632,0004ADD -19-03FEB15-1/1
020921
PN=57
020921
PN=58
Group 0360
Hydrostatic Components Repair
Directional Control Valve Disassemble and
Assemble
SP66632,0004AD3 -19-03FEB15-1/1
Hydrostatic Pump Disassemble For disassemble and assemble of servo piston assembly,
For detailed service information on John Deere 244K, use DFT1214 Hydrostatic Pump Servo Piston Snap Ring
244K-II, and 324K hydrostatic pump, see Hydrostatic Removal and Installation Tool. (Group 9900.)
SP66632,0004AD4 -19-30OCT15-1/1
Hydrostatic Pump Assemble For disassemble and assemble of servo piston assembly,
For detailed service information on John Deere 244K, use DFT1214 Hydrostatic Pump Servo Piston Snap Ring
244K-II, and 324K hydrostatic pump, see Hydrostatic Removal and Installation Tool. (Group 9900.)
SP66632,0004AD5 -19-30OCT15-1/1
Hydrostatic Motor Control Valve O-Rings and

Seals Remove and Install
1. Remove four socket head screws (L).
2. Remove parts (F—K).
3. Remove two check valve assemblies (A).
4. Replace O-rings (D, E, and G).
T115225B —UN—13MAY98
A—Hydrostatic Motor Inlet G—O-Ring
Check Valve Assembly (2 H—Spring Plate
Used) I— Regulating Spring
B—Check Valve (2 used) J— Spring Retainer
C—Check Valve Housing (2 K—Return Spring
used) L— Socket Head Screws
D—O-Ring (2 used)
E—O-Ring (2 used)
F— Control Valve Housing
Continued on next page CED,OUO1010,130 -19-22SEP04-1/2
020921
PN=59
5. Remove socket head screws (I) to remove parts

(E—H).
6. Replace O-rings (E).
7. Remove parts (B—D).
8. Inspect parts (B, C, G, and H). If scoring, wear, or
damage is indicated, replace whole control valve
assembly.
T115228B —UN—12MAY98
9. Assemble and install control valve assembly using
new O-rings.
A—Housing F— Solenoid (2 used)

B—Spool G—LO/HI Speed Solenoid
C—Sleeve Spool and Spring
D—Snap Ring H—Directional Solenoid Spool
E—O-Ring (2 used) and Spring
I— Socket Head Screws (8
used)
CED,OUO1010,130 -19-22SEP04-2/2
Hydrostatic Motor Flushing Valve O-Rings

and Servo Piston Seals Remove and Install
1. Remove socket head screws (A) and flushing valve
assembly (F).
2. Remove parts (C and D).
3. Replace O-ring (E) and piston seals (G).
T115230B —UN—12MAY98
A—Socket Head Screws E—O-Ring
B—Servo Piston Rod F— Flushing Valve Assembly
C—Servo Piston G—Piston Seals
D—Socket Head Screw
T115229B —UN—12MAY98
Continued on next page OUO1020,0001014 -19-22SEP04-1/2
020921
PN=60
T115231C —UN—21SEP00
4. Remove parts (A—E and G—N) from housing (F).
5. Replace O-rings (B, J, and N).
6. Inspect shuttle valve spool (E) and charge relief valve
(L) for scoring.
T115232B —UN—12MAY98
7. Inspect rate-of-shift orifices check valve (H) and check
valve seat (G) for wear. Make sure orifice is clear of
obstructions.
8. Assemble and install flushing valve assembly using
new O-rings.
9. Install check valve seat (G) into housing (F) so large ID
end (P) points away from housing. Install rate-of-shift
orifices check valve with beveled end toward valve
A—Plug (2 used) I— Screw
seat. Install screw (I) so end with large ID is toward B—O-Ring (2 used) J— O-Ring
check valve. C—Spring (2 used) K—Test Port Fitting
D—Spacer (2 used) L— Charge Relief Valve
E—Shuttle Valve Spool M—Spring
F— Housing N—O-Ring
G—Check Valve Seat O—Plug
H—Rate-of-Shift Orificed P—Large ID End
Check Valve
OUO1020,0001014 -19-22SEP04-2/2
020921
PN=61
Hydrostatic Motor Disassemble

1. Make a mark (C) across edge of servo piston housing
(A) and hydrostatic motor housing for assembly
purposes.
2. Remove socket head screws (B).
3. Carefully remove servo piston housing (A).
A—Servo Piston Housing C—Mark

B—Socket Head Screw (8 used)
T133139B —UN—25AUG00
OUO1020,0001015 -19-23SEP04-1/2
NOTE: O-ring (A) is the only serviceable item in this

section of hydrostatic motor. Replace hydrostatic
motor if valve plate, servo piston housing, or
rotating group are worn or damaged.
Scratches in mating surfaces of cylinder block
and valve plate can be removed using lapping
compound. See Hydrostatic Motor Rotating Group
Inspect and Recondition. (Group 0360.)
T133140B —UN—25AUG00
4. Replace O-ring (A).
5. Remove valve plate (C).
6. Remove cylinder block (B) only if inspection and
cleaning is needed.
A—O-Ring C—Valve Plate

B—Cylinder Block
OUO1020,0001015 -19-23SEP04-2/2
020921
PN=62
Hydrostatic Motor Rotating Group Inspect

and Recondition
Inspect Components
1. Replace hydrostatic motor if:
• Centering pin spring (C) is worn or damaged.
• Piston rings (A) are scored, worn, or damaged.
• Ball joints (B) have end play.
T115237B —UN—12MAY98
• Surfaces (E), pin (F), or piston rod (G) are worn.
2. Check that orifices (D) are free of obstructions.
A—Piston Rings E—Valve Plate Wear Surfaces

B—Ball Joint F— Pin
C—Centering Pin Spring G—Servo Piston Rod
D—Orifice
T115238B —UN—12MAY98
020921
PN=63
Recondition Lapped Surface of Cylinder Block

NOTE: If scratches can be detected with a fingernail
or lead pencil drawn across bronzed surface of
cylinder block, reconditioning of lapped surfaces or
replacement of hydrostatic motor is recommended.
T7160BM —UN—22JAN90
To determine if resurfacing is required, draw a
pencil line across valve plate or block sealing
area. Put cylinder block on valve plate, then turn
cylinder block at least one revolution. If pencil line
is erased, resurfacing is probably not required.
1. Inspect mating surfaces of cylinder block (A) and valve

plate (B).
A—Cylinder Block B—Valve Plate
T7160BN —UN—22JAN90
CED,OUO1010,128 -19-23SEP04-2/6
NOTE: Cylinder block can be resurfaced to remove

scratches from lapped surfaces if minimum
thickness is maintained.
2. Inspect thickness (A) of bronze material on cylinder

block.
T7160BQ —UN—22JAN90
Specification
Minimum Bronze
Material—Thickness..................................................................... 0.5 mm
0.02 in.
A—Thickness
020921
PN=64
3. Cut the head off a 5/8 inch diameter cap screw. Build
up the diameter of the cap screw with tape to match
valve plate center hole ID (A) and cylinder block center
hole ID (B).
4. Put valve plate on a clean paper towel or shop towel
with lapped surface up.
T7160BO —UN—22JAN90
5. Insert taped end of cap screw into center hole of valve
plate.
NOTE: Use fine and extra fine lapping compound. Start
with the fine lapping compound and finish with
the extra fine lapping compound.
6. Apply a generous amount of fine lapping compound to

mating surfaces of valve plate and cylinder block. A—Center Hole ID (Valve Plate) B—Center Hole ID (Cylinder
Block)
CED,OUO1010,128 -19-23SEP04-4/6
7. Carefully insert the cylinder block on the taped cap

screw. Allow cylinder block to rest on the valve plate
so mating surfaces (B) make contact.
IMPORTANT: Do not apply down force when lapping
surface of cylinder block. The weight of
cylinder block is sufficient.
T7160BP —UN—22JAN90
Inspect progress often so as to remove the
scratches without cutting through the bronze
material. If too much bronze material is removed,
the whole hydrostatic motor must be replaced.
8. With only the weight of the cylinder block against the

valve plate (do not apply additional down force), move
cylinder block (A) in small circles while rotating the A—Cylinder Block B—Mating Surfaces
cylinder block for two or three revolutions.
9. Inspect progress. Rotate cylinder block two or three
more revolutions, then reinspect. 12. Put a small amount of extra fine lapping compound on
cylinder block or valve plate.
10. Repeat steps 8 and 9 until scratches almost disappear.
Do not cut through bronze material. 13. Continue lapping as in steps 8 and 9 until scratches
disappear. Do not cut through bronze material.
11. Wipe the lapping compound from cylinder block and
valve plate.
020921
PN=65
IMPORTANT: Lapping compound will become

imbedded in the bronze bearing material of
the cylinder block. A brass bristle brush must
be used to remove the lapping compound.
Failure to remove the lapping compound will
shorten the hydrostatic motor life.
T7160BM —UN—22JAN90
14. Remove all lapping compound and residue from parts
using diesel fuel. Use a brass bristle brush to clean
bronze material (A) of cylinder block.
CAUTION: Reduce compressed air to less than

210 kPa (2.1 bar) (30 psi) when using for cleaning
purposes. Clear area of bystanders, guard
against flying debris, and wear appropriate safety A—Bronze Material B—Valve Plate
equipment including eye protection.
15. Dry valve plate (B) and cylinder block with compressed
air. Do not wipe with shop towel or paper towel. 17. Repeat steps 14—16 until all lapping compound is
Inspect for any remaining lapping compound and removed.
clean again if needed.
16. Carefully inspect bronze material (A) on cylinder block
and make sure all compound is removed.
CED,OUO1010,128 -19-23SEP04-6/6
Hydrostatic Motor Assemble

1. Apply a coating of clean hydraulic oil to pistons (B)
and cylinder block piston bores.
2. Invert and suspend hydrostatic motor housing (A),
allowing pistons (B) and centering pin (C) to hang
down vertically. Make sure centering pin spring is in
place before installing cylinder block (D).
3. Install cylinder block (D) into hydrostatic motor
housing, making sure centering pin and pistons enter
cylinder bores of cylinder block.
A—Hydrostatic Motor Housing C—Centering Pin

B—Pistons (7 used) D—Cylinder Block
T125721 —UN—18NOV99
Continued on next page OUO1020,0001016 -19-23SEP04-1/3
020921
PN=66
4. Install new O-ring (A).

5. Apply petroleum jelly to servo piston housing mating
surface of valve plate (D) to hold valve plate in position
while installing servo piston housing. Install valve
plate into servo piston housing channel (C) and onto
servo piston pin (E).
6. Move valve plate to a position in channel (C) relative
to position of cylinder block (B).
T133143B —UN—25AUG00
A—O-Ring D—Valve Plate
B—Cylinder Block E—Servo Piston Pin
C—Channel
OUO1020,0001016 -19-23SEP04-2/3
7. While aligning marks (C), install servo piston housing

onto hydrostatic motor housing.
8. Install socket head screws (B). Tighten screws evenly
by alternating in a criss-cross pattern.
A—Servo Piston Housing C—Marks

B—Socket Head Screw (8 used)
T133139B —UN—25AUG00
OUO1020,0001016 -19-23SEP04-3/3
020921
PN=67
020921
PN=68
Section 04
Engine
Contents
Page

V-Belt Remove and Install ......................... 04-0400-1
Engine Remove and Install........................ 04-0400-2
020921
PN=1
Contents
020921
PN=2
Group 0400
V-Belt Remove and Install
SPECIFICATIONS
Air Conditioner Compressor Cap 37 N·m 1
TX1180826 —UN—09JAN15
Alternator Cap Screw Torque 37 N·m 2
27 lb.-ft.
Air Conditioner Drive Belt 3
1. Remove belt guard.

2. Loosen adjusting cap screws on top and bottom of air
conditioner compressor (2) and remove air conditioner Air Conditioner Drive Belt Routing
drive belt (3).
3. Inspect the belt for cracks or frayed edges. Replace if
necessary.
4. Install new belt, and route according to diagram. 5
4
TX1180825 —UN—12JAN15
5. Adjust to proper tension. See Check and Adjust
Accessory Drive Belt Tension. (Operator’s Manual.) 6
1
6. Tighten cap screws on top and bottom of air
conditioner compressor to specification.
Accessory Drive Belt
NOTE: Air conditioner drive belt must be removed first Accessory Drive Belt Routing
to facilitate removal of accessory drive belt.
1. Loosen adjusting cap screws on top and bottom of 1— Crankshaft 4— Coolant Pump
alternator (5) and remove accessory drive belt (6). 2— Air Conditioner 5— Alternator
Compressor 6— Accessory Drive Belt
2. Inspect the belt for cracks or frayed edges. Replace if 3— Air Conditioner Drive Belt
necessary.
3. Install new belt, and route according to diagram. 5. Tighten cap screws on top and bottom of alternator
4. Adjust to proper tension. See Check and Adjust to specification.
Accessory Drive Belt Tension. (Operator’s Manual.)
SP66632,0004AC0 -19-14JAN15-1/1
020921
PN=71
Engine Remove and Install

SPECIFICATIONS
Engine Weight (approximate) 550 kg
1213 lb.
Hydraulic and Hydrostatic Pumps 56 kg
Assembly Weight (approximate) 124 lb.
Hydrostatic Pump Adapter Plate 80 N·m
Socket Head Cap Screw Torque 60 lb.-ft.
Engine Mount Bracket Cap Screw 68 N·m
TX1183701A —UN—16FEB15
Torque 50 lb.-ft.
Engine Mount Isolator Nut Torque 120 N·m
89 lb.-ft.
OTHER TOOLS AND EQUIPMENT

JDG23 Lifting Sling
Machine Preparation Air Cleaner Removal

• Turn battery disconnect switch to the OFF position. See
• Remove hood. See Hood Remove and Install. (Group
1910.)

TX1184327A —UN—10FEB15
burns or penetrating injury. Relieve pressure
• Relieve pressure from hydraulic system.Perform

Discharge Procedure. (Group 2160.)
NOTE: A special reservoir and engine coolant drain
hose is stored in operator's station. As drain hose Turbocharger Hose (324K)
is tightened on drain fitting, the drain fitting valve
will automatically open, allowing system to drain.
2— Air Cleaner-to-Air Intake 6— Turbocharger-to-Air Intake
Stack Hose Manifold Hose (324K)
• Drain cooling system. See Drain Cooling System. 3— Air Intake Stack 7— Air Cleaner
(Operator’s Manual.) 4— Pre-Cleaner B4—Engine Air Filter
5— Air Cleaner-to-Air Intake Restriction Switch
Removal Manifold Hose
1. Remove diesel particulate filter. See Diesel Particulate

Filter (DPF) Remove and Install. (Group 0530.)
4. Disconnect air cleaner-to-air intake manifold hose (5)
at engine.
CAUTION: Close all openings using caps
and plugs. 5. Disconnect turbocharger-to-air intake hose (6) at
turbocharger (324K ).
2. Tag and disconnect engine air filter restriction switch
6. Remove air cleaner (7).
(B4).
3. Disconnect air cleaner-to-air intake stack hose (2) at
air intake stack (3).
Continued on next page SP66632,0004AC1 -19-23AUG16-1/6
020921
PN=72
7. Remove ECU cover (8).

8. Disconnect engine interface harness (W19) from ECU
(A700).
9. Tag and disconnect solenoids (Y2 and Y3) from
hydrostatic pump (11) and solenoid (Y207) from high
flow valve (10).
10. Tag and disconnect fuel supply hose (12) and fuel
return hose (13). Close all openings using caps and
plugs.
TX1183702A —UN—16FEB15
11. Disconnect upper and lower engine coolant hoses (16
and 17) and heater hoses (14 and 15) from engine
block. Close all openings using caps and plugs.
12. Remove engine access cover from underside rear of
machine.
13. Remove hydraulic fan pump from engine block, leaving Electrical and Hose Removal
hoses attached, and set to the side. See Hydraulic
Fan Pump Remove and Install. (Group 0510.)
8— Engine Control Unit (ECU) 16— Upper Engine Coolant

Cover Hose
10— High Flow Valve 17— Lower Engine Coolant
11— Hydrostatic Pump Hose
12— Fuel Supply Hose A700— Engine Control Unit
13— Fuel Return Hose (ECU)
14— Heater Supply Hose W19—Engine Interface
15— Heater Return Hose Harness
Y2— Forward Travel Solenoid
Y3— Reverse Travel Solenoid
TX1184330A —UN—10FEB15
Y207— High Flow Solenoid
Hydrostatic Pump Electrical Connectors

SP66632,0004AC1 -19-23AUG16-2/6
14. Remove air conditioner compressor belt. See V-Belt

NOTE: It is not necessary to evacuate the A/C
system. Compressor can be set aside without
disconnecting the refrigerant hoses.
TX1183703A —UN—10FEB15
15. Remove air conditioner compressor (18) from air

conditioner mounting bracket (19). Set air conditioner
compressor to the side with refrigerant hoses still
attached.
18— Air Conditioner 19— Air Conditioner Mounting

Compressor Bracket
Air Conditioner Compressor Removal
020921
PN=73
CAUTION: Avoid crushing injury. Use appropriate

lifting device when lifting component.
16. Attach JDG23 Lifting Sling (20) to a hoist and attach

to lifting brackets (21). Remove slack from lifting sling
chains.
Specification
Engine—Weight
(approximate)................................................................................ 550 kg
1213 lb.
TX1183704A —UN—10FEB15
17. Using a second hoist, attach a lifting support strap
(22) to the hydraulic and hydrostatic pumps assembly
(23). Remove slack from lifting support strap so pump
assembly is fully supported by the hoist.
Specification
Hydraulic and
Hydrostatic Pumps Engine Removal
Assembly—Weight
(approximate).................................................................................. 56 kg
20— JDG23 Lifting Sling 22— Lifting Support Strap
124 lb.
21— Lifting Bracket (2 used) 23— Hydraulic and Hydrostatic
Pumps Assembly
SP66632,0004AC1 -19-23AUG16-4/6
18. Remove engine mount isolator nuts (24) from right

side (front and rear) engine mount brackets (25).
19. Remove cap screws (26) and engine mount brackets
from engine block to facilitate moving engine to the
right for removal.
24— Engine Mount Isolator 26— Cap Screws (8 used)

Nuts (2 used)
25— Engine Mount Brackets (2
used)
TX1183705A —UN—10FEB15
Engine Mounts
020921
PN=74
20. Remove socket head cap screws (27) and move

engine to the right until clear of hydrostatic pump
(approximately two inches) (A).
21. Remove engine.
22. Repair or replace engine as required.
23. Inspect engine mounts. Repair or replace as
necessary.
Installation
TX1183706A —UN—10FEB15
Installation is reverse of removal procedure.
• Fasten both right side engine mount brackets to engine
using engine mount bracket cap screws. Do not fully
tighten cap screws at this time. Lower engine into
machine.
NOTE: Rotate engine or hydrostatic pump assembly
Hydraulic and Hydrostatic Pumps Assembly
as needed to align pump drive gear with
damper drive on engine flywheel.
• Align and insert hydrostatic pump drive gear into

damper drive on flywheel and set engine mount
brackets onto engine mount isolators.
• Fasten hydrostatic pump adapter plate to engine using
socket head cap screws. Tighten to specification in a
crisscross pattern.
Specification
Hydrostatic Pump
TX1183708A —UN—10FEB15
Adapter Plate
Socket Head Cap
Screw—Torque..............................................................................80 N·m
60 lb.-ft.
• Tighten engine mount bracket cap screws to

specification.
Specification
Engine Mount Bracket Engine Clearance
Cap Screw—Torque..................................................................... 68 N·m
50 lb.-ft. 27— Hydrostatic Pump Adapter A—Clearance
Plate Socket Head Cap
• Tighten engine mount isolator nuts to specification. Screw (12 used)
Specification
Engine Mount Isolator
Nut—Torque................................................................................120 N·m • See 244K-II Drain and Refill Capacities. (Operator's
89 lb.-ft. Manual.)
• See 324K Drain and Refill Capacities. (Operator's
• Refill engine coolant. Manual.)
Manual.)
SP66632,0004AC1 -19-23AUG16-6/6
020921
PN=75
020921
PN=76
Section 05
Engine Auxiliary Systems
Contents
Page
Group 0510—Cooling System

High Flow Pump Remove and
Install ..................................................... 05-0510-1
Hydraulic Fan Pump Remove and
Install ..................................................... 05-0510-1
Hydraulic Fan Pump Disassemble
and Assemble........................................ 05-0510-2
Cooling Fan and Hydraulic Fan
Motor Remove and Install...................... 05-0510-3
Hydraulic Fan Motor Disassemble
and Assemble........................................ 05-0510-5
Cooling Package Remove and
Install ..................................................... 05-0510-6
Group 0530—External Exhaust Systems

Diesel Particulate Filter (DPF)
Group 0560—External Fuel Supply Systems

Fuel Tank Remove and Install ................... 05-0560-1
020921
PN=1
Contents
020921
PN=2
Group 0510
Cooling System
High Flow Pump Remove and Install
244K-II, and 324K high flow pump, see Hydraulic Fan
Pump Remove and Install. (Group 0510.)
SP66632,0004ADE -19-23AUG16-1/1
Hydraulic Fan Pump Remove and Install

NOTE: This procedure is for machines equipped with
optional high-flow pump. The standard equipment
pump removal and installation is similar.
1. Prepare machine for service. See Park and Prepare

for Service Safely. (Group 0001.)
2. Turn battery disconnect switch to OFF position. See
Battery Disconnect Switch. (Operator's Manual.)
3. Disconnect hydraulic lines (2, 3, and 4). Close all
4. Remove cap screws (5) and remove hydraulic fan
TX1181886A —UN—12JAN15
drive pump (1).
5. Repair or replace parts as necessary.
6. Install pump and apply PM37477 Thread Lock and
Sealer (medium strength) to threads of cap screws
and tighten to specification.
Specification Hydraulic Fan Pump (shown with optional high-flow pump)
Cap Screw—Torque......................................................................50 N·m
37 lb·ft
1— Hydraulic Fan Drive Pump 4— Hydraulic Fan Drive
7. Connect lower hydraulic lines to pump. 2— Hydraulic Reservoir-to- Pump-to-Directional
Hydraulic Fan Drive Pump Control Valve Line (optional
8. Fill pump with oil through upper line fitting on pump. Line with high-flow pump)
3— Hydraulic Fan Drive 5— Cap Screw (2 used)
9. Connect upper hydraulic line. Pump-to-Hydraulic Fan
Motor Line
10. Check hydraulic oil level. See Hydraulic Oil.
(Operator’s Manual.)
SP66632,0004AD9 -19-20DEC16-1/1
020921
PN=79
Cooling System
Hydraulic Fan Pump Disassemble and

Assemble
10
4
9 12
5
6
7
8
13
7
6
5
4
3 14
2
XJ1255170 —UN—13APR18
11 1
XJ1255170
Hydraulic Fan Pump—Exploded View
1— Snap Ring 5— Backup Seal 9— Body 13— Pin (4 used)
2— Shaft Seal 6— Internal Seal 10— Cover 14— Driven Shaft
3— Flange 7— Bearing Block 11— Cap Screw (8 used)
4— External Seal 8— Drive Shaft 12— Cap Screw (8 used)
1. Disassemble parts (1—14). 3. Assemble parts (1—14).

2. Repair or replace as necessary.
SP66632,0004ADB -19-12APR18-1/1
020921
PN=80
Cooling System
Cooling Fan and Hydraulic Fan Motor

Remove and Install
Machine Preparation

• Turn battery disconnect switch to OFF position. See
TX1183409A —UN—05FEB15
burns or penetrating injury. Relieve pressure
• Relieve pressure from hydraulic system.

Perform
Discharge Procedure. (Group 2160.) Hydraulic Fan Motor (S.N. —43492)
NOTE: A special reservoir drain hose is stored in

operator's station. As drain hose is tightened
on reservoir drain fitting, the drain fitting
valve will automatically open, allowing oil
to drain from reservoir.
TX1232565A —UN—20JAN17
• Apply a vacuum to hydraulic reservoir or drain hydraulic
system. See Change Hydraulic Oil. (Operator’s
Manual.)
Removal
1. Remove hood and right-side hood support bracket.
See Hood Remove and Install. (Group 1910.) Hydraulic Fan Motor (S.N. 43493— )
2. Disconnect hydraulic fan motor solenoid (Y13).
1— Hydraulic Fan Motor 5— Cap Screw and Washer (4
3. Tag and disconnect lines (2 and 3). Close all openings 2— Return Line used)
using caps and plugs. 3— Cooling Fan Pump-to- 6— Fan Guard
Cooling Fan Motor Line Y13— Hydraulic Fan Motor
4. Remove wire harness (4) from fan guard (6). 4— Wire Harness Solenoid
5. Remove cap screws and washers (5). Remove fan

motor, fan, and fan guard as an assembly.
SP66632,0004ADA -19-20JAN17-1/4
6. Remove fan nut (7) and lock washer.
7— Fan Nut
TX1051421A —UN—13NOV08
Fan Nut
Continued on next page SP66632,0004ADA -19-20JAN17-2/4
020921
PN=81
Cooling System
IMPORTANT: Pry only at hub center (9). Prying or

pulling at hub outer edges (8) may damage hub.
NOTE: Removal of one or two fan blades may be

necessary to access hub center.
TX1051435A —UN—13NOV08
7. Using two pry bars, apply force at hub center (9) to
remove fan. Do not pry or pull at hub outer edges (8).
8— Hub Outer Edge 9— Hub Center
Fan Motor Hub
SP66632,0004ADA -19-20JAN17-3/4
8. Remove shaft key (10).

9. Remove nuts (11) and lock washers (12) and remove
motor from fan guard.
TX1051436A —UN—13NOV08
Installation
• Apply PM37477 Thread Lock and Sealer (medium
strength) to threads of motor shaft. Install lock washer
and fan nut. Tighten fan nut to specification.
Specification Fan Motor Shaft and Key
Fan Nut—Torque...........................................................................30 N·m
22 lb.-ft. 10— Shaft Key 12— Lock Washer (4 used)
• Fill hydraulic reservoir to proper level. 11— Nut (4 used)
• See 244K Drain and Refill Capacities. (Operator’s
Manual.)
• See 244K-II Drain and Refill Capacities. (Operator’s • see 324K Drain and Refill Capacities. (Operator’s
Manual.) Manual.)
SP66632,0004ADA -19-20JAN17-4/4
020921
PN=82
Cooling System
Hydraulic Fan Motor Disassemble and

Assemble
15
16
17 20
18
19
14
22
8
9
10 21
12 7
11
10
9 13
6 7 8
TX1051983 —UN—26NOV08
23
5
4
3
2
1
TX1051983
1— Nut 8— Back-Up Seal 14— Body 20— Cap Screw (4 used)
2— Split Lock Washer 9— Internal Seal 15— Hydraulic Test Port 21— Cover
3— Snap Ring 10— Bearing Block 16— Plug Valve 22— Solenoid Valve
4— Support Ring 11— Key 17— O-Ring 23— Driven Shaft
5— Shaft Seal 12— Drive Shaft 18— Compression Spring
6— Flange 13— Pin (4 used) 19— Check Ball
7— External Seal
1. Disassemble parts (1—23).

Specification
2. Repair or replace parts as necessary. Solenoid Valve—Torque.............................................................33.9 N·m
25 lb-ft
3. Assemble parts (1—23). Tighten solenoid valve (22)
to specification.
CS33148,0002BD5 -19-30JAN09-1/1
020921
PN=83
Cooling System
Cooling Package Remove and Install

1. Remove grille from top of hydraulic reservoir.
1
2. Remove hood and right gas spring bracket. See Hood
3. Remove air intake hoses and snorkel.
NOTE: A special reservoir drain hose is stored in operator's 3
station. As drain hose is tightened on reservoir 4
drain fitting, the drain fitting valve will automatically 7
open, allowing oil to drain from reservoir.
4. Drain hydraulic reservoir. See Change Hydraulic Oil. 2

(Operator's Manual.) 5
TX1181344 —UN—09JAN15
6
5. Drain cooling system. See Drain Cooling System.
8
6. Disconnect hoses from radiator. 9
7. Remove hydraulic fan motor and fan as an assembly.
See Cooling Fan and Hydraulic Fan Motor Remove
and Install. (Group 0510.) Cooling Package Assembly
8. Disconnect hydraulic lines from hydraulic oil cooler.

1— Radiator/Hydraulic Oil 6— Lock Washer (4 used)
9. Remove nuts (9) and washers (5 and 6) from lower Cooler 7— Cap Screw (2 used)
mount studs (8). 2— Stand-Off (2 used) 8— Stud (2 used)
3— Stand-Off (2 used) 9— Nut (2 used)
10. Remove cap screws (7), stand-offs (2 and 3), and 4— Washer (4 used)
5— Washer (4 used)
washers (4, 5, and 6).
CAUTION: Avoid crushing injury. Use appropriate

lifting device when lifting component. 16. Connect hoses to radiator.
17. Fill cooling system. See Fill Cooling System.
11. Remove radiator/hydraulic oil cooler out right side of
machine.
Specification 18. Fill hydraulic reservoir.
Radiator/Hydraulic
Oil Cooler—Weight
Manual.)
Approximate.................................................................................... 45 kg
100 lb.
• See 244K-II Drain and Refill Capacities. (Operator's
Manual.)
12. Repair or replace parts as required. • See 324K Drain and Refill Capacities. (Operator's
Manual.)
13. Install cooler in machine and install cap screws, nuts,
and washers. 19. Install air intake hoses and snorkel.
14. Connect hydraulic lines to oil cooler. 20. Install right gas spring bracket and hood. See Hood
15. Install cooling fan and cooling fan motor.
SP66632,0004AC6 -19-23AUG16-1/1
020921
PN=84
Group 0530
External Exhaust Systems
Diesel Particulate Filter (DPF) Remove and
Install
SPECIFICATIONS
Diesel Particulate Filter (DPF) 34 kg
Machine Preparation

CAUTION: Avoid possible burns from

hot surface. Allow exhaust filter to cool
before servicing.
• Remove upper and lower exhaust stacks.

Removal
1. Disconnect sensors (B5109, B5201, and B5202).
Remove electrical harness securing bolt (1). Remove
engine interface harness (W19) from DPF.
TX1184040A —UN—19FEB15
2. Remove DPF-to-exhaust manifold nuts (2).

Specification
DPF Assembly—Weight
(approximate).................................................................................. 34 kg
75 lb. Diesel Particulate Filter (DPF)
3. Remove DPF mounting cap screws (3). Remove DPF 1— Bolt B5109—Aftertreatment
assembly. 2— DPF-to-Exhaust Manifold Pressure Sensor
Nut (4 used) B5201—Diesel Oxidation
4. Repair or replace as necessary. 3— DPF Mounting Cap Screw Catalyst (DOC) Inlet
(4 used) Temperature Sensor
Installation 4— Diesel Particulate Filter B5202—Diesel Oxidation
(DPF) Catalyst (DOC) Outlet
Installation is reverse of removal procedure. Temperature Sensor
W19—Engine Interface
Harness
RK40399,0001262 -19-17FEB15-1/1
020921
PN=85
External Exhaust Systems
020921
PN=86
Group 0560
External Fuel Supply Systems
Fuel Tank Remove and Install
2
4
5 3
T202901 —UN—14SEP04
T202901
1— Cap Screw and Washer 3— Fuel Hose 5— Fuel Level Sensor

2— Cap Screw and Washer (2 4— Fuel Hose
Used)
1. Turn battery disconnect switch to OFF position. 7. Slowly lower fuel tank bracket and fuel tank as an
2. Remove right rear fender. See Rear Fenders Remove assembly to access fuel hoses (3 and 4) and fuel level
and Install. (Group 1913.) sensor (5).
3. Drain fuel tank. The approximate capacity of fuel tank 8. Disconnect fuel hoses and fuel level sensor wire
is 80 L (21 gal). connector.
4. Remove cap screw and washer (1). 9. Remove tank from fuel tank bracket. Repair or replace
as necessary.
5. Support fuel tank bracket and fuel tank with a lifting
table or floor jack. 10. Connect fuel hoses and fuel level sensor wire
connector.
NOTE: It is not necessary to remove the cap screws
holding the fuel tank bracket to the frame. 11. Raise fuel tank and install cap screw and washer (1).
The bracket is slotted so bracket can be 12. Tighten cap screws (2).
lowered for tank removal.
13. Install right rear fender. See Rear Fenders Remove
6. Loosen cap screws and washers (2). and Install. (Group 1913.)
OUO1017,0000B41 -19-07SEP04-1/1
020921
PN=87
External Fuel Supply Systems
020921
PN=88
Section 07
Damper Drive
Contents
Page

Damper Drive Remove and Install.............. 07-0700-1
020921
PN=1
Contents
020921
PN=2
Group 0700
Damper Drive Remove and Install
SPECIFICATIONS
Hydraulic and Hydrostatic Pumps 38 kg
Damper Drive Socket Head Screw 25 N·m
Torque 20 lb.-ft.
Damper Drive Gear Bolt Torque 80 N·m
TX1182180A —UN—22JAN15
59 lb.-ft.
OTHER MATERIAL
PM37418 U.S. Thread Lock and Sealer (medium strength)
PM38621 Canadian Thread Lock and Sealer (medium strength)
242 Loctite® Thread Lock and Sealer (medium strength)
Machine Preparation Hydrostatic Pump Gear
• Prepare machine for service. See Park and Prepare for 1— Hydrostatic Pump Drive 2— Hydrostatic Pump Drive
Service Safely. (Group 0001.) Gear Bolt Gear
• Support left (flywheel) side of engine using a suitable
lifting device connected to left rear engine lift bracket.
• Remove hydrostatic pump. See Hydrostatic Pump
Removal

Specification
Hydraulic and
Hydrostatic Pumps
Assembly—Weight
(approximate) ................................................................................. 38 kg
84 lb.
1. Remove hydrostatic pump drive gear bolt (1) and

remove hydrostatic pump drive gear (2).
Loctite is a trademark of Henkel Corporation
Continued on next page RK40399,0001259 -19-26JAN15-1/2
020921
PN=91
2. Remove socket head screws (3) and damper (4).

3. Inspect for wear or damage on both damper and gear.
Replace if necessary.
Installation
• Apply PM37418 U.S. Thread Lock and Sealer (medium
TX1182181A —UN—22JAN15
strength) to threads of socket head screws (3).
• Install damper. In a crisscross pattern, tighten damper
drive socket head screws to specification.
Specification
Damper Drive Socket
Head Screw—Torque....................................................................25 N·m
20 lb.-ft.
Damper
• Install hydrostatic pump drive gear on pump shaft until
it bottoms on shoulder. Install set screws and tighten
to specification. 3— Socket Head Screw (8 used) 4— Damper
Specification
Hydrostatic Pump Drive
Gear Bolt—Torque.........................................................................80 N·m
• Align and insert pump drive gear into mating slots in
damper drive on flywheel.
59 lb.-ft.
NOTE: Rotate pump assembly as needed to align pump

drive gear with damper on engine flywheel.
RK40399,0001259 -19-26JAN15-2/2
020921
PN=92
Section 09
Steering System
Contents
Page

Orbital Steering Valve Remove and
Install ..................................................... 09-0960-1
Orbital Steering Valve Disassemble
and Inspect ............................................ 09-0960-2
Orbital Steering Valve Assemble ............... 09-0960-5
Steering Column Remove and
Install ..................................................... 09-0960-9
Steering Cylinder Remove and
Install ................................................... 09-0960-11
Steering Cylinder Disassemble and
Assemble............................................. 09-0960-13
020921
PN=1
Contents
020921
PN=2
Group 0960
Hydraulic System
Orbital Steering Valve Remove and Install
1. Park machine on level surface. Park and Prepare for
CAUTION: Prevent possible injury from
X9811 —UN—23AUG88
unexpected machine movement. Install frame
locking bar before working in frame hinge area.
2. Install frame lock bar.
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.
4. Drain hydraulic reservoir or apply a vacuum to retain
Never attempt to relieve hydraulic system or fluid in reservoir.
accumulator pressure by loosening a fitting.
Tighten all connections before applying pressure. If draining hydraulic reservoir, see Change Hydraulic
Oil. (Operator's Manual.)
3. Stop engine and relieve pressure from hydraulic
system. Perform Hydraulic System Pressure and
Accumulators Discharge Procedure. (Group 2160.)
PN50483,0002105 -19-23AUG16-1/2
IMPORTANT: An orifice disk is located in load

sense (LS) port fitting of steering valve. If
LS line (1) is disconnected, the orifice disk
must be removed and saved, to be installed
when LS line is connected.
5. Mark and disconnect all hydraulic lines from steering

valve. Close all openings with caps and plugs.
6. Remove steering column. See Steering Column
T203780A —UN—07OCT04
7. Remove mounting screws and steering valve.
8. Repair or replace steering valve as necessary. See
Orbital Steering Valve Disassemble and Inspect.
(Group 0960.)
9. Install steering valve and steering column. See
Steering Column Remove and Install. (Group 0960.)
1— LS Line
IMPORTANT: Orifice disk must be installed in LS
port fitting before connecting LS line.
11. Fill hydraulic reservoir to proper level, see Change
10. Connect all hydraulic lines as marked. Install orifice Hydraulic Oil. (Operator's Manual.)
disk in LS port fitting before connecting LS line (1).
See Orbital Steering System Component Location. 12. Remove frame lock bar.
(Group 9025-15.)
PN50483,0002105 -19-23AUG16-2/2
020921
PN=95
Hydraulic System
Orbital Steering Valve Disassemble and

Inspect
The steering valve is not serviceable. If parts are found
worn or damaged, replace steering valve.
NOTE: Mark location of spacer cap screw (B)
to aid in assembly.
1. Remove cap screws (A) and spacer cap screw (B).
LV10511 —UN—14SEP04
A—Cap Screw (6 used) B—Spacer Cap Screw
SF34961,000012B -19-04FEB09-1/8
2. Remove parts (A—F).
A—Cover D—Rotor Gear Set

B—O-Ring (3 used) E—Drive Shaft
C—Spacer F— Stop Disk
LV10515 —UN—14SEP04
SF34961,000012B -19-04FEB09-2/8
3. Remove threaded retainer (A) and ball (B).
A—Threaded Retainer B—Ball
LV10514 —UN—14SEP04
Continued on next page SF34961,000012B -19-04FEB09-3/8
020921
PN=96
Hydraulic System
IMPORTANT: If spool valve assembly must be removed

from valve body for cleaning, handle parts with
care. Tolerances on these parts are very close.
NOTE: The needle roller, which can be seen in the

spool valve assembly, must be (by rotating the
spool) in the horizontal position before removing
the assembly from steering valve housing.
4. Remove spool valve assembly (A) from steering valve
LV10512 —UN—14SEP04
housing (B).
A—Spool Valve Assembly B—Steering Valve Housing
SF34961,000012B -19-04FEB09-4/8
NOTE: Needle bearing (D) and bearing races

(C) may remain in housing after removal of
spool valve assembly.
5. Remove bearing races (C) and needle bearing (D).

6. Remove needle roller (F).
7. Carefully slide control spool (E) from spool sleeve (A).
NOTE: Spring set consists of two flat and two
LV10516 —UN—14SEP04
curved leaves.
8. Push spring set (B) from control spool (E).
A—Spool Sleeve D—Needle Bearing

B—Spring Set E—Control Spool
C—Bearing Race (2 used) F— Needle Roller
SF34961,000012B -19-04FEB09-5/8
9. Remove seal (A) and dust seal (B).
A—Seal B—Dust Seal
LV10510 —UN—14SEP04
Continued on next page SF34961,000012B -19-04FEB09-6/8
020921
PN=97
Hydraulic System
I
H
G
F
D
C
B
LV10547 —UN—11MAR13
A—Valve Body D—Control Spool F— Spring I— Plug
B—O-Ring E—Spacer Sleeve G—Locking Screw
C—Backing Ring H—Seal Ring
IMPORTANT: To ensure the correct steering relief 10. Remove parts (I—A) to inspect relief valve. Count
valve setting, count the number of turns number of turns needed to remove locking screw (G).
needed to remove locking screw (G). The
locking screw must be installed using the
same number of turns as removed.
SF34961,000012B -19-04FEB09-7/8
11. Remove hydraulic fitting from inlet port to inspect check

valve (A). Remove any obstructions from check valve.
12. Install and tighten hydraulic fitting.
13. Inspect all parts for wear or damage. Replace valve if
necessary.
A—Check Valve
LV10513 —UN—14SEP04
SF34961,000012B -19-04FEB09-8/8
020921
PN=98
Hydraulic System
Orbital Steering Valve Assemble
I
H
G
F
D
C
B
LV10547 —UN—11MAR13
A—Valve Body D—Control Spool F— Spring I— Plug
B—O-Ring E—Spacer Sleeve G—Locking Screw
C—Backing Ring H—Seal Ring
IMPORTANT: To ensure the correct steering relief

NOTE: Apply clean hydraulic oil to all internal
valve setting, locking screw (G) must be installed
parts before assembling.
using the same number of turns as removed.
Replace all O-rings and seals. Damaged 1. Install parts (A—I). Turn locking screw (G) in the same
or used parts will leak. number of turns as needed to remove.
SF34961,000012C -19-04FEB09-1/7
2. Install seal (A) and dust seal (B).
A—Seal B—Dust Seal
LV10510 —UN—14SEP04
Continued on next page SF34961,000012C -19-04FEB09-2/7
020921
PN=99
Hydraulic System
3. Install two flat leaves of spring set (B) into slot of

control spool (E). Install two curved leaves between
the flat leaves so centers of the curved leaves touch
each other as shown in lower illustration.
4. Slide control spool and springs into sleeve (A).
Squeeze spring ends together so springs fit into slot of
sleeve. Leaf ends must be aligned and centered.
5. Install needle roller (F).
LV10516 —UN—14SEP04
6. Install parts (C and D).
A—Sleeve D—Needle Bearing

B—Spring Set E—Control Spool
C—Bearing Races F— Needle Roller
Exploded View of Spool Valve Assembly
LV10549 —UN—05OCT04
Spring Set Orientation
SF34961,000012C -19-04FEB09-3/7
7. Position the cross pin so it is parallel to the hydraulic

fitting surface of the housing. Slide spool valve
assembly (A) into steering valve housing (B).
A—Spool Valve B—Steering Valve Housing
LV10512 —UN—14SEP04
020921
PN=100
Hydraulic System
8. Install ball (B) and threaded retainer (A).
A—Threaded Retainer B—Ball
LV10514 —UN—14SEP04
SF34961,000012C -19-04FEB09-5/7
9. Install parts (B—F).

IMPORTANT: Violent steering wheel oscillation
can occur if rotor gear and drive shaft
are not timed correctly.
10. Align timing mark (H) on end of drive shaft with timing
notch (G) inside splines of rotor gear.
11. Install cover (A).
LV10515 —UN—14SEP04
A—Cover E—Drive Shaft
B—O-Ring F— Stop Disk
C—Spacer G—Timing Notch
D—Rotor Gear Set H—Timing Mark
LV11244 —UN—13OCT04
G
020921
PN=101
Hydraulic System
12. Install spacer cap screw (B) in location shown. Install

cap screws (A). Tighten all cap screws to specification
in sequence shown.
Specification
Steering Valve Cover
22 lb-ft
LV10511 —UN—14SEP04
A—Cap Screw (6 used) B—Spacer Cap Screw
6
1 4
LV10548 —UN—20SEP04
3 2
5 7
SF34961,000012C -19-04FEB09-7/7
020921
PN=102
Hydraulic System
Steering Column Remove and Install 1

SPECIFICATIONS
Steering Wheel Nut Torque 68 N·m
50 lb.-ft.

Steering Wheel Puller
OTHER MATERIAL
PM37566 Silver-Grade Anti-Seize
5
Machine Preparation 2
• Park and prepare machine for service. See Park and 3
Removal
4
1. Remove steering wheel (1) using puller.
TX1181135 —UN—07JAN15
1— Steering Wheel 5— Steering Column Cover
2— Collar Screw 6— Clamp 6
3— Screw (2 used) 7— Boot
4— Cover Screw (4 used)
7
Steering Wheel and Cover Removal
RK40399,0001254 -19-13JAN15-1/3
2. Remove screws (8) and remove center console panel

(9).
3. Loosen clamp (6) and remove boot (7) from steering
column cover (5).
TX1181137A —UN—13JAN15
4. Disconnect steering column combination switch
connectors (X21 and X25). See Cab Main Harness
(W8) Component Location. (Group 9015-10.)
8— Screw (6 used) 9— Center Console Panel
Center Panel Removal
020921
PN=103
Hydraulic System
5. Remove screws (10) and steering column assembly

(11).
6. Replace parts as necessary.
Installation
IMPORTANT: Apply PM37566 Silver-Grade
Anti-Seize lubricant to tilt pivot points,
steering shaft threads, and spline of steering
shaft during reassembly.
Installation is removal of removal procedure.

• Tighten steering wheel nut to specification.
Specification
Steering Wheel
Nut—Torque..................................................................................68 N·m
50 lb.-ft.
10— Screw (4 used) 11— Steering Column
TX1181138 —UN—26JAN15
Assembly
Steering Column Assembly
RK40399,0001254 -19-13JAN15-3/3
020921
PN=104
Hydraulic System
Steering Cylinder Remove and Install
TX1050993 —UN—05NOV08
Steering Cylinder and Pins

1— Steering Cylinder 4— Snap Ring (4 used) 8— Cap Screw (2 used) 11— Cap (2 used)
2— Shim (4 used) 5— Cylinder Assembly 9— Lock Washer (2 used)
3— Roller Bearing (2 used) 6— Pin (2 used) 10— Lubrication Fitting (2 used)
7— Washer (2 used)

Service Safely. (Group 0001.) 3. Mark and disconnect hydraulic lines from steering
cylinder.
CAUTION: Prevent possible injury from 4. Close open lines and fittings with caps and plugs.
unexpected machine movement. Install frame
lock bar before working in frame hinge area. 5. Remove pins (6), shims (2), and steering cylinder (1).
6. Inspect roller bearings (3). Replace as necessary.
Continued on next page PN50483,0002102 -19-18DEC14-1/2
020921
PN=105
Hydraulic System
7. Repair or replace steering cylinder as necessary. See 10. Apply grease to pin lubrication fittings (10). See
Steering Cylinder Disassemble and Assemble. (Group Grease. (Operator's Manual.)
0960.)
11. Remove frame lock bar and perform loader start-up
8. Install steering cylinder, shims, and pins. procedure for steering cylinders. See Loader Start-Up
Procedure. (Group 3160.)
9. Connect hydraulic lines as marked.
PN50483,0002102 -19-18DEC14-2/2
020921
PN=106
Hydraulic System
Steering Cylinder Disassemble and Assemble
2 3
1 4
6 5
11 14
12 13 13
10 15 14
T203856 —UN—21OCT04
17 16 7 9 8 7
2
T203856
Steering Cylinder Cross Section
1— Rod Guide 6— Rod 11— Rod Seal 16— O-Ring
2— O-Ring 7— Wear Ring (2 used) 12— Rod Seal 17— Back-Up Ring
3— Piston 8— Piston Seal 13— O-Ring
4— Snap Ring 9— O-Ring 14— Wear Ring
5— Cylinder Barrel 10— O-Ring 15— Rod Seal
1. Install cylinder into JT30043 Cylinder Service Stand IMPORTANT: Rod guide seals are not alike. When
with pin in head end. removing, note location so new seals are
2. Extend rod (6) completely. installed in proper place. Install seals
with lips facing inward.
3. Loosen rod guide (1) using JDG347A Spanner Wrench
and JDG1231 Pin Set. 10. Remove seals (8, 11, 12, 15), O-rings (2, 9, 10, 13,
16), back-up ring (17) and wear rings (7 and 14) from
4. Remove rod guide (1), rod (6) and piston (3) from
rod guide and piston.
cylinder barrel (5).
11. Inspect piston and rod guide for nicks or burrs that
5. Inspect cylinder barrel for nicks or burrs that may
may damage seals or O-rings. Remove nicks or burrs
damage seals or O-rings. Remove nicks or burrs with
with fine crocus cloth.
fine crocus cloth.
IMPORTANT: Install seals with lips inward.
6. Remove cylinder barrel from service stand and install
piston rod assembly into stand.
12. Install parts (2) and (10—17) on rod guide (1).
7. Remove snap ring (4).
13. Apply petroleum jelly to rod guide seals, O-rings and
8. Using JT05794 Rod Guide Spanner Wrench, loosen wear rings. Install rod guide onto rod (6).
piston (3) and remove.
9. Remove rod guide (1).
Continued on next page OUO1020,0001459 -19-06OCT04-1/4
020921
PN=107
Hydraulic System
14. Install wear ring (7) and O-ring (9) on piston.

15. Install piston seal (8) using JDG1388-3 Pusher and
JDG1388-1 Steering Piston Seal Installer. Use pusher
from installer to compress seal to its original size.
16. Apply multipurpose grease to tapered area (mating
T116273B —UN—10JUL98
surfaces) of piston and rod. Install piston on rod.
17. Using cylinder service stand and JT05794 Rod Guide
Spanner Wrench, tighten piston to specification.
Specification
Steering Cylinder
Piston—Torque............................................................................350 N·m
258 lb-ft
18. Install snap ring (4).
T116275B —UN—10JUL98
OUO1020,0001459 -19-06OCT04-2/4
19. Apply OPTIMOLY PASTE WHITE T® to rod guide

threads.
20. Install rod with rod guide and piston into barrel using
JDG347A Spanner Wrench and JDG1231 Pin Set.
IMPORTANT: Before total length of measurement
T116595 —UN—27JUL98
(A + B) can be made, the centerline of the
extension must run along the centerline
of the torque wrench.
NOTE: When using an extension of any kind on a torque

wrench, the torque wrench setting must be adjusted
to compensate for the length of the extension.
Initial Torque
21. Use the formula shown to calculate the correct torque
wrench setting: A—Length of Torque Wrench C—Torque Wrench Setting
B—Length of Extension D—Torque Applied to Rod
• A—Length of torque wrench (measured from center Guide
of the drive to center of the grip).
• B—Length of extension (measured along the center
line of the torque wrench—from the center of the • C—Torque wrench setting.
drive to the center of the rod guide). • D—Torque applied to rod guide.
OPTIMOLY PASTE WHITE T is a registered trademark of
Optimal Lubricants, Inc.
Continued on next page OUO1020,0001459 -19-06OCT04-3/4
020921
PN=108
Hydraulic System
22. Tighten rod guide (1) to specification by performing

the following:
Specification
Steering Cylinder Rod
Guide—Torque Turn.........................................................50 N·m + 8 mm 5 20
T203891 —UN—21OCT04
37 lb-ft + 0.31 in.
a. Initially tighten rod guide to 50 N·m (37 lb-ft).

1
b. Put a starting mark (18) on cylinder barrel (5) and a 18 19
21
reference mark (21) on rod guide. T203891
NOTE: If a flexible ruler is not available, make marks

(18 and 19) 8 mm (0.31 in.) apart on a piece of
light colored tape (such as masking tape). Apply
the tape to OD of cylinder barrel (5). 1— Rod Guide 19— End Mark
5— Cylinder Barrel 20— 8 mm (0.31 in.)
c. Using a flexible scale or ruler, put a end mark (19) 18— Starting Mark 21— Reference Mark
8 mm (0.31 in.) to the right of starting mark (18) on
OD of barrel.
d. Turn the rod guide clockwise until mark (21) aligns
with mark (19).
OUO1020,0001459 -19-06OCT04-4/4
020921
PN=109
Hydraulic System
020921
PN=110
Section 10
Service Brakes
Contents
Page
Group 1011—Active Elements

Drum Brake Remove and Install................ 10-1011-1
Service Brakes (Wet Disk) Remove
and Install .............................................. 10-1011-2

Brake/Inching Valve Assembly
Brake Valve Disassemble and
Assemble............................................... 10-1060-3
Drum Brake Bleed ..................................... 10-1060-4
020921
PN=1
Contents
020921
PN=2
Group 1011
Active Elements
Drum Brake Remove and Install
2 3 4
5 14
6
15
13
12
1
10 11
T204187 —UN—26OCT04
7
8
16
T204187 17
1— Input Shaft Nut 5— Mounting Plate Socket Head 10— O-Ring 15— Right Brake Shoe
2— Brake Drum Screw (8 used) 11— Keeper Spring (2 used) 16— Positioning Spring
3— Backing Plate Socket Head 6— Mounting Plate 12— Return Spring (2 used) 17— Brake Adjuster
Screw (6 used) 7— O-Ring 13— Left Brake Shoe
4— Backing Plate 8— Seal 14— Brake Cylinder
9— Input Flange
1. Remove transmission-to-front axle drive shaft. See 12. Install mounting plate. Apply PM37418 Thread Lock
Drive Shaft Remove and Install. (Group 0225.) and Sealer (medium strength) to threads of mounting
2. Remove brake drum (2). plate socket head screws. Install and tighten to
specification.
3. Remove return springs (12) and keeper springs (11).
Specification
4. Remove left and right brake shoes (13 and 15), and Mounting Plate Socket
positioning spring (16). Head Screw—Torque................................................................. 122 N•m
90 lb-ft
5. Remove input shaft nut (1), O-ring (10), and input
flange (9). 13. Install backing plate. Apply PM37418 Thread Lock and
Sealer (medium strength) to threads of backing plate
6. Disconnect brake line. socket head screws. Install and tighten to specification.
7. Remove backing plate socket head screws (3) and Specification
backing plate (4) with brake cylinder (14) and brake Backing Plate Socket
adjuster (17) attached. Head Screw—Torque................................................................. 122 N•m
90 lb-ft
8. Remove mounting plate socket head screws (5) and
mounting plate (6). 14. Install input flange and O-ring. Apply PM37418 Thread
Lock and Sealer (medium strength) to threads of input
9. Remove O-ring (7) and seal (8).
shaft. Install input shaft nut and tighten to specification.
10. Clean and inspect parts for wear or damage. Replace Specification
parts as necessary. Input Shaft Nut—Torque............................................................. 295 N•m
11. Install O-ring (7) and seal (8) with lip facing in as 218 lb-ft
shown. Apply petroleum jelly to seal and O-ring.
Continued on next page OUO1020,000145E -19-13MAR09-1/2
020921
PN=113
Active Elements
15. Connect positioning spring to left and right brake 18. Install brake drum.
shoes and install brake shoes into notches of brake 19. Connect brake line and bleed drum brake. See Drum
cylinder and brake adjuster. Brake Bleed. (Group 1060.)
NOTE: Push and turn keeper springs to engage 20. Apply brakes several times and adjust brakes as
backing plate. needed.
16. Install keeper springs and return springs. 21. Install transmission-to-front axle drive shaft. See Drive
Shaft Remove and Install. (Group 0225.)
17. Center brake shoes on backing plate as necessary.
OUO1020,000145E -19-13MAR09-2/2
Service Brakes (Wet Disk) Remove and Install

For service brake repair, see Axle Shaft, Bearings, and
Rear Axle Reduction Gears. (Group 0250.)
RK40399,0001257 -19-06JAN15-1/1
020921
PN=114
Group 1060
Hydraulic System
Brake/Inching Valve Assembly Remove and
Install
1. Remove cap screws and lock nuts (1) to remove
brake/inching pedal (2).
TX1051180A —UN—10NOV08
2. Remove floor mat from cab.
3. Remove left rear fender. See Rear Fenders Remove
and Install. (Group 1913.)
NOTE: To ease access to the brake/inching valve
hydraulic line connections, it is recommend that
the cab be raised approximately 152 mm (6
in.). If the cab is only raised 152 mm (6 in.), Brake/Inching Pedal (View From Under Cab)
disconnection of wire connectors and hydraulic
lines, other than those going to the brake/inching
valve assembly, is not necessary.
4. Attach hoist and lifting chains to cab roof. Remove

cab mounting hardware and raise cab approximately
152 mm (6 in.). Go to Cab Remove and Install (Group
1800) and perform steps 12 and 22—25.
T204486A —UN—26OCT04
CAUTION: Prevent possible crushing injury. If
cab is raised to access brake/inching valve
hydraulic lines, wood blocks of sufficient height
must be installed between cab and frame before
proceeding with repair procedure.
5. Install blocks between cab and frame to prevent cab

from lowering. Brake/Inching Valve Assembly [Cab Raised Approximately
152 mm (6 in.)]
6. Disconnect hydraulic lines (3—7) and brake lines (8
and 9). See Power Train Description and see Service
1— Cap Screw and Lock Nut (2 7— Hydraulic Line
and Park Brake Operation. (Group 9020-05.) used) 8— Brake Line
2— Brake Pedal 9— Brake Line
7. Disconnect brake light pressure switch wire connectors 3— Hydraulic Line 10— Wire Connectors
(10). 4— Hydraulic Line 11— Cap Screw (5 used)
5— Hydraulic Line
6— Hydraulic Line
Continued on next page SF34961,0000131 -19-10FEB09-1/2
020921
PN=115
Hydraulic System
8. Remove five cap screws (11) from cab floor to remove

brake/inching valve assembly.
10. Put brake/inching valve assembly into position and
fasten to cab floor using cap screws (11).
T204487A —UN—26OCT04
11. Connect hydraulic and brake lines. See Power
Train Description and see Service and Park Brake
Operation. (Group 9020-05.)
12. Connect wire connectors to brake light pressure switch.
13. Remove blocks and lower cab into position. Install cab
mounting hardware. Go to Cab Remove and Install Brake/Inching Valve Assembly Mounting Cap Screws
(Group 1800) and perform steps 28—30 and 40.
14. Install left rear fender. See Rear Fenders Remove and 16. Install brake/inching pedal.
Install. (Group 1913.)
15. Install floor mat in cab.
SF34961,0000131 -19-10FEB09-2/2
020921
PN=116
Hydraulic System
Brake Valve Disassemble and Assemble
T204489 —UN—26OCT04
1— O-Ring 11— Check Valve 21— Back-Up Ring 31— Check Valve
2— Square Cut Seal 12— Sealing Washer 22— O-Ring 32— Spring
3— Banjo Fitting 13— Housing 23— Retaining Ring 33— Cap
4— Banjo Bolt 14— Piston 24— Washer 34— Ball
5— Sealing Washer (2 used) 15— Dowel 25— Bronze Bushing 35— Spring
6— Cap 16— Spring 26— O-Ring 36— Piston
7— Spring 17— O-Ring 27— Washer 37— Seal
8— Fitting 18— End plug 28— O-Ring 38— Special Washer
9— Back-Up Ring 19— Socket Head Screw (4 used) 29— Housing 39— Retaining Ring
10— O-Ring 20— Piston 30— Retaining Ring
1. Remove inching valve and brake valve bracket. 2. Repair or replace parts as necessary.
CAUTION: Remove end plug (18) carefully.

Brake valve housing (13) contains a
compressed spring (16).
OUO1010,00006AE -19-14MAY18-1/1
020921
PN=117
Hydraulic System
Drum Brake Bleed

Bleeding of the brake system will be necessary any time
the drum brake lines have been disconnected.
1. Park machine on level surface.
2. Install frame locking bar.
3. Lower bucket to ground.
4. Engage park brake. Stop engine.
T204488A —UN—26OCT04
CAUTION: Prevent possible injury from
unexpected machine movement. Never rely on
loader bucket to keep machine from moving.
Machine can unexpectedly roll, resulting in death
or serious injury. Always block wheels to hold
machine when working on park brake.
5. Put blocks in front and rear of tires.

1— Bleed Screw
IMPORTANT: Use SAE 10W engine oil in the service
brake system. DO NOT use DOT type brake fluid
or damage to brake system will occur. 8. Slowly push brake pedal down and hold.
The following are approved alternative 9. Open bleed screw (1) to release any trapped air in
oils that may be used if SAE 10W engine brake line and caliper. Close bleed screw.
oil is not available:
10. Slowly release pedal.
• SAE 5W engine oil
• SAE 5W20 engine oil 11. Repeat steps 8—10 until a steady stream of oil flows
• SAE 5W30 engine oil from bleed screw.
NOTE: Add SAE 10W oil to service brake reservoir as NOTE: Soft or “spongy” brakes indicate air is
necessary during brake bleeding procedure. present in the system.
6. Fill service brake reservoir with SAE 10W oil. See 12. Check for brake resistance.
Service (Drum) Brake Oil (Operator's Manual.) 13. Repeat the entire brake bleed procedure as necessary
7. Connect one end of a clear plastic hose to bleed screw to remove all air from system.
(1) and put other end of hose into a suitable container 14. Fill service brake reservoir with SAE 10W oil. See
to catch oil. Service (Drum) Brake Oil (Operator's Manual.)
NOTE: Two technicians are needed to bleed the brake
system—one to operate the brake pedal and the
other to open and close bleed screws.
OUO1010,00006B0 -19-22OCT04-1/1
020921
PN=118
Section 11
Park Brake
Contents
Page

Park Brake Disassemble and
Assemble................................................11-1160-1
Park Brake/Differential Lock Valve
Block Remove and Install .......................11-1160-1
020921
PN=1
Contents
020921
PN=2
Group 1160
Hydraulic System
Park Brake Disassemble and Assemble
For park brake repair, see Axle Shaft, Bearings, and Rear
Axle Reduction Gears. (Group 0250.)
RK40399,0001258 -19-06JAN15-1/1
Park Brake/Differential Lock Valve Block

Remove and Install
The park brake and differential lock solenoid valves can
be removed without removing valve block from machine.
The park brake circuit can not be operated to relieve
pressure like other accumulated circuits. The park brake
circuit pressure will bleed off due to internal leakage but
it requires that engine be off and that machine sit idle for
T202622A —UN—14SEP04
approximately 25 minutes.
1. Park machine on level surface. Raise boom and install
boom locking bar.
2. Stop engine.
3. Turn key on.
View Inside Loader Frame
CAUTION: Escaping fluid or gas from pressurized
hydraulic accumulator systems can cause serious
1— Park Brake/Differential
injury. Extreme heat can cause the accumulator to Lock Valve Block Assembly
burst, and pressurized lines can be accidentally
cut. Do not weld or use a torch near a pressurized
accumulator or pressurized lines.
9. Close lines and fittings using caps and plugs.
Relieve pressure from the hydraulic system
before removing accumulator. Never attempt 10. Remove valve block assembly. Repair or replace as
to relieve hydraulic system or accumulator needed.
pressure by loosening a fitting.
11. If removed, install solenoid valves making sure
back-up rings and O-rings are in place and lightly
4. Push and hold the pilot enable/boom down switch and
lubricated with clean hydraulic oil. Tighten solenoid
lower boom to rest on boom lock and dump bucket.
valve to specification.
Push and hold pilot enable/boom down switch while Specification
moving loader control lever to boom down then to Park Brake Solenoid
bucket dump positions. Repeat this cycle until no Valve—Torque.............................................................................. 70 N•m
movement is felt or seen in boom lower or bucket 52 lb-ft
dump function. Differential Lock Solenoid
5. Turn key off. Valve—Torque.............................................................................. 70 N•m
52 lb-ft
NOTE: The park brake circuit can not be operated to
relieve pressure like other accumulated circuits.
The park brake circuit pressure will bleed off due to 12. If removed, apply PM37418 Thread Lock and Sealer
internal leakage but it requires that engine be off and (medium strength) to threads of accumulator before
that machine sit idle for approximately 25 minutes. installing.
6. Wait for a minimum of 25 minutes to allow park brake 13. Install park brake/differential lock valve block.
accumulator to bleed off before removing any lines. 14. Connect hydraulic lines and electrical connectors.
7. Attach vacuum pump to reservoir to minimize oil
leakage while removing solenoid valves or solenoid
valve block.
8. Mark and disconnect hydraulic lines and electrical
connectors from park brake/differential lock valve
block assembly (1).
OUO1020,000144C -19-13MAR09-1/1
020921
PN=121
Hydraulic System
020921
PN=122
Section 16
Electrical System
Contents
Page

Monitor Display Remove and
Install ..................................................... 16-1600-1
Chassis Control Unit (CCU)
Engine Control Unit (ECU) Remove
and Install .............................................. 16-1600-2
Ground Speed Sensor Install .................... 16-1600-3
Installation of Repair Wire
Assembly (RWA) ................................... 16-1600-3
Replace Metri-Pack® (Push Type)
Connectors ............................................ 16-1600-7
Replace Metri-Pack® Connectors.............. 16-1600-8
Replace DEUTSCH® Circular
Connectors ............................................ 16-1600-9
Replace DEUTSCH® Rectangular
or Triangular Connectors ..................... 16-1600-10
Install DEUTSCH® Contact..................... 16-1600-11
Replace WEATHER PACK®
Connector ............................................ 16-1600-12
Install WEATHER PACK®
Contact ................................................ 16-1600-13
Replace CINCH™ Connectors ................ 16-1600-14
Install CINCH™ Contact.......................... 16-1600-15
Repair 32 and 48 Way CINCH™
Connectors .......................................... 16-1600-16
Remove Connector Body from
Blade Terminals ................................... 16-1600-18
020921
PN=1
Contents
020921
PN=2
Group 1600
Monitor Display Remove and Install
Machine Preparation

• Turn battery disconnect to the OFF position.
• Remove monitor display lower panel (2).
1— Monitor Display 2— Monitor Display Lower

Panel
TX1181155A —UN—07JAN15
Monitor Display
RK40399,0001255 -19-27JAN15-1/2
Removal
1. Disconnect monitor display electrical connectors (X14
or X15)
2. Remove thumb nuts (3) from display.
3. Remove monitor display (1) from front of console.
Installation
TX1181156A —UN—07JAN15
Installation is reverse of removal process.
3— Thumb Nut (4 used) X15— Monitor Display 10-Pin

X14— Monitor Display 15-Pin Connector
Connector
Monitor Display Hardware
RK40399,0001255 -19-27JAN15-2/2
020921
PN=125
Chassis Control Unit (CCU) Remove and

Install
1. Remove rear panel located behind seat.
2. Disconnect connectors X3 (2) and X4 (3).
3. Remove four socket head screws (1) to remove
chassis control unit (CCU) (4).
T202361A —UN—27AUG04
4. Install CCU and connect connectors.
5. Install rear panel.
1— Socket Head Screws (4 3— Connector X4

used) 4— Chassis Control Unit (CCU)
2— Connector X3
CS33148,0002B46 -19-04SEP08-1/1
Engine Control Unit (ECU) Remove and

Install
SPECIFICATIONS
Cap Screw Torque 30 N·m
22 lb.-ft.
NOTE: Battery disconnect switch and engine control unit

(ECU) are located in engine compartment.
Machine Preparation
TX1181161A —UN—07JAN15
• Turn battery disconnect to the OFF position.
Removal
1. Remove relay panel (1) and place to side.
Relay Panel
1— Relay Panel 2— Engine Control Unit (ECU)
020921
PN=126
2. Disconnect engine control unit (ECU) connectors

(X5501 and X5502)
3. Remove ECU. Repair or replace as necessary.
Installation
• Install ECU. Tighten cap screws to specification.
Specification
TX1181162A —UN—07JAN15
22 lb.-ft.
IMPORTANT: An incorrect ECU program can result

in misleading diagnostic messages, poor
performance, or engine damage.
• Check the Software Delivery System (SDS) for latest

ECU software update. Download and install software
as needed. Engine Control Unit
2— Engine Control Unit (ECU) X5502—Engine Control Unit

X5501—Engine Control Unit 94-Pin Connector
60-Pin Connector
RK40399,0001256 -19-23JAN15-2/2
Ground Speed Sensor Install Specification

1. Apply high flex form-in-place gasket material to Ground Speed
threads of speed sensor. Sensor—Torque............................................................. 50 N·m (37 lb-ft)
2. Install speed sensor and tighten to specification.

CS33148,0000876 -19-01DEC08-1/1
Installation of Repair Wire Assembly (RWA) A CORRECT

NOTE: There are two types of installation procedures:
• Method 1—RWA is the same gauge as
the wire being repaired.
• Method 2—RWA is a different gauge than
RG20576 —UN—17JUN11
the wire being repaired. B INCORRECT
Install Repair Wire Assembly (RWA)—Method 1
1. See your machine parts catalog for the correct RWA
for the connector to be repaired.
IMPORTANT: Ensure that there is adequate room
for the splice in the area of the harness where
the repair will be installed. A—Correct B—Incorrect
2. Ensure the area of the harness where the splice will

be installed is clean. Cut the wire on the harness and
the RWA to the desired length.
IMPORTANT: If multiple RWAs are being used, make
sure to stagger the splices (A) so that they
do not overlap each other (B).
Continued on next page DX,RWA -19-22MAR18-1/8
020921
PN=127
3. Using JDG110721 tool, remove 9.5 mm (3/8 in) of

insulation from the wire. Twist the strands to prevent
fraying. A
4. Insert the wire (A) into the splice sleeve until it hits B
the stop (B).
RG20521 —UN—26MAY11
A—Wire B—Stop
1
See the SERVICEGARD™ online tool catalog or your John
Deere dealer for additional information.
DX,RWA -19-22MAR18-2/8
5. Using JDG114091 tool (A), crimp the splice sleeve to A

the wire until the ratchet automatically releases.
IMPORTANT: Make sure that the color of the
splice sleeve matches the colored die (B)
on the crimping tool jaw.
6. Repeat Steps 2—5 on the other end of the splice.

7. Tightly grasp the wires coming out of each end of the
splice. Firmly pull on the wires to ensure that they are B
properly crimped and do not pull out. If either wire pulls
out, repeat Steps 2—5 to attain an adequate crimp.
22-18
16-14
12-10
8. Apply heat evenly around the diameter of the splice

from the center out to the ends until the tubing shrinks
RG20520 —UN—26MAY11
tightly around the wire and adhesive flows from both
ends of the splice.
splice. Firmly pull on the wires to ensure that they are
10. Apply tape along the length of the repair.
A—Crimp Tool B—Colored Dies
1
020921
PN=128
Install Repair Wire Assembly (RWA)—Method 2 A CORRECT

1. See your machine parts catalog for the correct RWA
for the connector to be repaired.
IMPORTANT: Ensure that there is adequate room
for the splice in the area of the harness where
RG20576 —UN—17JUN11
the repair will be installed. B INCORRECT
2. Ensure the area of the harness where the splice will
be installed is clean. Cut the wire on the harness and
the RWA to the desired length.
IMPORTANT: If multiple RWAs are being used, make
sure to stagger the splices (A) so that they
do not overlap each other (B).
A—Correct B—Incorrect
DX,RWA -19-22MAR18-4/8
3. Using JDG110721 tool, remove 9.5 mm (3/8 in) of

insulation from the larger wire (A). Twist the strands to
prevent fraying. A
C D
4. Insert the larger wire (A) into the splice sleeve until B
it hits the stop (B).
RG20522 —UN—26MAY11
A—Larger Wire C—Smaller Wire
B—Stop D—Folded Wire
1
020921
PN=129

22-18
16-14
12-10
RG20520 —UN—26MAY11
1
DX,RWA -19-22MAR18-6/8
6. Using JDG110721 tool, remove 19 mm (3/4 in) of

insulation from the smaller wire (C). Twist the strands
to prevent fraying. A
C D
7. Fold the wire strands in half (D) so that the stripped B
length is equal to the larger wires’ stripped length, 9.5
RG20522 —UN—26MAY11
mm (3/8 in).
8. Insert the folded wire (D) into the splice sleeve until
it hits the stop (B).
A—Larger Wire C—Smaller Wire

B—Stop D—Folded Wire
1
020921
PN=130

properly crimped and do not pull out. If either wire pulls B
11. Apply heat evenly around the diameter of the splice
from the center out to the ends until the tubing shrinks
22-18
16-14
12-10
tightly around the wire and adhesive flows from both
ends of the splice.
RG20520 —UN—26MAY11
13. Apply tape along the length of the repair.
1
DX,RWA -19-22MAR18-8/8
Replace Metri-Pack® (Push Type) Connectors

1. Disconnect the Metri-Pack® connector.
2. Remove the connector lock (A), and mark wire colors
for identification.
RW21325 —UN—29JUN92
3. Identify and record wire color locations with connector
terminal letters.
NOTE: JDG776 or JDG777 Terminal Extraction
Tool are included in JT07195B Technicians
Electrical Repair Kit.
4. Insert JDG776 or JDG777 Terminal Extraction Tool (B)

into connector body socket (C), pushing the terminal
locking tab inward. A—Connector Lock D—Terminal
B—JDG777 Terminal Extraction E—Locking Tab
NOTE: Use JDG776 Extraction Tool with 56, 280, Tool
and 630 series Metri-Pack® terminals. Use C—Connector Body Socket
JDG777 Extraction Tool with 150 series
Metri-Pack® terminals.
7. Push terminal into connector body socket until terminal
5. Remove extraction tool and pull terminal (D) out of locks.
the socket.
6. Replace terminal. Make sure locking tab (E) on the
new terminal is in the outward position.
Metri-Pack is a trademark of Delphi Connection Systems
CS33148,0002A92 -19-08JUL08-1/1
020921
PN=131
Replace Metri-Pack® Connectors

1. A small locking tab (A) is located inside the
Metri-Pack® connector. Use a small screwdriver (B)
to move tab outward to the first detent position; the
tab will “click.”
T104764B —UN—01NOV96
A—Tab B—Screwdriver
Metri-Pack is a trademark of Delphi Connection Systems

CS33148,0002A93 -19-08JUL08-1/3
2. Slide JDG939 Metri-Pack® Extractor Tool (B) into

connector body until it is positioned over terminal
contact.
3. Pull wire out of connector body.
T104763B —UN—01NOV96
IMPORTANT: Install contact in proper location
using correct size grommet.
4. Push contact straight into connector body until positive

stop is felt.
5. Pull on wire slightly to be certain contact is locked in
place.
6. Transfer remaining wires to correct terminal in new
connector. A—Wire B—Extractor Tool
CS33148,0002A93 -19-08JUL08-2/3
7. Use a small screwdriver (B) to move tab (A) inward to

the first detent position; the tab will “click” and lock the
wires in the connector body.
A—Tab B—Screwdriver
T104764B —UN—01NOV96
CS33148,0002A93 -19-08JUL08-3/3
020921
PN=132
Replace DEUTSCH® Circular Connectors

NOTE: JDG361 Extractor Tool, JDG362 Extractor Tool,
and JDG363 Extractor Tool are available in JDG359
DEUTSCH® Electrical Repair Tool Kit.
TS0124 —UN—23AUG88
1. Select correct size extractor tool for size of wire to be
removed:
• JDG361 Extractor Tool for 12 to 14 gauge wire.
• JDG362 Extractor Tool for 16 to 18 gauge wire.
• JDG363 Extractor Tool for 20 gauge wire.
2. Start correct size extractor tool (a) over wire at handle.
3. Slide extractor tool along wire until tool tip snaps onto
wire.
IMPORTANT: Avoid connector damage. Do not twist
tool when inserting in connector.
4. Slide extractor tool along wire into DEUTSCH®
connector body until it is positioned over terminal
contact.
5. Pull wire out of connector body using extractor tool (A).
A—Extractor Tool
DEUTSCH is a trademark of Deutsch Co.

CS33148,0002A8A -19-08JUL08-1/2
IMPORTANT: Avoid electrical malfunction. Install

contact in proper connector location using
correct size grommet.
6. Push contact straight into connector body until positive

stop is felt.
7. Pull on wire and verify contact is locked in place.
CS33148,0002A8A -19-08JUL08-2/2
020921
PN=133
Replace DEUTSCH® Rectangular or

Triangular Connectors
NOTE: Connector shown is the female half of a
4-pin square connector. Other similar styles
of DEUTSCH® connectors can be serviced
T130688B —UN—01MAY00
using the same procedure.
1. Pull connector (1) apart. Inspect and clean connector

seal and terminals.
NOTE: Locking wedge shown can be removed
using an O-ring pick or similar tool. Locking
wedges in male connector halves can be pried
out using a screwdriver.
1— Connector 2— Locking Wedge
2. Remove locking wedge (2) from connector.
RK40399,000125F -19-23JAN15-1/2
3. Release primary locking latch (3) next to the pin to be

removed using a small screwdriver.
4. Pull wire out from back of connector.
5. Replace connector contacts as necessary. See Install
DEUTSCH® Contact. (Group 1600.)
T130689B —UN—01MAY00
6. Install wire terminal back into connector until it clicks
into place.
NOTE: Locking wedge in 2-pin connector is
not symmetrical. Position latch shoulder
next to terminals.
7. Install locking wedge until it snaps into place.
3— Primary Locking Latches
T130690B —UN—01MAY00
RK40399,000125F -19-23JAN15-2/2
020921
PN=134
Install DEUTSCH® Contact

1. Strip 6 mm (1/4 in.) insulation from wire.
NOTE: JDG360 Crimper is included in JDG359
DEUTSCH® Electrical Repair Tool Kit.
2. Adjust selector (A) on JDG360 Crimper for correct
wire size.
3. Loosen lock nut (B) and turn adjusting screw (C) in
until it stops.
A—Selector C—Adjusting Screw

B—Lock Nut

CS33148,0002A8B -19-08JUL08-1/4
IMPORTANT: Select proper size contact “sleeve”

or “pin” to fit connector body.
4. Insert contact (A) and turn adjusting screw (D) until

contact is flush with cover (B).
5. Tighten lock nut (C).
TS0134 —UN—23AUG88
A—Contact C—Lock Nut
B—Cover D—Adjusting Screw
CS33148,0002A8B -19-08JUL08-2/4
IMPORTANT: Contact must remain centered between

indenters while crimping.
6. Insert wire in contact and crimp until handle touches

stop.
7. Release handle and remove contact.
Continued on next page CS33148,0002A8B -19-08JUL08-3/4
020921
PN=135
IMPORTANT: If all wire strands are not crimped into

contact, cut off wire at contact and repeat
contact installation procedures.
NOTE: Readjust crimping tool for each crimp-

ing procedure.
TS0135 —UN—23AUG88
8. Inspect contact to be certain all wires are in crimped
barrel.
CS33148,0002A8B -19-08JUL08-4/4
Replace WEATHER PACK® Connector

1. Identify and record wire color locations with connector
terminal letters.
2. Open WEATHER PACK® connector body.
TS0128 —UN—23AUG88
NOTE: JDG364 Extraction Tool is included in JT07195B
Technicians Electrical Repair Kit.
3. Insert JDG364 Extraction Tool over terminal contact in

connector body.
4. Fully seat extractor tool and pull wire from connector
body.
NOTE: If terminal cannot be removed, insert wire
or nail through extractor tool handle and push
terminal contact from connector.
WEATHER PACK is a trademark of Packard Electric
CS33148,0002A8C -19-08JUL08-1/2
IMPORTANT: Carefully spread contact lances to

ensure good seating on connector body.
NOTE: Connector bodies are “keyed” for proper contact

mating. Be sure contacts are in proper alignment.
5. Push contact into new connector body until fully seated. TS0130 —UN—23AUG88
6. Pull on wire slightly to be certain contact is locked in

place.
7. Transfer remaining wires to correct terminal in new
connector.
8. Close connector body.
CS33148,0002A8C -19-08JUL08-2/2
020921
PN=136
Install WEATHER PACK® Contact

NOTE: Cable seals are color coded for three sizes of wire:
• Green—18 to 20 gauge wire
• Gray—14 to 16 gauge wire
• Blue—10 to 12 gauge wire
TS0136 —UN—23AUG88
1. Slip correct size cable seal on wire.
2. Strip insulation from wire to expose 6 mm (1/4 in.) and
align cable seal with edge of insulation.
NOTE: Contacts have numbered identification
Correct Size Cable
for two sizes of wire:
• #15 for 14 to 16 gauge wire
• #19 for 18 to 20 gauge wire
3. Put proper size WEATHER PACK® contact on wire
and crimp in place with a “W” type crimp, using
JDG783 Packard Crimping Tool.
TS1623 —UN—02NOV94
Strip Insulation
WEATHER PACK is a trademark of Packard Electric

CS33148,0002A8D -19-08JUL08-1/2
NOTE: Proper contact installation for sleeve (A)

and pin (B) is shown.
4. Fasten cable seal to contact using JDG783 Packard

Crimping Tool.
TS0139 —UN—02DEC88
A—Sleeve B—Pin
Contact Installation
CS33148,0002A8D -19-08JUL08-2/2
020921
PN=137
Replace CINCH™ Connectors

1. Remove extraction tool (1) from the loading side of
connector.
2. Insert blade of extraction tool into locking tabs (2)
of secondary lock (3). Rotate tool away from the
CINCH™ connector to pry one side of the secondary
lock out of the locked position. Repeat this step for
the other locking tab.
NOTE: After unlocking one side of the secondary
lock, a screwdriver or similar device may be
used to hold it in the unlocked position while
unlocking the second locking tab.
T132105B —UN—29JUN00
1— Extraction Tool 3— Secondary Lock
2— Secondary Lock Locking
Tabs
CINCH is a trademark of the Cinch Co.

RK40399,0001260 -19-23JAN15-1/3
3. Remove secondary lock (3).
3— Secondary Lock
T132301B —UN—29JUN00
Remove Secondary Lock
RK40399,0001260 -19-23JAN15-2/3
4. Insert pointed side of extraction tool (1) into the contact

cavity so that the flat side of tool faces secondary lock
cavity (4). This will release the primary contact locking
tab.
5. Pull wire out of the connector.
T132107B —UN—29JUN00
6. Replace terminals as necessary. See Install CINCH™

Contact. (Group 1600.)
7. Insert contact and wire into connector until it clicks.
8. Install secondary lock.
1— Extraction Tool 4— Cavity
RK40399,0001260 -19-23JAN15-3/3
020921
PN=138
Install CINCH™ Contact
T138057 —UN—14FEB01
A—Top of Tool D—Wire G—Contact
B—Contact Support E—Micro Timer Slot I— Wire Tab
C—Locator F— Junior Timer Slot J— Insulation Tab
1. Hold JDG708 AMP® Crimper so that the tool is facing 3. Hold the contact in position and squeeze crimper
you as shown (left side of graphic). Squeeze crimper handles together until ratchet engages sufficiently to
handles together and allow them to open fully. hold the contact in position. Do not deform wire and
IMPORTANT: Make sure that both sides of the insulation tabs (I and J).
insulation barrel are started evenly into the 4. Insert stripped wire into contact insulation and wire
crimping section. Do not attempt to crimp tabs until it is against locator (C).
an improperly positioned contact.
5. Hold the wire in place. Squeeze crimper handles
2. Position the CINCH™ contact so that the mating end together until ratchet releases. Allow crimper handles
of the contact (G) is on the locator side of the tool to open and remove crimped contact.
(C). Wire and insulation tabs (I and J) should point to
top of tool (A). Push wire tab (I) against the movable 6. Install contact into connector. See Replace CINCH™
locator (C). Connectors. (Group 1600.)
AMP is a trademark of Tyco Electronics
CINCH is a trademark of the Cinch Co.
RK40399,0001261 -19-23JAN15-1/1
020921
PN=139
Repair 32 and 48 Way CINCH™ Connectors

1. Push tab (A) and rotate locking cam (B) 90° to
disconnect connector from controller.
2. Move cover locks (C) slightly outward with a small
RXA0070459 —UN—10SEP03
screwdriver.
3. Remove cover (D) away from wires.
A—Tab C—Cover Locks

B—Locking Cam D—Cover
RXA0070462 —UN—10SEP03
RXA0070463 —UN—10SEP03
CS33148,0002A90 -19-24JUN08-1/4
4. Pull terminal lock (A) out until it stops. Do not force

its removal.
A—Terminal Lock
RXA0070464 —UN—10SEP03
Continued on next page CS33148,0002A90 -19-24JUN08-2/4
020921
PN=140
NOTE: JDG1725 Terminal Extractor Tool is included in

JDG1725 Flexbox Terminal Repair Kit.
JDG1725 Terminal Extractor Tool has two different
sizes of pins: 0.6 for smaller 20 gauge holes (A)
and 1.5 for larger 16 and 18 gauge holes (B).
RXA0070471 —UN—10SEP03
5. Insert JDG1725 Terminal Extractor Tool into holes (C)
next to terminal opening (D) to unlock terminal.
6. Pull wire and terminal (E) from connector body.
A—20 Gauge Holes D—Terminal Hole

B—16 and 18 Gauge Holes E—Terminal
C—Holes
RXA0070472 —UN—10SEP03
RXA0070473 —UN—10SEP03
Continued on next page CS33148,0002A90 -19-24JUN08-3/4
020921
PN=141
7. Remove old terminal and strip 4.85 mm (0.191 in.) of

insulation from wire.
NOTE: JDG1727 Terminal Crimping Tool is included in
JDG1725 Flexbox Terminal Repair Kit.
RXA0070479 —UN—10SEP03
8. Firmly grip JDG1727 Terminal Crimping Tool (A).
Squeeze ratcheting mechanism until it bottoms out,
then allow it to open completely.
9. With tool in ready position (open handle), open
terminal receptacle (B).
10. Insert terminal (C) into correct wire gauge window so
crimp wings are facing up.
11. Close terminal receptacle (B).
12. Squeeze handle until two clicks are heard.
13. Insert stripped wire (D) into terminal.
RXA0070480 —UN—10SEP03
14. Hold wire stationary and squeeze tool together until
ratchet releases.
15. Remove terminated wire from tool.
16. Push terminal into connector body until fully seated.
Pull on wire slightly to ensure terminal is locked in
position.
17. Push terminal lock closed.
18. Install cover.
19. Install connector to controller and close connector
RXA0070481 —UN—10SEP03
body locking cam.
A—CINCH™ Terminal Crimping C—Terminal

Tool D—Wire
B—Terminal Receptacle
CS33148,0002A90 -19-24JUN08-4/4
Remove Connector Body from Blade

Terminals
1. Depress locking tang (A) on terminal, using a small
screw driver. Slide connector body off.
2. Be sure to bend locking tang back to its original
RW4218 —UN—23AUG88
position (B) before installing connector body.
A—Locking Tang (depressed B—Locking Tang (original

position) position)
DX,ECONN,V1 -19-29JAN18-1/1
020921
PN=142
Section 17
Frame or Supporting Structure
Contents
Page
Group 1740—Frame Installation

Welding on Machine .................................. 17-1740-1
Loader and Rear Frames
Separation ............................................. 17-1740-2
Upper Pivot Bushing Assembly
Lower Pivot Bushing Assembly
Group 1749—Chassis Weights

Counterweights Remove and
Install ..................................................... 17-1749-1
020921
PN=1
Contents
020921
PN=2
Group 1740
Frame Installation
Welding on Machine
CAUTION: Do not weld or apply heat on any 4. Cover, protect, or move any wiring harness sections
part of a reservoir or tank that has contained away from welding area.
oil or fuel. Heat from welding and cutting can
IMPORTANT: Have only a qualified welder perform
cause oil, fuel, or cleaning solution to create
this job. Connect welder ground clamp close to
gases which are explosive, flammable, or toxic.
each weld area so electrical current does not
Avoid welding or heating near pressurized fluid
pass through any bearings, articulation joints,
lines. Flammable spray may result and cause
or pivot points. Remove or protect all parts that
severe burns if pressurized lines fail as a result
can be damaged by heat or weld splatter.
of heating. Do not let heat go beyond work
area to nearby pressurized lines.
5. Connect welder ground close to welding point and
away from control units.
CAUTION: Avoid potentially toxic fumes and dust.
6. Use one of the following weld processes:
Hazardous fumes can be generated when paint is
heated by welding, soldering, or using a torch. • AWS-E-7018 covered electrode with shielded metal
Complete all work outside or in a well ventilated arc welding (SMAW) process.
area. Dispose of paint and solvent properly. • AWS-ER-70S-3 wire electrode with gas metal arc
welding (GMAW) process.
When sanding or grinding painted surfaces,
avoid breathing the dust. Wear an approved • AWS-E70T-1 or E71T-1 wire electrode with flux core
arc welding (FCAW) process.
respirator. If using solvent or paint stripper,
remove stripper with soap and water before Welding Repair of Major Structure—Specification
welding. Remove solvent or paint stripper Weld Metal—Tensile
containers and other flammable material from Strength...................................................................................482.6 MPa
area. Allow fumes to disperse at least 15 70 000 psi
minutes before welding or heating. 4 826 bar
Yield Strength .........................................................................413.7 MPa
1. Remove paint before welding or heating. 60 000 psi
4 137 bar
• When sanding or grinding paint, avoid breathing the Elongation......................................................................................... 22%
dust.
• Wear an approved respirator. When using solvent or IMPORTANT: Avoid insufficient weld penetration.
paint stripper, remove stripper with soap and water Preheat area that will be repaired to allow
before welding. better weld penetration. Insufficient weld
• Remove solvent or paint stripper containers and penetration can lead to further damage.
other flammable material from area.
• Allow fumes to disperse at least 15 minutes before 7. To repair weld metal failure, remove failed weld metal
welding or heating. using arc gouging or grinding equipment. Thoroughly
clean area to be welded. Preheat structural
IMPORTANT: Avoid machine damage to diesel assemblies to a minimum of 38°C (100°F). Preheat
exhaust fluid (DEF) system. After key switch ground engaging tools (cutting edges, skid shoes, and
is switched to OFF position, wait at least 10 teeth shanks) to 177°C (350°F).
minutes before turning battery disconnect
switch to OFF position or disconnecting battery To repair base metal failure remove enough material to
cables. During cold-weather exposure, if allow weld to penetrate to the bottom of crack. Preheat
adequate time is not allowed for lines to be structural assemblies to a minimum of 38°C (100°F).
purged, residual DEF can freeze and possibly Preheat ground engaging tools (cutting edges, skid
damage components of the DEF system. shoes, and teeth shanks) to 177°C (350°F).
Welding Repair of Major Structure—Specification
IMPORTANT: Avoid damage to electrical system Structural
from welding current. Disconnect negative Assemblies—Preheat
(-) and positive (+) battery cables before Temperature..................................................................................... 38°C
welding on machine. 100°F
Ground Engaging
2. Disconnect the negative (-) battery cable(s). Tools—Preheat
3. Disconnect the positive (+) battery cable(s). Temperature................................................................................... 177°C
350°F
TP97644,000011E -19-04MAR16-1/1
020921
PN=145
Frame Installation
Loader and Rear Frames Separation SERVICE EQUIPMENT AND TOOLS

D01047AA Puller Set
SPECIFICATIONS
Lower Pivot Pin Socket Head 68 N·m
Rotational Torque Spring Support 1400 N·m
Nut Torque 1033 lb.-ft.
Steering Tie Rod End Nut Torque 275 N·m
200 lb.-ft.
T216429 —UN—20OCT05
4
T216429
Left Side of Loader
1— Loader Frame Lift Point (1 on 2— Eyebolt 4— Block (4 used)
each side) 3— Floor Stand (3 used)
1. Park and prepare machine for service. See Park and NOTE: If a second hoist is not available, put a floor
Prepare for Service Safely. (Group 0001.) jack of appropriate lifting capacity and height
NOTE: Floor jack must be in line with machine so under center counterweight.
the jack wheels rotate freely as the loader
frame is moved forward. 6. Install an eyebolt into rear hitch. Connect hoist and a
chain to eyebolt (2).
2. Put a floor jack under center of bucket. Pivot bucket
so bottom of bucket is parallel with the ground. Lower CAUTION: During the separation process, a
the boom until bucket rests on the floor jack. gap is required between the floor stands and
machine frames to allow for maneuvering.
3. Relieve hydraulic system pressure. See Hydraulic
During this time the floor stands are only there
System Pressure and Accumulators Discharge
for added safety. When the machine has been
separated, make sure the machine frames are
4. Install blocks (4) at front and rear of rear wheels. supported securely by the floor stands before
proceeding with any further repair.
5. Connect hoist and chains to loader frame at lift points
(1).
Continued on next page SP66632,0004AE1 -19-23AUG16-1/7
020921
PN=146
Frame Installation
7. Put floor stands (3) under rear of loader frame and 11. Disconnect all electrical connectors and harnesses
under front and rear of rear frame. Keep at least 25 routed from loader frame to rear frame.
mm (1.0 in.) air gap between frame and floor stand to
allow room to maneuver. • See Loader/Rear Frame Harness (W7) Component
Location. (Group 9015-10.)
8. Remove loader control valve access panel.
• See Ride Control Harness (W14) Component
9. Apply vacuum to the hydraulic reservoir or drain Location. (Group 9015-10.)
reservoir. If draining reservoir, see Change Hydraulic 12. Disconnect steering cylinder from loader frame.
13. Disconnect right and left tie rods from loader frame.
10. Install identification tags and disconnect all hydraulic
lines that are routed between loader frame and rear 14. Disconnect drive shaft from front axle. See Drive Shaft
frame. This includes lines that connect to the following Remove and Install. (Group 0225.)
components:
15. Manually release park brake. See Towing Procedure.
• Loader Control Valve Assembly. See Loader System (Operator's Manual.)
Component Location. (Group 9025-10.)
• Front Axle Brake Lines. See Service and Park Brake
System Component Location. (Group 9020-10.)
SP66632,0004AE1 -19-23AUG16-2/7
16. Remove parts (1—6).
1— Cap (2 used) 6— Front Rotational Torque

2— Nut (2 used) Spring
3— Stud (2 used) 7— Spring Dowel Sleeve (2
4— Lock Washer (2 used) used)
5— Plate 8— Support
9— Rear Rotational Torque
Spring
T216378 —UN—19OCT05
Torque Spring
020921
PN=147
Frame Installation
17. Remove socket head cap screws (1) and end cap (2)
from lower pivot pin (4).
18. Remove lower pivot pin (4) using the 17-1/2 ton
hydraulic push-puller from D01047AA Puller Set.
Remove spacer (3).
T216436A —UN—19OCT05
1— Socket Head Cap Screw (6 3— Spacer
used) 4— Lower Pivot Pin
2— End Cap
Lower Pivot Pin
T216435A —UN—19OCT05
Lower Pivot Pin
020921
PN=148
Frame Installation
19. Have two assistants, one at each front tire, push the
loader frame slowly away from rear frame. Move the
hoist forward with loader frame. Make sure floor jack
rolls forward with bucket.
20. Make repairs as necessary.
T116622 —UN—28JUL98
Separate the Machine
020921
PN=149
Frame Installation
NOTE: Before rolling the loader frame toward the rear

frame, make sure the lower pivot self-aligning
bushing assembly is installed in the rear frame,
and the rotational torque spring support assembly
is installed on the loader frame upper pivot. See
Lower Pivot Bushing Assembly Remove and
Install and see Upper Pivot Bushing Assembly
21. Slowly roll loader frame toward rear frame until lower
pivot pin holes in frames are aligned.
T216437 —UN—19OCT05
22. Install spacer (3) on top of self-aligning bushing with
tapered side toward bushing.
NOTE: As pin (4) is driven into position, it may be
necessary to hold spacer (3) tightly against
the self-aligning bushing to ensure pin starts
squarely into the bushing.
Lower Pivot Pin
23. Install lower pivot pin (4). Make sure pin is square with
bushing as pin is started. 1— Socket Head Cap Screw (6 3— Spacer
used) 4— Lower Pivot Pin
24. Install end cap (2) and socket head cap screws 2— End Cap
(1). Tighten cap screws evenly by alternating in a
criss-cross pattern. Repeat tightening sequence until
final specification is obtained.
Specification
Lower Pivot Pin
Socket Head Cap
Screw—Torque..............................................................................68 N·m
50 lb.-ft.
020921
PN=150
Frame Installation
25. Apply grease to pins and mating surfaces of rear

rotational torque springs (9).
26. Attach support (8) to rear frame by installing parts
(1—6).
27. Tighten nuts (2) to specification.
Specification
Rotational Torque Spring
Support Nut—Torque.................................................................1400 N·m
1033 lb.-ft.
28. Connect left and right tie rod ends to loader frame.
Tighten nut to specification.
T216378 —UN—19OCT05
Specification
Steering Tie Rod End
Nut—Torque................................................................................275 N·m
200 lb.-ft.
29. Connect steering cylinder to loader frame.

30. Connect drive shaft to front axle. See Drive Shaft Torque Spring
1— Cap (2 used) 6— Front Rotational Torque
31. Connect brake lines to front axle. See Service and Park 2— Nut (2 used) Spring
Brake System Component Location. (Group 9020-10.) 3— Stud (2 used) 7— Spring Dowel Sleeve (2
4— Lock Washer (2 used) used)
32. Connect hydraulic lines to loader valve. See Loader 5— Plate 8— Support
System Component Location. (Group 9025-10.) 9— Rear Rotational Torque
Spring
33. Connect wire connectors. See Loader/Rear Frame
Harness (W7) Component Location. (Group 9015-10.)
34. Fill hydraulic reservoir to proper level if drained. See 37. Start engine. With engine at slow idle, slowly raise and
Change Hydraulic Oil. (Operator's Manual.) lower boom and pivot bucket several times to ensure
all air is removed from hydraulic system.
35. Bleed service brake system. See Drum Brake Bleed.
(Group 1060.) 38. Install loader control valve access panel.
36. Manually engage park brake. See Towing Procedure.
SP66632,0004AE1 -19-23AUG16-7/7
020921
PN=151
Frame Installation
Upper Pivot Bushing Assembly Remove and

Install
1. Separate machine. See Loader and Rear Frames
Separation. (Group 1740.)
2. Remove socket head screws (4) and end cap (3).
NOTE: The upper pivot pin (1) may bind in the top plate
of support (2) as upward force is applied to the pin.
To ease removal of the pin, strike downward on
the top plate of support (2) using a hammer while
T216438 —UN—19OCT05
upward force is being applied to the pivot pin.
3. Remove upper pivot pin (1) using the 17-1/2 ton

hydraulic push-puller from D01047AA Puller Set.
Remove support (2) and spacer (5).
4. Remove snap ring (8), shim (7), and self-aligning
bushing (6).
5. Install new self-aligning bushing (6). 1— Upper Pivot Pin 5— Spacer
2— Support 6— Self-Aligning Bushing
6. Install shim (7) and snap ring (8). 3— End Cap 7— Shim
4— Socket Head Screw (6 used) 8— Snap Ring
7. Install spacer (5) underneath bushing with tapered
side toward bushing.
8. Install support (2) and upper pivot pin (1). Make sure Specification
upper pivot pin is square with bushing as pin is initially Upper Pivot Pin
started. Mounting Socket Head
Screws—Torque............................................................................68 N·m
9. Install end cap (3) and socket head screws (4).
(50 lb-ft)
Tighten cap screws evenly by alternating in a
criss-cross pattern. Repeat tightening sequence until 10. Connect loader and rear frames. See Loader and
final specification is obtained. Rear Frames Separation. (Group 1740.)
SP66632,0004AE2 -19-10FEB15-1/1
020921
PN=152
Frame Installation
Lower Pivot Bushing Assembly Remove and

Install
1. Separate machine. See Loader and Rear Frames
Separation. (Group 1740.)
3. Inspect parts for wear or damage. Replace if
necessary.
4. Install parts (1—5). Tighten socket head screws (1)
evenly by alternating in a criss-cross pattern. Repeat
tightening sequence until final specification is obtained.
Specification
T216439 —UN—19OCT05
Lower Pivot Bushing
Mounting Cap
Screws—Torque............................................................................68 N·m
50 lb-ft
5. Connect loader and rear frames. See Loader and

Rear Frames Separation. (Group 1740.)
1— Socket Head Screw (8 used) 4— Shims (2 used)

2— Ring (2 used) 5— Self-Aligning Bushing
3— Seal (2 used)
SP66632,0004AE3 -19-10FEB15-1/1
020921
PN=153
Frame Installation
020921
PN=154
Group 1749
Chassis Weights
Counterweights Remove and Install
3
4 5
2
6
3
5
4
6 1
4
3
T203170 —UN—21SEP04
4
T203170 3
Exploded View of Counterweights
1— Left Counterweight 3— Cap Screw (6 used) 5— Plug (2 used)
2— Right Counterweight 4— Washer (6 used) 6— Threaded Hole (6 used)
3. Install three lifting eyes into threaded holes (6)

provided in each counterweight.
SPECIFICATIONS
244K and 244K-II Left 233 kg heavy component. Use appropriate lifting device.
Counterweight Weight 514 lb.
(approximate)
4. Attach an appropriate lifting device to the three lifting
244K and 244K-II Right 335 kg eyes in each counterweight. Support counterweight
Counterweight Weight 739 lb. using lifting device before removing mounting
(approximate)
hardware.
324K Left Counterweight Weight 405 kg
(approximate) 893 lb. 5. Remove cap screws (3) and washers (4) to remove
324K Right Counterweight Weight 483 kg counterweight.
6. Install and fasten counterweight using cap screws (3)
Cap Screw Torque 670 N·m and washers (4). Torque to specification.
494 lb.-ft.
7. Remove lifting eyes and install plugs (5).
1. Remove rear fender(s). See Rear Fenders Remove
and Install. (Group 1913.) 8. Install rear fender(s). See Rear Fenders Remove and
2. Remove plugs (5).
SP66632,0004AC4 -19-23AUG16-1/1
020921
PN=155
Chassis Weights
020921
PN=156
Section 18
Operator's Station
Contents
Page

Cab Remove and Install ............................ 18-1800-1
Group 1810—Operator Enclosure

Windowpanes Remove and
Install ..................................................... 18-1810-1
Group 1830—Heating and Air Conditioning System

R134a Refrigerant Cautions and
Proper Handling..................................... 18-1830-1
R134a Refrigerant Oil Information.............. 18-1830-2
R134a Refrigerant Recovery,
Recycling, and Charging Station
Installation Procedure............................ 18-1830-3
Recover R134a Refrigerant....................... 18-1830-4
Flush and Purge Air Conditioning
System................................................... 18-1830-5
Evacuate R134a System ........................... 18-1830-6
Charge R134a System .............................. 18-1830-7
Air Conditioner Compressor
Receiver-Dryer Remove and
Install ..................................................... 18-1830-9
Condenser Remove and Install ................. 18-1830-9
Air Conditioner/Heater Module
Remove and Install.............................. 18-1830-10
Heater Core Remove and Install ............. 18-1830-12
Evaporator Coil Remove and
Install ................................................... 18-1830-12
Expansion Valve Remove and
Install ................................................... 18-1830-13
Heater Control Valve Remove and
Install ................................................... 18-1830-13
Air Conditioner High/Low-Pressure
Switch Remove and Install .................. 18-1830-14
Air Conditioner Freeze Control
Switch Remove and Install .................. 18-1830-14
Blower Motor Remove and Install............ 18-1830-15
020921
PN=1
Contents
020921
PN=2
Group 1800
Cab Remove and Install
SPECIFICATIONS
Cab Weight (approximate) 544 kg
1200 lb.
Cab Mounting Cap Screw Torque 475 N·m
X9811 —UN—23AUG88
350 lb.-ft.

JT01748 Lifting Brackets
OTHER MATERIAL
TY24344 U.S. RTV Clear Silicon Escaping Fluid
Machine Preparation
Never attempt to relieve hydraulic system
• Prepare machine for service. See Park and Prepare for or accumulator pressure by loosening
Service Safely. (Group 0001.) a fitting. Tighten all connections before
• Turn battery disconnect to the OFF position. applying pressure.
• Drain cooling system. See Drain Cooling System.
(Operator’s Manual.) • Stop engine and relieve pressure from hydraulic system.
• If equipped with air conditioning, evacuate system. See Perform Hydraulic System Pressure and Accumulators
Evacuate R134a System. (Group 1830.) Discharge Procedure. (Group 2160.)
• Apply vacuum or drain hydraulic reservoir. See Change
Hydraulic Oil. (Operator’s Manual.)
under pressure, stop engine and relieve the • Remove floor mat.
RK40399,000125A -19-23AUG16-1/4
Removal
1. Tilt steering column back and remove forward panel.
Disconnect windshield washer fluid lines from motor
inside cab and push through cab floor.
TX1182194A —UN—13JAN15
2. Lower brake/inching valve assembly and allow valve
assembly to rest on machine frame. See Brake/Inching
Valve Assembly Remove and Install. (Group 1060.)
3. Lower steering valve and allow valve to rest on
machine frame. See Orbital Steering Valve Remove
4. Lower fuel tank and fuel tank bracket. See Fuel Tank Cab Floor Rubber Seal and Plate
5. Disconnect electrical connectors (X2, X6—X8 and 1— Rubber Seal 2— Cap Screw (4 used)
X10) from cab main harness. Disconnect ground wire
connectors from ground lug (W3). See Cab Main
Harness (W8) Component Location. (Group 9015-10.) NOTE: Close all hose and fitting openings using caps and
plugs to prevent contamination of hydraulic system.
NOTE: Photo shows cab floor seal as viewed through
fuse panel access door opening. 7. Tag and disconnect hydraulic lines from pilot control
valve. See Loader System Component Location.
6. Remove cap screws (2) and push rubber seal (1) (Group 9025-10.)
through cab floor.
Continued on next page RK40399,000125A -19-23AUG16-2/4
020921
PN=159
8. Install JT01748 Lifting Brackets (3) and chain to the

roof of cab using cap screws.
3— JT01748 Lifting Bracket (2

used)
TX1182195A —UN—13JAN15
Cab Lifting Brackets
Continued on next page RK40399,000125A -19-23AUG16-3/4
020921
PN=160
9. Remove cap screws (6) and lower isolators (5).
CAUTION: Avoid crushing injury. Use appropriate 4

lifting device when lifting component.
10. Raise cab approximately 152 mm (6 in.) to access

underside of cab.
Specification
Cab—Weight
(approximate) ............................................................................... 544 kg
1200 lb.
CAUTION: Prevent possible crushing injury.

5
TX1182198 —UN—13JAN15
If cab is raised to access heater hoses and
A/C refrigerant lines (if equipped), wood
blocks of sufficient height must be installed
6
between cab and frame before proceeding
with repair procedure.
11. Install blocks between cab and frame to prevent cab

from lowering while disconnecting lines.
Cab Mounting Hardware
12. Disconnect heater hoses from heater core.
13. If equipped with air conditioning, disconnect the A/C 4— Upper Isolator (4 used) 6— Cap Screw (4 used)
5— Lower Isolator (4 used)
refrigerant lines from expansion valve.
14. Slowly raise cab and guide pilot control valve hydraulic
hoses through the cab floor. Remove any straps or • Install isolators and cab mounting cap screws. Tighten
tie straps as needed. cap screws to specification.
Specification
Cab Mounting Cap
Installation Screws—Torque..........................................................................475 N·m
350 lb.-ft.
• Installation is reverse of removal procedure. • Fill radiator with proper coolant. See Fill Cooling
• Lower cab while routing hydraulic hoses through cab System. (Operator’s Manual.)
floor. Do not lower cab onto frame at this time. Lower
cab until cab is approximately 152 mm (6 in.) above • Charge air conditioning system. See Charge R134a
machine frame. System. (Group 1830.)
• Remove blocks and carefully lower cab onto machine • Fill hydraulic reservoir. See Change Hydraulic Oil.
frame while observing hydraulic lines and wire (Operator’s Manual.)
harnesses.
• Apply TY24344 U.S. RTV Clear Silicon to the flat
surface of the washers. Install cap screws and washers
into the threaded holes in top of cab.
RK40399,000125A -19-23AUG16-4/4
020921
PN=161
020921
PN=162
Group 1810
Operator Enclosure
Windowpanes Remove and Install
The adhesive used to hold the windowpanes in place is
3. Scrape broken glass off existing adhesive. DO NOT
a urethane adhesive that is used on most automobile
remove adhesive from window frame or cab.
windshields. Urethane adhesive manufactured by Loctite
Corporation or equivalent is recommended. DO NOT use IMPORTANT: Adhesive will not stick to bare metal.
any other type of adhesive. It is recommended that an
auto glass dealer install the windowpanes. 4. If existing adhesive is removed from frame and paint is
scraped off window frame, paint window frame. Paint
IMPORTANT: Windowpanes must have an ultraviolet
must be fully cured before installing windowpane.
barrier around the edge of the glass since
ultraviolet rays will deteriorate the adhesive. 5. Trim existing adhesive so it has a smooth surface.
Windowpanes ordered through John Deere Parts
have the ultraviolet barrier. If the windowpane 6. Follow the manufacturer’s instructions for using the
is purchased through a glass dealer, the dealer adhesive.
must put an ultraviolet barrier on the glass. DO 7. Apply a 6 mm (1/4 in.) bead of adhesive on top of the
NOT apply paint to the border of the glass. existing adhesive.
If an auto glass dealer is not installing the windowpanes, 8. Put a new windowpane into position. Use hand
use the following procedure: pressure to force windowpane down around the edges
until even with metal frame.
IMPORTANT: Follow instructions, warnings and
cautions for adhesive products. 9. If windowpane is installed directly on cab, use duct
tape to hold it in place while adhesive cures.
1. Purchase urethane adhesive from your local auto
glass dealer. 10. Allow adhesive to cure for 24 hours before operating
machine.
2. If window frame is removable, remove frame from cab.
TE14778,000000A -19-09AUG02-1/1
020921
PN=163
Operator Enclosure
020921
PN=164
Group 1830
Heating and Air Conditioning System
R134a Refrigerant Cautions and Proper If skin freezes to container, pour COOL water
Handling over container to free the skin. Go to a physician
SERVICE EQUIPMENT AND TOOLS or hospital immediately for treatment.
Refrigerant Identifier IMPORTANT: To meet government standards relating
to the use of refrigerants, R134a is used in
CAUTION: DO NOT allow liquid refrigerant to the air conditioning system. Because it does
contact eyes or skin. Liquid refrigerant will not contain chlorine, R134a is not detrimental
freeze eyes or skin on contact. Wear goggles, to the ozone in the atmosphere. However, it
gloves, and protective clothing. is illegal to discharge any refrigerant into the
atmosphere. It must be recovered using the
If liquid refrigerant contacts eyes or skin, DO appropriate recovery stations.
NOT rub the area. Splash large amounts of
COOL water on affected area. Go to a physician Use correct refrigerant recovery, recycling, and
or hospital immediately for treatment. charging stations. Do not mix refrigerants,
hoses, fittings, components, or refrigerant oils.
DO NOT allow refrigerant to contact open
flames or very hot surfaces such as electric Use only John Deere approved R134a
welding arc, electric heating element, and refrigerant products. Mixing of products not
lighted smoking materials. compatible will cause system damage and
contaminate recovery, recycling, and charging
DO NOT heat refrigerant over 52°C (125°F) in a station equipment. Care must be taken to
closed container. Heated refrigerant will develop identify and use equipment, refrigerant oil,
high pressure which can burst the container. and refrigerant designed only for R134a
Keep refrigerant containers away from heat refrigerant systems. Refrigerant should be
sources. Store refrigerant in a cool place. tested for type and purity before recovery,
recycling, or charging of system. Refrigerant
DO NOT handle damp refrigerant container identifier should be used before any testing
with bare hands. Skin may freeze to or repair to system is performed.
container. Wear gloves.
AS79221,00005A0 -19-03MAR16-1/2
Refrigerant Identifier Used to safely and correctly identify type and check
purity of refrigerant prior to recovery, recycling, and
charging of air conditioning systems.
AS79221,00005A0 -19-03MAR16-2/2
020921
PN=165
R134a Refrigerant Oil Information b. Remove and discard receiver-dryer. See

SPECIFICATIONS Receiver-Dryer Remove and Install. (Group 1830.)
System Oil Volume 140—160 mL c. Remove, clean, but do not disassemble expansion
4.7—5.4 fl oz valve. See Expansion Valve Remove and Install.
(Group 1830.)
OTHER MATERIAL
TY22101 U.S. R134a Compressor Oil
d. Flush complete system, if needed. See Flush and
Purge Air Conditioning System. (Group 1830.)
If installing a new compressor, make sure oil level is visible e. If compressor is serviceable, pour flushing solvent
through suction port. Oil level is normally below drive shaft. in manifold ports and internally wash out old oil.
Normal operating oil level of compressor removed f. Install expansion valve. See Expansion Valve
from operation cannot be seen through suction port of Remove and Install. (Group 1830.)
compressor.
g. Install new receiver-dryer. See Receiver-Dryer
Compressors can be divided into three categories when Remove and Install. (Group 1830.)
determining correct oil charge for system:
6. Install compressor. See Air Conditioner Compressor
• New compressor Remove and Install. (Group 1830.)
• Used compressor removed from operation
• Compressor internally washed with flushing solvent IMPORTANT: Prevent possible air conditioning
system damage. Do not add any more oil than
CAUTION: Avoid possible injury. All new required or maximum cooling will be reduced.
compressors are charged with a mixture Do not leave system or R134a compressor oil
of nitrogen, R134a refrigerant, and R134a containers open. Refrigerant oil easily absorbs
refrigerant oil. Wear safety goggles and moisture. Do not spill R134a compressor
discharge compressor slowly. oil on acrylic or ABS plastic. This oil will
deteriorate these materials rapidly. Identify
1. Handle refrigerant carefully. See R134a Refrigerant R134a oil containers and measures to eliminate
Cautions and Proper Handling. (Group 1830.) accidental mixing of different oils.
2. Park and prepare machine for service safely. See
Park and Prepare for Service Safely. (Group 0001.) 7. Add required amount of R134a compressor oil. If any
section of hose is removed and flushed or replaced,
3. Remove and repair or replace compressor. See Air measure length of hose and use formula 3 mL per 30
Conditioner Compressor Remove and Install. (Group cm (0.1 fl. oz. per ft.) to determine correct amount of
1830.) oil to be added.
4. Drain oil into graduated container while rotating Specification
compressor shaft if a new compressor is required. System Oil—Volume...........................................................140—160 mL
4.7—5.4 fl oz
5. Record measured oil and discard oil properly.
8. Connect all components.
If oil drained from a compressor removed from
operation is very black or amount of oil is less than 9. Evacuate air conditioning system. See Evacuate
specification, perform the following: R134a System. (Group 1830.)
a. Determine if R134a leakage was detected. See 10. Charge R134a air conditioning system. See Charge
R134a Refrigerant Leak Test. (Group 9031-25.) R134a System. (Group 1830.)
SP66632,0004ACC -19-21AUG18-1/1
020921
PN=166
R134a Refrigerant Recovery, Recycling, and

Charging Station Installation Procedure 1 2
CAUTION: Avoid possible injury. Liquid

3
refrigerant will freeze eyes or skin on contact.
Wear goggles, gloves, and protective clothing.
1. Handle refrigerant carefully. See R134a Refrigerant

Cautions and Proper Handling. (Group 1830.)
2. Park and prepare machine for service safely. See 4
Park and Prepare for Service Safely. (Group 0001.)
CAUTION: Prevent possible crushing injury
TX1153908 —UN—18FEB14
from unexpected machine movement. Install
articulation locking pin when machine is raised
5
or when working in articulation joint area.
3. Install articulation locking pin. See Locking Machine

Frame. (Operator’s Manual.)
IMPORTANT: Prevent possible air conditioning Refrigerant Recovery, Recycling, and Charging Station
system contamination. Use correct refrigerant
recovery, recycling, and charging station.
Do not mix refrigerant, hoses, fittings, 1— Cap (2 used) 4— Air Conditioner
components, or refrigerant oils. 2— Low Side Pressure (blue) Compressor
Hose 5— Refrigerant Recovery,
3— High Side Pressure (red) Recycling, and Charging
Hose Station
CAUTION: Avoid possible injury. Do not remove
high-pressure relief valve. Air conditioning
system will discharge.
7. Connect high side pressure (red) hose (3) to
4. Close both high and low-pressure valves on refrigerant high-pressure test port on compressor.
recovery, recycling, and charging station (5).
8. Follow manufacturer’s instructions when using
5. Remove caps (1) from test ports. refrigerant recovery, recycling, and charging station.
6. Connect low side pressure (blue) hose (2) from
refrigerant recovery, recycling, and charging station to
low-pressure test port on compressor.
SP66632,0004ACB -19-30JAN15-1/1
020921
PN=167
Recover R134a Refrigerant high-pressure relief valve. Air conditioning

system will discharge rapidly.
CAUTION: Prevent possible injury. Liquid
refrigerant will freeze eyes or skin on contact. IMPORTANT: Prevent possible air conditioning
Wear goggles, gloves, and protective clothing. system damage. Use correct refrigerant
recovery, recycling, and charging stations.
1. Handle refrigerant carefully. See R134a Refrigerant Do not mix refrigerant, hoses, fittings,
Cautions and Proper Handling. (Group 1830.) components, or refrigerant oils.
2. Park and prepare machine for service safely. See 5. With engine OFF, connect refrigerant recovery,
Park and Prepare for Service Safely. (Group 0001.) recycling, and charging station. See R134a
Refrigerant Recovery, Recycling, and Charging
3. Run air conditioning system for 3 minutes to help in Station Installation Procedure. (Group 1830.)
recovery process.
6. Follow the air conditioning refrigerant recovery,
4. Turn air conditioning system off before proceeding recycling, and charging station manufacturer’s
with recovery steps. instruction.
CAUTION: Avoid possible injury from air

conditioning system refrigerant. Do not remove
AS79221,0000598 -19-08DEC16-1/1
020921
PN=168
Flush and Purge Air Conditioning System

SPECIFICATIONS
3. Attach return hose and aerator nozzle to end of
Air Pressure Minimum Pressure 620 kPa receiver/dryer inlet hose using appropriate adapter.
(for flushing and purging) 6.2 bar Put nozzle in container to collect cooling system
90 psi
cleaner.
ESSENTIAL TOOLS 4. Open air valve to force cooling system cleaner into
TY25601 Cooling System Cleaner condenser circuit. Air pressure must be at least to
specification for flushing and purging.
JT02075 Air Conditioner Flusher
Specification
Procedure Set-Up Air Pressure—Minimum
Pressure (for flushing and
purging)....................................................................................... 620 kPa
CAUTION: Prevent possible injury. Liquid 6.2 bar
refrigerant will freeze eyes or skin on contact. 90 psi
NOTE: Purging condenser circuit takes 10—12 minutes
1. Handle refrigerant carefully. See R134a Refrigerant to thoroughly remove solvent.
Additional flushing cycles are required if
2. Park and prepare machine for service safely. See system is heavily contaminated with burned
Park and Prepare for Service Safely. (Group 0001.) oil or metal particles.
3. Recover refrigerant from system. See Recover R134a 5. Disconnect hose from aeration nozzle to check circuit
Refrigerant. (Group 1830.) for cooling system cleaner. Hold hose close to piece
IMPORTANT: Do not attempt to flush through air of cardboard; continue purging until cardboard is dry.
conditioner compressor or receiver-dryer. 6. Dispose of cooling system cleaner properly.
Flushing solution may not be completely
removed from components and could Evaporator and Expansion Valve Flush and Purge
cause system malfunction.
1. Add TY25601 Cooling System Cleaner and connect
4. Remove air conditioner compressor. See Air JT02075 Air Conditioner Flusher outlet hose to
Conditioner Compressor Remove and Install. (Group receiver/dryer outlet hose using appropriate adapter.
1830.) 2. Attach hose and aerator nozzle to compressor inlet
NOTE: Anytime air conditioning system is discharged, line using appropriate adapter. Put nozzle in container
a new receiver-dryer must be installed. to collect cooling system cleaner.
3. Open air valve to force cooling system cleaner into
5. Remove and discard receiver-dryer. See condenser circuit. Air pressure must be at least to
Receiver-Dryer Remove and Install. (Group 1830.) specification for flushing and purging.
Condenser Flush and Purge Specification
Air Pressure—Minimum
IMPORTANT: Determine if condenser is continuous Pressure (for flushing and
loop or parallel flow style. purging)....................................................................................... 620 kPa
Continuous loop style has either multiple round 6.2 bar
tubes or an extruded serpentine construction. 90 psi
If condenser is parallel flow style, do not NOTE: Purging condenser circuit takes 10—12 minutes
flush, it should be replaced. Potential to thoroughly remove solvent.
blockages in parallel flow style condenser Additional flushing cycles are required if
will not flush completely and could result system is heavily contaminated with burned
in system malfunction. oil or metal particles.
1. Determine if condenser is continuous loop or parallel 4. Disconnect hose from aeration nozzle to check circuit
flow style. for cooling system cleaner. Hold hose close to piece
2. Add TY25601 Cooling System Cleaner and connect of cardboard; continue purging until cardboard is dry.
JT02075 Air Conditioner Flusher outlet hose to inlet 5. Dispose of cooling system cleaner properly.
end of compressor discharge line using appropriate
adapter.
Continued on next page SP66632,0004ACD -19-22DEC14-1/2
020921
PN=169
Procedure Wrap-Up 3. Install air conditioner compressor. See Air Conditioner

Compressor Remove and Install. (Group 1830.)
1. Install new receiver-dryer. See Receiver-Dryer
Remove and Install. (Group 1830.) 4. Charge system. See Charge R134a System. (Group
1830.)
2. Add required oil. See R134a Refrigerant Oil
Information. (Group 1830.)
SP66632,0004ACD -19-22DEC14-2/2
Evacuate R134a System NOTE: Vacuum specifications listed are for sea level
SPECIFICATIONS conditions. Subtract 3.4 kPa (34 mbar) (1 in Hg)
from 98 kPa (980 mbar) (29 in Hg) for each 300
Vacuum Pressure at Sea Level 98 kPa
980 mbar m (1000 ft) elevation above sea level.
29 in Hg
6. Evacuate system until low-pressure gauge registers
Vacuum Pressure Above Sea Subtract 3.4 kPa from 98 kPa for
Level each 300 m elevation specified vacuum.
Subtract 34 mbar from 980 mbar
for each 300 m elevation If specified vacuum cannot be obtained in 15 minutes,
Subtract 1 in Hg from 29 in Hg for a leak may be present. Locate and repair leak. See
each 1000 ft elevation R134a Refrigerant Leak Test. (Group 9031-25.)
Leak Present Decrease in 3.4 kPa Specification
Vacuum 34 mbar Vacuum—Pressure at
1 in Hg
Sea Level...................................................................................... 98 kPa
980 mbar
CAUTION: Prevent possible injury. Liquid 29 in Hg
refrigerant will freeze eyes or skin on contact. Pressure Above Sea
Wear goggles, gloves, and protective clothing. Level ..................................................................... Subtract 3.4 kPa from
98 kPa for each 300 m elevation
1. Handle refrigerant carefully. See R134a Refrigerant Subtract 34 mbar from 980 mbar for
Cautions and Proper Handling. (Group 1830.) each 300 m elevation
Subtract 1 in Hg from 29 in Hg for each
2. Park and prepare machine for service safely. See 1000 ft elevation
7. When vacuum reaches specified level, close low side
CAUTION: Avoid possible injury from air and high side valves. Turn vacuum pump off.
conditioning system refrigerant. Do not remove 8. If vacuum decreases more than specified amount in 5
high-pressure relief valve. Air conditioning minutes, there is a leak in system.
Specification
IMPORTANT: Prevent possible air conditioning Leak Present—Decrease
system damage. Use correct refrigerant in Vacuum..................................................................................... 3.4 kPa
recovery, recycling, and charging stations. 34 mbar
Do not mix refrigerant, hoses, fittings, 1 in Hg
components, or refrigerant oils.
9. Locate and repair leak. See R134a Refrigerant Leak
Test. (Group 9031-25.)
3. Connect refrigerant recovery, recycling, and charging
station. See R134a Refrigerant Recovery, Recycling, 10. Start evacuation. Open low side and high side valves.
and Charging Station Installation Procedure. (Group
1830.) 11. Evacuate system for 30 minutes after initial specified
vacuum is reached.
4. Open low and high-pressure valves on refrigerant
recovery, recycling, and charging station. 12. Stop evacuation. Close low side and high side valves.
5. Follow manufacturer’s instructions and evacuate 13. Charge system. See Charge R134a System. (Group
system. 1830.)
AS79221,000059A -19-07NOV17-1/1
020921
PN=170
Charge R134a System and Charging Station Installation Procedure. (Group

1830.)
SPECIFICATIONS
Evacuate System Vacuum Subtract 3.4 kPa from 98 kPa for 4. Evacuate system. See Evacuate R134a System.
each 300 m elevation above sea (Group 1830.)
level
Subtract 34 mbar from 980 mbar NOTE: Before beginning to charge air conditioning
for each 300 m elevation above system, the following conditions must exist:
sea level Engine STOPPED, the pump must be capable of
Subtract 1 in. Hg from 29 in. Hg
for each 1000 ft. elevation above
pulling at least 28.6 in. Hg vacuum (sea level).
sea level Subtract 3.4 kPa (34 mbar) (1 in. Hg) from 98
kPa (980 mbar) (29 in. Hg) for each 300 m
Air Conditioning System 1.10—1.12 kg
Refrigerant Charge Weight 2.43—2.47 lb.
(1000 ft.) elevation above sea level.
Specification
Evacuate
CAUTION: Prevent possible injury. Liquid
System—Vacuum........................ Subtract 3.4 kPa from 98 kPa for each
refrigerant will freeze eyes or skin on contact.
300 m elevation above sea level
Subtract 34 mbar from 980 mbar for each
300 m elevation above sea level
1. Handle refrigerant carefully. See R134a Refrigerant
Subtract 1 in. Hg from 29 in. Hg for each
1000 ft. elevation above sea level
Park and Prepare for Service Safely. (Group 0001.) 5. Follow manufacturer’s instructions and charge system.
IMPORTANT: Use correct refrigerant recovery, 6. Add refrigerant until system is charged to specification.
recycling, and charging stations. Do not Specification
mix refrigerant, hoses, fittings, components, Air Conditioning System
or refrigerant oils. Refrigerant—Charge
Weight................................................................................1.10—1.12 kg
CAUTION: Avoid possible injury from air 2.43—2.47 lb.
conditioning system refrigerant. Do not remove 7. Perform air conditioning check. See Operational
high-pressure relief valve. Air conditioning Checkout. (Group 9005-10.)
3. Connect refrigerant recovery, recycling, and charging

station. See R134a Refrigerant Recovery, Recycling,
SP66632,0004AC9 -19-30JAN15-1/1
020921
PN=171
Air Conditioner Compressor Remove and

Install
1. Park machine on a flat level surface.
2. Recover refrigerant. See Recover R134a Refrigerant.
(Group 1830.)
IMPORTANT: Close A/C lines with caps or plugs
immediately after disconnecting to prevent
contamination of system. If system is
TX1181287A —UN—09JAN15
left open, receiver-dryer must be replaced
before charging system.
3. Disconnect high and low-pressure lines (2 and 3).

4. Remove V-belt.
5. Disconnect wire harness connector (4).
6. Remove cap screws (1), washers, and lock nuts. Air Conditioner Compressor
7. Remove air conditioner compressor (5).

1— Cap Screw (3 used) 4— Wire Harness Connector
8. Repair or replace parts as necessary. 2— High-Pressure Output Line 5— Air Conditioner
3— Low-Pressure Input Line Compressor
9. Install air conditioner compressor.
10. Install V-belt and connect wire harness connector. Air Conditioner
11. Connect high and low-pressure lines to air conditioner Compressor
compressor. Low-Pressure Input Line
Nut—Torque.......................................................................... 24—33 N·m
Specification 18—24 lb.-ft.
Air Conditioner
Compressor 12. Evacuate and charge air conditioning system. See
High-Pressure Output Evacuate R134a System and see Charge R134a
Line Nut—Torque.................................................................. 20—27 N·m System. (Group 1830.)
177—239 lb.-in.
SP66632,0004ACE -19-30JAN15-1/1
020921
PN=172
Receiver-Dryer Remove and Install

2. Recover refrigerant. Perform Recover R134a
Refrigerant. (Group 1830.)
T204176A —UN—19OCT04
3. Disconnect refrigerant lines (1).
5. Remove high/low pressure switch (4) if receiver-dryer
is to be replaced.
6. Remove cap screws and retainer (3), and
receiver-dryer (2). Receiver-Dryer

1— AC Refrigerant Lines 4— High/Low Pressure Switch
8. Install receiver-dryer. 2— Receiver-Dryer 5— Wire Harness Connector
3— Cap Screws and Retainer
9. Install high/low pressure switch, if removed.
10. Connect refrigerant lines.
11. Evacuate and charge air conditioning system. See
Specification
Evacuate R134a System and see Charge R134a
Receiver-Dryer
System. (Group 1830.)
Refrigerant
Lines—Torque....................................................................... 14—20 N·m
139—177 lb-in.
TF19527,0001FC6 -19-19FEB16-1/1
Condenser Remove and Install

2. Recover refrigerant. See Recover R134a Refrigerant.
(Group 1830.)
T204177A —UN—19OCT04
3. Disconnect refrigerant lines (3 and 4).
4. Remove cap screws (1), washers, and lock nuts.
5. Remove condenser (2).
Air Conditioner Condenser
7. Install condenser.
8. Connect refrigerant lines. 1— Cap Screw (4 used) 3— High Pressure Gas Input
2— Condenser Line
Specification 4— High Pressure Liquid
Condenser High Output Line
Pressure Gas Input Line
Nut—Torque.......................................................................... 20—27 N·m
177—239 lb-in.
Condenser High
9. Evacuate and charge air conditioning system. See
Pressure Liquid Output
Evacuate R134a System and see Charge R134a
Line Nut—Torque.................................................................. 14—20 N·m
System. (Group 1830.)
139—177 lb-in.
CS33148,0002BB7 -19-20NOV08-1/1
020921
PN=173
Air Conditioner/Heater Module Remove and

Install
2. Recover refrigerant. Perform Recover R134a
T204179A —UN—19OCT04
Refrigerant. (Group 1830.)
3. Drain cooling system. or
Manual.)
• See 244K-II Drain and Refill Capacities. (Operator's
Manual.)
• See 324K Drain and Refill Capacities. (Operator's Refrigerant Lines-to-Expansion Valve Connections
Manual.)
1— Refrigerant Lines 2— Expansion Valve
4. Remove seat and floor plate as an assembly.
5. For machines not equipped with air conditioning, go
to step 6. connections under cab, wood blocks of sufficient
height must be installed between cab and frame
For machines equipped with air conditioning, perform before proceeding with repair procedure.
the following:
a. Remove left rear fender. See Rear Fenders c. Install blocks between cab and frame to prevent
Remove and Install. (Group 1913.) cab from lowering.
NOTE: To ease access to the A/C refrigerant line IMPORTANT: Close A/C lines with caps or plugs
connections under cab, raise cab approximately immediately after disconnecting to prevent
152 mm (6 in.). When cab is raised approximately contamination of system. If system is
152 mm (6 in.), disconnection of wire connectors left open, receiver-dryer must be replaced
and hydraulic lines is not necessary. before charging system.
b. Attach hoist and lifting chains to cab roof. Remove NOTE: Refrigerant lines-to-expansion valve connections
cab mounting hardware and raise cab approximately are located under the cab floor, just to the
152 mm (6 in.). See Cab Remove and Install. rear of the brake valve.
(Group 1800.)
d. Disconnect refrigerant lines (1) from expansion
valve (2), then continue to step 6.
CAUTION: Prevent possible crushing injury.
When cab is raised to access A/C refrigerant line
Continued on next page SP66632,0004AD1 -19-23AUG16-1/2
020921
PN=174
6. Remove air filter housing (4) and set aside.

7. Disconnect heater hoses (8) from heater core.
8. Disconnect air ducting (7) and air vent (10).
9. Disconnect air conditioning thermostat and blower
harness connectors (6).
10. Remove screws (5 and 9).
T204180A —UN—19OCT04
11. Remove air conditioner/heater module (3). Be careful
not to damage expansion valve and the refrigerant
lines between expansion valve and evaporator coil,
if equipped.
13. Install air conditioner/heater module. Add insulation
Air Conditioner/Heater Module and Air Filter Housing
as necessary around expansion valve and refrigerant
lines, if equipped.
14. Connect heater hoses and air ducting.
15. Connect wire harness connectors.
16. Install air filter housing.
17. For machines not equipped with air conditioning, go
to step 18.
T204181A —UN—19OCT04
For machines equipped with air conditioning, perform
the following:
a. Connect refrigerant lines, located under cab, to
expansion valve using new O-rings.
b. Remove blocks and carefully lower cab into position.
Install cab mounting hardware. See Cab Remove Heater Hoses and Air Ducting
c. Install left rear fender. See Rear Fenders Remove 3— Air Conditioner/Heater 7— Air Ducting
and Install. (Group 1913.) Module 8— Heater Hoses
4— Air Filter Housing 9— Screw
d. Evacuate air conditioning system and charge. See 5— Screws (3 used) 10— Air Vent
Evacuate R134a System and see Charge R134a 6— Air Conditioning
Thermostat and Blower
System. (Group 1830.) Harness Connectors (2
used)
18. Fill cooling system to proper level.
Manual.) 20. Check air conditioning system for leaks. See R134a
• See 244K-II Drain and Refill Capacities. (Operator's Refrigerant Leak Test. (Group 9031-25.)
Manual.)
• See 324K Drain and Refill Capacities. (Operator's 21. Install seat and floor plate assembly.
Manual.)
19. Start engine and check heater hoses for leaks.
SP66632,0004AD1 -19-23AUG16-2/2
020921
PN=175
Heater Core Remove and Install

1. Remove air conditioner/heater module. See Air
Conditioner/Heater Module Remove and Install.
(Group 1830.)
2. Remove three screws and carefully slide heater core
(1) out of air conditioner/heater module.
T204194 —UN—26OCT04
4. Install heater core.
5. Install air conditioner/heater module. See Air
(Group 1830.) 1
T204194
1— Heater Core
CS33148,0002BCE -19-09MAY18-1/1
Evaporator Coil Remove and Install

1
1. Remove air conditioner/heater module. See Air 2
(Group 1830.)
2. Carefully remove air conditioner freeze control switch
capillary tube (1) from hole in air conditioner/heater
module.
3. Remove upper section (2) of air conditioner/heater
module.
IMPORTANT: Close A/C lines with caps or plugs 3
contamination of system. If system is left
open, receiver- dryer must be replaced
4. Remove expansion valve (4).

5. Carefully remove evaporator coil (3). 4
T204195 —UN—26OCT04
7. Install expansion valve using new O-rings.
8. Install evaporator coil into housing. Making sure foam
insulation is in place.
9. Install upper section of air conditioner/heater module.
T204195
10. Fully insert bare portion of air conditioner freeze control
switch capillary tube into hole in air conditioner/heater
module.
1— Air Conditioner Freeze 3— Evaporator Coil
11. Install air conditioner/heater module. See Air Control Switch Capillary 4— Expansion Valve
Conditioner/Heater Module Remove and Install. Tube
2— Upper Section
(Group 1830.)
CS33148,0002BCF -19-09MAY18-1/1
020921
PN=176
Expansion Valve Remove and Install

1. Remove air conditioner/heater module. See Air
(Group 1830.)
T204196 —UN—26OCT04
2. Remove insulation.
3. Remove expansion valve (1). 1
T204196
4. Replace if necessary.
5. Attach expansion valve to evaporator coil inlet and
outlet lines using new O-rings. 1— Expansion Valve
6. Wrap expansion valve and connections with
insulation.
(Group 1830.)
CS33148,0002BB2 -19-09MAY18-1/1
Heater Control Valve Remove and Install

1. Drain cooling system. See Drain Cooling System.
3. Remove corner vent tubing.
4. Remove mounting screw (1).
T204185A —UN—19OCT04
5. Disconnect upper heater hose (2) from control valve.
6. Pull up on heater control valve to disconnect lower
heater hose (3).
7. Remove clip (6) and disconnect control cable (5).
8. Remove heater control valve (4).
Heater Control Valve (corner vent tubing removed for clarity)
9. Replace heater control valve if necessary.
10. Connect end of control cable to control valve lever. 1— Mounting Screw 4— Heater Control Valve
Fasten cable to control valve housing using clip (6). 2— Upper Heater Hose 5— Control Cable
3— Lower Heater Hose 6— Clip
11. Connect hoses to control valve using new hose clamps.
12. Install mounting screw (1).
15. Start engine and check for leaks.
13. Adjust control cable by loosening clip and repositioning
cable as necessary. 16. Stop engine.
14. Fill cooling system to proper level. See Fill Cooling 17. Install seat and floor plate assembly.
System. (Operator's Manual.)
SP66632,0004AD2 -19-30JAN15-1/1
020921
PN=177
Air Conditioner High/Low-Pressure Switch

Remove and Install
2. Remove air conditioner high/low-pressure switch (2)
T204176B —UN—22OCT04
from receiver-dryer (3).
4. Install air conditioner high/low-pressure switch.
5. Connect wire harness connector.
1— Wire Harness Connector 3— Receiver-Dryer Air Conditioner High/Low-Pressure Switch

2— Air Conditioner
High/Low-Pressure Switch
SP66632,0004ACF -19-30JAN15-1/1
Air Conditioner Freeze Control Switch

Remove and Install
2. Remove knob (1).
3. Remove nut and lock washer (3).
4. Remove air conditioner freeze control switch (2) from
T204270A —UN—22OCT04
mounting bracket and disconnect wires from switch.
5. Remove switch and capillary tube (4).
7. Insert end of air conditioner freeze control switch
capillary tube (1) into hole in air conditioner/heater
module until bare portion is fully inserted. Bend
capillary tube around side of air conditioner/heater
module. 1— Knob 3— Nut and Lock Washer
2— Air Conditioner Freeze 4— Air Conditioner Freeze
8. Connect wires to air conditioner freeze control switch Control Switch Control Switch Capillary
and fasten switch body to mounting bracket using nut Tube
and lock washer (3).
9. Install knob.
11. Install seat and floor plate assembly.
10. Adjust air conditioner freeze control switch. See
Air Conditioner Freeze Control Switch Test. (Group
9031-25.)
CS33148,0002BB4 -19-19NOV08-1/1
020921
PN=178
Blower Motor Remove and Install

1
1. Remove air conditioner/heater module. See Air 2
(Group 1830.)
2. Carefully remove air conditioner freeze control switch
capillary tube (1) from hole in air conditioner/heater
module.
3. Remove upper section (2) of air conditioner/heater
module.
3
4. Disconnect blower motor wiring connector.
5. Remove blower motor (3).
7. Install blower motor.
8. Connect blower motor wiring connector.
9. Install upper section of air conditioner/heater module.
T204197 —UN—26OCT04
10. Fully insert bare portion of air conditioner freeze control
switch capillary tube into hole in air conditioner/heater
module.
Conditioner/Heater Module Remove and Install. T204197
(Group 1830.)
1— Air Conditioner Freeze 3— Blower Motor

Control Switch Capillary
Tube
2— Upper Section
CS33148,0002BB9 -19-09MAY18-1/1
020921
PN=179
020921
PN=180
Section 19
Sheet Metal and Styling
Contents
Page
Group 1910—Hood or Engine Enclosure

Hood Remove and Install .......................... 19-1910-1
Group 1913—Miscellaneous Shields

Rear Fenders Remove and Install.............. 19-1913-1
020921
PN=1
Contents
020921
PN=2
Group 1910
Hood or Engine Enclosure
Hood Remove and Install
1. Lower boom and bucket to the ground. Stop engine
and turn battery disconnect switch to the OFF position.
2. Open hood. Disconnect connector (X23).
CAUTION: Prevent possible crushing injury;

3. Support hood (1) using lifting straps and an appropriate
TX1183367A —UN—12FEB15
lifting device.
Specification
Hood—Weight
(approximate).................................................................................. 36 kg
80 lb.
4. Disconnect hood supports (2).

5. Remove cap screws, washers, and backing plates Hood Remove and Install
from hood pivot point on both sides of hood. Remove
hood (1). 1— Hood X23— Loader/Rear Frame
2— Hood Support (2 used) Harness-to-Rear Lights
6. Repair or replace as necessary. Harness Connector
7. Lower hood to machine. Install cap screws, washers,

and backing plates to hood pivot points on both sides
of hood. 10. Remove lifting straps. Make sure that hood opens and
closes without binding.
8. Install hood supports (2).
11. Turn battery disconnect switch to the ON position.
9. Connect connector (X23).
SP66632,0004ADC -19-12FEB15-1/1
020921
PN=183
Hood or Engine Enclosure
020921
PN=184
Group 1913
Miscellaneous Shields
Rear Fenders Remove and Install
5
4 4
T202920 —UN—27SEP04
6
7
2
T202920
Remove and Install Rear Fenders
1— Right Rear Fender 3— Cap Screw (2 used) 5— Cap Screw
2— Left Rear Fender 4— Cap Screw (2 used) 6— Cap Screw (3 used)
7— Cap Screw (2 used)
1. Turn battery disconnect switch to OFF position. 2. Support fender and remove cap screws (3, 4, and 5)
for right rear fender or cap screws (6 and 7) for left
CAUTION: Prevent possible crushing injury rear fender.
from heavy component. Use appropriate 3. Repair or replace fenders as required.
lifting device. Weight may increase due to
buildup of mud and debris.
Specification
Rear Fender—Weight
(approximate).................................................................................. 47 kg
104 lb.
SP66632,0004AC5 -19-14JAN15-1/1
020921
PN=185
Miscellaneous Shields
020921
PN=186
Section 21
Main Hydraulic System
Contents
Page

General Oil Cleanup Procedure ................ 21-2160-1
Hydraulic Component Failure
Cleanup Procedure................................ 21-2160-3
Hydraulic System Pressure
and Accumulators Discharge
Procedure .............................................. 21-2160-4
Hydraulic Pump/Priority Valve
Hydraulic Pump/Priority Valve
Hydraulic Reservoir Remove and
Install ................................................... 21-2160-10
020921
PN=1
Contents
020921
PN=2
Group 2160
Hydraulic System
General Oil Cleanup Procedure
This procedure is to be used on machines that have
had hydraulic system repair without a catastrophic
component failure. Filter procedure must be done
prior to starting machine after a component has
been repaired or replaced. The use of attachments
increase the need to monitor and filter oil to a safe
contamination value.
X9811 —UN—23AUG88
IMPORTANT: Oil types and filters must not be
intermixed. To avoid intermixing of oils, use
filter element in same type oil.
Avoid operating Super Caddy™ in dusty or wet
conditions. Oil contamination will result.
NOTE: Instrument cleanliness and clean work practices Never attempt to relieve hydraulic system or
are critical when filtering oil or taking oil samples. accumulator pressure by loosening a fitting.
Dust, wind, and moisture, as well as contaminated Tighten all connections before applying pressure.
sample pumps, bottles and tubing can affect results.
1. Park machine on a flat level surface. See Park and system. Perform Hydraulic System Pressure and
Prepare for Service Safely. (Group 0001.) Accumulators Discharge Procedure. (Group 2160.)
CAUTION: To avoid injury from escaping fluid 3. Open hood and remove grille. See Opening Hood and
under pressure, stop engine and relieve the Removing Grille. (Operator’s Manual.)
Super Caddy is a trademark of Deere & Company
PN50483,0002108 -19-23AUG16-1/3
TX1181328A —UN—05JAN15
TX1181329A —UN—05JAN15
Hydraulic Tank Fill Cap Fill Tank Strainer
1— Fill Cap 2— Tank Strainer
4. Clean oil fill cap (1) and area surrounding it to prevent 7. Remove tank strainer (2) and store in sealed plastic
contamination. bag.
5. Slowly remove tank fill cap (1).
6. Clean and store fill cap in sealed plastic bag.
Continued on next page PN50483,0002108 -19-23AUG16-2/3
020921
PN=189
Hydraulic System
8. Cover hydraulic tank fill tube (3) opening with plastic

bag or all purpose tape.
9. Place both wands through cover on tank fill opening.
Position suction wand near bottom of tank and
discharge wand below oil surface.
TX1181331A —UN—05JAN15
10. Wands must maintain position in tank.
11. Filter oil until Super Caddy™ shuts off and contaminant
value is to specification. Refer to operator's manual
included with Super Caddy™ in Service ADVISOR™
for operating procedure.
12. Install fill cap and tank strainer. Hydraulic Tank Fill Tube
13. Install new hydraulic oil filter for cleanup procedure.
See Replace Hydraulic System Return Suction Filter. 3— Hydraulic Tank Fill Tube
CAUTION: Avoid entanglement and possible 18. When oil reaches acceptable value of cleanliness,
electrocution from filter caddy power cord. install new machine oil filter. See Replace Hydraulic
Do not operate machine while filter caddy System Return Suction Filter. (Operator’s Manual.)
is connected to machine.
NOTE: Instrument cleanliness and clean work practices
14. Make sure area is clear and large enough to operate are critical when filtering oil or taking oil samples.
all functions of machine. Dust, wind, and moisture, as well as contaminated
sample pumps, bottles and tubing can affect results.
15. Fill hydraulic reservoir to specified operating level.
See Check Hydraulic Oil Level. (Operator's Manual.) 19. Obtain oil sample for fluid analysis. Oil sample must
IMPORTANT: Do not force the hydraulic system be taken from system before oil passes through the
over system relief. return filter when oil is warm.
20. Check hydraulic oil level. See Check Hydraulic Oil
16. Run machine at slow idle. Operate each circuit a Level. (Operator's Manual.)
minimum of 2 minutes in each direction to flush any
remaining contaminants through hydraulic oil filter. 21. Return machine to service.
17. Cycle through all functions 3—5 times. 22. After a 100 hours of service obtain oil sample for fluid
analysis. Confirm oil is within specification.
PN50483,0002108 -19-23AUG16-3/3
020921
PN=190
Hydraulic System
Hydraulic Component Failure Cleanup Procedure

IMPORTANT: Oil types and filters must not be 14. Clean all lines and hoses using Ultra Clean hose kit.
intermixed. To avoid intermixing of oils, use Install all removed lines and hoses.
filter element in same type oil.
15. Fill reservoir to operating level. See Change Hydraulic
Avoid operating Super Caddy™ in dusty or wet Oil. (Operator’s Manual.)
conditions. Oil contamination will result.
CAUTION: Avoid entanglement and possible
NOTE: Instrument cleanliness and clean work practices electrocution from Super Caddy™ power
are critical when filtering oil or taking oil samples. cord. Do not operate machine while Super
Dust, wind, and moisture, as well as contaminated Caddy™ is connected to machine.
sample pumps, bottles, and tubing affects results.
Prevent possible personal injury from unexpected
1. Park machine on a flat level surface. See Park and machine movement. Clear all persons from
Prepare for Service Safely. (Group 0001.) area before operating machine.
2. Turn battery disconnect switch to OFF position or 16. Make sure that area is clear and large enough to
disconnect negative (-) battery cable. operate all functions of machine.
3. Clean all machine components and surrounding areas. 17. Turn battery disconnect switch to ON position or
4. Release pressure in reservoir. Perform Hydraulic connect negative (-) battery cable.
System Pressure and Accumulators Discharge IMPORTANT: Do not force the hydraulic system
Procedure. (Group 2160.) over system relief.
5. Remove and clean fill cap and strainer. In sealed
plastic bag, store fill cap and strainer. 18. To prevent component damage during start-up, See
Loader Start-Up Procedure. (Group 3160.)
6. Cover fill tube with plastic bag or all purpose tape.
19. Check hydraulic oil level. See Check Hydraulic Oil
7. To remove oil contaminants before reservoir is Level. (Operator’s Manual.)
drained, use Super Caddy™. See General Oil
Cleanup Procedure. (Group 3160.) IMPORTANT: Trapped air suddenly compressed in
a cylinder makes enough heat to ignite the oil
8. Use Super Caddy™ to transfer oil from reservoir to used for assembly causing cap seal and ring
a clean container or drain reservoir. See Change damage. Start with cylinder rod retracted and
Hydraulic Oil. (Operator’s Manual.) the rod end filled with clean oil. Operate function
to extend rod. Procedure eliminates most of the
9. Remove, disassemble, clean, and inspect system air and reduce the possibility of damage.
components.
10. Repair or replace damaged components. Install all 20. Run machine at slow idle. To move air and
components. contaminants back through machines oil filter, operate
each circuit a minimum of 2 minutes in each direction.
IMPORTANT: Oil cooler and accumulators cannot be
cleaned of contamination and must be replaced. 21. Cycle cylinders an additional 10 times to be sure that
air is eliminated from circuit.
System manifolds cannot always be cleaned
of contamination and must be replaced. 22. Operate all functions for 3—5 minutes in each direction.
23. Filter oil until Super Caddy™ shuts off and contaminant
11. Replace oil cooler and system accumulators. Some value is to specification. Refer to operator's manual
manifolds cannot be cleaned. Replace manifolds as included with Super Caddy™ or see Super Caddy™ in
required. Service ADVISOR™ for operating procedure.
12. Replace hydraulic oil filter. See Replace Hydraulic 24. Replace hydraulic oil filter. See Replace Hydraulic
System Return Suction Filter. (Operator’s Manual.) System Return Suction Filter. (Operator’s Manual.)
IMPORTANT: Ultra Clean process must have all NOTE: Instrument cleanliness and clean work practices
T-fittings disconnected. Lines or hoses with are critical when filtering oil or taking oil samples.
T-fittings must be cleaned individually. Dust, wind, and moisture, as well as contaminated
sample pumps, bottles, and tubing affects results.
13. Locate and disconnect all circuit hoses and lines from
pumps, motors, valves, manifolds, and T-fittings. 25. Obtain oil sample for fluid analysis. Oil sample must
NOTE: To minimize contamination, close all openings of be taken from system before oil passes through the
lines and components with caps and plugs. return filter when oil is warm.
Continued on next page PN50483,00020FF -19-23AUG16-1/2
020921
PN=191
Hydraulic System
26. Check hydraulic oil level. See Check Hydraulic Oil 28. After 100 hours of service obtain oil sample for fluid
Level. (Operator’s Manual.) analysis. Confirm oil is within specification.
27. Return machine to service.
PN50483,00020FF -19-23AUG16-2/2
Hydraulic System Pressure and

Accumulators Discharge Procedure
The purpose of this procedure is to relieve all working or
static pressure from the hydraulic system before breaking
TX1008787A —UN—02JUN06
lines or performing any hydraulic maintenance.
1. Park machine on level surface. Lower boom to the
ground or raise boom and install boom locking bar.
2. Stop engine and turn key switch to ON position.
3. Push and hold the pilot enable/boom down switch.
4. Move control lever to boom lower position for 5
seconds, then move control lever in each direction
until no movement is felt or seen in boom lower or 1— Ride Control Valve 2— Plug
bucket rollback functions.
5. Turn key switch to OFF position.
to internal leakage, but it requires that the
6. If equipped with ride control—the ride control engine is OFF and that the machine sits idle
accumulator must be relieved of pressure. Remove for approximately 25 minutes.
plug (2) from ride control valve (1). Insert hex
wrench and turn manual pressure relieving valve out 7. To relieve pressure in park brake circuit—after step
(counterclockwise) three complete turns. 5, wait for a minimum of 25 minutes to allow park
brake accumulator to bleed off before removing any
NOTE: The park brake circuit cannot be operated to park brake lines.
relieve pressure like other accumulated circuits.
The park brake circuit pressure bleeds off due
OUO1020,00018E0 -19-10DEC08-1/1
020921
PN=192
Hydraulic System
Hydraulic Pump/Priority Valve Remove and

Install
SPECIFICATIONS
244K and 244K-II Hydraulic Pump 10 kg
Weight (approximate) 23 lb.
X9811 —UN—23AUG88
324K Hydraulic Pump Weight 14 kg
Hydraulic Pump Cap Screw 140 N·m
Torque 105 lb.-ft.
1. Park machine on a level surface. See Park and

Prepare for Service Safely. (Group 0001.) Escaping Fluid

under pressure, stop engine and relieve the NOTE: A special reservoir drain hose is stored in operator's
pressure in the system before disconnecting station. As drain hose is tightened on reservoir
or connecting hydraulic or other lines. drain fitting, the drain fitting valve will automatically
open, allowing oil to drain from reservoir.
Never attempt to relieve hydraulic system or
accumulator pressure by loosening a fitting. 3. Apply a vacuum to hydraulic reservoir or drain
Tighten all connections before applying pressure. hydraulic reservoir. See Change Hydraulic Oil.
system. Perform Hydraulic System Pressure and 4. Clean pump in area of connections to prevent system
Accumulators Discharge Procedure. (Group 2160.) contamination.
020921
PN=193
Hydraulic System
TX1181367A —UN—07JAN15
TX1181368A —UN—05JAN15
Hydraulic Pump Hydraulic Pump Lines
1— Cap Screw and Washer (2 4— High Flow Solenoid 5— Priority Valve-to-Loader

used) Valve-to-Loader Control Valve Control Valve Line
2— Reservoir-to-Pump Line Line (if equipped) 6— Steering Valve LS
3— Priority Valve-to-Steering Port-to-Priority Valve Line
Valve P Port Line
NOTE: Mark all lines before disconnecting to 324K Hydraulic

aid in installation. Pump—Weight
(approximate).................................................................................. 14 kg
5. Mark and disconnect lines (2—6). Close all openings 30 lb.
using caps and plugs.
7. Repair or replace pump as needed. See Hydraulic
NOTE: Machines not equipped with the high flow option Pump/Priority Valve Disassemble and Assemble.
will not have a tee fitting or high flow solenoid (Group 2160.)
valve-to-loader control valve line.
8. Remove pump mounting base O-ring. Apply petroleum
jelly to new O-ring and install.
heavy component. Use appropriate lifting device. 9. Install pump, washers, and cap screws. Tighten cap
screws to specification.
6. Remove cap screws and washers (1) and pump using Specification
appropriate lifting device. Hydraulic Pump Cap
Specification Screw—Torque............................................................................140 N·m
244K and 244K-II 105 lb.-ft.
Hydraulic Pump—Weight
10. Connect lines as marked during disassembly.
(approximate).................................................................................. 10 kg
23 lb. 11. Fill reservoir to proper level. See Change Hydraulic
PN50483,0002109 -19-23AUG16-2/2
020921
PN=194
Hydraulic System
Hydraulic Pump/Priority Valve Disassemble and Assemble

Nomenclature SPECIFICATIONS — SPECIFICATIONS —
244K and 244K-II 324K
Body Cap 70 N·m 100 N·m
Screws 33 lb.-ft. 74 lb.-ft.
Priority Valve N/A 70 N·m
Cap Screw 51 lb.-ft.
Priority Valve 100 N·m 100 N·m
Cap 74 lb.-ft. 74 lb.-ft.
Load Sense 100 N·m 15 N·m
Fitting 74 lb.-ft. 11 lb.-ft.
Pilot Spring N/A 100 N·m
Cap 74 lb.-ft.
Case Drain 45 N·m 90 N·m
Plug 33 lb.-ft. 66 lb.-ft.
14
15 16
17 18
22
19 21
13 20
12
11
9 7
10
23
4 9
5 7 27 24
28
1 26
TX1180415 —UN—19DEC14
2 8 25
1
29
8
3 6
TX1180415
Hydraulic Pump Exploded View — 244K and 244K-II
1— Shaft Seal (2 used) 9— Bearing Block (2 used) 17— O-Ring 25— O-Ring
2— Snap Ring 10— Drive Shaft 18— Filter 26— Load Sense Fitting
3— Backup Washer 11— Body 19— Priority Valve Spool 27— Pin (2 used)
4— Flange 12— Internal Seal 20— Lock Screw 28— Case Drain Plug
5— Dowel Pin (2 used) 13— Priority Valve Assembly 21— Washer (4 used) 29— Driven Shaft
6— External Seal 14— Priority Valve Cap 22— Body Cap Screw (4 used)
7— Back-Up Seal (2 used) 15— O-Ring 23— Pushing Spring
8— Internal Seal (2 used) 16— Adjustment Screw 24— Main Pilot Spring
IMPORTANT: Thoroughly clean outside of pump 2. Repair or replace as necessary.

before disassembly.
1. Disassemble parts (1-29) for 244K and 244K-II pump.
Continued on next page PN50483,00020FE -19-23AUG16-1/3
020921
PN=195
Hydraulic System
Load Sense
3. Assemble parts (1-29) for 244K and 244K-II pump.
Fitting—Torque............................................................................100 N·m
Hydraulic Pump—Specification 74 lb.-ft.
Body Cap Case Drain
Screws—Torque............................................................................70 N·m Plug—Torque.................................................................................45 N·m
51 lb.-ft. 33 lb.-ft.
Priority Valve
Cap—Torque...............................................................................100 N·m
74 lb.-ft.
Continued on next page PN50483,00020FE -19-23AUG16-2/3
020921
PN=196
Hydraulic System
19
20 21
22 23
26 27
24
18
16 17 25
15
14
12 13
28
7 29
9
10 30
9
3 7 31 32
5 33
4
2 11
TX1180416 —UN—19DEC14
1 8
34
6 8
1
TX1180416
Hydraulic Pump Exploded View — 324K
1— Shaft Seal 10— Drive Shaft 19— Priority Valve Cap 28— Load Sense Fitting
2— Snap Ring 11— Bushing (4 used) 20— O-Ring 29— Pushing Spring
3— Flange 12— Sleeve Bearing 21— Adjustment Screw 30— Main Pilot Spring
4— Dowel Pin (2 used) 13— Body Seal 22— Filter 31— O-Ring
5— Bearing (4 used) 14— Body 23— O-Ring 32— Pilot Spring Cap
6— Lock Screw 15— O-Ring 24— Priority Valve Spool 33— Case Drain Plug
7— External Seal (2 used) 16— Washer (4 used) 25— Lock Screw 34— Driven Shaft
8— Back-Up Seal (2 used) 17— Body Cap Screw (4 used) 26— Washer (4 used)
9— Bearing Block (2 used) 18— Priority Valve Assembly 27— Priority Valve Cap Screw (4
used)
1. Disassemble parts (1-34) for 324K pump. Priority Valve

Cap—Torque...............................................................................100 N·m
2. Repair or replace as necessary. 74 lb.-ft.
3. Assemble parts (1-34) for 324K pump. Pilot Spring
Cap—Torque...............................................................................100 N·m
Hydraulic Pump—Specification 74 lb.-ft.
Body Cap Case Drain
Screws—Torque..........................................................................100 N·m Plug—Torque.................................................................................90 N·m
74 lb.-ft. 66 lb.-ft.
Priority Valve Cap
Screws—Torque............................................................................70 N·m
51 lb.-ft.
Load Sense
Fitting—Torque..............................................................................15 N·m
11 lb.-ft
PN50483,00020FE -19-23AUG16-3/3
020921
PN=197
Hydraulic System
Hydraulic Reservoir Remove and Install

SPECIFICATIONS
1
244K
Hydraulic Reservoir Weight 150 kg
(approximate) 331 lb
324K
Hydraulic Reservoir Weight 172 kg 1
(approximate) 379 lb
Hydraulic Reservoir Sight Glass 8 N·m
Cap Screw Torque 71 lb·in
1. Remove cooling package. See Cooling Package

3
2. Remove washer pump and brackets.
3. Remove service (drum) brake reservoir and mounting 4 3
bracket. Drain brake reservoir and disconnect 3
reservoir brake line. 2 4
T202377 —UN—02SEP04
4
4. Tag and disconnect hoses from hydraulic reservoir
and return suction filter. 2
2
heavy component. Use proper lifting device.
T202377
5. Attach suitable hoist to lifting points (1) on reservoir. Hydraulic Reservoir
244K—Specification
Hydraulic 1— Lift Point (2 used) 3— Flat Washer (4 used)
2— Hydraulic Reservoir 4— Lock Washer (4 used)
Reservoir—Weight
Mounting Cap Screw (4
(approximate)................................................................................ 150 kg used)
331 lb
324K—Specification
Hydraulic reservoir brake hose through grommet in hydraulic
Reservoir—Weight reservoir frame.
(approximate)................................................................................ 172 kg
379 lb
6. Remove hydraulic reservoir mounting cap screws (2).

7. Slowly raise reservoir while guiding hydraulic hoses
through cutout in hydraulic reservoir. Push drum brake
Continued on next page PN50483,0002101 -19-05DEC16-1/2
020921
PN=198
Hydraulic System
9. When installing the hydraulic reservoir sight glass (5),

tighten hydraulic reservoir sight glass cap screws (6)
to specification.
Specification
Hydraulic Reservoir
XJ1229271A —UN—25NOV16
Sight Glass Cap
Screw—Torque................................................................................8 N·m
71 lb·in
10. Lower reservoir onto frame while guiding hoses

through cutout. Insert brake hose through grommet in
reservoir frame.
11. Install hydraulic reservoir mounting cap screws (2) Hydraulic Reservoir Sight Glass
through frame and into reservoir.
12. Connect hoses to reservoir and return suction filter. 5— Hydraulic Reservoir Sight 6— Hydraulic Reservoir Sight
Glass Glass Cap Screw (2 used)
13. Install service (drum) brake reservoir and connect
brake hose.
14. Add oil to brake reservoir. See Check Service (Drum) 16. Install radiator, oil cooler, and charge air cooler. See
Brake Oil Level. (Operator's Manual.) Cooling Package Remove and Install. (Group 0510.)
15. Bleed brakes. See Drum Brake Bleed. (Group 1060.)
PN50483,0002101 -19-05DEC16-2/2
020921
PN=199
Hydraulic System
020921
PN=200
Section 31
Loader
Contents
Page
Group 3102—Bucket
Welded-On Bucket Cutting Edge
Bolt-On Cutting Edge Remove and
Install ..................................................... 31-3102-2
Cracked Cutting Edge Repair.................... 31-3102-2
Group 3104—Attachment Coupler

Quick Disconnect Hitch
Quick Disconnect Hitch Pivot Pin
Quik-Tatch™ Actuator Remove
and Install .............................................. 31-3104-6
Quik-Tatch™ Coupler Remove and
Install ..................................................... 31-3104-6
Group 3140—Frames
Boom and Bucket Linkage Remove
and Install .............................................. 31-3140-1
Bucket Linkage Bushings Remove
and Install .............................................. 31-3140-3
Loader Boom Bushings Remove
and Install .............................................. 31-3140-4

Loader Control Valve Remove and
Install ..................................................... 31-3160-1
Loader Control Valve Disassemble
and Assemble........................................ 31-3160-3
Loader System and Circuit Relief
Valves Disassemble and
Assemble............................................... 31-3160-4
Ride Control Valve Remove and
Install ..................................................... 31-3160-5
Ride Control Valve Disassemble
and Assemble........................................ 31-3160-6
Boom Cylinder Remove and
Install ..................................................... 31-3160-7
Bucket Cylinder Remove and
Install ..................................................... 31-3160-8
Boom and Bucket Cylinders
Boom and Bucket Cylinder
Bushings Remove and Install .............. 31-3160-12
Loader Start-Up Procedure ..................... 31-3160-12
Pilot Control Valve Remove and
Install ................................................... 31-3160-13
Pilot Control Valve Disassemble
and Assemble...................................... 31-3160-15
Pilot Enable Solenoid Valve
Remove and Install.............................. 31-3160-19
Pilot Accumulator Remove and
Install ................................................... 31-3160-20
020921
PN=1
Contents
020921
PN=2
Group 3102
Bucket
Welded-On Bucket Cutting Edge Remove and Install
T133038 —UN—23AUG00
1— Cutting Edge 2— Bucket
IMPORTANT: Avoid damage to machine. See Welding throughout the entire welding operation. Tempilstiks
on Machine. (Operator's Manual.) should be used if possible.
1. Remove the cutting edge (1) using air-arc equipment 6. Tack weld preheated cutting edge starting at center of
to blow out original welds. bucket and working toward the outside ends.
2. Perform welding in an environment with a minimum 7. Final weld preheated cutting edge starting at the center
ambient temperature of 10°C (50°F). of the top side and working toward the outside ends.
3. Clean all joints to be welded of all foreign matter such Repeat this operation on bottom side of cutting edge.
as dirt, rust, mill scale, oil, etc., with grinders and/or Tack welds may be incorporated into the final weld,
solvents. providing they have been made with electrodes that
4. Use dry AWS-E7018 low hydrogen electrodes or either meet the requirements of the final welds and no
of the following equivalent low hydrogen wire feed cracking has occurred in the weld metal. Tack welds
electrodes: gas metal arc welding (CO2 or argon CO2) not meeting these requirements must be completely
AWS-E70S6 or flux cored arc welding AWS-E70T1. removed by grinding or air-arc gouging just prior to
making the final weld in that area.
IMPORTANT: Preheat temperature must be throughout
the entire thickness of the parts joined and at 8. Do not remove bucket from welding environment until
least 51 mm (2 in.) back from the joint. weld metal temperature has dropped to the ambient
temperature. Do not force cooling rate of weld metal.
5. Preheat parts to be welded (both tack and final welds)
to minimum of 204°C (400°F). Maintain preheat
CED,OUO1020,4057 -19-15AUG00-1/1
020921
PN=203
Bucket
Bolt-On Cutting Edge Remove and Install
T133039 —UN—23AUG00
1— Cutting Edge (2 used) 3— Bolt (10 used) 5— Cutting Edge (weld-on)
2— Cutting Edge (2 used) 4— Nut (10 used)
1. Lower bucket to the ground. Remove nuts (4). Raise 2. Make sure underside of bucket cutting edge (5) is
bucket and lower onto wooden blocks placed behind free of foreign material. Position cutting edges under
cutting edge. Remove cutting edges (1 and 2). bucket and install new bolts and nuts. Tighten nuts.
IMPORTANT: Use new bolts and nuts when
replacing cutting edges.
CED,OUO1020,4058 -19-15AUG00-1/1
Cracked Cutting Edge Repair IMPORTANT: Avoid damage to machine. See Welding
1. If cutting edge has any cracks, clean the area to find on Machine. (Operator's Manual.)
end of crack.
5. Fill the V-grooves with weld. Use E7018 electrodes.
2. Drill a small hole at end of crack to prevent spreading. Extend the weld approximately 13 mm (0.5 in.) beyond
end of crack.
3. Grind V-grooves along crack on top and bottom of
cutting edge.
4. Preheat the cracked area to approximately
149—260°C (300—500°F).
CED,OUO1020,2338 -19-05JUN98-1/1
020921
PN=204
Group 3104
Attachment Coupler
Quick Disconnect Hitch Disassemble and
Assemble
NOTE: Each side of the quick disconnect cylinder can
be individually disassembled on the machine
for seal and O-ring replacement.
1. Disconnect bucket from hitch.
TX1055554A —UN—09FEB09
2. Vertically align quick disconnect pins as shown.
3. Install frame articulation lock bar.
4. Engage park brake.
Quick Disconnect Pins Vertical Alignment
PN50483,0002106 -19-27JAN15-1/8

X9811 —UN—23AUG88
Tighten all connections before applying pressure.

Escaping Fluid
PN50483,0002106 -19-27JAN15-2/8
6. Disconnect hydraulic cylinder hoses (1). Close all

1— Hydraulic Cylinder Hose (2

used)
TX1055559A —UN—09FEB09
Hydraulic Cylinder Hose Removal
Continued on next page PN50483,0002106 -19-27JAN15-3/8
020921
PN=205
Attachment Coupler

7. Attach lifting strap (2) to bucket link (3) as shown.

Attach appropriate lifting device to lifting strap and
support weight of quick disconnect hitch.
Specification
TX1055575A —UN—10FEB09
Quick Disconnect
Hitch—Weight
(approximate).................................................................................. 45 kg
100 lb.
2— Lifting Strap 3— Bucket Link
Bucket Link and Lifting Strap
PN50483,0002106 -19-27JAN15-4/8
8. Remove socket head screw (4).

NOTE: Left side rod guide uses left hand threads while
right side rod guide uses conventional threads.
TX1055606A —UN—09FEB09
9. Remove rod guide (5) using JDG347 Spanner Wrench
and JDG1231 Pin Set.
10. Remove washer (6).
4— Socket Head Screw 6— Washer

5— Rod Guide
Socket Head Screw
TX1055607A —UN—09FEB09
Rod Guide
020921
PN=206
Attachment Coupler
11. Install an M10 x 100 mm cap screw (7) in end of

cylinder rod (8). Remove cylinder rod.
12. Remove cylinder rod on opposite end of quick
disconnect cylinder using the same procedure.
TX1055610A —UN—09FEB09
7— M10 x 100 mm Cap Screw 8— Cylinder Rod
Cylinder Rod Removal
PN50483,0002106 -19-27JAN15-6/8
IMPORTANT: Note location of O-rings, backup rings

and seals, and direction of seal lips before
removing. All these parts must be installed
correctly for cylinder to operate properly.
TX1055614A —UN—09FEB09
Apply petroleum jelly to all O-rings, backup
rings, and seals at installation.
13. Clean and inspect rod guide (9). Replace parts as

necessary.
9— Rod Guide 13— Outer Seal

10— O-Ring 14— Middle Seal
11— Backup Ring 15— Inner Seal Rod Guide—Outer View
12— O-Ring
TX1055613A —UN—09FEB09
Rod Guide—Inner View
020921
PN=207
Attachment Coupler
IMPORTANT: Note location of guide rings, backup

rings, wear rings, and seal rings before
removing. All parts must be installed correctly
for cylinder to operate properly.
Apply petroleum jelly to all guide rings, backup
rings, wear rings, and seal rings at installation.
TX1055615A —UN—09FEB09
14. Clean and inspect cylinder rod (19). Replace parts as
necessary.
15. Align cylinder barrel with pivot hole in boom. Install
cylinder rod into cylinder barrel and remove cap screw.
16. Apply OPTIMOLY PASTE WHITE T® to threads of
rod guide. Cylinder Rod
17. Install rod guide and washer into cylinder. Tighten rod
guide until boom has zero side play. 16— Guide Ring 20— Wear Ring
17— Backup Ring 21— Seal Ring
18. Fill clamp slot on bottom of cylinder with ULTRA 18— Backup Ring 22— Wear Ring
BLUE® RTV Silicone. 19— Cylinder Rod
19. Install socket head screws into cylinder. Tighten to

specification. 21. Connect hydraulic cylinder hoses.
Specification
Rod Guide Clamp Socket
22. Start machine. With engine at slow idle, slowly extend
Head Screw—Torque..................................................................310 N·m
and retract cylinder fully several times to ensure that
228 lb.-ft.
air is out of cylinder.
23. Fill hydraulic reservoir to proper level. See Check
Hydraulic Oil Level. (Operator's Manual.)
20. Repeat assembly procedure for opposite side of
cylinder. 24. Remove frame articulation lock bar.
OPTIMOLY PASTE WHITE T is a trademark of Optimal Lubricants, Inc.
ULTRA BLUE is a trademark of Henkel Corporation.
PN50483,0002106 -19-27JAN15-8/8
Quick Disconnect Hitch Pivot Pin Remove

and Install
1. Disconnect bucket from hitch.
2. Vertically align quick disconnect pins as shown.
TX1055554A —UN—09FEB09
Quick Disconnect Pins Vertical Alignment
Continued on next page MH66088,0000A59 -19-10FEB09-1/2
020921
PN=208
Attachment Coupler
3. Support quick disconnect hitch (1) on wood blocks (2)

as shown.
5. Engage park brake.

TX1055631A —UN—09FEB09
6. Attach lifting strap (3) to bucket link (4) as shown.
Attach appropriate lifting device to lifting strap and
support weight of quick disconnect hitch.
Specification
Quick Disconnect
Hitch—Weight
(approximate).................................................................................. 45 kg Pivot Pin Removal
100 lb.
7. Remove socket head screws (5) and remove pivot pin 1— Quick Disconnect Hitch 4— Bucket Link
2— Wood Block (2 used) 5— Socket Head Screw (2 used)
(6). 3— Lifting Strap 6— Pivot Pin
NOTE: Do not grease pivot pin before installing in bucket
link. Clean old grease from inside of bucket link.
11. Lubricate quick disconnect hitch pivot until grease
9. Install pivot pin to bucket link making sure equal length escapes around pins. See Grease. (Operator's
of pivot pin protrudes from each end of bucket link. Manual.)
10. Install socket head screws and tighten to specification. 12. Remove frame lock bar.
Specification 13. Connect bucket to hitch.
Pivot Pin Socket Head
Screw—Torque............................................................................125 N·m
92 lb-ft
MH66088,0000A59 -19-10FEB09-2/2
020921
PN=209
Attachment Coupler
Quik-Tatch™ Actuator Remove and Install

2. Disconnect Quik-Tatch™ connector (X501).
3. Remove cotter keys (2), pins (1), and Quik-Tatch™
actuator.
5. Install Quik-Tatch™ actuator, pins, and cotter keys.
6. Connect Quik-Tatch™ connector (X501).
TX1146641A —UN—31OCT13
1— Pin (2 used) X501— Quik-Tatch™
2— Cotter Key (2 used) Connector
Quik-Tatch™ Actuator
Quik-Tatch is a trademark of Deere & Company

BG71631,00007EE -19-04NOV13-1/1
Quik-Tatch™ Coupler Remove and Install

SPECIFICATIONS
Lower Bucket Link Weight 45 kg
Quik-Tatch Weight (approximate) 91 kg
TX1145182A —UN—18OCT13
200 lb.

2. Remove attachment. See Operating Attachment
Mounting System—Quik-Tatch™. (Operator’s
Manual.)
Front Attachment
3. Position Quik-Tatch™ coupler forward and lower onto
ground.
1— Lower Bucket Link 5— Shim (2 used)
2— Cap Screw (2 used) 6— Pin (2 used)
CAUTION: Prevent possible crushing injury from 3— Nut (2 used) 7— Upper Bucket Link
heavy component. Use appropriate lifting device. 4— Pin
4. Attach appropriate lifting device and support lower

bucket link (1).
5. Remove nuts (3), cap screws (2), pin (4), and shims (5).
Specification
Lower Bucket 6. Position lower bucket link against upper bucket link
Link—Weight (7) and secure.
(approximate).................................................................................. 45 kg
100 lb.
Continued on next page RK40399,000125B -19-16FEB15-1/3
020921
PN=210
Attachment Coupler
7. Disconnect Quik-Tatch™ connector (X501). See

Quik-Tatch™ Extension Harness (W16) Component
X501— Quik-Tatch™
TX1145193A —UN—14OCT13
Connector
Electrical Connector
RK40399,000125B -19-16FEB15-2/3

8. Attach appropriate lifting device to Quik-Tatch™.

Specification
Quik-Tatch™—Weight
(approximate).................................................................................. 91 kg
200 lb.
TX1145194A —UN—14OCT13
9. Remove cap screws (8), pins (6), and shims (9).
10. Remove Quik-Tatch™.
11. Inspect and replace parts as necessary.

heavy component. Use appropriate lifting device. Quick-Tatch™ Pin (right pin shown)
12. Using appropriate lifting device, install Quik-Tatch™.

6— Pin (2 used) 9— Shim (4 used)
Specification 8— Cap Screw (2 used)
Quik-Tatch™—Weight
(approximate).................................................................................. 91 kg
200 lb.
Specification
Lower Bucket
Link—Weight
13. Install shims (9), pins (6), and cap screws (8). (approximate).................................................................................. 45 kg
14. Connect Quik-Tatch™ connector (X501). See 100 lb.
Quik-Tatch™ Extension Harness (W16) Component 16. Install shims (5), pin (4), cap screws (2), and nuts (3).
17. Install attachment. See Operating Attachment
CAUTION: Prevent possible crushing injury from Mounting System—Quik-Tatch™. (Operator’s
heavy component. Use appropriate lifting device. Manual.)
15. Attach appropriate lifting device and install lower

bucket link.
RK40399,000125B -19-16FEB15-3/3
020921
PN=211
Attachment Coupler
020921
PN=212
Group 3140
Frames
Boom and Bucket Linkage Remove and Install
T204138 —UN—28OCT04
Boom and Bucket Linkage
1— Bucket Link 5— Washer (7 used) 8— Loader Boom 13— Bucket Adapter
2— Shim (4 used) 6— Cap Screw (7 used) 9— Pin (4 used)
3— Bell Crank 7— Shim (2 used) 10— Pin
4— Pin (2 used) 11— Pin
12— Shim (6 used)
1. Lower bucket to the ground.

Continued on next page DE88008,0000253 -19-13MAR09-1/2
020921
PN=213
Frames

X9811 —UN—23AUG88
2. Stop engine. Relieve pressure from hydraulic system

and ride control, if equipped. Perform Hydraulic
3. Disconnect or remove hydraulic lines as necessary. Boom —Weight
Close all openings with caps or plugs. (approximate)................................................................................ 516 kg
1138 lb.
Attach hoist to component before removing pins. 4. Disconnect or remove hydraulic cylinders as
Removing pins before supporting component necessary. Close all openings with caps or plugs.
could result in personal injury.
5. Remove parts as shown. Repair or replace as
Specification necessary.
Bucket Cylinder—Weight
(approximate)............................................................................... 35.5 kg 6. Apply PM37566 Silver-Grade Anti-Seize Lubricant or
78 lb. an equivalent to bore of bell crank pivot pin (10).
Boom Cylinder—Weight 7. Install parts as shown. Apply PM37509 Cure Primer,
(approximate)............................................................................... 36.8 kg then PM38654 Thread Lock and Sealer (high strength)
81 lb. to cap screws (6). Tighten cap screws to specification.
Bucket Adapter—Weight
(approximate).................................................................................. 44 kg Specification
97 lb. Boom and Bucket
Bell Crank—Weight Linkage Pin Cap
(approximate)................................................................................ 384 kg Screws—Torque..........................................................................275 N·m
847 lb. 200 lb-ft
Bucket Link—Weight
(approximate).................................................................................. 88 kg
194 lb.
DE88008,0000253 -19-13MAR09-2/2
020921
PN=214
Frames
Bucket Linkage Bushings Remove and Install
TX1054619 —UN—09FEB09
Bucket Link Assembly
1— Bushing (3 used) 3— Lubrication Fitting (3 used) 4— Bucket Link
2— Seal (2 used)
1. Remove bucket link (4). See Boom and Bucket

Linkage Remove and Install. (Group 3140.) 5. Install bushings using JT01800 Driver Set.
2. Remove seals (2). 6. Install seals.
3. Remove bushings (1) using D01047AA Puller Set. 7. Install bucket link. See Boom and Bucket Linkage
4. Apply anti-seize lubricant to outer surfaces of new
bushings and inner surfaces of bucket link bushing
bores.
DE88008,0000240 -19-06FEB09-1/1
020921
PN=215
Frames
Loader Boom Bushings Remove and Install
TX1054625 —UN—09FEB09
Loader Boom Assembly
1— Loader Boom 3— Lubrication Fitting (7 used) 4— Bushing (2 used)
2— Bushing (4 used) 5— Bushing
1. Remove loader boom (1). See Boom and Bucket 2. Replace bushings (2, 4 and 5) using D01047AA Puller
Linkage Remove and Install. (Group 3140.) Set and JT01800 Driver Set.
NOTE: Apply LOCTITE® Silver-Grade Anti-Seize 3. Install loader boom. See Boom and Bucket Linkage
Lubricant or an equivalent on outer surface of new Remove and Install. (Group 3140.)
bushings and inner surfaces of bores. Center
new bushings in boom bores.
LOCTITE is a trademark of Henkel Corporation
DE88008,0000241 -19-16FEB09-1/1
020921
PN=216
Group 3160
Hydraulic System
Loader Control Valve Remove and Install
Service Safely. (Group 0001.) Raise boom and install
boom articulation lock bar.
X9811 —UN—23AUG88
Tighten all connections before applying pressure. Escaping Fluid

system. Perform Hydraulic System Pressure and If draining hydraulic reservoir. See Change Hydraulic
Accumulators Discharge Procedure. (Group 2160.) Oil. (Operator's Manual.)
If equipped with ride control, make sure to follow 4. Remove loader control valve access panel.
instructions on releasing ride control system pressure.
3. Apply a vacuum to hydraulic reservoir or drain
hydraulic reservoir.
020921
PN=217
Hydraulic System
TX1057221 —UN—25MAR09
Loader Control Valve
1— Bucket Rollback Pilot Port 5— Boom Raise Work Port 9— Outlet Port 13— Bucket Dump Pilot Port
2— Boom Raise Pilot Port 6— Auxiliary Function Work Port 10— Auxiliary Function Work 14— Inlet Port
3— Bucket Rollback Relief Port 7— Bucket Dump Work Port Port
4— Auxiliary Function Pilot Port 8— Boom Lower Work Port 11— Auxiliary Function Pilot Port
12— Boom Lower Pilot Port
NOTE: Tag or mark hydraulic lines before disconnecting 10. If equipped with fourth function, connect hydraulic
to aid in installation. lines. See Loader Auxiliary Systems Component
5. Tag and disconnect all hydraulic lines. Close all
openings using caps and plugs. 11. Install control valve access panel.
6. If equipped with fourth function, tag and disconnect 12. Remove vacuum or fill hydraulic reservoir. See
hydraulic lines and close all openings using caps and Change Hydraulic Oil. (Operator's Manual.)
plugs.
13. If loader is equipped with ride control, the ride control
7. Remove mounting cap screws and loader control system accumulator bleed valve must be closed and
valve. plug installed.See Ride Control Valve Remove and
8. Repair or replace as necessary. See Loader Control
Valve Disassemble and Assemble. (Group 3160.)
9. Install loader control valve and connect all hydraulic
lines. See Loader System Component Location.
(Group 9025-10.)
PN50483,0002107 -19-23AUG16-2/2
020921
PN=218
Hydraulic System
Loader Control Valve Disassemble and

Assemble
9 11
1 12
10
2 5
3 18
7 13
6 14
15
4 16
30 8
17
21
20
25 22
29 19
XJ1238555 —UN—09MAY17
26
27
28
31 24
XJ1238555 23
Loader Control Valve
1— Load Holding Valve (3 used) 10— Cap Screw (4 used) 20— Boom Raise Circuit Relief 27— Spring Retainer
2— Plug 11— Boom Spool End Cap (2 Valve 28— Spring Retainer
3— O-Ring (7 used) used) 21— Bucket Rollback Circuit 29— Auxiliary Circuit Spool
4— Spring Retainer (2 used) 12— Spring Retainer Relief Valve 30— Loader System Relief Valve
5— Spring (2 used) 13— Spring 22— Plug 31— Bucket Dump Circuit Relief
6— Spring Retainer (2 used) 14— Spring Retainer 23— Boom Circuit Feeder Valve Valve
7— Spool Plug (2 used) 15— Spring (2 used) 24— Auxiliary Circuit Relief Valve
8— Auxiliary Spool End Cap (2 16— Spring Retainer 25— Bucket Circuit Spool
used) 17— Spacer 26— Boom Circuit Spool
9— Cap Screw (20 used) 18— Bucket Spool End Cap (2
used)
19— Auxiliary Circuit Relief Valve
NOTE: Clean loader control valve as necessary 3. Replace parts as necessary.

before disassembling.
4. Apply clean hydraulic oil to all internal parts and
1. Disassemble and assemble as shown. surfaces during assembly.
NOTE: Valve body is not serviceable. If valve body is NOTE: Auxiliary circuit is identical to fourth function
found worn or damaged, complete valve body circuit (if equipped).
must be replaced. Do not reuse O-rings.
2. Clean and inspect parts for wear or damage.

MH66088,0000A64 -19-09MAY17-1/1
020921
PN=219
Hydraulic System
Loader System and Circuit Relief Valves Disassemble and Assemble
1 2
1
15
3
15 2
14
3 4
14
4
13
5
5 12
13
12 11
11 10 6
9
TX1057258 —UN—17MAR09
TX1057259 —UN—17MAR09
10 6
9
8 7
8
7
System Relief Valve Circuit Relief Valve
1— Adjustment Screw 5— Pilot Poppet 9— Backup Ring 14— O-Ring

2— Lock Nut 6— Anticavitation Poppet 10— O-Ring 15— O-Ring
3— Pilot Poppet Spring 7— Orifice 11— O-Ring
4— Anticavitation Poppet Spring 8— Main Poppet 12— O-Ring
13— Backup Ring
NOTE: Count the number of turns needed to remove IMPORTANT: To prevent damage to machine,
adjustment screw to aid in assembly of valve. install adjustment screw the same number
of turns as removed.
1. Disassemble relief valve as shown.
NOTE: Only O-rings, seals, and backup rings are 3. Assemble relief valve.
serviceable. If any other parts are worn or 4. Perform Loader System Relief Valve Pressure Test
damaged, replace relief valve. or perform Loader Circuit Relief Valve Pressure Test
(Group 9025-25) to adjust relief valves to specification.
2. Clean and inspect parts for wear or damage. Apply
clean hydraulic oil to parts before assembly.
DE88008,0000294 -19-08APR09-1/1
020921
PN=220
Hydraulic System
Ride Control Valve Remove and Install

Service Safely. (Group 0001.) Raise boom and install
boom lock bar.
X9811 —UN—23AUG88
Tighten all connections before applying pressure. Escaping Fluid

system. Perform Hydraulic System Pressure and 3. Attach vacuum pump to reservoir to keep oil leakage
Accumulators Discharge Procedure. (Group 2160.) from open lines to a minimum.
PN50483,000210A -19-20JAN15-1/2
4. Remove plug (2) and turn manual pressure relieving

valve three complete turns to the left (CCW).
5. Hold union (3) and remove accumulator.
6. Mark and disconnect all hydraulic lines and electrical
TX1054631A —UN—16JAN09
connectors. Close all openings using caps or plugs to
prevent system contamination.
7. Remove mounting cap screws and ride control valve.
8. Repair or replace as necessary. See Ride Control
Valve Disassemble and Assemble. (Group 3160.)
9. Install ride control valve and connect all lines and
Ride Control Valve Ports
electrical connectors as marked. See Loader System
Component Location. (Group 9025-10.)
1— Ride Control Valve 4— Port T
10. Clean threads of union. 2— Plug 5— Port A
3— Union 6— Port B
NOTE: Accumulator is a non-serviceable item. If damage
is suspected, replace accumulator.
Specification
11. Apply PM37418 Thread Lock and Sealer (medium
Manual Pressure
strength) to threads of union and install accumulator.
Relieving
12. Turn manual pressure relieving valve three complete Valve—Torque..............................................................................3.5 N·m
turns to the right (CW) and tighten to specification. 31 lb.-in.
Install plug. Plug—Torque...................................................................................7 N·m
62 lb.-in.
PN50483,000210A -19-20JAN15-2/2
020921
PN=221
Hydraulic System
Ride Control Valve Disassemble and

Assemble
X9811 —UN—23AUG88
1. If repair of ride control valve is to be done while valve is

installed on machine, stop engine and relieve pressure
from hydraulic system. Perform Hydraulic System
Pressure and Accumulators Discharge Procedure. To remove ride control valve, see Ride Control Valve
(Group 2160.) Remove and Install. (Group 3160.)
DE88008,0000249 -19-19FEB16-1/2
CAUTION: Prevent injury, spool valve cap

is spring loaded. 4
3
2. Remove components (2—5) from valve block (1).
3. Clean and inspect components for wear or damage.
Replace as necessary.
2
4. Apply clean hydraulic oil to internal components before
installation.
5. Install components to specification.
Specification
Manual Pressure
TX1004085 —UN—23FEB06
Relieving
Valve—Torque..............................................................................3.5 N·m
31 lb-in.
Manual Pressure
Relieving Valve
Plug—Torque...................................................................................7 N·m
62 lb-in. 1 5
TX1004085
Spool Valve
Cap—Torque.................................................................................90 N·m
66 lb-ft 1— Valve Block 4— Solenoid Valve
Solenoid Valve—Torque................................................................15 N·m 2— Manual Pressure Relieving 5— Relief Valve
133 lb-in. Valve Plug
Relief Valve—Torque.....................................................................70 N·m 3— Spool Valve
52 lb-ft
DE88008,0000249 -19-19FEB16-2/2
020921
PN=222
Hydraulic System
Boom Cylinder Remove and Install

NOTE: Boom cylinder may be disassembled on the
machine for seal and packing replacement.
1. Install frame articulation lock bar.

NOTE: If both boom cylinders will be removed,
support boom with a hoist.
TX1054662A —UN—09FEB09
2. Raise boom and install boom lock (1) on cylinder that
is not being removed.
1— Boom Lock 4— Hydraulic Line

2— Pin 5— Pin
3— Hydraulic Line
Boom Cylinder
PN50483,0002104 -19-19JAN15-1/2

X9811 —UN—23AUG88
3. Stop engine. Relieve pressure from hydraulic system

and ride control, if equipped. Perform Hydraulic
Procedure. (Group 2160.) Escaping Fluid
If equipped with ride control, make sure to follow
instructions on releasing ride control system pressure.
7. Remove cylinder. Repair or replace as needed.
NOTE: Tag or mark hydraulic lines before disconnecting See Boom and Bucket Cylinders Disassemble and
to aid in installation. Assemble. (Group 3160.)
4. Tag and disconnect hydraulic lines (3 and 4). 8. Position cylinder on machine. Install pins and connect
hydraulic lines.
5. Close all openings using caps and plugs.
9. Remove frame articulation lock bar and perform loader
start-up procedure for steering cylinders. See Loader
CAUTION: Prevent possible crushing injury from Start-Up Procedure. (Group 3160.)
10. Fill hydraulic reservoir to proper level. See Check
6. Support cylinder with hoist and remove pins (2 and 5). Hydraulic Oil Level. (Operator's Manual.)
Specification
Boom Cylinder—Weight
(approximate).................................................................................. 37 kg
82 lb.
PN50483,0002104 -19-19JAN15-2/2
020921
PN=223
Hydraulic System
Bucket Cylinder Remove and Install

NOTE: Bucket cylinder may be disassembled on the
machine for seal and packing replacement.
1. Park machine on a level surface and lower boom and

bucket to the ground.
1— Bucket Leveler 4— Hydraulic Line

2— Hydraulic Line 5— Pin
T202412A —UN—01SEP04
3— Pin
Bucket Cylinder
PN50483,0002103 -19-19JAN15-1/2

X9811 —UN—23AUG88

NOTE: Measure length of exposed bucket leveler Escaping Fluid
rod before removing bucket leveler. Record
measurement and use for installation. 9. Repair or replace cylinder as needed. See Boom and
Bucket Cylinders Disassemble and Assemble. (Group
3. Remove bucket leveler (1). 3160.)
CAUTION: Prevent possible crushing injury from 10. Position cylinder on machine and install pins.
heavy component. Use appropriate lifting device. 11. Connect hydraulic lines.
4. Attach hoist to bucket cylinder, using lifting straps. 12. Install bucket leveler using recorded measurement
Specification
taken prior to removing leveler.
Bucket Cylinder—Weight 13. Perform loader start-up procedure for steering
(approximate).................................................................................. 35 kg cylinders. See Loader Start-Up Procedure. (Group
77 lb. 3160.)
5. Mark and disconnect hydraulic lines (2 and 4). 14. Fill hydraulic reservoir to proper level. See Check
6. Close open lines and fittings using caps and plugs. Hydraulic Oil Level. (Operator's Manual.)
7. Remove pins (3 and 5). 15. Perform Return-to-Dig Adjustment. (Group 9015-20.)
8. Remove cylinder.
PN50483,0002103 -19-19JAN15-2/2
020921
PN=224
Hydraulic System
Boom and Bucket Cylinders Disassemble ESSENTIAL TOOLS

and Assemble JDG347A Spanner Wrench
SPECIFICATIONS JDG1231 Pin Set
Boom Cylinder Weight 40 kg D05112ST Spanner Wrench

(approximate) 88 lb
OTHER MATERIAL
Bucket Cylinder Weight 35 kg
(approximate) 77 lb Loctite® 271™ Threadlocker (high strength)
350 N·m NEVER-SEEZ® Anti-Seize Lubricant
Piston Torque (244K)
258 lb·ft
450 N·m DISASSEMBLE
Piston Torque (324K)
332 lb·ft
80 N·m CAUTION: Prevent possible crushing injury from
Piston Lock Nut Torque (244K)
59 lb·ft heavy component. Use appropriate lifting device.
100 N·m
Piston Lock Nut Torque (324K) 1. Attach appropriate lifting device to boom or bucket
74 lb·ft
cylinder.
700 N·m
Piston Rod Bearing Torque (244K)
516 lb·ft Specification
800 N·m Boom Cylinder—Weight
Piston Rod Bearing Torque (324K)
590 lb·ft (approximate).................................................................................. 40 kg
88 lb
Bucket Cylinder—Weight
(approximate).................................................................................. 35 kg
77 lb
B 3 4
A 2
TX1267896 —UN—08NOV18
4
5 3
A B
TX1267896
Boom Cylinder
1— Cylinder Tube 3— Piston 5— Piston Lock Nut
2— Piston Rod 4— Piston Rod Bearing
2. Install cylinder into an appropriate cylinder service

stand with pin in head end.
Loctite and its related brand marks are trademarks of Henkel Corporation
NEVER-SEEZ is a trademark of Emhart Chemical Group
Continued on next page NK60711,00000C6 -19-02JUL20-1/3
020921
PN=225
Hydraulic System
6 11
D
C 8 9
7
TX1267897 —UN—08NOV18
9
10 8
C D
TX1267897
Bucket Cylinder
6— Cylinder Tube 8— Piston 10— Piston Lock Nut
7— Piston Rod 9— Piston Rod Bearing 11— Pivot Bushing
IMPORTANT: Prevent hydraulic system 4. Remove piston (3 or 8), piston rod (2 or 7), and piston
contamination. Absolute cleanliness is essential rod bearing from cylinder tube (1 or 6).
when working on hydraulic components. Clean
component and adjacent areas before starting 5. Loosen and remove piston lock nut (5 or 10) and
work. Close all openings using caps and plugs. piston from piston rod.
3. Loosen piston rod bearing (4 or 9) using JDG347A 6. Remove piston rod bearing from piston rod.
Spanner Wrench and JDG1231 Pin Set.
Continued on next page NK60711,00000C6 -19-02JUL20-2/3
020921
PN=226
Hydraulic System
7. Inspect cylinder tube and piston rod bearing for nicks

or burrs that can damage seals or O-rings. Remove
nicks or burrs with a fine crocus cloth.
IMPORTANT: Seals are not alike. When removing
seals, note location so new seals are installed in
the proper place and in the correct direction.
T6119AO —UN—19OCT88
8. Inspect seals on piston rod bearing and piston.
Replace seals using seal kit.
ASSEMBLE
Assemble components in reverse order of disassembly.
Removing Nicks and Burrs
• Apply multipurpose grease to tapered area (mating
surfaces) of piston and piston rod when assembling.
• Tighten piston to specification.
Specification
Piston—Torque (244K)................................................................350 N·m
258 lb·ft
Piston—Torque (324K)................................................................450 N·m
T116595 —UN—27JUL98
332 lb·ft
• Tighten piston lock nut to specification using D05112ST

Spanner Wrench.
Specification
Piston Lock Nut—Torque
(244K)............................................................................................80 N·m
Torque Wrench
59 lb·ft
Piston Lock Nut—Torque
(324K)..........................................................................................100 N·m A—Length of Torque Wrench C—Torque Wrench Setting
74 lb·ft B—Length of Extension D—Torque Applied to Rod
Guide
• Apply Loctite® 271™ Threadlocker (high strength) to
piston rod bearing threads.
- Torque wrench setting (C)
NOTE: Before total length of measurement (A + - Torque applied to rod guide (D)
B) can be determined, the center line of the
extension must run along the center line of • Tighten piston rod bearing to specification using
the torque wrench. When using an extension JDG347A Spanner Wrench and JDG1231 Pin Set.
of any kind on a torque wrench, the torque Specification
wrench setting must be adjusted to compensate Piston Rod
for the length of the extension. Bearing—Torque (244K)..............................................................700 N·m
516 lb·ft
• Use the formula shown to calculate the correct torque Piston Rod
wrench setting (C): Bearing—Torque (324K)..............................................................800 N·m
- Length of torque wrench (A) (measured from center of 590 lb·ft
the drive to center of the grip)
- Length of extension (B) (measured along the center • Inspect pivot bushing (11) and replace if needed.For
line of the torque wrench; from the center of the drive initial lubrication, apply NEVER-SEEZ® Anti-Seize
to the center of the rod guide) Lubricant to bushing.
Loctite and its related brand marks are trademarks of Henkel Corporation
NEVER-SEEZ is a trademark of Emhart Chemical Group
NK60711,00000C6 -19-02JUL20-3/3
020921
PN=227
Hydraulic System
Boom and Bucket Cylinder Bushings

Remove and Install
1. Remove bushing (A).
2. Install and center new bushing in bore.
T132337B —UN—12JUL00
3. For initial lubrication, apply silver-grade anti-seize
lubricant or an equivalent to bushing.
A—Bushing
DE88008,000024D -19-06FEB09-1/1
Loader Start-Up Procedure 6. Slowly lower boom to ground.

IMPORTANT: Remove air from cylinders to prevent 7. Repeat steps (5 and 6) three times.
internal seal and premature component
damage. This procedure must be performed 8. Bucket cylinder: Position boom half way between
whenever boom, bucket or steering ground and full height. Roll bucket within 0.6 m (2 ft.)
cylinders are purged of oil. of full roll back position.
The following procedure is recommended 9. Position bucket within 0.3 m (1 ft.) of full dump.
to purge all air from system.
10. Repeat steps (8 and 9) five times.
1. Prefill cylinder before connecting hydraulic lines. 11. Position bucket to full rollback position.
IMPORTANT: “Dieseling” of oil inside cylinder can 12. Position bucket to full dump.
occur causing seal damage if cylinders are
cycled too fast. Perform procedure with engine 13. Repeat steps (11 and 12) three times.
at slow idle (no acceleration) and cycle cylinders
slowly to purge air from components. 14. Steering cylinders: Slowly articulate machine to the
right until loader frame is 50—75 mm (2—3 in.) from
2. Boom cylinder: Raise boom until within 0.6—1.0 m stops. Repeat procedure 4 times.
(2—4 ft.) of full height. 15. Slowly articulate machine to the left until loader frame
3. Slowly lower boom until bucket is 0.6—1.0 m (2—4 is 50—75 mm (2—3 in.) from stops. Repeat procedure
ft.) from ground and stop. 4 times.
4. Repeat steps (2 and 3) five times. 16. Slowly articulate machine fully to the right stop then
fully to the left stop. Repeat this step four times.
5. Slowly raise boom to full height.
DI77374,0000D70 -19-14MAY12-1/1
020921
PN=228
Hydraulic System
Pilot Control Valve Remove and Install

X9811 —UN—23AUG88

system. Perform Hydraulic System Pressure and 3. Attach vacuum pump to reservoir to keep oil leakage
Accumulators Discharge Procedure. (Group 2160.) from open lines to a minimum.
CS33148,0002C3C -19-27JAN09-1/3
4. Remove pilot control valve boot and console.
1— Pilot Control Lever 4— Pilot Control Valve Support

2— Quick Disconnect/Auxiliary 5— Pilot Control Valve/Quick
Pilot Control Lever Disconnect/Auxiliary Pilot
3— Cap Screw (4 used) Control Valve
6— Electrical Connector (2
used)
TX1052941A —UN—17DEC08
Pilot Control
Continued on next page CS33148,0002C3C -19-27JAN09-2/3
020921
PN=229
Hydraulic System
NOTE: Tag or mark hydraulic lines before disconnecting

to aid in installation.
5. Tag and disconnect lines (7—14) and electrical

connectors (6).
6. Remove cap screws (3).
7. Remove pilot control valve/quick disconnect/auxiliary
TX1052944A —UN—17DEC08
pilot control valve (5).
8. Repair or replace control valve as needed.
9. Install control valve and connect hydraulic lines.
10. Connect electrical connectors.
11. Install loader control valve console and boot.
Pilot Control Hydraulic Lines
7— Pilot Control Valve Port 11— Pilot Control Valve Port
5-to-Loader Control Valve P-to-Pilot Enable Solenoid 10
Port b3 Line Port A Line 7 8 9
8— Pilot Control Valve Port 12— Pilot Control Valve Port
T-to-Reservoir Line 4-to-Loader Control Valve
9— Pilot Control Valve Port Port b2 Line 11
2-to-Loader Control Valve 13— Pilot Control Valve Port
Port a2 Line 3-to-Loader Control Valve
10— Pilot Control Valve Port Port b1 Line
1-to-Loader Control Valve 14— Pilot Control Valve Port
Port a1 Line 6-to-Loader Control Valve 12
Port a3 Line
TX1052942 —UN—17DEC08
14 13
Pilot Control Valve Ports
CS33148,0002C3C -19-27JAN09-3/3
020921
PN=230
Hydraulic System
Pilot Control Valve Disassemble and Assemble

8 31
7
30 32
6
29 33
5
10
4 28 34
11
9 35
3 12 27
15 36
2 13
14 26
1
16
17 25 24
18 23
19
22
TX1057892 —UN—07APR09
21
20
TX1057892
Pilot Control Valve Exploded View
1— Socket Head Cap Screw 13— Push Rod (4 used) 21— Bucket Rollback Spool Bore 30— Detent Plunger (2 used)
2— Rocker 14— Snap Ring (4 used) 22— Boom Raise Spool Bore 31— Snap Ring (2 used)
3— Shim (as needed) 15— Spring Retainer (6 used) 23— Spring (2 used) 32— Nut
4— Two-Way Rocker Plate 16— Spool (6 used) 24— Spring Retainer (2 used) 33— Washer
5— Nut 17— Spring Retaining Washer (12 25— Bucket Dump Spool Bore 34— Four-Way Rocker Plate
6— Pin used) 26— Detent Coil (2 used) 35— Shim (as needed)
7— Lever 18— Spring Assembly (6 used) 27— Detent Rod (2 used) 36— U-Joint Shaft
8— Socket Head Rocker Pin 19— Auxiliary Spool Bore (2 28— Detent Coil Retainer Plate
9— Washer (3 used) used) 29— Washer and Detent Coil
10— Push Rod Guide O-Ring (4 20— Boom Down Spool Bore Alignment Pin (5 used)
used)
11— Push Rod Guide (4 used)
12— Push Rod Guide Internal
Seal (4 used)
Continued on next page MH66088,0000A65 -19-09APR09-1/8
020921
PN=231
Hydraulic System
1. Remove socket head rocker pin (8). Remove parts

(2—7) as an assembly.
2— Rocker 8— Socket Head Rocker Pin

3— Shim (as needed) 32— Nut
4— Two-Way Rocker Plate 33— Washer
5— Nut 34— Four-Way Rocker Plate
TX1058022A —UN—08APR09
6— Pin 35— Shim (as needed)
7— Lever
Two-Way and Four-Way Rocker Plate Removal
MH66088,0000A65 -19-09APR09-2/8
3. Remove socket head cap screw (1).

4. Remove U-joint shaft (36).
NOTE: Remove detent rods (27) and detent plungers
(30) as an assembly.
TX1058035A —UN—08APR09
5. Remove parts (27 and 30) as an assembly.
NOTE: Note location of washers (9) under detent coil
retainer plate to aid in assembly.
6. Remove detent coil retainer plate (28). Note location

of washers (9) under retainer plate to aid in assembly.
Detent Coil Retainer Plate Removal
1— Socket Head Cap Screw 30— Detent Plunger (2 used)
27— Detent Rod (2 used) 36— U-Joint Shaft
28— Detent Coil Retainer Plate
MH66088,0000A65 -19-09APR09-3/8
7. Remove push rod guides (11) and push rods (13).

Remove detent coils (26).
11— Push Rod Guide (4 used) 26— Detent Coil (2 used)

13— Push rod (4 used)
TX1058038A —UN—08APR09
Detent Coil Removal
020921
PN=232
Hydraulic System
8. Disassemble and assemble push rod guides (11)

and push rods (14) as shown. Clean and inspect all
parts, replace as necessary. Install new push rod
guide O-ring (10) and internal seal (12). Apply clean
hydraulic oil to all parts before assembly.
TX1058043A —UN—08APR09
10— Push Rod Guide O-Ring (4 13— Push Rod (4 used)
used) 14— Snap Ring (4 used)
11— Push Rod Guide (4 used)
12— Push Rod Guide Internal
Seal (4 used)
Push Rod and Guide
MH66088,0000A65 -19-09APR09-5/8
IMPORTANT: Avoid damage to spools or spool ports.

Spools must be installed into the same spool
bores as removed. Mark spool locations before
removing spools to aid in assembly.
TX1058045A —UN—08APR09
9. Mark spool locations before removing spools to aid in
assembly. Remove spools as needed.
19— Auxiliary Spool Bore (2 22— Boom Raise Spool Bore

used) 25— Bucket Dump Spool Bore
20— Boom Down Spool Bore
21— Bucket Rollback Spool
Bore
Spool Bores
MH66088,0000A65 -19-09APR09-6/8
10. Disassemble and assemble spools as shown. Clean

and inspect all parts. Replace parts as necessary.
Apply clean hydraulic oil to all parts before assembly.
15— Spring Retainer 17— Spring Retaining Washers
TX1058051A —UN—08APR09
16— Spool 18— Spring Assembly
Auxiliary, Boom Raise, and Bucket Dump Spools
020921
PN=233
Hydraulic System
11. Disassemble and assemble spools as shown. Clean

and inspect all parts. Replace parts as necessary.
Apply clean hydraulic oil to all parts before assembly.
IMPORTANT: Avoid damage to spools or spool ports.
Spools must be installed into the same spool
TX1058054A —UN—08APR09
bores as removed. Spools must align properly
with spool ports in bottom of spool bores.
12. Apply clean hydraulic oil to spool assemblies and

install into the same spool bores as removed. Push
down on the top of each spool assembly. Make sure
spool moves freely into and out of spool port at the
bottom of spool bore. Boom Down and Bucket Rollback Spools
13. Apply clean hydraulic oil to push rods (13) and push
rod guide O-rings (10). Install push rods and push rod 15— Spring retainer 18— Spring Assembly
guides into top of spool bores. 16— Spool 23— Spring
17— Spring Retaining Washers 24— Spring Retainer
14. Install new O-rings to detent coils, apply clean
hydraulic oil to O-rings, and install coils.
IMPORTANT: Avoid damage to detent coil retainer 17. Apply PM37421 Thread Lock and Sealer
plate and detent coils. Alignment pins on detent (high-strength) to threads on U-joint shaft (36). Install
coil retainer plate must align correctly with and tighten securely.
notches on washers and detent coils. 18. Install detent plungers (30) and detent rods (27).
15. Install washers (9) in same location as removed. 19. Apply multi-purpose grease to U-joint, top of push rods
Make sure alignment pins (29) on detent coil retainer (13), and top of detent rods (27).
plate (28) align with notches on washers and detent
20. Install parts (32—35).
coils (26).
21. Install parts (2—7) as an assembly. Install socket
16. Apply PM37421 Thread Lock and Sealer
head rocker pin (8) and tighten securely.
(high-strength) to threads on socket head cap screw
(1). Install and tighten securely.
MH66088,0000A65 -19-09APR09-8/8
020921
PN=234
Hydraulic System
Pilot Enable Solenoid Valve Remove and

Install
NOTE: Solenoid valve can be removed without removing
valve block from machine.
X9811 —UN—23AUG88
2. Stop engine, then turn key to ON position.

or connecting hydraulic or other lines. 4. Hold loader control lever bucket rollback partially
Never attempt to relieve hydraulic system or engaged in boom raise function. Push and release
accumulator pressure by loosening a fitting. pilot enable/boom down switch. A kickback should be
Tighten all connections before applying pressure. felt in control lever. Hold lever to partial engagement
in each function and repeat push and release pilot
3. Stop engine and relieve pressure from hydraulic enable/boom down switch procedure until no kickback
system. Perform Hydraulic System Pressure and is felt.
Accumulators Discharge Procedure. (Group 2160.) 5. Apply a vacuum to reservoir to minimize oil leakage
NOTE: This procedure will take approximately 20 while removing pilot enable solenoid valve.
applications to bleed pilot accumulator circuit.
DE88008,000021A -19-05MAR09-1/2
6. Mark and disconnect hydraulic lines and electrical

connector.
7. Close lines and fittings using caps and plugs.
8. Remove pilot enable solenoid valve (1). Repair or
replace as needed.
9. If removed, install solenoid valve. Make sure backup
rings and O-rings are in place and lightly lubricated
with clean hydraulic oil. Tighten solenoid valve to
specification.
Specification
Pilot Enable Solenoid
Valve—Torque...............................................................................70 N·m
52 lb-ft
10. Install pilot enable solenoid valve.

11. Connect hydraulic lines and electrical connector.
TX1055068A —UN—28JAN09
1— Pilot Enable Solenoid Valve 2— Pilot Accumulator
Pilot Enable Solenoid Location
DE88008,000021A -19-05MAR09-2/2
020921
PN=235
Hydraulic System
Pilot Accumulator Remove and Install

X9811 —UN—23AUG88

DE88008,0000242 -19-13MAR09-1/2
3. Hold fitting (1) so adapter does not move and remove

accumulator (2).
4. Clean threads of adapter fitting (1).
NOTE: Accumulator is a non-serviceable item. If failure
is suspected, replace accumulator.
5. Apply PM37418 Thread Lock and Sealer (medium

strength) to threads of adapter fitting and install
T202605A —UN—14SEP04
accumulator.
1— Adapter Fitting 2— Accumulator
View From Behind Rear Axle
DE88008,0000242 -19-13MAR09-2/2
020921
PN=236
Section 99
Dealer Fabricated Tools
Contents
Page
Group 9900—Dealer Fabricated Tools

DFT1214 Hydrostatic Pump Servo
Piston Snap Ring Removal and
Installation Tool...................................... 99-9900-1
DFT1254 Differential Bevel Gear
Holding Tool........................................... 99-9900-2
DFT1255 Differential Bevel Gear
Pin Installation Tool................................ 99-9900-3
020921
PN=1
Contents
020921
PN=2
Group 9900
DFT1214 Hydrostatic Pump Servo Piston
Snap Ring Removal and Installation Tool
Use to remove and install snap ring and split lock rings on
the hydrostatic pump servo piston.
Material Required:
Pipe—1-5/8 in. OD
T134079B —UN—29SEP00
Cut pipe to the following approximate dimensions:
• OD—41mm (1.625 in.)
• Length—50 mm (2.0 in.)
• Slot Width—25 mm (1.0 in.)
OUO1020,0001050 -19-26SEP00-1/1
020921
PN=239
DFT1254 Differential Bevel Gear Holding Tool
1 1
2 3
2
4
5
6
7
9
7
TX1072771 —UN—05MAR10
TX1072771
DFT1254
Continued on next page OUO1017,0000B54 -19-30OCT15-1/2
020921
PN=240
1— 90° Typ. 3— Steel Pipe Coupling (1.0 in. 5— Steel Close Nipple (1.0 in. 8— 53.97 mm (2.12in.)
2— 4.78 mm (1.87 in.) Dia. Thru NPT) NPT) 9— Assemble As Shown
Hole (4 Places) 4— 25.4 mm (1.00 in.) 6— Part-A
7— Part-B
Used to hold differential bevel gears when removing bevel

gear pins.
• Cut steel pipe coupling to 25.4 mm (1.00 in.) in length
• Drill four 4.78 mm (1.87 in.) diameter holes in close
Material Required: nipple and pipe coupling 90° apart.
• A maximum overall length of 53.97 mm (2.12 in.) when
Steel Close Nipple 1.0 in. NPT close nipple is threaded into pipe coupling.
Steel Pipe Coupling 1.0 in. NPT
OUO1017,0000B54 -19-30OCT15-2/2
DFT1255 Differential Bevel Gear Pin

Installation Tool
Used to install bevel gear pin with snap ring into differential
housing
Material Required:
20 mm 6 point socket
• Grind approximately a 15° taper inside of socket
opposite the drive end.
• Cut drive end off of socket so socket is approximately
19 mm (0.75 in.) long
1— 19 mm (0.75 in.) 3— Remove Drive End

2— 15° Taper 4— 20 mm Socket (6-Point)
TX1072773 —UN—05MAR10
DFT1255
OUO1017,0000B55 -19-30OCT15-1/1
020921
PN=241
020921
PN=242
Index
Page
Page
A
Brake
Accumulator Drum bleed .................................................... 10-1060-4
Pilot, remove and install............................... 31-3160-20 Drum, remove and install ............................... 10-1011-1
Pressure discharge procedure....................... 21-2160-4 Service (wet disk), remove and install ........... 10-1011-2
Actuator Brake valve
Quik-Tatch™, remove and install ................... 31-3104-6 Disassemble and assemble ........................... 10-1060-3
Air conditioner Remove and install ........................................ 10-1060-1
Air conditioner/heater module, remove Bucket
and install ................................................... 18-1830-10 Bolt-on cutting edge, remove and
Binary pressure switch, remove and install ............................................................ 31-3102-2
install .......................................................... 18-1830-14 Cutting edge crack, repair.............................. 31-3102-2
Blower motor, remove and install................. 18-1830-15 Linkage, remove and install ........................... 31-3140-1
Compressor, remove and install .................... 18-1830-8 Welded-on cutting edge, remove and
Condenser, remove and install ...................... 18-1830-9 install ............................................................ 31-3102-1
Evaporator, remove and install .................... 18-1830-12 Bucket cylinder
Expansion valve, remove and install............ 18-1830-13 Disassemble and assemble ........................... 31-3160-9
Freeze control switch, remove and Remove and install ........................................ 31-3160-8
install .......................................................... 18-1830-14 Bucket linkage
Receiver-dryer, remove and install ................ 18-1830-9 Bushings, remove and install ......................... 31-3140-3
Air conditioner binary pressure switch Bushings
Remove and install ...................................... 18-1830-14 Bucket linkage, remove and install ................ 31-3140-3
Air conditioner system Loader boom, remove and install................... 31-3140-4
Flush and purge ............................................. 18-1830-5 Bushings and seals
Air conditioning Boom and bucket cylinder, remove and
Charge ........................................................... 18-1830-7 install .......................................................... 31-3160-12
R134a refrigerant oil information.................... 18-1830-2
Refrigerant cautions and proper C
handling........................................................ 18-1830-1
Alternator belt Cab
Remove and install ........................................ 04-0400-1 Remove and install ........................................ 18-1800-1
Attachments Charge pump
Adding safely ............................................... 00-0001-13 Remove and install ........................................ 03-0300-1
Operating safely........................................... 00-0001-13 Chassis control unit (CCU)
Avoid static electricity risk when fueling ............ 00-0001-6 Remove and install ........................................ 16-1600-2
Axle Cleanup procedure
Front, remove and install ............................... 02-0200-1 Hydraulic component failure .......................... 21-2160-3
Rear, remove and install ................................ 02-0200-3 Condenser
Axle front and rear Remove and install ........................................ 18-1830-9
Disassemble and Assemble........................... 02-0250-1 Connector repair
Axle shaft, bearings and rear reduction gears CINCH.......................................................... 16-1600-14
Disassemble and assemble ........................... 02-0250-1 CINCH, 32 and 48 way ................................ 16-1600-16
Axle shaft, bearings, and rear axle reduction CINCH, contact ............................................ 16-1600-15
gears DEUTSCH, circular ........................................ 16-1600-9
Repair ............................................................ 02-0250-1 DEUTSCH, contact ...................................... 16-1600-11
DEUTSCH, rectangular or triangular ........... 16-1600-10
B ECU ............................................................. 16-1600-16
FLC .............................................................. 16-1600-16
Backover Accidents ......................................... 00-0001-11 Metri-Pack...................................................... 16-1600-8
Blower motor Metri-Pack, push type .................................... 16-1600-7
Remove and install ...................................... 18-1830-15 WEATHER PACK, connector....................... 16-1600-12
Boom WEATHER PACK, contact ........................... 16-1600-13
Linkage, remove and install ........................... 31-3140-1 Cooling fan and cooling fan motor
Boom cylinder Remove and install ........................................ 05-0510-3
Disassemble and assemble ........................... 31-3160-9 Counterweights
Loader start-up procedure ........................... 31-3160-12 Remove and install ........................................ 17-1749-1
Remove and install ........................................ 31-3160-7 Coupler
Quik-Tatch™, remove and install ................... 31-3104-6
Continued on next page
TM13279X19 (09FEB21) Index-1 244K, 244K-II, and 324K Compact

4WD Loader
020921
PN=1
Index
Page Page
Cutting edge Expansion valve

Bolt-on, remove and install ............................ 31-3102-2 Remove and install ...................................... 18-1830-13
Crack repair ................................................... 31-3102-2
Welded-on, remove and install ...................... 31-3102-1 F
Cylinder
Boom and bucket bushings, remove and Fan and fan motor
install .......................................................... 31-3160-12 Remove and install ........................................ 05-0510-3
Boom, disassemble and assemble ................ 31-3160-9 Fan belt
Boom, remove and install .............................. 31-3160-7 Remove and install ........................................ 04-0400-1
Bucket, disassemble and assemble............... 31-3160-9 Fan motor
Bucket, remove and install............................. 31-3160-8 Disassemble and assemble ........................... 05-0510-5
Steering, disassemble and assemble .......... 09-0960-13 Fan pump
Steering, remove and install ........................ 09-0960-11 Disassemble and assemble ........................... 05-0510-2
Cylinder, boom Remove and install ........................................ 05-0510-1
Loader start-up procedure ........................... 31-3160-12 Fender
Rear, remove and install ................................ 19-1913-1
D Filter
Diesel particulate filter (DPF), remove and
Dampener drive install ............................................................ 05-0530-1
Remove and install ........................................ 07-0700-1 Fire prevention................................................... 00-0001-5
DFT1214 servo piston snap ring Frame
Removal and installation tool ......................... 99-9900-1 Separation...................................................... 17-1740-2
DFT1254 Differential Bevel Gear Freeze Control Switch
Holding tool .................................................... 99-9900-2 Remove and install ...................................... 18-1830-14
DFT1254 Differential Bevel Gear Pin Front axle
Installation tool ............................................... 99-9900-3 Disassemble and assemble ........................... 02-0250-1
Diesel particulate filter (DPF) Remove and install ........................................ 02-0200-1
Remove and install ........................................ 05-0530-1 Fuel tank
Differential lock Remove and install ........................................ 05-0560-1
Solenoid valve, remove and install .................11-1160-1
Directional control valve G
Disassemble and assemble ........................... 03-0360-1
Remove and install ........................................ 03-0300-1 Ground speed sensor adjustment ..................... 16-1600-3
Disassemble and assemble
Brake valve .................................................... 10-1060-3 H
Display monitor
Remove and install ........................................ 16-1600-1 Heater
Drive shaft Blower motor, remove and install................. 18-1830-15
Remove and install ........................................ 02-0225-1 Control valve, remove and install................. 18-1830-13
Drum brake Core, remove and install .............................. 18-1830-12
Bleed.............................................................. 10-1060-4 Heater and air conditioner module
Remove and install ........................................ 10-1011-1 Remove and install ...................................... 18-1830-10
High flow pump
E Remove and install ........................................ 05-0510-1
Hitch
Electrical connectors Quick disconnect, disassemble and
Remove connector body from blade assemble...................................................... 31-3104-1
terminals..................................................... 16-1600-18 Hood
Engine Remove and install ........................................ 19-1910-1
Remove and install ........................................ 04-0400-2 HVAC
Engine control unit (ECU) Charge ........................................................... 18-1830-7
Remove and install ........................................ 16-1600-2 Hydraulic
Evaporator coil Component failure cleanup
Remove and install ...................................... 18-1830-12 procedure ..................................................... 21-2160-3
Exhaust filter...................................................... 00-0001-7 General oil cleanup procedure....................... 21-2160-1
Exhaust Filter, Safety System pressure and accumulator
Safety, Exhaust Filter ................................... 00-0001-17 discharge procedure .................................... 21-2160-4

4WD Loader
020921
PN=2
Index
Page Page
Hydraulic fan motor Loader control valve

Disassemble and assemble ........................... 05-0510-5 Disassemble and assemble ........................... 31-3160-3
Hydraulic fan pump Remove and install ........................................ 31-3160-1
Disassemble and assemble ........................... 05-0510-2 Loader system relief valve
Remove and install ........................................ 05-0510-1 Disassemble and assemble ........................... 31-3160-4
Hydraulic fitting
Non-restricted banjo (adjustable)................... 00-0003-5 M
O-ring boss with shoulder .............................. 00-0003-6
Hydraulic oil cooler Machine
Remove and install ........................................ 05-0510-6 Welding .......................................................... 17-1740-1
Hydraulic pump Machine modifications
Disassemble and assemble ........................... 21-2160-7 Avoid .............................................................. 00-0001-2
Remove and install ........................................ 21-2160-5 Machine separation ........................................... 17-1740-2
Hydraulic reservoir Machine,inspect................................................. 00-0001-3
Remove and Install ...................................... 21-2160-10 Manual
Hydrostatic Identification............................................................... --3
Pump valves, remove and install ................... 03-0300-1 Metric bolt and cap screw
Pump, component identification..................... 03-0300-1 Torque value .................................................. 00-0003-1
Hydrostatic motor Monitor
Assemble ....................................................... 03-0360-8 Remove and install ........................................ 16-1600-1
Control valve O-rings and seals..................... 03-0360-1 Motor
Disassemble .................................................. 03-0360-4 Hydrostatic flushing valve O-rings, remove
Flushing valve O-rings and seals................... 03-0360-2 and install ..................................................... 03-0360-2
Remove and install ........................................ 03-0300-3 Hydrostatic servo piston seals, remove
Rotating group, inspect and and install ..................................................... 03-0360-2
recondition.................................................... 03-0360-5 Hydrostatic, assemble.................................... 03-0360-8
Servo piston seals, remove and Hydrostatic, control valve O-rings and
install ............................................................ 03-0360-2 seals............................................................. 03-0360-1
Hydrostatic pump Hydrostatic, disassemble ............................... 03-0360-4
Assemble ....................................................... 03-0360-1 Hydrostatic, remove and install...................... 03-0300-3
Disassemble .................................................. 03-0360-1 Hydrostatic, rotating group inspect and
Remove and install ........................................ 03-0300-2 recondition.................................................... 03-0360-5
Hydrostatic transmission
Start-up procedure ......................................... 03-0300-5 O
I O-ring seal, metric 24
Service recommendation ............................... 00-0003-4
Identification Oil cleanup
Manual ....................................................................... --3 Hydraulic, general procedure......................... 21-2160-1
Inch bolt and cap screw Oil information
Torque value .................................................. 00-0003-3 R134a refrigerant ........................................... 18-1830-2
Inch series four bolt flange fitting Operation qualification....................................... 00-0001-1
Service recommendation, torque value for Orbital steering
high pressure ............................................. 00-0003-10 Valve, assemble............................................. 09-0960-5
Inching valve Valve, disassemble and inspect..................... 09-0960-2
Remove and install ........................................ 03-0300-5 Valve, remove and install ............................... 09-0960-1
Inching/brake valve Orbital valve
Remove and install ........................................ 10-1060-1 Steering, assemble ........................................ 09-0960-5
Steering, disassemble and inspect ................ 09-0960-2
L Steering, remove and install .......................... 09-0960-1
Linkage P
Boom and bucket, remove and install............ 31-3140-1
Loader Park brake
Boom bushings, remove and install ............... 31-3140-4 Disassemble and assemble ............................11-1160-1
Loader circuit relief valve Solenoid valve, remove and install .................11-1160-1
Disassemble and assemble ........................... 31-3160-4

4WD Loader
020921
PN=3
Index
Page Page
Parts, moving Recovery/charging station

Stay clear ....................................................... 00-0001-3 Installation procedure..................................... 18-1830-3
Pilot accumulator Refrigerant cautions and proper handling
Remove and install ...................................... 31-3160-20 Air conditioning .............................................. 18-1830-1
Pilot control valve Refrigerant oil information
Disassemble and assemble ......................... 31-3160-15 R134a ............................................................ 18-1830-2
Remove and install ...................................... 31-3160-13 Refueling, avoid static electricity risk................. 00-0001-6
Pilot enable solenoid valve Repair wire assembly (RWA),
Remove and install ...................................... 31-3160-19 installation........................................................ 16-1600-3
Pins, metal Reservoir
Drive safely .................................................. 00-0001-15 Hydraulic, remove and install....................... 21-2160-10
Pivot bearing Ride control valve
Lower, remove and install .............................. 17-1740-9 Disassemble and assemble ........................... 31-3160-6
Upper, remove and install .............................. 17-1740-8 Remove and install ........................................ 31-3160-5
Pivot pin Roads
Remove and install ........................................ 31-3104-4 Operating or traveling .................................. 00-0001-13
Priority valve ROPS
Disassemble and assemble ........................... 21-2160-7 Inspect ......................................................... 00-0001-13
Remove and install ........................................ 21-2160-5 Maintain ....................................................... 00-0001-13
Pump
High flow S
Remove and install..................................... 05-0510-1
Hydrostatic, assemble.................................... 03-0360-1 Safety
Hydrostatic, component identification ............ 03-0300-1 Add cab guarding for special
Hydrostatic, disassemble ............................... 03-0360-1 uses............................................00-0001-1, 00-0001-2
Hydrostatic, remove and install...................... 03-0300-2 Clean debris from machine ............................ 00-0001-6
Operator's seat .............................................. 00-0001-8
Q Protective equipment ..................................... 00-0001-2
Safety hazards
Quick disconnect Travel ........................................................... 00-0001-13
Hitch pivot pin Safety, Avoid High-Pressure Fluids
Remove and install..................................... 31-3104-4 Avoid High-Pressure Fluids ........................... 00-0001-4
Hitch, disassemble and assemble ................. 31-3104-1 Safety, information
Quik-Tatch™ actuator Recognize ...................................................... 00-0001-1
Remove and install ........................................ 31-3104-6 Serpentine belt
Quik-Tatch™ coupler Remove and install ........................................ 04-0400-1
Remove and install ........................................ 31-3104-6 Service brakes
Wet disk, remove and install .......................... 10-1011-2
R Service recommendation
Inch series four bolt flange fitting for high
R134a refrigerant pressure ..................................................... 00-0003-10
Recover.......................................................... 18-1830-4 O-ring seal, metric 24..................................... 00-0003-4
R134a system Shoes
Charge ........................................................... 18-1830-7 Drum brake, remove and install ..................... 10-1011-1
Evacuate ........................................................ 18-1830-6 Solenoid valve
Radiator Pilot enable, remove and install ................... 31-3160-19
Remove and install ........................................ 05-0510-6 Speed sensor
Rear axle Ground, adjustment ....................................... 16-1600-3
Disassemble and assemble ........................... 02-0250-1 Start-up procedure
Remove and install ........................................ 02-0200-3 Hydrostatic system......................................... 03-0300-5
Rear fender Steering
Remove and install ........................................ 19-1913-1 Column, remove and install ........................... 09-0960-9
Receiver-dryer Cylinder, disassemble and assemble........... 09-0960-13
Remove and install ........................................ 18-1830-9 Cylinder, remove and install......................... 09-0960-11
Recognize Steps
Safety, information ......................................... 00-0001-1 Use correctly
Handholds .................................................. 00-0001-8

4WD Loader
020921
PN=4
Index
Page Page
System Hydrostatic pump component

Pressure and accumulators discharge identification ................................................. 03-0300-1
procedure ..................................................... 21-2160-4 Hydrostatic pump, assemble.......................... 03-0360-1
Hydrostatic pump, disassemble ..................... 03-0360-1
T Hydrostatic pump, remove and install............ 03-0300-2
Traveling
Tire On public roads............................................ 00-0001-13
Remove and install ........................................ 01-0110-1
Torque value V
Inch SAE four bolt flange fitting...................... 00-0003-9
Inch series four bolt flange fitting for high Valve
pressure ..................................................... 00-0003-10 Brake, remove and install .............................. 10-1060-1
Metric bolt and cap screw .............................. 00-0003-1 Inching, remove and install ............................ 03-0300-5
Metric cap screw ............................................ 00-0003-2 Loader circuit relief, disassemble and
Metric four bolt flange fitting........................... 00-0003-8 assemble...................................................... 31-3160-4
Non-restricted banjo fittings ........................... 00-0003-5 Loader control, disassemble and
O-ring boss fittings with shoulder................... 00-0003-6 assemble...................................................... 31-3160-3
O-ring seal, metric 24..................................... 00-0003-4 Loader control, remove and install................. 31-3160-1
Unified inch bolt and cap screw ..................... 00-0003-3 Loader system relief, disassemble and
Transmission assemble...................................................... 31-3160-4
Directional control valve, disassemble and Pilot control, disassemble and
assemble...................................................... 03-0360-1 assemble.................................................... 31-3160-15
Hydrostatic charge pump, remove and Pilot control, remove and install ................... 31-3160-13
install ............................................................ 03-0300-1 Ride control, disassemble and
Hydrostatic directional control valve, assemble...................................................... 31-3160-6
remove and install ........................................ 03-0300-1 Ride control, remove and install..................... 31-3160-5
Hydrostatic motor disassemble...................... 03-0360-4 Service brake, disassemble and
Hydrostatic motor flushing valve O-rings, assemble...................................................... 10-1060-3
remove and install ........................................ 03-0360-2
Hydrostatic motor servo piston seals, W
remove and install ........................................ 03-0360-2
Hydrostatic motor, assemble.......................... 03-0360-8 Welding on machine .......................................... 17-1740-1
Hydrostatic motor, control valve O-rings Welding repairs................................................ 00-0001-15
and seals...................................................... 03-0360-1 Wheel
Hydrostatic motor, remove and install............ 03-0300-3 Remove and install ........................................ 01-0110-1
Hydrostatic motor, rotating group inspect Windowpanes
and recondition............................................. 03-0360-5 Remove and install ........................................ 18-1810-1

4WD Loader
020921
PN=5
Index

4WD Loader
020921
PN=6

244K, 244K-II, and 324K Compact 4WD Loader Repair

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244K, 244K-II, and 324K Compact 4WD Loader Repair

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244K, 244K-II, and 324K

Compact 4WD Loader

REPAIR TECHNICAL MANUAL

TM13279X19 (09FEB21) 244K, 244K-II, and 324K Compact 4WD Loader

Manual Identification—READ THIS FIRST!

Choosing the Correct Supporting Manuals

1— PIN Plate 2— 17-Character PIN

The PIN identifies the producing factory, machine model

Continued on next page WC20922,0004FB6 -19-24JUN16-1/2

TM13279X19 (09FEB21) 244K, 244K-II, and 324K Compact 4WD Loader

17-Character PIN Example

• (9) Manufacturing Year Code: Identifies year of

TM13279X19 (09FEB21) 244K, 244K-II, and 324K Compact 4WD Loader

Section 02—Axles and Suspension System Section 21—Main Hydraulic System

Section 05—Engine Auxiliary Systems

Section 07—Damper Drive

Section 09—Steering System

Section 10—Service Brakes

Section 11—Park Brake

Section 16—Electrical System

Section 17—Frame or Supporting Structure

Section 18—Operator's Station

Original Instructions. All information, illustrations and specifications in this

TM13279X19 (09FEB21) i 244K, 244K-II, and 324K Compact 4WD Loader

TM13279X19 (09FEB21) ii 244K, 244K-II, and 324K Compact 4WD Loader

Follow Safety Instructions

Wear Protective Equipment

Avoid Unauthorized Machine Modifications

Stay Clear of Moving Parts

Avoid High-Pressure Oils

Avoid High-Pressure Fluids

Work In Ventilated Area

Avoid Static Electricity Risk When Refueling

Clean Debris from Machine

Prevent Battery Explosions

Do not charge a frozen battery; it may explode. Warm

Handle Chemical Products Safely

Decommissioning — Proper Recycling and

Prepare for Emergencies

Use Steps and Handholds Correctly

Start Only From Operator's Seat

Use and Maintain Seat Belt

CAUTION: Prevent personal injury. Check

Prevent Unintended Machine Movement

Avoid Work Site Hazards

Avoid Contact With Overhead Electrical Lines

Operate Only on Solid Footing

Use Special Care When Operating Loader

Keep Riders Off Machine

Avoid Backover Accidents

Avoid Machine Tip Over and Machine Damage

Operating or Traveling On Public Roads

Inspect and Maintain ROPS To maintain the ROPS:

Park and Prepare for Service Safely

Service Cooling System Safely

Remove Paint Before Welding or Heating

Make Welding Repairs Safely

Do not weld or apply heat on any part of a reservoir or

Remove paint properly. Do not inhale paint dust or fumes.

Drive Metal Pins Safely

Follow Tire Recommendations

Service Tires Safely

Clean Exhaust Filter Safely