TM10147 Reparacion 410J

410J
Backhoe Loader
Repair
TECHNICAL MANUAL
410J Backhoe Loader
TM10147 08JUN07 (ENGLISH)
For complete service information also see:

410J Backhoe Loader Operation and
Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TM10132
410J Backhoe Loader Operator’s Manual . . OMT211053
Alternators and Starting Motors . . . . . . . . . . CTM77
POWERTECH 4.5 L & 6.8 L Diesel
Engines—Base Engine . . . . . . . . . . . . . . . . . CTM104
POWERTECH 4.5L & 6.8L Diesel Engines—
Level 12 Electronic Fuel Systems with
Stanadyne DE10 Pump . . . . . . . . . . . . . . . . . CTM331
Front Wheel Drive Axles AS and MS
Series . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CTM4687
100 Series Hydraulic Cylinders . . . . . . . . . . TM-H100A
Super Caddy Oil Cleanup Procedure . . . . . . CTM310
Specifications Manual . . . . . . . . . . . . . . . . . . SP458
Worldwide Construction
And Forestry Division
LITHO 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 components requiring service instruction. At the
work are identified in this manual and are beginning of each group are summary listings of all
recommended for use. applicable essential tools, service equipment and tools,
other materials needed to do the job, service parts kits,
Live with safety: Read the safety messages in the specifications, wear tolerances, and torque values.
introduction of this manual and the cautions presented
throughout the text of the manual. Technical Manuals are concise guides for specific
machines. They are on-the-job guides containing only
the vital information needed for diagnosis, analysis,
This is the safety-alert symbol. When you see this
testing, and repair.
symbol on the machine or in this manual, be alert to
the potential for personal injury.
Fundamental service information is available from
other sources covering basic theory of operation,
Technical manuals are divided in two parts: repair and
fundamentals of troubleshooting, general maintenance,
operation and tests. Repair sections tell how to repair
and basic type of failures and their causes.
the components. Operation and tests sections help you
identify the majority of routine failures quickly.
TX03399,0001836 –19–01SEP06–1/1
TM10147 (08JUN07) 410J Backhoe Loader

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Introduction
Technical Information Feedback Form
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TX,TM,FAX –19–03JUL01–1/1

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Introduction

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Contents
00
SECTION 00—General Information SECTION 17—Frame or Supporting Structure
Group 0001—Safety Information Group 1740—Frame Installation
Group 0003—Torque Values Group 1749—Chassis Weights
SECTION 01—Wheels SECTION 18—Operator’s Station

01
Group 0110—Powered or Non-Powered Wheels Group 1800—Removal and Installation
and Fastenings Group 1810—Operator Enclosure
Group 1821—Seat and Seat Belt
SECTION 02—Axles and Suspension Systems Group 1830—Heating and Air Conditioning
Group 0225—Input Drive Shafts and U-Joints
Group 0230—Non-Powered Wheel Axles SECTION 19—Sheet Metal and Styling 02
Group 0240—Powered Wheel Axle (MFWD) Group 1910—Hood and Engine Enclosure
Group 0250—Axle Shaft, Bearings, and Reduction Group 1913—Miscellaneous Shields
Gears Group 1921—Grille and Grille Housing
Group 1927—Fenders
SECTION 03—Transmission 03
Group 0300—Removal and Installation SECTION 20—Safety, Convenience and
Group 0315—Controls Linkage Miscellaneous
Group 0350—Gears, Shafts, and Power Shift Group 2001—Radio
Clutches Group 2004—Horn and Warning Devices
Group 0360—Hydraulic System
SECTION 21—Main Hydraulic System 04
SECTION 04—Engine Group 2160—Hydraulic System
Group 0400—Removal and Installation
SECTION 31—Loader
SECTION 05—Engine Auxiliary Systems Group 3100—Loader
Group 0505—Cold Weather Starting Aid Group 3102—Bucket
05
Group 0510—Cooling System Group 3104—Attachment Coupler
Group 0515—Speed Controls Group 3115—Control Linkages
Group 0520—Intake System Group 3160—Hydraulic System
Group 0530—Exhaust System
Group 0560—External Fuel Supply System SECTION 33—Backhoe
Group 3302—Bucket 06
Group 3315—Control Linkage
SECTION 06—Torque Converter
Group 3340—Frames
Group 0651—Turbine, Gears and Shaft
SECTION 09—Steering System
SECTION 99—Dealer Fabricated Tools
Group 0960—Hydraulic System 09
Group 9900—Dealer Fabricated Tools
SECTION 10—Service Brakes
Group 1011—Active Elements
10
SECTION 11—Park Brake
All information, illustrations and specifications in this manual are based on

the latest information available at the time of publication. The right is
reserved to make changes at any time without notice. 11
COPYRIGHT  2007
DEERE & COMPANY
Moline, Illinois
All rights reserved
A John Deere ILLUSTRUCTION Manual
TM10147 (08JUN07) i 410J Backhoe Loader

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INDX
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00
Section 00
General Information
Contents
Page Page
Group 0001—Safety Information Additional Metric Cap Screw Torque

Safety and Operator Convenience Values . . . . . . . . . . . . . . . . . . . . . . . . . . . .00-0003-2
Features . . . . . . . . . . . . . . . . . . . . . . . . . .00-0001-1 Torque Value
Recognize Safety Information . . . . . . . . . . . .00-0001-2 Unified Inch Bolt and Cap Screw . . . . . . . .00-0003-4
Follow Safety Instructions . . . . . . . . . . . . . . .00-0001-2 Service Recommendations for 37° Flare
Operate Only If Qualified. . . . . . . . . . . . . . . .00-0001-3 and 30° Cone Seat Connectors . . . . . . . . .00-0003-5
Wear Protective Equipment . . . . . . . . . . . . . .00-0001-3 Service Recommendations for O-Ring
Avoid Unauthorized Machine Boss Fittings . . . . . . . . . . . . . . . . . . . . . . .00-0003-6
Modifications . . . . . . . . . . . . . . . . . . . . . . .00-0001-3 Service Recommendation
Inspect Machine . . . . . . . . . . . . . . . . . . . . . .00-0001-4 O-Ring Boss Fittings In Aluminum
Stay Clear of Moving Parts . . . . . . . . . . . . . .00-0001-4 Housing—Excavators . . . . . . . . . . . . . . .00-0003-8
Avoid High-Pressure Fluids . . . . . . . . . . . . . .00-0001-4 Service Recommendations For Flared
Avoid High-Pressure Oil . . . . . . . . . . . . . . . .00-0001-5 Connections—Straight or Tapered
Beware of Exhaust Fumes . . . . . . . . . . . . . .00-0001-5 Threads . . . . . . . . . . . . . . . . . . . . . . . . . .00-0003-10
Prevent Fires. . . . . . . . . . . . . . . . . . . . . . . . .00-0001-6 Service Recommendations For Flat Face
Prevent Battery Explosions . . . . . . . . . . . . . .00-0001-6 O-Ring Seal Fittings. . . . . . . . . . . . . . . . .00-0003-11
Handle Chemical Products Safely . . . . . . . . .00-0001-7 Service Recommendation
Dispose of Waste Properly . . . . . . . . . . . . . .00-0001-7 O-Ring Face Seal Fittings with SAE
Prepare for Emergencies. . . . . . . . . . . . . . . .00-0001-7 Inch Hex Nut and Stud End for High
Use Steps and Handholds Correctly . . . . . . .00-0001-8 Pressure. . . . . . . . . . . . . . . . . . . . . . . .00-0003-12
Start Only From Operator’s Seat . . . . . . . . . .00-0001-8 O-Ring Face Seal Fittings with Metric
Use and Maintain Seat Belt. . . . . . . . . . . . . .00-0001-8 Hex Nut and Stud End for Standard
Prevent Unintended Machine Movement . . . .00-0001-9 Pressure. . . . . . . . . . . . . . . . . . . . . . . .00-0003-14
Prevent Unintended Machine Movement— O-Ring Face Seal Fittings with Metric
If Equipped With Pilot Controls . . . . . . . . .00-0001-9 Hex Nut and Stud End for High
Avoid Work Site Hazards . . . . . . . . . . . . . .00-0001-10 Pressure. . . . . . . . . . . . . . . . . . . . . . . .00-0003-16
Keep Riders Off Machine . . . . . . . . . . . . . .00-0001-10 Service Recommendations for Metric
Avoid Backover Accidents . . . . . . . . . . . . . .00-0001-11 Series Four Bolt Flange Fitting . . . . . . . .00-0003-18
Avoid Machine Tipover . . . . . . . . . . . . . . . .00-0001-11 Service Recommendations For Inch
Add and Operate Attachments Safely . . . . .00-0001-12 Series Four Bolt Flange Fittings. . . . . . . .00-0003-19
Use Special Care When Operating . . . . . . .00-0001-12 Service Recommendation
Operating or Traveling On Public Roads . . .00-0001-13 Inch Series Four Bolt Flange For High
Inspect and Maintain ROPS . . . . . . . . . . . .00-0001-13 Pressure. . . . . . . . . . . . . . . . . . . . . . . .00-0003-20
Park and Prepare for Service Safely . . . . . .00-0001-14 Service Recommendations For
Service Cooling System Safely . . . . . . . . . .00-0001-14 Non-Restricted Banjo (Adjustable)
Remove Paint Before Welding or Fittings. . . . . . . . . . . . . . . . . . . . . . . . . . .00-0003-21
Heating . . . . . . . . . . . . . . . . . . . . . . . . . .00-0001-15 Service Recommendations For O-Ring
Make Welding Repairs Safely . . . . . . . . . . .00-0001-15 Boss Fittings With Shoulder . . . . . . . . . . .00-0003-23
Drive Metal Pins Safely . . . . . . . . . . . . . . . .00-0001-16 Service Recommendation
Safety Signs . . . . . . . . . . . . . . . . . . . . . . . .00-0001-17 Metric 24° O-Ring Seal DIN 20078 . . . . .00-0003-26
Safety Signs—Backhoe Coupler (If
Equipped) . . . . . . . . . . . . . . . . . . . . . . . .00-0001-19
Group 0003—Torque Values

Torque Value
Metric Bolt and Cap Screw . . . . . . . . . . . .00-0003-1
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Group 0001
Safety Information
00
Safety and Operator Convenience Features 0001
1
2 3
1
17 5
16
6
13
4
15
12 7 8
14 10 9
–UN–05SEP01
11
T145296
T145296
Please remember, the operator is the key to 9. Bypass Start Protection. Shielding over the starter
preventing accidents. solenoid helps prevent dangerous bypass starting.
10. Ground-Level Fueling, Daily Service Checks.
1. Headlights/Taillights. Two front halogen Ground-level fueling feature eliminates the need to
driving/work lights and two rear halogen work lights. climb on the machine to fuel it.
2. Signal/Warning Lights. Roof mounted turning 11. Steps. Wide, skid-resistant steps provide excellent
signal lights and warning lights for on-road use. footing for getting in/out of operator’s station.
3. ROPS Protection. Certified rollover protection 12. Independent Parking/Secondary Brake.
structure surrounds the operator. Integral roof Independent, electrically controlled, parking brake
provides overhead protection. electrically engages when the engine is stopped.
4. Seat Position Sensor. An audio/visual warning 13. Neutral Start. The machine will not move until the
alerts operator when Transmission Control Lever Transmission Control Lever (TCL) is cycled back
(TCL) is in forward/reverse and the seat turned to neutral and the park brake is released,
toward the backhoe position. regardless of TCL position at startup.
5. Interior Rearview Mirror. Offers the operator a 14. Backup Alarm. Alerts bystanders when the
view of activity behind him. machine is shifted into reverse.
6. Handholds. Large and conveniently placed 15. Seat Belt Retractors. Seat belt retractors help
handholds, make it easy to enter or exit the keep belts clean and convenient to use.
operator’s station. 16. Exceptional Visibility. Views to either side and
7. Loader Boom Service Lock. Provided for working front or rear working tools are unrestricted.
on or around this machine with the boom raised. 17. Operator Manual Holder. A sealed manual holder
8. Engine Fan Guard. A secondary engine fan guard keeps manual clean and dry.
inside engine compartment encloses rotating fan
blades.
VD76477,0001270 –19–15DEC06–1/1
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Safety Information
00
0001 Recognize Safety Information
2
This is the safety alert symbol. When you see this
–UN–28AUG00
symbol on your machine or in this manual, be alert
for the potential of personal injury.
Follow the precautions and safe operating practices
T133555
highlighted by this symbol.
A signal word — DANGER, WARNING, or CAUTION — is

used with the safety alert symbol. DANGER identifies the
most serious hazards.
–19–28AUG00
On your machine, DANGER signs are red in color,
WARNING signs are orange, and CAUTION signs are
yellow. DANGER and WARNING signs are located near
specific hazards. General precautions are on CAUTION
T133588
labels.
TX03679,00016CC –19–04DEC06–1/1
Follow Safety Instructions
Read the safety messages in this manual and on the
–UN–24AUG00
machine. Follow these warnings and instructions carefully.
Review them frequently. Keep safety signs in good
condition. Replace missing or damaged safety signs. Be
sure new equipment components and repair parts include
T133556
the current safety signs. Replacement safety signs are
available from your authorized John Deere dealer.
Be sure all operators of this machine understand every

safety message. Replace operator’s manual and safety
labels immediately if missing or damaged.
TX03679,00016F9 –19–07SEP06–1/1

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Safety Information
00
Operate Only If Qualified 0001
3
Do not operate this machine unless the operator’s machine functions with the machine in an open area
manual has been read carefully, and you have been before starting to work.
qualified by supervised training and instruction.
Know and observe all safety rules that may apply to
Operator should be familiar with the job site and every work situation and work site.
surroundings before operating. Try all controls and
TX03679,00016FA –19–03JAN07–1/1
Wear Protective Equipment
Guard against injury from flying pieces of metal or debris;

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

appropriate to the job.
–UN–23AUG88
Prolonged exposure to loud noise can cause impairment
or loss of hearing. Wear suitable hearing protection such
as earmuffs or earplugs to protect against objectionable or
TS206
uncomfortable loud noises.
TX03679,00016D0 –19–15DEC06–1/1
Avoid Unauthorized Machine Modifications
John Deere recommends using only genuine John for the operator or others near the machine. The
Deere replacement parts to ensure machine installer of any modification which may affect this
performance. Never substitute genuine John Deere machine is responsible for establishing that the
parts with alternate parts not intended for the modification does not adversely affect the machine or
application as these can create hazardous situations or its performance. This applies to all aspects of the
hazardous performance. Non-John Deere Parts, or any machine, including electronic controls.
damage or failures resulting from their use are not
covered by any John Deere warranty. Always contact an authorized dealer before making
machine modifications that change the intended use,
Modifications of this machine, or addition of weight or balance of the machine, or that alter
unapproved products or attachments, may affect machine controls, performance or reliability.
machine stability or reliability, and may create a hazard
AM40430,0000084 –19–29MAR05–1/1

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Safety Information
00
0001 Inspect Machine
4
Inspect machine carefully each day by walking around it

before starting.
Keep all guards and shields in good condition and
–UN–18OCT88
properly installed. Fix damage and replace worn or broken
parts immediately. Pay special attention to hydraulic
hoses and electrical wiring.
T6607AQ
TX03679,0001734 –19–04DEC06–1/1
Stay Clear of Moving Parts
–UN–12SEP01
Entanglements in moving parts can cause serious injury.
Stop engine before examining, adjusting or maintaining

any part of machine with moving parts.
T133592
Keep guards and shields in place. Replace any guard or
shield that has been removed for access as soon as
service or repair is complete.
TX03679,00016D2 –19–12FEB07–1/1
Avoid High-Pressure Fluids
Escaping fluid under pressure can penetrate the skin

causing serious injury.
Avoid the hazard by relieving pressure before
–UN–23AUG88
disconnecting hydraulic or other lines. Tighten all
connections before applying pressure.
Search for leaks with a piece of cardboard. Protect hands

X9811
and body from high pressure fluids.
If an accident occurs, see a doctor immediately. Any fluid

injected into the skin must be surgically removed within a
few hours or gangrene may result. Doctors unfamiliar with
this type of injury should reference a knowledgeable
medical source. Such information is available from Deere
& Company Medical Department in Moline, Illinois, U.S.A.
DX,FLUID –19–03MAR93–1/1

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Safety Information
00
Avoid High-Pressure Oil 0001
5
This machine uses a high-pressure hydraulic system.

Escaping oil under pressure can penetrate the skin
causing serious injury.
–UN–17MAR06
Never search for leaks with your hands. Protect hands.
Use a piece of cardboard to find location of escaping oil.
Stop engine and relieve pressure before disconnecting
lines or working on hydraulic system.
T133509
If hydraulic oil penetrates your skin, see a doctor
immediately. Injected oil must be removed surgically
within hours or gangrene may result. Contact a
knowledgeable medical source or the Deere & Company
Medical Department in Moline, Illinois, U.S.A.
–UN–20SEP00
T133840
OUT4001,0000028 –19–11SEP06–1/1
Beware of Exhaust Fumes
Prevent asphyxiation. Engine exhaust fumes can cause

sickness or death.
–UN–24AUG00
If you must operate in a building, provide adequate
ventilation. Use an exhaust pipe extension to remove the
exhaust fumes or open doors and windows to bring
T133546
outside air into the area.
TX03679,00016D4 –19–12FEB07–1/1

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Safety Information
00
0001 Prevent Fires
6
–UN–14SEP00
Handle Fuel Safely: Store flammable fluids away from
fire hazards. Never refuel machine while smoking or when
near sparks or flame.
T133552
Clean Machine Regularly: Keep trash, debris, grease
and oil from accumulating in engine compartment, around
fuel lines, hydraulic lines and electrical wiring. Never store
oily rags or flammable materials inside a machine
compartment.
–UN–07SEP00
Maintain Hoses and Wiring: Replace hydraulic hoses
immediately if they begin to leak, and clean up any oil
T133553
spills. Examine electrical wiring and connectors frequently
for damage.
Keep A Fire Extinguisher Available: Always keep a

multi-purpose fire extinguisher on or near the machine.
–UN–07SEP00
Know how to use extinguisher properly.
T133554
TX03679,00016F5 –19–04DEC06–1/1
Prevent Battery Explosions
Battery gas can explode. Keep sparks, lighted matches,

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

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

battery to 16°C (60°F).
TS204
TX03679,000174A –19–04DEC06–1/1

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Safety Information
00
Handle Chemical Products Safely 0001
7
Exposure to hazardous chemicals can cause serious
–UN–25AUG00
injury. Under certain conditions, lubricants, coolants,
paints and adhesives used with this machine may be
hazardous.
T133580
If uncertain about safe handling or use of these chemical
products, contact your authorized dealer for a Material
Safety Data Sheet (MSDS) or go to internet website
http://www.jdmsds.com. The MSDS describes physical
and health hazards, safe use procedures, and emergency
response techniques for chemical substances. Follow
MSDS recommendations to handle chemical products
safely.
TX03679,00016D7 –19–03JAN07–1/1
Dispose of Waste Properly
Improper disposal of waste can threaten the environment.
–UN–25AUG00
Fuel, oils, coolants, filters and batteries used with this
machine may be harmful if not disposed of properly.
Never pour waste onto the ground, down a drain, or into
T133567
any water source.
Air conditioning refrigerants can damage the atmosphere.

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

local environmental or recycling center or your authorized
dealer for more information.
TX03679,0001733 –19–12FEB07–1/1
Prepare for Emergencies
Be prepared if an emergency occurs or a fire starts.
Keep a first aid kit and fire extinguisher handy.
Keep emergency numbers for doctors, ambulance service,

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

TS291
TX03679,000174B –19–12FEB07–1/1

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Safety Information
00
0001 Use Steps and Handholds Correctly
8
Prevent falls by facing the machine when you get on and
–UN–30AUG00
off. Maintain 3-point contact with steps and handrails.
Never use machine controls as handholds.
Use extra care when mud, snow, or moisture present
T133468
slippery conditions. Keep steps clean and free of grease
or oil. Never jump when exiting machine. Never mount or
dismount a moving machine.
TX03679,00016F2 –19–12FEB07–1/1
Start Only From Operator’s Seat
–UN–07SEP00
Avoid unexpected machine movement. Start engine only
while sitting in operator’s seat. Ensure all controls and
working tools are in proper position for a parked machine.
T133715
Never attempt to start engine from the ground. Do not
attempt to start engine by shorting across the starter
solenoid terminals.
TX03679,0001799 –19–03JAN07–1/1
Use and Maintain Seat Belt
Use seat belt when operating machine. Remember to
–19–14SEP00
fasten seat belt when loading and unloading from trucks
and during other uses.
T133716
Examine seat belt frequently. Be sure webbing is not cut
or torn. Replace seat belt immediately if any part is
damaged or does not function properly.
The complete seat belt assembly should be replaced

every three years, regardless of appearance.
TX03679,00016DD –19–19MAR07–1/1

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Safety Information
00
Prevent Unintended Machine Movement 0001
1 9
Always set the park lock brake switch to the ON

position (1) before leaving the operator’s seat for any
reason.
–UN–19DEC06
Be careful not to accidentally actuate steering, travel or
other controls. Engage park brake and lower work
P
equipment to the ground during work interruptions. Stop
TX1014609
the engine before allowing anyone to approach the
machine. Follow proper parking procedures before leaving
the operator’s station.
Park Brake Switch
1—ON Position
VD76477,0001206 –19–15DEC06–1/1
Prevent Unintended Machine Movement—If

Equipped With Pilot Controls
Be careful not to accidentally actuate control levers when

co-workers are present. Always lock hydraulics on
–UN–12DEC06
backhoe during work interruptions. Lock hydraulics before
allowing anyone to approach machine.
TX1014474
VD76477,0001201 –19–02NOV06–1/1

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Safety Information
00
0001 Avoid Work Site Hazards
10
Avoid contact with gas lines, buried cables and water

lines. Call utility line location services to identify all
underground utilities before you dig.
–UN–01NOV01
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.
T147554
Avoid boom or attachment contact with overhead
obstacles or overhead electrical lines. Never move any
part of machine or load closer than 3 m (10 ft) plus twice
the line insulator length to overhead wires.
Keep bystanders clear at all times. Use barricades or a

signal person to keep vehicles and pedestrians away. Use
a signal person if moving machine in congested areas or
–UN–13DEC01
where visibility is restricted. Always keep signal person in
view. Coordinate hand signals before starting machine.
Operate only on solid footing with strength sufficient to
T147555
support machine. Be especially alert working near
embankments or excavations.
Avoid working under over-hanging embankments or

stockpiles that could collapse on machine.
Reduce machine speed when operating with tool on or

near ground when obstacles may be hidden (e.g., during
snow removal or clearing mud, dirt, etc.). At high speeds
hitting obstacles (rocks, uneven concrete or manholes)
can cause a sudden stop. Always wear your seat belt.
TX03768,0000BAA –19–03JAN07–1/1
Keep Riders Off Machine
Only allow the operator on the machine. Keep riders off.
Riders on machine are subject to injury such as being

struck by foreign objects and being thrown off of the
–UN–06DEC01
machine. Riders also obstruct the operator’s view resulting

in the machine being operated in an unsafe manner.
T148715
TX03768,0000BAF –19–07SEP06–1/1

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Safety Information
00
Avoid Backover Accidents 0001
11
Before moving machine, be sure all persons are clear

of the machine travel path. Turn around and look
–UN–06SEP01
directly for best visibility. Use mirror to assist in checking
behind the machine. Keep windows and mirror clean and
in good repair.
T145317
Be certain backup warning alarm is working properly.
Use a signal person when backing if view is

obstructed or when in close quarters. Keep signal
person in view at all times. Use prearranged hand signals
to communicate.
TX03768,0000B8B –19–20DEC06–1/1
Avoid Machine Tipover
Use seat belt at all times.
Do not jump if the machine tips. You will be unlikely to

jump clear and the machine may crush you.
Load and unload from trucks or trailers carefully. Be

sure truck is wide enough and secured on a firm level
surface. Use loading ramps and attach them properly to
truck bed.
Be careful on slopes. Use extra care on soft, rocky or

frozen ground because machine may slip sideways in
these conditions.
Ensure solid footing. Use extra care when operating on

stockpile materials, or near banks or excavations that may
cave-in and cause machine to tip or fall. –19–26OCT01
T147495
TX03768,0000BA3 –19–07SEP06–1/1

060807
PN=19
Safety Information
00
0001 Add and Operate Attachments Safely
12
Always verify compatibility of attachments by contacting

your authorized dealer. Adding unapproved attachments
may affect machine stability or reliability and may create a
hazard for others near the machine.
Ensure that a qualified person is involved in attachment

installation. Add guards to machine if operator protection
is required or recommended. Verify that all connections
are secure and attachment responds properly to controls.
Carefully read attachment manual and follow all

instructions and warnings. In an area free of bystanders
and obstructions, carefully operate attachment to learn its
characteristics and range of motion.
TX03679,00016F0 –19–12FEB07–1/1
Use Special Care When Operating
Never use the loader to lift people. Do not allow anyone

to ride in the bucket or use the bucket as a work platform.
Operate carefully with raised loads. Raising the load
–UN–05DEC01
reduces machine stability, especially on side slopes on
soft terrain. Drive and turn slowly with a raised load.
Ensure that objects in the bucket are secure. Do not
T148749
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
stability and hydraulic capability with a test lift before
attempting other maneuvers. Use an adequate chain or
–UN–26OCT01
sling and proper rigging techniques to attach and stabilize

loads.
Never lift an object above or near another person.

T147438
TX03768,0000B70 –19–07SEP06–1/1

060807
PN=20
Safety Information
00
Operating or Traveling On Public Roads 0001
13
Machines that work near vehicle traffic or travel slower

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

(SMV) emblems, or other devices and use as required to
T141891
make the machine visible and identify it as a work
machine. Check state and local regulations to assure
compliance. Keep these devices clean and in working
condition.
TX03679,00017C8 –19–02MAR07–1/1
Inspect and Maintain ROPS
A damaged roll-over protective structure (ROPS) To maintain the ROPS:

should be replaced, not reused.
• Replace missing hardware using correct grade
The protection offered by ROPS will be impaired if hardware.
ROPS is subjected to structural damage, is involved in • Check hardware torque.
an overturn incident, or is in any way altered by • Check isolation mounts for damage, looseness or
welding, bending, drilling, or cutting. wear; replace them if necessary.
• Check ROPS for cracks or physical damage.
If ROPS was loosened or removed for any reason,
inspect it carefully before operating the machine again.
TX03679,000179F –19–07SEP06–1/1

060807
PN=21
Safety Information
00
0001 Park and Prepare for Service Safely
14
Warn others of service work. Always park and prepare

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

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

tools or attachments.
• Do not support machine with cinder blocks or wooden
pieces that may crumble or crush.
• Do not support machine with a single jack or other
–UN–23AUG88
devices that may slip out of place.
• Always install boom lock before working on or around
this machine with the loader boom raised.
TS229
Understand service procedures before beginning repairs.
Keep service area clean and dry. Use two people
whenever the engine must be running for service work.
TX03679,0001809 –19–02MAR07–1/1
Service Cooling System Safely
Explosive release of fluids from pressurized cooling

system can cause serious burns.
Do not service radiator through the radiator cap. Only fill

through the surge tank filler cap. Shut off engine. Only
–UN–23AUG88
remove surge tank filler cap when cool enough to touch

with bare hands. Slowly loosen cap to relieve pressure
before removing completely.
TS281
VD76477,0001158 –19–26OCT06–1/1

060807
PN=22
Safety Information
00
Remove Paint Before Welding or Heating 0001
15
Avoid potentially toxic fumes and dust.
Hazardous fumes can be generated when paint is heated

by welding, soldering, or using a torch.
–UN–23AUG88
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,
TS220
wear an approved respirator before heating or welding.
• If you sand or grind paint, avoid breathing the dust.
Wear an approved respirator.
• If you use solvent or paint stripper, remove stripper with
soap and water before welding. Remove solvent or
paint stripper containers and other flammable material
from area. Allow fumes to disperse at least 15 minutes
before welding or heating.
Do not use a chlorinated solvent in areas where welding

will take place.
Do all work in an area that is well ventilated to carry toxic

fumes and dust away.
Dispose of paint and solvent properly.
DX,PAINT –19–24JUL02–1/1
Make Welding Repairs Safely
NOTE: Disable electrical power before welding. Turn off

–UN–31AUG00
main battery switch or disconnect positive battery
cable. Separate harness connectors to engine and
vehicle microprocessors.
T133547
Avoid welding or heating near pressurized fluid lines.

Flammable spray may result and cause severe burns if
pressurized lines fail as a result of heating. Do not let heat
go beyond work area to nearby pressurized lines.
Remove paint properly. Do not inhale paint dust or fumes.

Use a qualified welding technician for structural repairs.
Make sure there is good ventilation. Wear eye protection
and protective equipment when welding.
TX03679,00016D5 –19–07SEP06–1/1

060807
PN=23
Safety Information
00
0001 Drive Metal Pins Safely
16
–UN–14SEP00
Always wear protective goggles or safety glasses and
other protective equipment before striking hardened parts.
Hammering hardened metal parts such as pins and
bucket teeth may dislodge chips at high velocity.
T133738
Use a soft hammer or a brass bar between hammer and
object to prevent chipping.
TX03679,0001745 –19–07SEP06–1/1

060807
PN=24
Safety Information
00
Safety Signs 0001
17
–19–14DEC06
TX1016262
Continued on next page VD76477,0001118 –19–07DEC06–1/2

060807
PN=25
Safety Information
00
0001
18
–19–14DEC06
TX1016263
VD76477,0001118 –19–07DEC06–2/2

060807
PN=26
Safety Information
00
Safety Signs—Backhoe Coupler (If Equipped) 0001
19
–19–07JUN07
TX1024059
Safety Signs—If Equipped with Backhoe Coupler

VD76477,000152B –19–05JUN07–1/1

060807
PN=27
Safety Information
00
0001
20

060807
PN=28
Group 0003
Torque Values
00
Metric Bolt and Cap Screw Torque Values 0003
1
–UN–07SEP99
TORQ2
Top—Property Class and Head Markings; Bottom—Property Class and Nut Markings
METRIC BOLT AND CAP SCREW TORQUE VALUES—Tolerance is ±10% unless otherwise specified
Class 4.8 Class 8.8 or 9.8 Class 10.9 Class 12.9
Thread Lubricateda Dryb Lubricateda Dryb Lubricateda Dryb Lubricateda Dryb
Size N•m (lb-ft) N•m (lb-ft) N•m (lb-ft) N•m (lb-ft) N•m (lb-ft) N•m (lb-ft) N•m (lb-ft) N•m (lb-ft)
M6 4.7 (3.5) 6 (4.4) 9 (6.6) 11.5 (8.5) 13 (9.5) 16.5 (12.2) 15.5 (11.5) 19.5 (14.5)
M8 11.5 (8.5) 14.5 (10.7) 22 (16) 28 (20.5) 32 (23.5) 40 (29.5) 37 (27.5) 47 (35)
M10 23 (17) 29 (21) 43 (32) 55 (40) 63 (46) 80 (59) 75 (55) 95 (70)
M12 40 (29.5) 50 (37) 75 (55) 95 (70) 110 (80) 140 (105) 130 (95) 165 (120)
M14 63 (46) 80 (59) 120 (88) 150 (110) 175 (130) 220 (165) 205 (150) 260 (190)
M16 100 (74) 125 (92) 190 (140) 240 (175) 275 (200) 350 (255) 320 (235) 400 (300)
M18 135 (100) 170 (125) 265 (195) 330 (245) 375 (275) 475 (350) 440 (325) 560 (410)
M20 190 (140) 245 (180) 375 (275) 475 (350) 530 (390) 675 (500) 625 (460) 790 (580)
M22 265 (195) 330 (245) 510 (375) 650 (480) 725 (535) 920 (680) 850 (625) 1080 (800)
M24 330 (245) 425 (315) 650 (480) 820 (600) 920 (680) 1150 (850) 1080 (800) 1350 (1000)
M27 490 (360) 625 (460) 950 (700) 1200 (885) 1350 (1000) 1700 (1250) 1580 (1160) 2000 (1475)
M30 660 (490) 850 (625) 1290 (950) 1630 (1200) 1850 (1350) 2300 (1700) 2140 (1580) 2700 (2000)
M33 900 (665) 1150 (850) 1750 (1300) 2200 (1625) 2500 (1850) 3150 (2325) 2900 (2150) 3700 (2730)
M36 1150 (850) 1450 (1075) 2250 (1650) 2850 (2100) 3200 (2350) 4050 (3000) 3750 (2770) 4750 (3500)
a
"Lubricated" means coated with a lubricant such as engine oil, or fasteners with phosphate and oil coatings.
b
"Dry" means plain or zinc plated without any lubrication.
Fasteners should be replaced with the same or higher property class.

CAUTION: Use only metric tools on metric hardware. If higher property class fasteners are used, these should only be
Other tools may not fit properly. Tool may slip and tightened to the strength of the original.
cause injury.
Make sure fastener threads are clean and that you properly start
thread engagement. This will prevent them from failing when
DO NOT use these values if a different torque value or tightening tightening.
procedure is given for a specific application. Torque values listed are
for general use only. Check tightness of fasteners periodically. Tighten plastic insert or crimped steel-type lock nuts to approximately
50 percent of the dry torque shown in the chart, applied to the nut,
Shear bolts are designed to fail under predetermined loads. Always not to the bolt head. Tighten toothed or serrated-type lock nuts to the
replace shear bolts with identical property class. full torque value.
OUT3035,TORQUE2 –19–22MAR04–1/1

060807
PN=29
Torque Values
00
0003 Additional Metric Cap Screw Torque Values
2
–UN–18OCT88
CAUTION: Use only metric tools on metric
hardware. Other tools may not fit properly. They
may slip and cause injury.
T6873AA
Check tightness of cap screws periodically. Torque values
listed are for general use only. Do not use these values if
a different torque value or tightening procedure is listed
for a specific application.
–UN–18OCT88
Shear bolts are designed to fail under predetermined
loads. Always replace shear bolts with identical grade.
Fasteners should be replaced with the same or higher
T6873AB
grade. If higher grade fasteners are used, these should
only be tightened to the strength of the original.
Make sure fastener threads are clean and you properly

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

060807
PN=30
Torque Values
00
METRIC CAP SCREW TORQUE VALUESa 0003
3
T-Bolt H-Bolt M-Bolt
Nominal
Dia N•m lb-ft N•m lb-ft N•m lb-ft
8 29 21 20 15 10 7
10 63 46 45 33 20 15
12 108 80 88 65 34 25
14 176 130 137 101 54 40
16 265 195 206 152 78 58
18 392 289 294 217 118 87
20 539 398 392 289 167 125
22 735 542 539 398 216 159
24 931 687 686 506 274 202
27 1372 1012 1029 759 392 289
30 1911 1410 1421 1049 539 398
33 2548 1890 1911 1410 735 542
36 3136 2314 2401 1772 931 687
a
Torque tolerance is ±10%.
04T,90,M170 –19–29SEP99–2/2

060807
PN=31
Torque Values
00
0003 Unified Inch Bolt and Cap Screw Torque Values
4
–UN–27SEP99
TORQ1A
Top—SAE Grade and Head Markings; Bottom—SAE Grade and Nut Markings
UNIFIED INCH BOLT AND CAP SCREW TORQUE VALUES—Tolerance is ±10% unless otherwise specified
Grade 1 (No Mark) Grade 2a (No Mark) Grade 5, 5.1 or 5.2 Grade 8 or 8.2
b c
Thread Lubricated Dry Lubricatedb Dryc Lubricatedb Dryc Lubricatedb Dryc
Size N•m (lb-ft) N•m (lb-ft) N•m (lb-ft) N•m (lb-ft) N•m (lb-ft) N•m (lb-ft) N•m (lb-ft) N•m (lb-ft)
1/4 3.8 (2.8) 4.7 (3.5) 6 (4.4) 7.5 (5.5) 9.5 (7) 12 (9) 13.5 (10) 17 (12.5)
5/16 7.7 (5.7) 9.8 (7.2) 12 (9) 15.5 (11.5) 19.5 (14.5) 25 (18.5) 28 (20.5) 35 (26)
3/8 13.5 (10) 17.5 (13) 22 (16) 27.5 (20) 35 (26) 44 (32.5) 49 (36) 63 (46)
7/16 22 (16) 28 (20.5) 35 (26) 44 (32.5) 56 (41) 70 (52) 80 (59) 100 (74)
1/2 34 (25) 42 (31) 53 (39) 67 (49) 85 (63) 110 (80) 120 (88) 155 (115)
9/16 48 (35.5) 60 (45) 76 (56) 95 (70) 125 (92) 155 (115) 175 (130) 220 (165)
5/8 67 (49) 85 (63) 105 (77) 135 (100) 170 (125) 215 (160) 240 (175) 305 (225)
3/4 120 (88) 150 (110) 190 (140) 240 (175) 300 (220) 380 (280) 425 (315) 540 (400)
7/8 190 (140) 240 (175) 190 (140) 240 (175) 490 (360) 615 (455) 690 (510) 870 (640)
1 285 (210) 360 (265) 285 (210) 360 (265) 730 (540) 920 (680) 1030 (760) 1300 (960)
1-1/8 400 (300) 510 (375) 400 (300) 510 (375) 910 (670) 1150 (850) 1450 (1075) 1850 (1350)
1-1/4 570 (420) 725 (535) 570 (420) 725 (535) 1280 (945) 1630 (1200) 2050 (1500) 2600 (1920)
1-3/8 750 (550) 950 (700) 750 (550) 950 (700) 1700 (1250) 2140 (1580) 2700 (2000) 3400 (2500)
1-1/2 990 (730) 1250 (930) 990 (730) 1250 (930) 2250 (1650) 2850 (2100) 3600 (2650) 4550 (3350)
a
Grade 2 applies for hex cap screws (not hex bolts) up to 6 in. (152 mm) long. Grade 1 applies for hex cap screws over 6 in. (152 mm) long,
and for all other types of bolts and screws of any length.
b
"Lubricated" means coated with a lubricant such as engine oil, or fasteners with phosphate and oil coatings.
c
"Dry" means plain or zinc plated without any lubrication.
DO NOT use these values if a different torque value or tightening Make sure fastener threads are clean and that you properly start
procedure is given for a specific application. Torque values listed are thread engagement. This will prevent them from failing when
for general use only. Check tightness of fasteners periodically. tightening.
Shear bolts are designed to fail under predetermined loads. Always Tighten plastic insert or crimped steel-type lock nuts to approximately
replace shear bolts with identical grade. 50 percent of the dry torque shown in the chart, applied to the nut,
not to the bolt head. Tighten toothed or serrated-type lock nuts to the
Fasteners should be replaced with the same or higher grade. If full torque value.
higher grade fasteners are used, these should only be tightened to
the strength of the original.
OUT3035,TORQUE1 –19–14JAN04–1/1

060807
PN=32
Torque Values
00
Service Recommendations for 37° Flare and 0003
5
30° Cone Seat Connectors
1. Inspect flare and flare seat. They must be free of dirt

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

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

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

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

060807
PN=33
Torque Values
00
0003 Service Recommendations for O-Ring Boss
6
Fittings
Straight Fitting
1. Inspect O-ring boss seat for dirt or defects.
–UN–18OCT88
2. Lubricate O-ring with petroleum jelly. Place electrical
tape over threads to protect O-ring. Slide O-ring over
tape and into O-ring groove of fitting. Remove tape.
T6243AE
3. Tighten fitting to torque value shown on chart.
Continued on next page 04T,90,K66 –19–29SEP99–1/2

060807
PN=34
Torque Values
00
Angle Fitting 0003
7
1. Back-off lock nut (A) and back-up washer (B)

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

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

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

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

060807
PN=35
Torque Values
00
0003 O-Ring Boss Fittings In Aluminum Housing Service Recommendations—Excavators
8
–UN–17NOV03
T196315
O-Ring Boss Straight and Adjustable Fittings
1—Straight Fitting 3—Stud End 5—Hex Nut 6—Backup Washer

2—O-Ring 4—Adjustable Fitting
O-RING BOSS STRAIGHT OR ADJUSTABLE FITTING STUD

END NUT WITH METRIC THREAD IN ALUMINUM HOUSING
TORQUE VALUES—Tolerance is ± 10% unless otherwise
specified
Thread Size Hex Nut Size
mm mm N•m (lb-ft)
M12 x 1.5 17 39 (29)
M14 x 1.5 19 39 (29)
M16 x 1.5 22 55 (41)
M22 x 1.5 27 75 (55)
M27 x 2 32 110 (81)
M30 x 2 36 141 (104)
M33 x 2 41 165 (122)
M38 x 2 46 165 (122)
M42 x 2 50 275 (203)
Continued on next page OUT3035,0000353 –19–14JAN04–1/2

060807
PN=36
Torque Values
00
O-RING BOSS STRAIGHT OR ADJUSTABLE FITTING STUD 1. Inspect fitting and O-ring boss sealing surfaces and 0003
END NUT WITH INCH THREAD IN ALUMINUM HOUSING 9
the O-ring. They must be free of dirt, scratches,
TORQUE VALUES—Tolerance is ± 10% unless otherwise
specified
nicks, or burrs. O-ring must be free of dirt, cuts,
cracks, swelling or flatten condition.
Thread Size
in. N•m (lb-ft)
2. Back the stud end hex nut (5) off as far as possible.
1/8 —
Push backup washer (6) towards the nut to fully
1/4 28 (20) expose the turn down section of stud end. Washer
3/8 39 (29) must fit turned down section and not be too loose
1/2 75 (55)
3/4 126 (93) 3. Wrap electrical tape over threads to protect O-ring.
1 165 (122)
Slide O-ring over the tape into turned down section.
Remove tape. Apply hydraulic oil to the threads of
1-1/8 —
stud end, turned down section, and O-ring.
1-1/4 259 (191)
1-3/8 — 4. Turn fitting into the boss by hand until face of nut or
1-1/2 330 (243) backup washer squeezes O-ring into the seat and
1-3/4 — contacts face of boss. Loosen an adjustable fitting
2 —
no more than one turn for alignment.
O-RING BOSS PLUG STUD END WITH INCH THREAD IN

5. Tighten straight fitting or hex nut to the torque value
ALUMINUM HOUSING TORQUE VALUES—Tolerance is ± 10% given. Hold body of adjustable fitting using a
unless otherwise specified second wrench when tightening hex nut.
Thread Size
in. N•m (lb-ft)
1/8 7.8 (5.80)
1/4 11.8 (8.70)
3/8 23 (17)
1/2 39 (29)
3/4 55 (41)
1 86 (64)
1-1/4 126 (93)
1-1/2 157 (116)
2 204 (150)
OUT3035,0000353 –19–14JAN04–2/2

060807
PN=37
Torque Values
00
0003 Service Recommendations For Flared
10
Connections—Straight or Tapered Threads
1. Inspect flare and flare seat. They must be free of dirt

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

chart. Do not allow hoses to twist when tightening
–UN–18OCT88
fittings.
a
TORQUE CHART
T6873AD
b
Straight Thread Tapered Thread
Thread
Size N•m lb-ft N•m lb-ft Tapered Thread
1/8 15 11
1/4 20 15 45 33
3/8 29 21 69 51
1/2 49 36 93 69
3/4 69 51 176 130
1 157 116 343 253
1-1/2 196 145 539 398
2 255 188 588 434
a
Torque tolerance is ±10%.
b
With seat face.
NOTE: If female thread is cast iron (control valves, brake

valves motors, etc.), torque must be reduced
approximately 10%.
04T,90,M171 –19–28JAN92–1/1

060807
PN=38
Torque Values
00
Service Recommendations For Flat Face O-Ring Seal Fittings 0003
11
1. Inspect the fitting sealing surfaces and O-ring. They fittings, use backup wrench on straight hose
must be free of dirt or defects. couplings.
2. Lubricate O-rings and install into grove using IMPORTANT: Tighten fittings to 150% of listed
petroleum jelly to hold in place. torque value if indexing is necessary
or if fitting is attached to an
3. Index angle fittings and tighten by hand pressing actuating devise.
joint together to insure O-ring remains in place.
Tighten fittings to 50% of listed
4. Tighten fitting or nut to torque value shown on the torque value if used in aluminum
chart. Do not allow hoses to twist when tightening housing.
FLAT FACE O-RING SEAL FITTING TORQUE*

Nomial Tube O.D. Thread Size Swivel Nut Bulkhead Nut
mm in. in. N•m lb-ft N•m lb-ft
6.35 0.250 9/16-18 16 12 12 9
9.52 0.375 11/16-16 24 18 24 18
12.70 0.500 13/16-16 50 37 46 34
15.88 0.625 1-14 69 51 62 46
19.05 0.750 1 3/16-12 102 75 102 75
22.22 0.875 1 3/16-12 102 75 102 75
25.40 1.000 1 7/16-12 142 105 142 105
31.75 1.250 1 11/16-12 190 140 190 140
38.10 1.500 2-12 217 160 217 160
*Torque tolerance is +15 -20% unless otherwise specified.
Stud End O-ring Seal Torque for Straight and Adjustable Fittings*
Thread Size Straight Hex Size Locknut Hex Size Straight Fitting or Locknut Toque
Inch Inch Inch N•m lb-ft
3/8-24 5/8 9/16 12 9
7/16-20 5/8 5/8 21 15
1/2-20 3/4 11/16 26 19
9/16-18 3/4 3/4 34 25
3/4-16 7/8 15/16 73 55
7/8-14 1 1/16 1 1/16 104 76
1 1/16-12 1 1/4 1 3/8 176 130
1 3/16-12 1 3/8 1 1/2 230 170
1 5/16-12 1 1/2 1 5/8 285 210
*Torque tolerance is +15 -20% unless otherwise specified.
04T,90,K67 –19–02MAR00–1/1

060807
PN=39
Torque Values
00
0003 O-Ring Face Seal Fittings With SAE Inch Hex Nut And Stud End For High Pressure
12
Service Recommendations
A B
C D
–UN–12DEC01
E
H F
F
H70406
E
A—90° Swivel Elbow and Tube C—Stud Straight and Tube Nut E—Stud End G—Swivel Nut
Nut D—Bulkhead Union and Nut F—Tube Nut H—Hex Nut
B—90° Adjustable Stud Elbow
O-RING FACE SEAL FITTINGS WITH SAE INCH HEX NUT AND STUD END FOR HIGH PRESSURE, ABOVE 27 600 kPa (276 bar) (4000
psi), TORQUE VALUES—Tolerance is +15 -20% unless otherwise specified
Nominal Tube OD or Hose ID O-Ring Face Seal Hose or Tube Swivel Nut Bulkhead Nut
Metric Tube Inch Tube OD or Hose ID Thread Size Hex Size Torque Hex Size Torque
OD
mm Dash Size mm (in.) in. in. N•m (lb-ft) in. N•m (lb-ft)
5 -3 4.78 (0.188) — — — — —
6 -4 6.35 (0.250) 9/16-18 11/16 24 (18) 13/16 32 (24)
8 -5 7.92 (0.312) — — — — —
10 -6 9.53 (0.375) 11/16-16 13/16 37 (27) 1 42 (31)
12 -8 12.70 (0.500) 13/16-16 15/16 75 (55) 1-1/8 93 (69)
16 -10 15.88 (0.625) 1-14 1-1/8 103 (76) 1-5/16 118 (87)
20 -12 19.05 (0.750) 1-3/16-12 1-3/8 152 (112) 1-1/2 175 (129)
22 -14 22.23 (0.875) 1-3/16-12 — 152 (112) — 175 (129)
25 -16 25.40 (1.000) 1-7/16-12 1-5/8 214 (158) 1-3/4 247 (182)
32 -20 31.75 (1.250) 1-11/16-12 1-7/8 286 (211) 2 328 (242)
38 -24 38.10 (1.500) 2-12 2-1/4 326 (240) 2-3/8 374 (276)

060807
PN=40
Torque Values
00
O-RING STRAIGHT, ADJUSTABLE, AND EXTERNAL HEX PLUG WITH SAE INCH STUD END FOR HIGH PRESSURE, ABOVE 27 600 0003
kPa (276 bar) (4000 psi), TORQUE VALUES—Tolerance is +15 -20% unless otherwise specified 13
Thread Size Straight Hex Sizea Adjustable Nut Hex Size Steel or Gray Iron Torque
in. in. in. N•m (lb-ft)
3/8-24 5/8 9/16 18 (13)
7/16-20 5/8 5/8 24 (18)
1/2-20 3/4 11/16 30 (22)
9/16-18 3/4 3/4 37 (27)
3/4-16 7/8 15/16 75 (55)
7/8-14 1-1/16 1-1/16 103 (76)
1-1/16-12 1-1/4 1-3/8 177 (131)
1-3/16-12 1-3/8 1-1/2 231 (170)
1-5/16-12 1-1/2 1-5/8 270 (199)
1-5/8-12 1-3/4 1-7/8 286 (211)
1-7/8-12 2-1/8 2-1/8 326 (240)
a
Straight hex size applies to fittings only and may not be the same as the corresponding plug of the same thread size.
1. Inspect fitting and connector sealing surfaces and To protect an O-ring from threads, wrap electrical
the O-rings. They must be free of dirt, scratches, tape over the threads. Slide O-ring over the tape
nicks, and burrs. O-ring must be free of dirt, cuts, into the turned down section. Remove the tape.
4. Turn fitting into the boss by hand until face of nut or
2. Back the stud end hex nut off as far as possible. washer squeezes the O-ring into the seat and
Push backup washer towards the nut to fully contacts face of boss. Loosen adjustable fittings no
expose the turn down section. Washer must fit more than one turn for alignment.
turned down section and not be too loose
Hold connections together while tightening nut to
3. Lubricate O-rings using a thin film of clean hydraulic ensure O-ring remains in place.
oil or as needed, petroleum jelly to hold O-ring in
place. 5. Tighten fitting or nut to torque value shown. Use a
second wrench to hold the fitting in position or to
Install O-ring into groove making sure it is seated at keep hose from twisting while tightening nut.
the bottom. Excess petroleum jelly will prevent
seating of O-ring and cause it to pop out.
OUT3035,0000420 –19–14JAN04–2/2

060807
PN=41
Torque Values
00
0003 O-Ring Face Seal Fittings With Metric Hex Nut And Stud End For Standard Pressure
14
Service Recommendations
1 2 3 4
10
–UN–18NOV03
7 9
11 8 11
6 6 5
10 11
T196337
10
8 8
T196337
1—90° Swivel Elbow 4—Bulkhead Union and Nut 7—Swivel Nut 10—O-Ring
2—90° Adjustable Stud Elbow 5—External Hex Stud End Plug 8—Stud End 11—Identification Groove
3—Stud Straight 6—Tube Nut 9—Hex Nut
O-RING FACE SEAL AND FITTINGS WITH METRIC HEX NUT AND STUD END FOR STANDARD PRESSURE, BELOW 27 600 kPa
(275.8 bar) (4,000 psi), TORQUE VALUES—Tolerance is +15 -20% unless otherwise specified
OD
mm Dash Size mm (in.) in. mm N•m (lb-ft) mm N•m (lb-ft)
4 -2 3.18 (0.125) — — — — —
5 -3 4.78 (0.188) — — — — —
6 -4 6.35 (0.250) 9/16-18 17 16 (12) 22 32 (24)
8 -5 7.92 (0.312) — — — — —
10 -6 9.53 (0.375) 11/16-16 22 24 (18) 27 42 (31)
12 -8 12.70 (0.500) 13/16-16 24 50 (37) 30 93 (69)
16 -10 15.88 (0.625 1-14 30 69 (51) 36 118 (87)
20 -12 19.05 (0.750) 1-3/16-12 36 102 (75) 41 175 (129)
22 -14 22.23 (0.875) 1-3/16-12 36 102 (75) 41 175 (129)
25 -16 25.40 (1.000) 1-7/16-12 41 142 (105) 46 247 (182)
28 — — — — — — —
32 -20 31.75 (1.250) 1-11/16-12 50 190 (140) 50 328 (242)
38 -24 38.10 (1.500) 2-12 60 217 (160) 60 374 (276)
50 -32 50.80 (2.000) — — — — —

060807
PN=42
Torque Values
00
O-RING STRAIGHT, ADJUSTABLE, AND EXTERNAL HEX PLUG WITH METRIC STUD END FOR STANDARD PRESSURE, BELOW 27 0003
600 kPa (275.8 bar) (4,000 psi), TORQUE VALUES—Tolerance is +15 -20% unless otherwise specified 15
Thread Sizea Straight Hex Sizeb Adjustable Nut Hex Steel or Gray Iron Torque Aluminum or Brass
Size Torque
mm. mm mm N•m (lb-ft) N•m (lb-ft)
M8 x 1 12 12 8 (6) 5 (4)
M10 x 1 14 14 15 (11) 10 (7)
M12 x 1.5 17 17 25 (18) 17 (12)
M14 x 1.5 19 19 40 (30) 27 (20)
M16 x 1.5 22 22 45 (33) 30 (22)
M18 x 1.5 24 24 50 (37) 33 (25)
M22 x 1.5 27 27 69 (51) 46 (34)
M27 x 2 32 32 100 (74) 67 (49)
M30 x 2 36 36 130 (96) 87 (64)
M33 x 2 41 41 160 (118) 107 (79)
M38 x 2 46 46 176 (130) 117 (87)
M42 x 2 50 50 210 (155) 140 (103)
M48 x 2 55 55 260 (192) 173 (128)
M60 x 2 65 65 315 (232) 210 (155)
a
Stud end threads are identified as metric by an identification groove in the hex nut next to the O-ring.
b
OUT3035,0000366 –19–14JAN04–2/2

060807
PN=43
Torque Values
00
0003 O-Ring Face Seal Fittings With Metric Hex Nut And Stud End For High Pressure Service
16
Recommendations
1 2 3 4
10
–UN–18NOV03
7 9
11 8 11
6 6 5
10 11
T196337
10
8 8
T196337
1—90° Swivel Elbow 4—Bulkhead Union and Nut 7—Swivel Nut 10—O-Ring
2—90° Adjustable Stud Elbow 5—External Hex Stud End Plug 8—Stud End 11—Identification Groove
3—Stud Straight 6—Tube Nut 9—Hex Nut
O-RING FACE SEAL FITTINGS WITH METRIC HEX NUT AND STUD END FOR HIGH PRESSURE, ABOVE 27 600 kPa (275.8 bar) (4,000
psi), TORQUE VALUES—Tolerance is +15 -20% unless otherwise specified
OD
mm Dash Size mm (in.) in. mm N•m (lb-ft) mm N•m (lb-ft)
4 -2 3.18 (0.125) — — — — —
5 -3 4.78 (0.188) — — — — —
6 -4 6.35 (0.250) 9/16-18 17 24 (18) 22 32 (24)
8 -5 7.92 (0.312) — — — — —
10 -6 9.53 (0.375) 11/16-16 22 37 (27) 27 42 (31)
12 -8 12.70 (0.500) 13/16-16 24 75 (55) 30 93 (69)
16 -10 15.88 (0.625) 1-14 30 103 (76) 36 118 (87)
20 -12 19.05 (0.750) 1-3/16-12 36 152 (112) 41 175 (129)
22 -14 22.23 (0.875) 1-3/16-12 36 152 (112) 41 175 (129)
25 -16 25.40 (1.000) 1-7/16-12 41 214 (158) 46 247 (182)
28 — — — — — — —
32 -20 31.75 (1.250) 1-11/16-12 — 286 (211) 50 328 (242)
38 -24 38.10 (1.500) 2-12 — 326 (240) 60 374 (276)

060807
PN=44
Torque Values
00
O-RING STRAIGHT, ADJUSTABLE, AND EXTERNAL HEX PLUG WITH METRIC STUD END FOR HIGH PRESSURE, ABOVE 27 600 0003
KPA (275.8 BAR) (4,000 PSI), TORQUE VALUES—Tolerance is +15 -20% unless otherwise specified 17
Thread Sizea Straight Hex Sizeb Adjustable Nut Hex Size Steel or Gray Iron Torque
mm. mm mm N•m (lb-ft)
M8 x 1 12 12 8 (6)
M10 x 1 14 14 15 (11)
M12 x 1.5 17 17 35 (26)
M14 x 1.5 19 19 45 (33)
M16 x 1.5 22 22 55 (41)
M18 x 1.5 24 24 70 (52)
M22 x 1.5 27 27 100 (74)
M27 x 2 32 32 170 (125)
M30 x 2 36 36 215 159)
M33 x 2 41 41 260 (192)
M38 x 2 46 46 320 (236)
M42 x 2 50 50 360 (266)
M48 x 2 55 55 420 (310)
a
Stud end threads are identified as metric by an identification groove in the hex nut next to the O-ring.
b
OUT3035,0000421 –19–14JAN04–2/2

060807
PN=45
Torque Values
00
0003 Service Recommendations for Metric Series Four Bolt Flange Fitting
18
–UN–01MAR90
T6890BB
A—Sealing Surface B—Split Flange C—Pinched O-Ring D—Single Piece Flange
1. Clean sealing surfaces (A). Inspect. Scratches then tighten the diagonally opposite cap screw.
cause leaks. Roughness causes seal wear. Tighten two remaining cap screws. Tighten all cap
Out-of-flat causes seal extrusion. If defects cannot screws as specified in the chart below.
be polished out, replace component.
DO NOT use air wrenches. DO NOT tighten one
2. Install the correct O-ring (and backup washer if cap screw fully before tightening the others. DO
required) into groove using petroleum jelly to hold it NOT over tighten.
in place.
TORQUE CHARTa
3. Split flange: Loosely assemble split flange (B) Thread b
N•m lb-ft
halves. Make sure split is centrally located and M6 12 9
perpendicular to the port. Hand tighten cap screws M8 30 22
to hold parts in place. Do not pinch O-ring (C).
M10 57 42
4. Single piece flange (D): Place hydraulic line in M12 95 70

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

060807
PN=46
Torque Values
00
Service Recommendations For Inch Series Four Bolt Flange Fittings 0003
19
–UN–01MAR90
T6890BB
1. Clean sealing surfaces (A). Inspect. Scratches TORQUE CHART

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

cap screw fully before tightening the others. DO
NOT over tighten.
04T,90,K174 –19–01AUG94–1/1

060807
PN=47
Torque Values
00
0003 Inch Series Four Bolt Flange Fitting For High Pressure Service Recommendations
20
–UN–01MAR90
T6890BB
INCH SERIES FOUR BOLT FLANGE FITTING FOR 41 400 kPa 2. Install the O-ring (and backup ring, if used) into
(414 bar) (6000 psi) PRESSURE SERIES TORQUE VALUES— groove. Use petroleum jelly to hold it in place.
Tolerance is ± 10% unless otherwise specified
Nominal Cap Screw Sizea Min—Max Torque IMPORTANT: DO NOT use air wrenches. DO NOT
Flange Size
tighten one cap screw fully before
in. in. N•m (lb-ft)b tightening the others. DO NOT over
1/2 5/16-18 UNC 20—31 (15—23) tighten.
3/4 3/8-16 UNC 34—54 (25—40)
1 7/16-14 UNC 57—85 (42—63) 3. Split flange: Loosely assemble split flange (B)
1-1/4 1/2-13 UNC 85—131 (63—97)
halves. Make sure split is centrally located and
perpendicular to port. Hand tighten cap screws to
1-1/2 5/8-11 UNC 159—264 (117—195)
hold flange halves and line in place. Do not pinch
2 3/4-10 UNC 271—468 (200—345) O-ring (C).
a
JDM A17D, SAE Grade 5 or better cap screws with plated
hardware. Single piece flange (D): Make sure flange is
Lock washers are permissible but not recommended.
centrally located on port and line is centered in
b
Minimum torques given are enough for the given size connection flange. Install the cap screws. Hand tighten cap
with the recommended working pressure. Torques can be
increased to the maximum shown for each cap screw size if
screws to hold flange and line in place. Do not
desired. Increasing cap screw torque beyond the maximum will pinch O-ring.
result in flange and cap screw bending and connection failures.
4. Tighten one cap screw and then the diagonally
1. Clean sealing surfaces (A). Inspect. Scratches, opposite cap screw. Tighten the two remaining cap
nicks, and burrs cause leaks. Roughness causes screws. Tighten cap screws within the specified
O-ring wear. Out-of-flat causes O-ring extrusion. If torque values.
imperfection cannot be polished out, replace
component.
OUT3035,0000422 –19–14JAN04–1/1

060807
PN=48
Torque Values
00
Service Recommendations For 0003
21
Non-Restricted Banjo (Adjustable) Fittings
1. Inspect all fitting sealing surfaces. They must be free of

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

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

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

060807
PN=49
Torque Values
00
0003 Torque Value
22
Tube Fitting Inch Size N•m lb-ft
O.D. Size
6L 1/8 25 18
8L 1/4 50 37
10 L 1/4 50 37
12 L 3/8 90 66
15 L 1/2 130 96
18 L 1/2 150 111
22 L 3/4 250 184
28 L 1 400 295
35 L 1-1/4 600 443
42 L 1-1/2 800 590
6S 1/4 50 37
8S 1/4 50 37
10 S 3/8 90 66
12 S 3/8 100 74
14 S 1/2 130 96
16 S 1/2 150 111
20 S 3/4 250 184
25 S 1 400 295
30 S 1-1/4 600 443
38 S 1-1/2 800 590
CED,OUO1002,562 –19–09MAR98–2/2

060807
PN=50
Torque Values
00
Service Recommendations For O-Ring Boss 0003
23
Fittings With Shoulder
1. Inspect component seal boss seat for dirt or defects.
2. Inspect EOlastic seal (A) for damage. Replace seal or
–UN–06MAR98
fitting as necessary.
To replace seal, put electrical tape over threads to

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

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

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

060807
PN=51
Torque Values
00
0003 Torque Value
24
Tube Fitting Inch Size N•m lb-ft
O.D. Size
6L 1/8 20 15
8L 1/4 40 30
10 L 1/4 40 30
12 L 3/8 80 59
15 L 1/2 140 103
18 L 1/2 100 74
22 L 3/4 180 133
28 L 1 300 221
35 L 1-1/4 600 443
42 L 1-1/2 800 590
6S 1/4 50 37
8S 1/4 50 37
10 S 3/8 90 66
12 S 3/8 90 66
14 S 1/2 160 118
16 S 1/2 140 103
20 S 3/4 250 184
25 S 1 400 295
30 S 1-1/4 650 479
38 S 1-1/2 800 590

060807
PN=52
Torque Values
00
Hex Socket Head Plugs Only 0003
25
Torque Value
M 10 x 1 13 10
M 12 x 1.5 30 22
M 14 x 1.5 40 30
M 16 x 1.5 60 44
M 18 x 1.5 70 52
M 20 x 1.5 90 66
M 22 x 1.5 100 74
M 26 x 1.5 120 89
M 27 x 2 150 111
M 33 x 2 250 184
M 42 x 2 400 295
M 48 x 2 500 369
1/8 15 11
1/4 33 24
3/8 70 52
1/2 90 66
3/4 150 111
1 220 162
1-1/4 600 443
1-1/2 800 590
CED,OUO1002,563 –19–09MAR98–3/3

060807
PN=53
Torque Values
00
0003 Metric 24° O-Ring Seal DIN 20078 Service
26
Recommendations
METRIC 24° O-RING SEAL DIN 20078 TORQUE VALUES

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

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

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

of dirt scratches, nicks, and burrs.
Continued on next page CED,OUO1002,517 –19–14JAN04–1/2

060807
PN=54
Torque Values
00
2. Inspect the O-ring. It must be free dirt, cuts, cracks, 0003
27
swelling or flatten condition.
3. Lubricate O-rings using a thin film of clean hydraulic

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

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

then an additional 1/4—1/3 turn using a wrench.
CED,OUO1002,517 –19–14JAN04–2/2

060807
PN=55
Torque Values
00
0003
28

060807
PN=56
Section 01
Wheels
Contents 01
Page
Group 0110—Powered or Non-Powered Wheels and

Fastenings
Rear Wheel Assembly Remove and
Install. . . . . . . . . . . . . . . . . . . . . . . . . . . . .01-0110-1
Front Wheel Assembly Remove and
Install. . . . . . . . . . . . . . . . . . . . . . . . . . . . .01-0110-3
Tire Remove and Install . . . . . . . . . . . . . . . .01-0110-4

060807
PN=1
Contents
01

060807
PN=2
Group 0110
Powered or Non-Powered Wheels and Fastenings
Rear Wheel Assembly Remove and Install
CAUTION: Prevent possible crushing injury

from heavy component. Use appropriate lifting
device. 01
–UN–04APR07
0110
1
1. Loosen cap screws (2) before lifting wheel off ground.
2. Raise machine approximately 15 cm (6 in.) and put
TX1019543A
shop floor stands under main frame.
3. Put wheel lift (1) under wheel. Fasten safety chain Rear Wheel Assembly Remove and Install
around upper portion of tire.
1—Wheel Lift
Specification 2—Cap Screws (10 used)
Rear Wheel (without fluid)—
Weight (approximate) ...................................................................... 141 kg
310 lb
Specification
Rear Wheel (with fluid)—Weight
(approximate)................................................................................... 420 kg
930 lb
4. Remove cap screws (2). Pull wheel assembly away

from axle.
5. Inspect all parts for damage; replace parts as

necessary.
6. Thoroughly clean cap screws, washers, mounting

surfaces and tapped holes in flanged axle. Use
compressed air to dry all parts and tapped holes.
7. Install wheel using wheel lift (1).
8. Install and snug tighten cap screws (2). Lower machine

to the ground.
Continued on next page KK70125,000073C –19–08MAR07–1/2

060807
PN=59
IMPORTANT: If a power wrench is used, be sure that

cap screws are engaged to prevent
stripping. Operate wrench slowly to
prevent thread damage.
01
0110 9. Tighten cap screws to specification.
2
Specification
Rear Wheel Cap Screws (19.5L x
24)—Torque.................................................................................. 725 N•m
535 lb-ft
KK70125,000073C –19–08MAR07–2/2

060807
PN=60
Front Wheel Assembly Remove and Install

device. 01
0110
–UN–27MAR90
3
1. Loosen cap screws or nuts for MFWD machines.
2. Lift wheel off ground and put shop floor stand under
axle housing.
T6382BJ
3. Put wheel lift under wheel. Fasten safety chain around
upper portion of tire.
Specification
Front Wheel (without fluid)—
Weight (approximate) ...................................... 50 kg (110 lb) without fluid
110 lb
Front Wheel (with fluid)—Weight
(approximate)................................................................................... 186 kg
411 lb
4. Remove cap screws. Pull wheel assembly away from

axle.

necessary.
6. Clean lug nuts and tapped studs. Use compressed air

to dry all parts.
IMPORTANT: If a power wrench is used, be sure that

lug nuts are engaged to prevent
stripping. Operate wrench slowly to
prevent thread damage.
7. Install wheel assembly. Install nuts or cap screws and

tighten to specification.
Specification
Front Wheel-to-Hub Cap Screw
without MFWD (11L x 16 Tire
Size)—Torque............................................................................... 126 N•m
170 lb-ft
Front Wheel-to-Hub Cap Screw
without MFWD (14.5/75 -16.1 Tire
Size)—Torque............................................................................... 290 N•m
214 lb-ft
Continued on next page KK70125,000073D –19–08MAR07–1/2

060807
PN=61
Specification
Front Wheel-to-Hub Nut With
MFWD (12.5/80-18 Tire Size)—
Torque ......................................................................................... 725 N•m
535 lb-ft
01
0110 8. Lower machine to the ground.
4
KK70125,000073D –19–08MAR07–2/2
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 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.
–UN–23AUG88
Check wheels for low pressure, cuts, bubbles,
damaged rims or missing lug bolts and nuts. TS211
NOTE: See John Deere Off-The-Road Tire Maintenance

Manual to remove tire from wheel.
1. The tire can be removed without removing the wheel

from the machine.
Continued on next page KK70125,000073E –19–11JAN07–1/4

060807
PN=62
2. Always completely deflate tire by removing the valve

core (A) from valve before attempting any demounting
operation. Check valve stem by running a probe
through it to make sure the valve stem is not plugged.
Remove valve nut (B).
01
0110
–UN–13FEB90
3. Remove tire. 5
A—Valve Core
B—Valve Nut
T91801
KK70125,000073E –19–11JAN07–2/4

necessary.
5. Make sure all parts are clean and free from rust or
grease before assembly.
6. To prevent slipping of the wheel under load, the inside

and outside of wheel must be free of paint, rust, oil,
grease, dirt or other foreign material before installation.
7. Install valve stem in rim base and tighten valve core

housing finger tight.
CAUTION: Serious bodily injury can occur from

explosion when mounting and inflating tires if
safe procedures are not followed.
8. Before mounting tire on rim, add soap lubricant to bead

of the tire.
–UN–13FEB90
9. Install tire.
10. Clear area of all persons.
A—Rim T91802
B—Valve Core
C—Side Flange

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PN=63
11. Turn tire so valve stem is positioned at 12 o’clock.

Use a pressure regulating valve with clip-on chuck
and extension hose long enough to allow you to stand
to one side and NOT in front of tire while inflating.
01
0110 12. Use only recommended air pressure. Pressure over
6 this limit can cause an explosion.
13. Add air until side flange of tire slides out against rim.
14. Adjust air pressure to proper specification.
A—Pressure Regulating Valve with Clip-On Chuck
–UN–13FEB90
T91803
KK70125,000073E –19–11JAN07–4/4

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PN=64
Section 02
Axles and Suspension Systems
Contents
Page
Group 0225—Input Drive Shafts and U-Joints

Drive Shaft Remove and Install . . . . . . . . . . .02-0225-2 02
Drive Shaft and U-Joints Remove and
Install. . . . . . . . . . . . . . . . . . . . . . . . . . . . .02-0225-4
Group 0230—Non-Powered Wheel Axles

Hub Assembly Remove and Install . . . . . . . .02-0230-1
Spindle Assembly Remove and Install. . . . . .02-0230-2
Tie Rod Remove and Install . . . . . . . . . . . . .02-0230-5
Non-Powered Front Axle Remove and
Install. . . . . . . . . . . . . . . . . . . . . . . . . . . . .02-0230-7
Group 0240—Powered Wheel Axle (MFWD)

Mechanical Front Wheel Drive (MFWD)
Axle Remove and Install . . . . . . . . . . . . . .02-0240-1
Axle Disassemble and Assemble . . . . . . . .02-0240-4
Group 0250—Axle Shaft, Bearings, and Reduction

Gears
Service Brakes Inspection . . . . . . . . . . . . . . .02-0250-1
Rear Axle Remove and Install . . . . . . . . . . . .02-0250-3
Rear Axle Disassemble . . . . . . . . . . . . . . . . .02-0250-7
Park Brake Disassemble and Assemble . . .02-0250-22
Rear Axle Assemble . . . . . . . . . . . . . . . . . .02-0250-40
Gear Tooth Contact Pattern Check . . . . . . .02-0250-62

060807
PN=1
Contents
02

060807
PN=2
Group 0225
Input Drive Shafts and U-Joints
02
0225
1

060807
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Drive Shaft Remove and Install
02
0225
2
–UN–12DEC06
TX1014964
Rear Drive Shaft

Continued on next page KK70125,000073F –19–08MAY07–1/3

060807
PN=68
1—Driveshaft 3—Cap Screw (4 used) 5—Cross and Bearing (2 used) 7—Universal Joint Yoke
2—Snap Ring (4 used) 4—Half Clamp (2 used) 6—Cap Screw (4 used)
IMPORTANT: Always replace drive shaft cap 1. To remove rear drive shaft (1), remove cap screws
screws when removed. (3 and 6) and half-clamps (3) . Discard cap screws.
02
0225
KK70125,000073F –19–08MAY07–2/3 3
2. To remove MFWD drive shaft (3) (if equipped), remove

and discard four cap screws (2) and two half-clamps
(1) at front axle.
3. Slide drive shaft from transmission output shaft.
–UN–17AUG00
IMPORTANT: Do not reuse drive shaft cap screws.
4. Apply PM37418 thread lock and sealer (medium

strength) to drive shaft cap screws.
T133130B
5. Install drive shaft(s) with half-clamps and new cap
screws. Tighten to specification.
1—Half-Clamps (2 used)
Specification 2—Cap Screw (4 used)
Universal Joint Yoke Cap 3—MFWD Drive Shaft
Screws—Torque ............................................................................. 94 N•m
69 lb-ft
Rear Drive Shaft Half Clamp Cap
Screws—Torque ............................................................................. 40 N•m
30 lb-ft
MFWD Drive Shaft Half Clamp
Cap Screws—Torque ..................................................................... 40 N•m
30 lb-ft
KK70125,000073F –19–08MAY07–3/3

060807
PN=69
Drive Shaft and U-Joints Remove and Install
IMPORTANT: Always replace drive shaft cap screws

when removed.
1. Remove drive shaft.
–UN–05FEB90
• For front drive shaft, remove and discard four cap
screws at front axle. Slide drive shaft from spline.
• For rear drive shaft, remove four cap screws and two
T94751
02 half-clamps at each end of drive shaft. Discard cap
0225 screws.
4
2. Remove grease fitting and snap rings. A—Bearing Cap
3. Put drive shaft on a vise so both ears of one of the

drive shaft yokes rests on the open jaws of the vise.
Force the opposite yoke down, using a hammer and
brass rod, until bearing cap (A) is approximately
halfway out.
4. Remove bearing cap (A) and cross. Remove opposite

bearing cap. Replace parts if necessary.
KK70125,0000740 –19–26FEB07–1/2
5. Install needle bearings (A). Use grease to hold needle

bearings in position.
6. Install seal (B) on bearing cap.
7. Put cross (C) between yoke ears.
–UN–05FEB90
8. Push bearing caps into yoke just far enough to install
snap ring. Install snap ring. T94754
9. Install grease fitting and inject grease into U-joint. Do

not force grease out seal (B).See Grease. (Operator’s
Manual.)
A—Needle Bearing
B—Seal
IMPORTANT: Do not reuse drive shaft cap screws.
C—Cross
10. Install drive shaft. See Drive Shaft Remove and

Install. (Group 0225.)
KK70125,0000740 –19–26FEB07–2/2

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PN=70
Group 0230
Non-Powered Wheel Axles
Hub Assembly Remove and Install
02
0230
1
–UN–13NOV02
T161378
1—Seal Ring 4—O-Ring 6—Thrust Plate 8—Wheel Hub Cover
2—Bearing Cone 5—Bearing Cone 7—Cap Screw (3 used) 9—Wheel Hub Cover Plug
3—Wheel Hub
1. Raise machine and install jack stands so front 6. Remove and inspect wheel hub (3) with bearing
wheels are off ground. cups. To replace bearing cups, place wheel hub on
flat surface and drive bearing cups out with a
hammer and driver.
CAUTION: Secure wheel hub (3) with a lift
strap before removing any components.
IMPORTANT: Removing seal ring (1) will destroy
it. Do not remove seal ring unless
2. Remove front wheel. See Front Wheel Assembly
damage is noted.
Remove and Install. (Group 0110.)
7. Remove bearing cone (2) using wedges.
3. Remove wheel hub cover plug (9) and remove
wheel hub cover (8) using wedges. Remove and
8. Clean all dirt and grease from bearings, spindle and
inspect O-ring (4), replace if necessary.
hub assembly.
4. Remove capscrews (7) and thrust plate (6).
9. Inspect grease seals for damage or hardened lips
and replace as necessary.
5. Remove wheel bearing (5).
Continued on next page KK70125,0000741 –19–11JAN07–1/2

060807
PN=71
10. Pack bearings and coat seal lips with grease. 15. Grease and install O-ring (4) on wheel hub cover
(8). Install wheel hub cover into wheel hub.
11. Install bearing cone (2) on spindle using a
hammer and driver. 16. Install hub cover plug (9) and tighten to
specification.
12. Install wheel hub (3) on spindle.
Specification
13. Install bearing cone (5) to hub and spindle. Wheel Hub Cover Plug—
Torque...................................................................................... 15 N•m
11 lb-ft
14. Apply TY9371 LOCTITE to cap screws (7).
02 Position thrust plate (6) on spindle in hub and 17. Install wheel. See Front Wheel Assembly Remove
0230 install cap screws (7). Torque cap screws to
2 and Install. (Group 0110.)
specification.
Specification
Thrust Plate Cap Screws—
Torque.................................................................................... 120 N•m
89 lb-ft
LOCTITE is a trademark of Loctite Corp. KK70125,0000741 –19–11JAN07–2/2
Spindle Assembly Remove and Install
1. Remove wheel hub. See Hub Assembly Remove and

KK70125,0000742 –19–08MAY07–1/7
2. Loosen tie rod lock nut (1).
3. Break loose ball joint using separator (2).
4. Remove and discard locking nut and remove tie rod

threaded pin from swivel housing.
–UN–25SEP02
1—Locking Nut
2—Ball Joint Separator
T159793B
Continued on next page KK70125,0000742 –19–08MAY07–2/7

060807
PN=72
IMPORTANT: Secure swivel housing with lifting strap.
5. Remove cap screws (1) from swivel housing king pins

(2).
NOTE: Be aware of belleville washer placement between
–UN–01APR03
king pins and swivel housing.
6. Remove king pins using pry bars.
T189164B
02
1—Cap Screws (4 used)
0230
2—King Pin
3
KK70125,0000742 –19–08MAY07–3/7
NOTE: King pin is serviced as an assembly.
7. Inspect king pins (1,2) for wear or damage. Replace if

necessary.
–UN–02APR03
1—Lower King Pin
2—Upper King Pin
T189226B
KK70125,0000742 –19–08MAY07–4/7
8. Remove swivel housing (1).
1—Swivel Housing
–UN–25SEP02
T159826B

060807
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02
0230
4
–UN–13NOV02
T161376
1—Axle Beam 3—Washer (2 used) 5—Bushing (2 used) 6—Washer (2 used)
2—Bushing (2 used) 4—Bushing (2 used)
9. Inspect axle beam bushings (4) for damage or IMPORTANT: Upper king pin must be installed
wear. with grease fitting pointed towards
center of axle.
10. Replace if necessary.
15. Install upper king pin with spring washer (3)
IMPORTANT: Bushings must be fully seated or positioned as shown.
king pins will be damaged.
16. Tighten cap screws to specification.
11. Fill king pin seat with grease.
Specification
12. Position swivel housing on axle beam. Upper and Lower King Pin Cap
Screws—Torque .................................................................... 120 N•m
86 lb-ft
13. Grease king pin surfaces.
NOTE: Loosely install locking nut at this point.
14. Install lower king pin with spring washer (6)
positioned as shown. Tighten cap screws to 17. Install tie rod threaded pin into swivel housing with
specification. new locking nut.
Specification
Upper and Lower King Pin Cap
18. Install wheel hub. See Hub Assembly Remove and
Screws—Torque .................................................................... 120 N•m Install. (Group 0110)
86 lb-ft

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NOTE: If tie rod, spindle assembly, or steering Adjust toe-in. See Toe-In Check and Adjust.
cylinder are adjusted or serviced, perform the (Group 9020-20.)
following procedures.
Adjust steering angle. See Steering Angle Check
19. Adjust tracking angle. See Tracking Angle Check and Adjust. (Group 9020-20.)
and Adjust. (Group 9020-20.)
02
0230
KK70125,0000742 –19–08MAY07–7/7 5
Tie Rod Remove and Install
1. Remove front wheels. See Front Wheel Assembly

KK70125,0000743 –19–05JUN07–1/3
NOTE: Start engine and turn wheel to extend cylinder rod

beyond machine main frame for left or right side
tie rod.
2. Loosen tie rod lock nut (1).
–UN–25SEP02
3. Break loose ball joint using separator (2).
4. Remove and discard lock nut and remove tie rod

threaded pin from swivel housing.
T159793B
1—Lock Nut
2—Ball Joint Separator
Continued on next page KK70125,0000743 –19–05JUN07–2/3

060807
PN=75
5. Separate tie rod (3) from steering cylinder by loosening

jam nut (4).
6. Replace parts as necessary.
7. Install tie rod (3) to ball joint (2).
–UN–27SEP02
NOTE: If tie rod, spindle assembly, or steering cylinder
are adjusted or serviced, perform the following
procedures.
T159910B
02
0230 8. Adjust tracking angle. See Tracking Angle Check and
6
Adjust. (Group 9020-20.)
1—Cylinder Rod
2—Ball Joint
Adjust toe-in. See Toe-In Check and Adjust. (Group
3—Tie Rod
9020-20.) 4—Jam Nut
Adjust steering angle. See Steering Angle Check and

KK70125,0000743 –19–05JUN07–3/3

060807
PN=76
Non-Powered Front Axle Remove and Install
1. Raise loader and install boom lock bar.
2. Remove counterweights if equipped. See

Counterweight Remove and Install. (Group 1749.)
3. Operate all hydraulic functions to release system

pressure.
02
CAUTION: Heavy component; use appropriate 0230
lifting device. 7
Specification
310SJ—Weight .............................................................................. 7693 kg
16 960 lb
410J—Weight ................................................................................ 8391 kg
18 500
4. Raise and support front of machine. Position floor

stands under main frame.
5. Remove both front wheels. See Remove and Install

Front Wheel Assembly. (Group 0110.)
6. Tag and disconnect steering cylinder lines. Close all

openings using caps and plugs.

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PN=77
02
0230
8
–UN–21MAR03
T188853
1—Thrust Washer (3 used) 4—Bushing 7—Nut (2 used) 9—Hydraulic Hose (2 used)
2—Axle 5—Washer 8—Lubrication Fitting (2 used) 10—Adapter (2 used)
3—Pin 6—Cap Screw (M16 x 40)
7. Position a low lift jack under center of front axle. 9. Remove remote lubrication lines from rear of pin
(3).
8. Remove cap screw (6), washer (5), and bushing
(4). 10. Remove pin and axle.

060807
PN=78
02
0230
9
–UN–13NOV02
T161376
1—Axle Beam 3—Washer (2 used) 5—Bushing (2 used) 6—Washer (2 used)
2—Bushing (2 used) 4—Bushing (2 used)
11. Inspect pivot bushings (2). Replace if worn or Specification

damaged. Axle Pivot Pin Cap Screw—
Torque.................................................................................... 215 N•m
158 lb-ft
NOTE: Surfaces must be free of grease, oil, dirt or
paint. 16. Connect remote lubrication lines and steering
cylinder hoses.
12. Install pivot bushings.
17. Install front wheels. See Remove and Install Front
13. Position axle under front frame assembly. Wheel Assembly. (Group 0110.)
NOTE: Use as many thrust washers as will fit between 18. Install counterweights. See Counterweight
axle and frame. Remove and Install. (Group 1749.)
14. Apply multi-purpose grease on pin. Install pin into 19. Remove boom lock bar and lower loader.
bore with thrust washers.
15. Install axle pivot pin bushing, washer, and cap

screw. Tighten to specification.
KK70125,0000744 –19–05JUN07–3/3

060807
PN=79
02
0230
10

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PN=80
Group 0240
Powered Wheel Axle (MFWD)
Mechanical Front Wheel Drive (MFWD) Axle

Remove and Install
1. Raise loader and install boom lock bar.
CAUTION: Use a lifting device for heavy
–UN–23AUG88
components.
2. Remove counterweights (if equipped).
X9811
02
0240
CAUTION: The approximate weight of total
1
machine is 6237 kg (13750 lb). Use appropriate
lifting device and floor stands.
Specification
Machine—Weight (approximate) ................................................... 6606 kg
14565 lb

stands under main frame—one at each side.
4. Remove front wheels. See Front Wheel Assembly

CAUTION: Escaping fluid under pressure can

penetrate the skin causing serious injury. Avoid
the hazard by relieving pressure before
disconnecting hydraulic or other lines. Tighten
all connections before applying pressure.
Search for leaks with a piece of cardboard.
Protect hands and body from high pressure
fluids.
If an accident occurs, see a doctor immediately.

Any fluid injected into the skin must be
surgically removed within a few hours or
gangrene may result. Doctors unfamiliar with
this type of injury should reference a
knowledgeable medical source. Such
information is available from Deere & Company
5. Operate all hydraulic control valves to release pressure

in hydraulic system. Disconnect steering cylinder lines.
Close all openings with caps or plugs.

060807
PN=81
6. Remove cap screws to disconnect drive shaft.
02
0240
2

060807
PN=82
02
0240
3
–UN–12AUG98
T107054
1—Cap Screw 4—Pin 6—Thrust Washer (2 used) 8—Adapter (2 used)

2—Washer 5—Thrust Washer (as 7—Bushing (2 used)
3—Bushing required)

060807
PN=83
7. Position a low lift jack under center of front axle. 15. Install mounting hardware (1—3). tighten cap
Attach the adjustable-grip arms and safety chains of screw to specifications.
the low lift jack to the axle housing.
Specification
8. Remove cap screw (1) washer (2) and bushing (3). Axle Pivot Pin Cap Screw—
Torque.................................................................................... 215 N•m
158 lb-ft
9. Disconnect two lubrication lines from adapters (8).
16. Install drive shaft. Tighten cap screws to
10. Remove pin (4), thrust washers (5 and 6) and axle specification.
assembly.
02 Specification
0240 11. Inspect bushings (7) for wear or damage. Remove MFWD Drive Shaft U-Joint
4 Strap-to-Axle Yoke Cap
only if replacement is necessary.
Screw—Torque ........................................................................ 41 N•m
30 lb-ft
12. Put TY15969 LOCTITE retaining compound on
new bushings.
17. Connect steering cylinder lines.
13. Raise axle into position under front frame
18. Install front wheels and lower machine to ground.
assembly. Install thrust washers (5) as required
See Front Wheel Assembly Remove and Install.
between pin (4) and frame until axle pivot end play
(Group 0110.)
is within specification.
Specification
19. Remove boom lock bar and lower loader.
MFWD Axle Pivot—End Play ............................................ 0—1.5 mm
0—0.060 in.
14. Apply multi-purpose grease on pin (4). Install pin

into bore. Install two adapters (8) and connect
lubrication lines.
LOCTITE is a trademark of Loctite Corp. KK70125,0000746 –19–11JAN07–4/4
Mechanical Front Wheel Drive (MFWD) Axle

Disassemble and Assemble
For additional information on mechanical front wheel drive

axles (MS-3025), see Front Wheel Drive Axles—AS and
MS Series (CTM4687).
–UN–17JAN89
TS225
KK70125,0000745 –19–07MAY07–1/1

060807
PN=84
Group 0250
Axle Shaft, Bearings, and Reduction Gears
Service Brakes Inspection
1. Remove plugs from inspection ports (1 and 2).
NOTE: If axle is removed from machine, skip steps 2 and
–UN–10JAN06
3 and apply hydraulic pressure directly to axle
service brake ports using a manually operated
hydraulic pump.
TX1002474A
2. Start engine. Do not release park brake.
02
3. Apply the service brakes. 0250
Right External Inspection Port 1
1—Right Side Brake Inspection Port

2—Left Side Brake Inspection Port
–UN–10JAN06
TX1002475A
Left Side External Inspection Port

060807
PN=85
NOTE: When the service brakes are applied, gap (A) will
equal the overall thickness of brake disk (C).
A piece of metal bar stock with a thickness of 4.5

mm (0.177 in.) can be used as a gauge to check
–UN–30APR07
gap (B). If the 4.5 mm (0.177 in.) gauge cannot fit
between two separator disks , replace brake
disks.
TX1022768A
4. Check gap (A) between two separator disks (B) using
02 a feeler gauge.
0250
2 Left Service Brake Inspection Port Shown
5. Replace brake disks if gap (A) is less than 4.5 mm
(0.177 in.) See Rear Axle Disassemble. (Group 0250)
Rear Axle—Specification
Service Brake Disk—Thickness
(minimum) ....................................................................................... 4.5 mm
0.177 in.
A—Gap Measurement
B—Separator Plates (4 used)
C—Disk (3 used)
D—Brake Inspection Port
–UN–30APR07
TX1022769
Disk Clearance
KK70125,0000747 –19–01MAY07–2/2

060807
PN=86
Rear Axle Remove and Install

device.
1. Raise and support rear of machine. Position floor

stands under main frame—one at each side.
Specification
310SJ—Weight .............................................................................. 7693 kg 02
16 960 lb 0250
410J—Weight ................................................................................ 8391 kg 3
18 500
2. Remove both rear wheels.See Rear Wheel Assembly

NOTE: The approximated capacity of rear axle is 18 L

(4.8 gal).
3. Drain rear axle.

060807
PN=87
02
0250
4
2 1
–UN–04APR07
TX1019540
TX1019540
Rear Axle Lines

060807
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1—Service Brake Hydraulic 2—Service Brake Hydraulic 3—Differential Lock Hydraulic 4—Park Brake Hydraulic Line
Line (Right) Line (Left) Line
4. Disconnect hydraulic lines to service brakes (1 and of axle housing. Close all hydraulic line opening
2), differential lock (3), and park brake (4) from top using caps and plugs.
02
0250
Continued on next page KK70125,0000748 –19–05JUN07–3/5 5

060807
PN=89
5. Position a low lift jack under center of rear axle. Attach

the adjustable-grip arms and safety chains of the low
lift jack to the axle housing.
–UN–04APR07
device.
6. Remove cap screws (5) on each side of axle and lower
TX1019542A
axle from machine.
02
0250
6 Specification
Rear Axle—Weight .......................................................................... 490 kg
1080 lb 5—Cap Screws (8 used)
7. Repair axle as necessary.See Rear Axle Disassemble.

(Group 0250.)

device.
8. Install rear axle using low lift jack.
Specification
Rear Axle—Weight .......................................................................... 490 kg
1080 lb
9. Install and tighten axle mounting cap screws (5) to

specification.
Rear Axle—Specification
Mounting Cap Screws—Torque ................................................... 620 N•m
457 lb-ft
10. Connect hydraulic lines to service brakes, differential

lock, and park brake.
11. Install rear wheels and lower machine to ground.See

Rear Wheel Assembly Remove and Install. (Group
0110.)
12. Install drain plug.

060807
PN=90
NOTE: It will take approximately five minutes for oil to

settle into outer housing when oil is warm.
13. Fill axle to proper level. See Backhoe Loader Drain

and Refill Capacities. (Operator’s Manual.) Use
proper oil.See Transmission, Axles and Mechanical
Front Wheel Drive (MFWD) Oil. (Operator’s Manual.)
Wait five to ten minutes for oil to settle. Recheck level

and add as necessary. If oil is cold, settle time may
increase. 02
0250
7
KK70125,0000748 –19–05JUN07–5/5
Rear Axle Disassemble

device.
1. Place rear axle on steel table.
Specification
Rear Axle—Weight (approximate)................................................... 490 kg
1080 lb
Continued on next page JH38101,0000442 –19–05JUN07–1/33

060807
PN=91
NOTE: The left and right sides of rear axle are similar in
disassembly. Differential lock assembly is on the
left side of axle.
Remove cap screws (1).
1—Cap Screw (2 used)
–UN–23APR07
02
0250
8
TX1022366A
Planetary Cap Screws
JH38101,0000442 –19–05JUN07–2/33

device.
2. Remove planetary (2).
–UN–23APR07
Specification
Planetary—Weight (approximate) ..................................................... 36 kg
79 lb
TX1022367A
2—Planetary
Planetary Remove

060807
PN=92
3. Remove snap ring (3).
3—Snap Ring (3 used)
–UN–23APR07
02
0250
9
TX1022368A
Planetary Snap Ring Remove
JH38101,0000442 –19–05JUN07–4/33
4. Remove planetary gears (4).
4—Planetary Gear (3 used)
–UN–23APR07
TX1022369A
Planetary Gear Remove

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PN=93
5. Remove sun gear shaft (5).
5—Sun Gear Shaft

6—O-ring
–UN–23APR07
TX1022371A
02
0250
10 Sun Gear Shaft Remove
JH38101,0000442 –19–05JUN07–6/33
6. Loosen cap screws (7).
–UN–23APR07
TX1022372A
Internal Gear Remove

060807
PN=94
7. Install M14 guide screws (8).
8. Remove internal gear from hub (10).
8—M14 Guide Screw (2 used)
–UN–23APR07
10—Hub
TX1022373A
02
0250
Guide Screws 11
JH38101,0000442 –19–05JUN07–8/33
NOTE: Remove bushings (9) only if necessary.
9. Remove bushings (9).
–UN–23APR07
device.
10. Remove hub (10).
TX1022375A
Specification
Rear Axle Hub—Weight
(approximate)..................................................................................... 23 kg Bushings Remove
50 lb-ft
9—Bushing (8 used)

060807
PN=95
11. Remove hub seal (11) and remove both outer bearing
races.
11—Hub Seal
–UN–23APR07
TX1022376A
02
0250
12 Hub Seal
JH38101,0000442 –19–05JUN07–10/33
12. Remove bearing inner ring (21).
21—Bearing Inner Ring
–UN–23APR07
TX1022377A
JH38101,0000442 –19–05JUN07–11/33
13. Remove cap screws (22).

–UN–23APR07
TX1022383A
Rear Axle Housing Remove

060807
PN=96
14. Install M16 guide screws (23).

device.
–UN–23APR07
15. Remove axle housing.
Specification
TX1022384A
Axle Housing—Weight....................................................................... 82 kg
181 lb 02
0250
13
JH38101,0000442 –19–05JUN07–13/33
16. Remove shaft (24).
24—Shaft
–UN–23APR07
TX1022385A
Shaft Remove

060807
PN=97
25—Snap Ring
–UN–23APR07
TX1022386A
02
0250
14 Shaft Snap Ring Remove
JH38101,0000442 –19–05JUN07–15/33
18. Remove brake disks (26).
19. Remove O-rings (27—29).
26—Brake Disks
27—O-Ring
28—O-Ring
29—O-Ring
–UN–23APR07
TX1022387A
Disk Package Remove
JH38101,0000442 –19–05JUN07–16/33
20. Remove cap screws (30) to remove coupling.

–UN–23APR07
TX1022389A

060807
PN=98
21. Preload bevel spring (32) and remove snap ring (31).
22. Remove disk spring (32) and washer.
31—Snap Ring
32—Disk Spring
–UN–23APR07
02
0250
15
TX1022391A
Snap Ring Bevel Springs
JH38101,0000442 –19–05JUN07–18/33
CAUTION: Wear proper face and body

protection when using compressed air.
23. Remove piston (36) by use of compressed air.
–UN–23APR07
36—Piston
TX1022393A
JH38101,0000442 –19–05JUN07–19/33
24. Remove piston O-ring.
37—O-Ring
–UN–30APR07
TX1022734A
Piston O-Ring

060807
PN=99
25. Remove O-ring (37).
37—O-Ring
–UN–23APR07
TX1022394A
02
0250
16 Axle Housing O-ring Remove
JH38101,0000442 –19–05JUN07–21/33
26. Remove differential cover (38).
38—Differential Cover
–UN–23APR07
TX1022395A
Differential Cover Remove

060807
PN=100

27. Use compressed air to remove piston.
–UN–23APR07
39—O-Ring
TX1022396A
02
0250
Piston Remove 17
JH38101,0000442 –19–05JUN07–23/33
29. Remove race (40) and shim (41).
40—Race
41—Shim
–UN–23APR07
TX1022397A
Race and Shim Remove

060807
PN=101
30. Remove O-rings (42 and 43).
42—O-ring
43—O-ring
–UN–23APR07
TX1022398A
02
0250
18 O-Ring Remove
JH38101,0000442 –19–05JUN07–25/33
31. Remove O-rings (44).
32. Remove differential lock (45).
44—O-ring (2 used)
–UN–23APR07
45—Differential Lock
TX1022399A
O-Ring and Differential Lock Coil Spring Remove

060807
PN=102
33. Remove items (46—48) from differential lock.
34. Refer to previous steps to disassemble right side of

axle.
–UN–23APR07
46—Needle Bearing
47—Locking Slide
48—Compression Spring
TX1022400A
02
0250
Differential Lock 19
JH38101,0000442 –19–05JUN07–27/33

device.
35. Remove differential.
Specification
Differential—Weight
(approximate)..................................................................................... 23 kg
50 lb
–UN–25APR07
TX1022486A
Differential Install

060807
PN=103
36. Remove bearing (52 and 53).
52—Bearing
53—Bearing
–UN–23APR07
02
0250
20
TX1022404A
Differential Bearing Remove
JH38101,0000442 –19–05JUN07–29/33
–UN–23APR07
TX1022405A
Differential Case Cap Screws

060807
PN=104
38. Separate differential case halves (59 and 60).
39. Remove items (55—58).
55—Bevel Gear
–UN–23APR07
56—Thrust Washer (2 used)
57—Side Gear and Thrust Washer (4 used)
58—Bevel Gear
59—Differential Case Half
60—Differential Case Half
TX1022406A
02
0250
Differential Assembly 21
JH38101,0000442 –19–05JUN07–31/33
40. Remove ring gear (61).
61—Ring Gear
–UN–23APR07
TX1022407A
Ring Gear Remove

060807
PN=105
NOTE: Mark shim location to aid in assembly.
41. Remove differential race and shim from axle housing.
–UN–23APR07
TX1022408A
02
0250
22 Differential Bearing Outer Race and Shim Remove
JH38101,0000442 –19–05JUN07–33/33
Park Brake Disassemble and Assemble
1. Remove input flange nut (1).
1—Nut
–UN–25APR07
TX1022409A
Input Flange Nut Remove

060807
PN=106
2. Remove cap screws (3 and 13).
3. Remove shaft seal (2).
2—Shaft Seal
–UN–25APR07
TX1022410A
02
0250
Park Brake Case Remove 23
JH38101,0000443 –19–05JUN07–2/35
4. Remove cover (4).
4—Cover
–UN–25APR07
TX1022411A
Park Brake Cover Remove

060807
PN=107
5. Remove disk carrier (5).
6. Remove springs (6 and 14).
5—Disk Carrier
–UN–25APR07
6—Outer Spring
14—Inner Spring
TX1022412A
02
0250
24 Disk Carrier and Spring Remove
JH38101,0000443 –19–05JUN07–4/35

7. Use compressed air to remove piston (7).
–UN–25APR07
7—Piston
TX1022413A
Park Brake Piston Remove

060807
PN=108
8. Remove disk and plates (8).
8—Disk and Plate Assembly
–UN–25APR07
TX1022414A
02
0250
Disks and Plate Remove 25
JH38101,0000443 –19–05JUN07–6/35
9. Remove O-rings (9, 10 and 12).
9—O-Ring
10—O-Ring
12—O-Ring
–UN–25APR07
TX1022415A
O-ring Remove

060807
PN=109
10. Remove pins (11).
11—Pin (2 used)
–UN–25APR07
TX1022416A
02
0250
26 Pin Remove
JH38101,0000443 –19–05JUN07–8/35
11. Remove pinon.
–UN–25APR07
TX1022417A
Pinion Removal

060807
PN=110
12. Remove spacer (18) and pinion bearing.
18—Spacer
02
0250
27
–UN–25APR07
TX1022418A
Spacer and Bearing Remove
JH38101,0000443 –19–05JUN07–10/35
NOTE: Mark shim location for aid in assembly.
13. Tap out inner bearing race using hammer and punch.
–UN–25APR07
TX1022419A

060807
PN=111
14. Remove outer bearing race.
–UN–25APR07
TX1022420A
02
0250
28 Outer Bearing Race Remove
JH38101,0000443 –19–05JUN07–12/35
16. Install M16 guide screws.
17. Inspect and replace parts as necessary.
–UN–30APR07
TX1022632A
Park Brake Housing Remove

060807
PN=112
NOTE: It is recommended to reuse shim found in

disassembly of park brake.
18. Install shim.
–UN–30APR07
TX1022633A
02
0250
Shim Install 29
JH38101,0000443 –19–05JUN07–14/35
19. Install outer bearing race.
–UN–30APR07
TX1022634A
Race Install

060807
PN=113
20. Install outer bearing race.
–UN–30APR07
TX1022636A
02
0250
30 Race Install
JH38101,0000443 –19–05JUN07–16/35
NOTE: Make sure return port (22) is completely covered

with PM38657 High Flex Form-In-Place Gasket.
21. Apply PM37509 cure primer, then PM37509 high flex

form-in-place gasket to park brake housing.
–UN–30APR07
22—Return Port
TX1022635A
Park Brake Housing Seal

060807
PN=114
22. Install park brake housing and tighten cap screws

(21).
Specification
Park Brake Housing Cap
Screws—Torque ........................................................................... 195 N•m
–UN–30APR07
144 lb-ft
23. Determine pinion position: Dimension I is the

measurement from axle center line to bearing contact.
TX1022632A
02
a. Dimension I is the measurement from axle center
0250
line to bearing contact position. 31
Park Brake Housing Install
Example of Dimension I
Axle center line-to-inner bearing contact 165.04 mm
6.5 in.
JH38101,0000443 –19–05JUN07–18/35
b. An etched number at end of the pinion shaft is

used to identify dimension II.
–UN–25APR07
TX1022425A
Dimension II
Example of Dimension II
Etched on top of pinion gear 126.90 mm
4.998 in.
c. Rotate bearing inner ring in both directions several

times to determine roller setting.

060807
PN=115
d. Measure and record bearing width.
–UN–25APR07
02
0250
32
TX1022426A
Dimension III
Example of Dimension III

Width of bearing—experience value of 0.05 mm (0.002 in.) 36.60-0.05=35.5 mm
1.44-.002=1.42 in.
e. Determine number of shims required behind pinion

shaft inner bearing race.
Example of Shim Calculation

Dimension (I)- Dimension (II+III)
Dimension (I) 165.04 mm - (126.9 mm +36.55 mm)
6.5 in.
Minus dimension (II+III) —163.45 mm
126.9 mm + 36.55 mm —6.40 in.
(4.98 in.+ 1.42 in.)
Result =1.59 mm
=0.10 in.
Required Shim =1.60 mm
=0.10 in.

060807
PN=116
24. Install heated bearing until contact is obtained.
Specification
Bearing—Temperature ..................................................................... 120°C
248°F
–UN–25APR07
TX1022427A
02
0250
Pinion Bearing Install 33
JH38101,0000443 –19–05JUN07–21/35
NOTE: If pinion shim was replaced install a spacer ring

adjusted by the same correction value.
25. Inspect spacer ring. Reuse spacer ring if not

damaged.
–UN–25APR07
TX1022428A
Spacer Ring Install

060807
PN=117
26. Install pinion.
27. Install heated bearing until contact is obtained.
Specification
–UN–25APR07
248°F
TX1022429A
02
0250
34 Pinion and Outer Bearing Install
JH38101,0000443 –19–05JUN07–23/35
28. Install disk carrier (5).
29. Apply PM37509 cure primer, then EPL142411 black

toughened instant adhesive to outer diameter of input
flange (20).
–UN–25APR07
30. Install input flange (20).
31. Tighten input flange nut.
TX1022430A
Specification
Input Flange Nut—Torque ............................................................ 600 N•m
443 lb-ft
Disk Carrier Install
NOTE: Set rolling torque to higher end of specification. 5—Disk Carrier

20—Input Flange
32. Check rolling torque.
Specification
New Bearing—Rolling Drag
Torque ................................................................................... 1.5—3.0 N•m
13.28—26.55 lb-ft
Old Bearing—Rolling Drag
Torque ................................................................................... 0.5—1.0 N•m
4.43—8.85 lb-ft

060807
PN=118
33. If rolling torque is not within specification remove

pinion and replace spacer ring.
34. Remove input flange and inner disk carrier.
–UN–25APR07
02
0250
35
TX1022428A
Spacer Ring Install
JH38101,0000443 –19–05JUN07–25/35
35. Install O-rings (9, 10 and 12).
9—O-Ring
10—O-Ring
12—O-Ring
–UN–25APR07
TX1022415A
O-Ring Install

060807
PN=119
36. Install pins (11).
11—Pin (2 used)
–UN–25APR07
TX1022416A
02
0250
36 Pin Install
JH38101,0000443 –19–05JUN07–27/35
37. Install brake pack as shown. Start with plate (20).
20—Plate
–UN–25APR07
TX1022421A
Disk and Plate Install

060807
PN=120
38. Press park brake piston into place.
–UN–25APR07
TX1022422A
02
0250
Park Brake Piston Install 37
JH38101,0000443 –19–05JUN07–29/35
39. Install cap screws (3).
Specification
Park Brake Housing Cap
Screws—Torque ............................................................................. 46 N•m
34 lb-ft
–UN–25APR07
2—Shaft Seal
TX1022410A
Park Brake Case Install

060807
PN=121
40. ’Install inner disk carrier (5).
41. Apply PM37509 Cure Primer, then PM38657 High

Flex Form-In-Place Gasket to contacting parts of park
brake seal.
–UN–30APR07
5—Inner Disk Carrier
TX1022630A
02
0250
38 Inner Disk Carrier Install
JH38101,0000443 –19–05JUN07–31/35
42. Install shaft seal (2) using JDG10527 Park Brake Seal
Driver.
–UN–25APR07
TX1022433A
Park Brake Seal Install

060807
PN=122
43. Install screen sheet onto input flange until contact is

made.
–UN–25APR07
02
0250
39
TX1022436A
Dust Cover Install
JH38101,0000443 –19–05JUN07–33/35
44. Install input flange.
NOTE: While tightening input flange nut, rotate pinion in

both directions several times.
–UN–25APR07
45. Tighten input flange nut.
Specification
Input Flange Nut—Torque ............................................................ 600 N•m
443 lb-ft
TX1022437A
Input Flange

060807
PN=123
46. Tighten cap screws (13).
Specification
Park Brake Release Cap Screw—
Torque ............................................................................................ 46 N•m
34 lb-ft
–UN–02MAY07
TX1022631A
02
0250
40 Park Brake Release Cap Screws
JH38101,0000443 –19–05JUN07–35/35
Rear Axle Assemble
NOTE: Spring pins can be removed (if necessary) by

tapping threads in each pin (1/4 in. tap inner pin,
1/2 in. tap outer pin). Install slide hammer and
remove pins from bore.
Slot on outer spring pin must be located as

shown.
1. Install spring pins (if removed) into blind holes of

differential hub. Install inner spring pin with slot 180°
from outer pin.
–UN–19MAR97
NOTE: Make sure spring pins are aligned with bores in
bevel gear. T108091
–UN–16JAN97
T106495

060807
PN=124
IMPORTANT: Thrust washer must be installed with

dimpled side facing side gear. If thrust
washer is installed improperly,
inadequate lubrication of side gear
could lead to a differential failure.
–UN–25APR07
3. Install thrust washer and bevel gear.
55—Bevel Gear
TX1022476A
56—Thrust Washer
02
0250
Bevel Gears and Thrust Washer Install 41
JH38101,0000444 –19–05JUN07–2/44
4. Install items (62—64) with locking tabs of thrust

washers upwards (as shown).
62—Thrust Washer (4 used)

63—Side Gear (4 used)
–UN–03MAY07
64—Differential Shaft
TX1022847
Differential Assembly
–UN–23APR07
TX1022478A
Differential Assembly

060807
PN=125
NOTE: A light coat of grease on the back side of thrust

washer may be used to keep the washer in place
during housing assembly.
5. Install thrust washer (56) and bevel gear (58).
–UN–25APR07
56—Thrust Washer
58—Bevel Gear
TX1022479A
02
0250
42 Differential Bevel Gear and Thrust Washer Install
JH38101,0000444 –19–05JUN07–4/44
6. Align differential housings with punched marks on

housing.
–UN–30APR07
TX1022480A
Alignment of Differential Housing

060807
PN=126
7. Install ring gear (65) on to slotted pins and press until

bottomed.
65—Ring Gear
–UN–25APR07
TX1022481A
02
0250
Ring Gear Install 43
JH38101,0000444 –19–05JUN07–6/44
Specification
Differential Case Cap Screws—
Torque .......................................................................................... 135 N•m
100 lb-ft
–UN–23APR07
TX1022405A
Differential Case Cap Screws Install

060807
PN=127
9. Press bearing (66 and 67) until bottomed.
66—Bearing
67—Bearing
–UN–25APR07
TX1022483A
02
0250
44 Bearing Install
JH38101,0000444 –19–05JUN07–8/44
NOTE: It is recommended to use shim found in

disassembly. If shim is damaged install a nominal
shim of 1.7 mm (0.067 in).
10. Align mark previously made and install shim (69) and
–UN–25APR07
outer bearing race (68).
68—Outer Bearing Race

69—Shim
TX1022484A
Shim and Race Install

060807
PN=128

device.
11. Install differential.
Specification
Differential—Weight
(approximate)..................................................................................... 23 kg
50 lb
–UN–25APR07
02
0250
45
TX1022486A
Differential Install
JH38101,0000444 –19–05JUN07–10/44
12. Measure and record dimension I using gauge blocks

and a depth gauge.
EXAMPLE OF DIMENSION (I)

Flange mounting 6.64 mm
surface-to-bearing outer race 0.261 in.
–UN–25APR07
TX1022487A
Dimension I

060807
PN=129
13. Measure and record dimension II.
EXAMPLE OF DIMENSION (II)

Brake housing flange-to-shoulder 5.35 mm
of outer bearing race 0.217 in.
–UN–25APR07
02
0250
46
TX1022488A
Dimension II
JH38101,0000444 –19–05JUN07–12/44
14. Adjust shim pack (as necessary) behind differential

bearing. Round off dimension to the nearest shim
size.
EXAMPLE Calculation
Dimension I 6.64 mm
0.261 in.
Minus dimension II —5.35 mm
—0.217 in.
Difference 1.29 mm
–UN–25APR07
0.051 in.
Plus required bearing preload + 0.10 mm
+0.003 in.
Equals 1.39 mm
TX1022489A
0.055 in.
Equals total differential bearing = 1.40 mm
shim pack =0.051 in.
70—Race
71—Shim

060807
PN=130
15. Install brake housing.
Specification
Differential Housing Cap
Screws—Torque ........................................................................... 195 N•m
144 lb-ft
–UN–30APR07
TX1022728A
02
0250
Differential Housing Install 47
JH38101,0000444 –19–05JUN07–14/44
16. Install DFT1286 Backlash Bar.
NOTE: Straightedge of DFT1286 tool indicates position to

record backlash.
–UN–30APR07
17. Install a dial indicator so it’s positioned 126 mm from
center of input flange to correspond to the outer tooth
diameter of the ring gear.
TX1022729A
Specification
Rear Axle Ring Gear—Backlash ...................................... 0.15—0.25 mm
0.006—0.010 in.
Backlash Tool
• Too little backlash —install thicker shim behind
outer bearing cup shown in previous steps. The
shim thickness for bearing preload shown in
previous steps must be reduced accordingly.
• Too much backlash —install thinner shim behind
outer bearing cup shown in previous steps. The
shim thickness for bearing preload shown in
previous steps must be increased accordingly.
18. Remove differential housing cover.
19. To verify measurements are correct. See Gear Tooth

Contact Pattern Check. (Group 0250.)

060807
PN=131
20. Install locking slide (47) with compression spring (48).
21. Apply petroleum jelly to needle bearing (46) and

install onto locking slide (47).
–UN–23APR07
22. Apply petroleum jelly to O-rings (44) and install on to
axle housing.
44—O-Ring (2 used)
TX1022400A
45—Differential Lock
02 46—Needle Bearing
0250 47—Locking Slide
48 48—Compression Spring Differential Lock
–UN–23APR07
TX1022399A
Differential Lock Install
JH38101,0000444 –19–05JUN07–16/44
23. Apply petroleum jelly to O-rings (42 and 43) and

install on to differential housing cover.
42—O-Ring
43—O-Ring
–UN–23APR07
TX1022398A
O-ring Install

060807
PN=132
24. Apply petroleum jelly to O-ring (77) and install on to

differential housing cover.
25. Press piston (76) into place.
–UN–30APR07
76—Piston
77—O-Ring
TX1022731A
02
0250
Differential Housing Piston and O-ring Install 49
JH38101,0000444 –19–05JUN07–18/44
26. Install differential housing cover (38).
38—Differential Housing Cover
–UN–23APR07
TX1022395A
Differential Housing Cover

060807
PN=133
27. Install O-rings (37).
–UN–23APR07
TX1022394A
02
0250
50 Axle Housing O-ring Install
–UN–30APR07
TX1022734A
Piston O-Ring
JH38101,0000444 –19–05JUN07–20/44
28. Install disk springs (78).
78—Disk Spring (2 used)
–UN–30APR07
TX1022735A
Bevel Spring Install

060807
PN=134
29. Apply clean transmission oil to piston. Press piston

into place.
–UN–25APR07
TX1022492A
02
0250
Piston Install 51
JH38101,0000444 –19–05JUN07–22/44
30. Install washer onto coupling ring.
31. Install disk spring onto coupling ring.
–UN–25APR07
TX1022493A
Washer and Bevel Spring

060807
PN=135
32. Press disk spring (32) to install snap ring (31).
31—Snap Ring
32—Disk Spring
–UN–23APR07
02
0250
52
TX1022391A
Snap Ring Install
JH38101,0000444 –19–05JUN07–24/44
33. Install coupling ring and tighten cap screws (30).
Specification
Coupling Ring Cap Screws—
Torque ............................................................................................ 23 N•m
204 lb-in
–UN–23APR07
TX1022389A
JH38101,0000444 –19–05JUN07–25/44
34. Alternately install four separator plates and three

brake disks starting with a separator plate.
35. Apply petroleum jelly to O-rings (27 and 29).
36. Apply clean transmission oil to O-ring (28).
26—Brake Disks
27—O-Ring
28—O-Ring
–UN–23APR07
29—O-Ring
TX1022387A
Disk Package Install

060807
PN=136
37. Install snap ring (25).
25—Snap Ring
–UN–23APR07
TX1022386A
02
0250
Shaft Snap Ring Install 53
JH38101,0000444 –19–05JUN07–27/44
38. Install shaft (24).
24—Shaft
–UN–23APR07
TX1022385A
Shaft Install

060807
PN=137

device.
39. Insert axle onto guide screws (23) until contact with
–UN–23APR07
differential housing.
Specification
Axle Housing—Weight....................................................................... 82 kg
TX1022384A
181 lb
02
0250
54 23—M16 Guide Screw (2 used)
JH38101,0000444 –19–05JUN07–29/44
Specification
Axle Housing Cap Screw—
Torque .......................................................................................... 195 N•m
144 lb-ft
–UN–23APR07
TX1022383A
Rear Axle Housing Install

060807
PN=138
41. Press wheel bolts until bottomed.
–UN–30APR07
TX1022497A
02
0250
Wheel Bolts Install 55
JH38101,0000444 –19–05JUN07–31/44
IMPORTANT: Hub must not be supported by wheel

bolts. Wheel bolts can push out of hub.
42. Install outer bearing races using JDG10524 driver and

JDG10525 handle.
–UN–30APR07
TX1022496A
Bearing Race Install

060807
PN=139
43. Apply PM37509 Cure Primer and PM38657 High Flex

Form-In-Place Gasket to outer face of hub seal.
–UN–23APR07
TX1022376A
02
0250
56 Hub Seal
JH38101,0000444 –19–05JUN07–33/44
IMPORTANT: Replace with new seal. If old seal is

used the axle may leak.
44. Install hub seal using JDG10526 driver tool.
–UN–30APR07
TX1022498A
Hub Seal Install

060807
PN=140
45. Install heated bearing onto hub shaft until bottomed.
Specification
248°F
–UN–25APR07
46. Clean off axle contacting parts of hub seal with
mineral spirit.
TX1022495A
02
0250
Bearing Install 57
JH38101,0000444 –19–05JUN07–35/44

device.
47. Install hub until it is bottomed.
Specification
Rear Axle Hub—Weight
(approximate)..................................................................................... 23 kg
50 lb-ft
48. Install heated bearing inner ring.

–UN–30APR07
Specification
248°F
TX1022758A
Hub and Bearing Inner Ring Install

060807
PN=141
49. If removed, install bushings (9) using a press.
–UN–25APR07
TX1022494A
02
0250
58 Dowel Pin Install
JH38101,0000444 –19–05JUN07–37/44
50. Install gear with cap screws (7).
–UN–23APR07
TX1022372A
Internal Gear Install

060807
PN=142
51. Install heated planetary gear (4) with the larger

opening facing downward.
Specification
Planetary Gear—Temperature ......................................................... 120°C
248°F
52. If removed, install stop pin (75).
4—Planetary Gear (3 used)
–UN–23APR07
74—Not Used 02
75—Stop Pin 0250
59
TX1022369A
Planetary Gear Install
–UN–30APR07
TX1022500A
Stop Pin Install
JH38101,0000444 –19–05JUN07–39/44
53. Install snap rings (3).

–UN–23APR07
TX1022368A
Snap Ring Assemble

060807
PN=143
54. Apply clean transmission oil to O-ring (6) and install

O-ring onto hub.
5—Sun Gear Shaft

6—O-Ring
–UN–23APR07
TX1022371A
02
0250
60 O-Ring Install
JH38101,0000444 –19–05JUN07–41/44
55. Install sun gear shaft (76).
76—Sun Gear Shaft
–UN–30APR07
TX1022501A
Sun Gear Shaft

060807
PN=144

device.
56. Install planetary carrier (2).
–UN–23APR07
Specification
Planetary—Weight (approximate) ..................................................... 36 kg
79 lb
TX1022367A
02
2—Planetary
0250
Planetary Carrier Install 61
JH38101,0000444 –19–05JUN07–43/44
Specification
Planetary Carrier Cap Screw—
Torque ............................................................................................ 55 N•m
41 lb-ft
–UN–23APR07
TX1022366A
Planetary Cap Screws
JH38101,0000444 –19–05JUN07–44/44

060807
PN=145
Gear Tooth Contact Pattern Check
02
0250
62
–UN–18APR89
T94966
A—Ideal Tooth Contact Pattern C—Cone Point Must Be E—Cone Point Must Be G—Coast Side (Concave)
B—Cone Point Must Be Increased Decreased H—Drive Side (Convex)
Decreased D—Ideal Tooth Contact Pattern F—Cone Point Must Be
Increased
IMPORTANT: Gear tooth contact pattern must be 2. Apply pressure to park brake using a hydraulic
checked on the coast side and drive hand pump or park brake release screws. If park
side with a load applied. The pattern brake release screws are used, return them to
may be correct on the drive side and original position after test is complete.
incorrect on the coast side causing
the differential to “whine” when it is 3. Turn pinion in both directions to determine
not engaged. gear-tooth contact pattern. If pattern is not correct,
cone point distance must be increased or
1. Apply grease to several teeth of ring gear with a decreased.
load applied.
KK70125,000074D –19–11JAN07–1/1

060807
PN=146
Section 03
Transmission
Contents
Page

Transmission Remove. . . . . . . . . . . . . . . . . .03-0300-1
Transmission Install. . . . . . . . . . . . . . . . . . . .03-0300-8
Group 0315—Controls Linkage

Transmission Control Lever (TCL) Remove
and Install . . . . . . . . . . . . . . . . . . . . . . . . .03-0315-1
03
Group 0350—Gears, Shafts, and Power Shift

Clutches
Remove Outer Components to Disassemble
Transmission . . . . . . . . . . . . . . . . . . . . . . .03-0350-1
Torque Converter Side of Transmission Case
Disassemble . . . . . . . . . . . . . . . . . . . . . . .03-0350-5
Clutch Packs Remove . . . . . . . . . . . . . . . . . .03-0350-8
Transmission Pump Remove. . . . . . . . . . . .03-0350-12
Transmission Pump Disassemble and
Assemble. . . . . . . . . . . . . . . . . . . . . . . . .03-0350-14
High Range Forward, Low Range Forward,
and Reverse Clutch Packs Disassemble and
Assemble. . . . . . . . . . . . . . . . . . . . . . . . .03-0350-15
First Speed and Third Speed Clutch
Disassemble and Assemble. . . . . . . . . . .03-0350-29
Second Speed Clutch Disassemble and
Assemble. . . . . . . . . . . . . . . . . . . . . . . . .03-0350-44
Clutch Disassemble and Assemble . . . . .03-0350-59
Pump Drive Shaft Install . . . . . . . . . . . . . . .03-0350-69
Clutch Packs Install. . . . . . . . . . . . . . . . . . .03-0350-69
Assemble. . . . . . . . . . . . . . . . . . . . . . . . .03-0350-74
Install Outer Components to Assemble
Transmission . . . . . . . . . . . . . . . . . . . . . .03-0350-80

Transmission Charge Pump Remove and
Install. . . . . . . . . . . . . . . . . . . . . . . . . . . . .03-0360-1
Transmission Charge Pump Disassemble and
Assemble. . . . . . . . . . . . . . . . . . . . . . . . . .03-0360-4

060807
PN=1
Contents
03

060807
PN=2
Group 0300
Removal and Installation
Transmission Remove

device.
1. Raise machine so bottom of battery and fuel tank

frames are approximately 940 mm (37 in.) off the floor.
Specification
410J—Weight ................................................................................ 8391 kg
18 500
2. Put floor stands under machine.
3. Drain hydraulic system reservoir. The approximate

03
capacity of reservoir is 37 L (9.8 gal). 0300
1
Specification
Hydraulic System Reservoir—
Capacity ............................................................................................... 37 L
9.8 gal
4. Drain transmission. The approximate capacity of

transmission is 15 L (4.0 gal).
Specification
Torque Converter and
Transmission System—Capacity......................................................... 15 L
4.0 gal
5. Remove rear drive shaft.
6. Remove mechanical front wheel drive (MFWD) drive

shaft (if equipped).
NOTE: Hydraulic hoses, wire harness connectors, and

harness clamps can be accessed through
openings in the cab floor.
7. Remove floor mat.
8. Remove the two cab floor access plates between the

seat and steering console.
Continued on next page KK70125,000074E –19–05JUN07–1/10

060807
PN=149
03
0300
2
9
8
11
7
10
3 12
14
13 –UN–13FEB07
TX1017737
TX1017737

060807
PN=150
1—Hydraulic 8—Brake Boost Pressure Line 11—Transmission-to-Park 14—Transmission

Pump-to-Solenoid Valve 9—Brake Boost Return Line Brake Line Cooler-to-Transmission
Line 10— 12—Transmission Dipstick Line
3—Pump Suction Hose Transmission-to-Transmission
13—
7—Hydraulic Cooler Line Transmission-to-Differential
Pump-to-Hydraulic Lock Line
Reservoir Line
10. Remove cap screws (2) to disconnect pump

CAUTION: To avoid injury from escaping
suction hose (3).
fluid under pressure, relieve the pressure in
the system before disconnecting hydraulic
11. Disconnect the dipstick fill tube from transmission.
hoses. Tighten all connections before
Install cap and plug.
applying pressure.
9. Disconnect lines (1 and 4) and (7—14). Tag

hydraulic hoses. Close all openings with caps and
plugs. 03
0300
3

060807
PN=151
This page is intentionally left blank.
TX1017745 –UN–24JAN07
19 20
18
23
22
21
15
28 26 25 24
27
16
TX1017745
Transmission Wire Harness Component Location

060807
PN=152
-----> - A -----> - B
TX1017745 –
15
16
TX1017745
TM10147 (
Page - A
TX1017745 –UN–24JAN07
19 20
18
23
22
21
28 26 25 24
27

060807
PN=152
Page - B
15—Torque Converter Oil 20—Transmission Reverse 24—Return-to-Dig 27—Transmission Speed

Temperature Sensor Direction Solenoid Harness-to-Transmission Solenoid 4
16—Not Used 21—Transmission Forward Harness Connector 28—Mechanical Front Wheel
18—Transmission Speed Direction Solenoid 25—Not Used Drive (MFWD) Solenoid
Solenoid 1 22—Differential Lock Solenoid 26—Transmission Speed
19—Transmission 23—Park Brake Release Solenoid 2
Harness-to-Cab/Canopy Solenoid
Harness Connector
12. Disconnect harnesses (15—28). 14. Remove access plate at bottom of flywheel
housing.
13. Remove hydraulic pump (if necessary). See
Hydraulic Pump Remove and Install. (Group
2160.)
03
0300
5
KK70125,000074E –19–05JUN07–5/10
15. Remove cover to flywheel access port (40) and insert

JDG820 Flywheel Turning Tool.
40—Flywheel Access Port
–UN–01MAR07
TX1020055A
JDG820 Tool Use Location

060807
PN=153
16. Remove four torque converter flex plate-to-flywheel

cap screws (32). Use JDG820 flywheel turning tool to
rotate flywheel as necessary.
31—Transmission-To-Flywheel Housing Cap Screws
–UN–12FEB07
(6 used on lower half of transmission)
32—Torque Converter Flex Plate-To-Flywheel Cap
Screws (4 used)
TX1017753A
Torque Converter and Flywheel Housing Cap Screws
03
0300
6
KK70125,000074E –19–05JUN07–7/10
17. Install engine support bracket (30).
18. Remove the 6 transmission-to-flywheel housing cap

screws (31) from the lower half of the
flywheel/transmission housings. Do not remove the 6
–UN–12FEB07
transmission-to-flywheel housing cap screws located
at the upper half of the flywheel and transmission
housings at this time.
TX1017748A
29—Cap Screw (4 Used)
30—Engine Support Bracket
Engine Support Bracket

060807
PN=154

device.
19. Attach a low lift jack to transmission as follows:
–UN–12FEB07
a. Install blocks (34) between JT02156A Low Lift
Jack and bottom of transmission as necessary.
TX1017774A
b. Raise and adjust low lift jack until jack’s mounting
plate and block are tight against bottom of
transmission. Low Lift Transmission Jack and Mounting Brackets (Right Side)
c. Fasten jack to transmission using at least two

DO1004AA Universal Mounting Arms (33).
03
d. To provide as much offset and stability as 0300
7
possible, fasten angle brackets (35 and 36) to
–UN–12FEB07
transmission so each points in opposite direction,
then fasten mounting arms to opposite (diagonal)
corners of jack’s mounting plate.
TX1017775A
e. Make sure all mounting arm hardware are tight
before removing transmission.
Specification
Transmission—Weight 33—D01004AA Universal Mounting Arms (2 used)
(approximate)................................................................................... 247 kg 34—Block (2 used)
545 lb 35—Angle Bracket (Part of D01004AA)
36—Angle Bracket (Part of D01004AA)
37—JT01642A Low Lift Jack
20. Remove remaining 6 transmission-to-flywheel housing

cap screws.

060807
PN=155
CAUTION: Use care when removing

transmission. Torque converter could fall out of
housing.
21. Move transmission away from engine until torque
–UN–12FEB07
converter (38) clears flywheel housing.
22. Lower transmission until top of transmission clears

bottom of battery box or fuel tank.
TX1017803A
23. Carefully move jack and transmission out from under
machine. Torque Converter
24. Make repairs as necessary. 38—Torque Converter
03
0300
8
KK70125,000074E –19–05JUN07–10/10
Transmission Install

device.
1. Install hydraulic pump (if removed). See Hydraulic

Pump Remove and Install. (Group 2160.)
Specification
Hydraulic Pump—Weight
(approximate)..................................................................................... 34 kg
75 lb
2. Move jack and transmission (with torque converter) into

position under machine.
Continued on next page KK70125,000074F –19–05JUN07–1/8

060807
PN=156
3. Use JDG820 Flywheel Turning Tool to aid in installing

flexplate-to-flywheel cap screws.
40—Tool Use Location
–UN–01MAR07
TX1020055A
JDG820 Tool Use Location
03
0300
9
KK70125,000074F –19–05JUN07–2/8
4. Install transmission with cap screws (31). Tighten cap

screws to specification.
Specification
Transmission-to-Flywheel
Housing Cap Screws—Torque ....................................................... 73 N•m
–UN–12FEB07
54 lb-ft
5. Install four torque converter-to-flywheel cap screws.

Tighten cap screws to specification.
TX1017753A
Specification
Torque Converter-to-Flywheel
Housing Cap Screws—Torque ....................................................... 73 N•m Torque Converter and Flywheel Housing Cap Screws
54 lb-ft
31—Transmission-To-Flywheel Housing Cap
Screw (12 used)
6. Remove low lift jack.
32—Torque Converter Flexplate-To-Flywheel Cap
Screw (4 used)

060807
PN=157
7. Remove engine support bracket (30).
8. Install torque converter access plate.
9. Install hydraulic pump (if removed). See Hydraulic
–UN–12FEB07
Pump Remove and Install. (Group 2160.)
29—Cap Screw (4 Used)

30—Engine Support Bracket
TX1017748A
Engine Support Bracket
03
0300
10

060807
PN=158
03
0300
11

060807
PN=159
TX1017745 –UN–24JAN07
19 20
18
23
22
21
15
28 26 25 24
27
16
TX1017745

060807
PN=160
-----> - A -----> - B
TX1017745 –
15
16
TX1017745
TM10147 (
Page - A
TX1017745 –UN–24JAN07
19 20
18
23
22
21
28 26 25 24
27

060807
PN=160
Page - B
15—Torque Converter Oil 20—Transmission Reverse 24—Return-to-Dig 27—Transmission Speed

Temperature Sensor Direction Solenoid Harness-to-Transmission Solenoid 4
16—Ground-to-Frame Starter 21—Transmission Forward Harness Connector 28—Mechanical Front Wheel
Motor Direction Solenoid 25—Not Used Drive (MFWD) Solenoid
18—Transmission Speed 22—Differential Lock Solenoid 26—Transmission Speed
Solenoid 1 23—Park Brake Release Solenoid 2
19—Transmission Solenoid
Harness-to-Cab/Canopy
Harness Connector
10. Connect harnesses (15—28).
03
0300
13

060807
PN=161
03
0300
14
9
8
11
7
10
3 12
14
13 –UN–13FEB07
TX1017737
TX1017737

060807
PN=162
1—Hydraulic 8—Brake Boost Pressure Line 11—Transmission-to-Park 14—Transmission

Pump-to-Solenoid Valve 9—Brake Boost Return Line Brake Line Cooler-to-Transmission
Line 10— 12—Transmission Dipstick Line
3—Pump Suction Hose Transmission-to-Transmission
13—
7—Hydraulic Cooler Line Transmission-to-Differential
Pump-to-Hydraulic Lock Line
Reservoir Line
11. Connect lines (1 and 4) and (7—14) 14. Fill reservoir and transmission with correct type of
oil. See Transmission, Axles, and Mechanical
12. Install rear drive shaft and MFWD drive shaft (if Front Wheel Drive (MFWD) Oil (Operator’s
equipped). See Drive Shaft Remove and Install. Manual.) See Backhoe Loader Drain and Refill
(Group 0325.) Capacities. (Operator’s Manual.)
13. Install cab floor access plates. Install floor mat.
03
0300
15
KK70125,000074F –19–05JUN07–8/8

060807
PN=163
03
0300
16

060807
PN=164
Group 0315
Controls Linkage
Transmission Control Lever (TCL) Remove

and Install
1. Remove cap screws (1) to remove TCL cover (2).
–UN–04APR07
2—TCL Cover
TX1019587A
KK70125,0000750 –19–05JUN07–1/2
2. Disconnect harness (3).

03
3. Remove cap screws (4). 0315
1
–UN–04APR07
5. Apply PM37509 cure primer, then PM37418 thread
lock and sealer (medium strength) to steering column
cap screws (2).
TX1019588A
6. Tighten cap screws (4) to specification.
Specification TCL Harness and Cap Screws

Steering Column Cap Screws—
Torque ........................................................................................... 7.2 N•m 3—TCL Harness
64 lb-in. 4—Cap Screws (2 used)
7. Install TCL cover.
KK70125,0000750 –19–05JUN07–2/2

060807
PN=165
Controls Linkage
03
0315
2

060807
PN=166
Group 0350
Gears, Shafts, and Power Shift Clutches
Remove Outer Components to Disassemble

Transmission
1. Attach transmission to D05223ST Engine Roll Over

Stand using JDG10476 Bracket.
–UN–30APR07
2. Remove transmission oil filter.
TX1022766A
Transmission Roll Over Stand Bracket
03
0350
1
KK70125,0000752 –19–09MAY07–1/8
3. Remove cap screws (2) to remove filter head (1).
1—Filter Head
–UN–03APR07
TX1019989
Filter Head

060807
PN=167
3—O-rings (2 used)
–UN–03APR07
TX1020000
Filter Head O-rings
03
0350
2
KK70125,0000752 –19–09MAY07–3/8
5. Remove dipstick tube (27).
27—Dipstick Tube
–UN–30APR07
TX1022773
Dipstick Tube Install

060807
PN=168
6. Remove output flange (13).
13—Output Flange
–UN–02APR07
TX1020008
03
Output Flange 0350
3
KK70125,0000752 –19–09MAY07–5/8
7. Remove and mark solenoids (4—12).
4—Transmission Speed Solenoid 1

5—Park Brake Solenoid
6—Differential Lock Solenoid
7—Transmission Forward Direction Solenoid
8—Transmission Reverse Direction Solenoid
12—Mechanical Front Wheel Drive (MFWD) Solenoid
–UN–02APR07
TX1020006

060807
PN=169
8. Remove orifices (14—17).
14—Directional Clutch Orifice

15—1st Speed Clutch Orifice
16—2nd Speed Clutch Orifice
17—3rd Speed Clutch Orifice
–UN–02APR07
TX1020010
03
0350
4
–UN–02APR07
TX1020014
Gear Clutch Orifices
KK70125,0000752 –19–09MAY07–7/8
9. Remove plugs (18—20).
10. Repair or replace parts as necessary.
18—Plug
19—Plug
20—Plug
–UN–02APR07
TX1020013
Plugs
KK70125,0000752 –19–09MAY07–8/8

060807
PN=170

Disassemble
1. Remove flex plate (2).
–UN–02APR07
2. Remove torque converter (1).
1—Torque Converter
2—Flex Plate
TX1020033
Flex Plate Removal
03
0350
5
KK70125,0000753 –19–24MAY07–1/6

–UN–02APR07
TX1020034
Transmission Pump and Bell Housing Cap Screw Removal

060807
PN=171
NOTE: Transmission pump can not be removed until the

transmission case is separated and the
transmission pump inner cap screws have been
removed.
4. Remove torque converter bell housing (7).
–UN–09APR07
5. Remove plug and O-ring (6).
TX1020036
6—Plug and O-ring
7—Torque Converter Bell Housing
Plug and O-Ring Removal
03
0350
6
KK70125,0000753 –19–24MAY07–3/6
6. Remove system relief valve assembly (11—15).
11—Plug
12—O-ring
13—Piston
–UN–03APR07
16—System Relief Port
TX1020042
System Relief Valve

060807
PN=172
7. Remove torque converter safety valve (12).
12—Torque Converter Safety Valve

13—Not Used to Remove
–UN–30APR07
TX1022772
Torque Converter Safety Valve
03
0350
7
KK70125,0000753 –19–24MAY07–5/6
NOTE: Remove pins (9) only if necessary.
8. Remove screen (10).
9. Install M10 guide screws (8) to assure the transmission

pump is centered before transmission pump inner cap
–UN–09APR07
screws have been removed.
TX1020038
9—Pin (2 used)
10—Screen
Pins and Screen Remove
KK70125,0000753 –19–24MAY07–6/6

060807
PN=173
Clutch Packs Remove
1. Drive dowel pins (1) out of transmission case halves.
–UN–04APR07
1—Dowel Pin (2 used)
TX1020103
Transmission Case Cap Screws and Pin Removal
03
0350
8
KK70125,0000754 –19–16MAY07–1/9
3. Install eye bolts (3) in case.

device.
4. Attach a chain and hoist to eye bolts (3) and separate

case halves approximately 1 cm.
Specification
–UN–23APR07
Transmission Case Half—Weight

(approximate)..................................................................................... 42 kg
93 lb
TX1021409
5. Tap on mechanical front wheel drive (MFWD) output

shaft with plastic hammer to separate screen (4) from
transmission housing.
Tap MFWD Shaft to Remove
Screen
3—Eyebolt (2 used)
4—Screen
10—MFWD Clutch Shaft

060807
PN=174
6. Separate transmission housing and remove screen.
4—Screen
–UN–04APR07
TX1020106
03
Transmission Case Removal 0350
9
KK70125,0000754 –19–16MAY07–3/9
7. Mark clutch pack and transmission case for aid of

assembly, before removing clutch packs from case.
8. Remove high range forward clutch (6).
9. Remove low range forward clutch pack (5) and reverse
–UN–04APR07
clutch pack (7) together.
10. Slightly lift second speed clutch pack (9) to remove

first speed clutch pack (1).
TX1020108
5—Low Range Forward Clutch Pack
6—High Range Forward Clutch Pack
7—Reverse Clutch Pack
8—First Speed Clutch Pack
9—Second Speed Clutch Pack
10—Mechanical Front Wheel Drive (MFWD) Clutch
Pack
11—Third Speed Clutch Pack

060807
PN=175
11. Install eye bolts (12).

device.
12. Remove clutch packs (9—11) together with screen

sheet (13).
Specification
Second, Third, and MFWD Clutch
Pack—Weight (approximate)............................................................. 27 kg
60 lb
–UN–04APR07
03
Pack
0350
TX1020112
10
13—Screen Sheet
Second, Third, and MFWD Clutch Pack Removal
KK70125,0000754 –19–16MAY07–5/9
13. Remove snap ring (14) to remove pump drive shaft

(15).
14—Snap Ring
15—Pump Drive Shaft
–UN–04APR07
TX1020113
Pump Drive Shaft Removal

060807
PN=176
15. Remove ball bearing (16).
16—Ball Bearing
17—Snap Ring
–UN–04APR07
TX1020115
03
Pump Shaft Bearing Removal 0350
11
KK70125,0000754 –19–16MAY07–7/9
IMPORTANT: If either the bearing cone or cup

requires replacement, replace both as a
set.
–UN–22MAY07
17. Mark bearing cup and transmission case for aid of
assembly and remove bearing cups (19), if
necessary.
TX1023851
19—Bearing Cup (5 used)
O-ring and Bearing Outer Races

060807
PN=177
18. Remove suction tube (22).
IMPORTANT: If either the bearing cone or cup

requires replacement, replace both as a
set.
19. Mark bearing cup and transmission case for aid of

assembly and remove bearing cups (20), if
necessary.
–UN–04APR07
22—Oil Suction Tube
TX1020118
03
0350 Torque Converter Side Bearing Outer Rings and Suction Tube
12 Removal
KK70125,0000754 –19–16MAY07–9/9
Transmission Pump Remove
1.
IMPORTANT: Transmission pump may fall out of

transmission case while removing cap
–UN–09APR07
screws (1 and 2) causing damage to
transmission pump. Hold transmission
pump in place while removing cap
screws.
TX1020123
Remove cap screws (1 and 2).
Transmission Pump Inner Cap Screws

Continued on next page JH38101,00002C3 –19–13APR07–1/2

060807
PN=178
2. Remove transmission pump (3).
3—Transmission Pump
–UN–09APR07
03
0350
TX1020125
13
JH38101,00002C3 –19–13APR07–2/2

060807
PN=179
Transmission Pump Disassemble and Assemble
03
0350
14
–UN–13DEC06
TX1014801
Transmission Pump Assembly

Continued on next page JH38101,00002CC –19–09APR07–1/2

060807
PN=180
1—Screw (8 used) 3—Transmission Pump 5—Cap Screw (2 used) 6—Cap Screw (2 used)
2—Seal Ring 4—O-ring
1. Remove shaft seal ring (2) and O-ring (4). 3. Install O-ring (4).
2. Use driver tool JDG10478 to install seal ring (2).
JH38101,00002CC –19–09APR07–2/2
High Range Forward, Low Range Forward,

and Reverse Clutch Packs Disassemble and 03
Assemble 0350
15
NOTE: High range forward directional clutch pack is

shown for disassembly and assembly procedures.
Disassembly and assembly of low range forward
and reverse clutch packs are the same.
1. Remove seal ring (5).
–UN–11APR07
5—Seal Ring
TX1020432

060807
PN=181
2. Remove inner disc carrier (7), plates (8 and 10),

needle bearing (9) and bearing (11).
6—Bearing Puller
7—Inner Disc Carrier
8—Plate
9—Roller Bearing
10—Plate
11—Bearing
–UN–11APR07
TX1020433
03
0350 Bearing Puller
16
–UN–09APR07
TX1020439
Bearing and Inner Disk Carrier Removal

060807
PN=182
3. Remove needle bearings (12).
–UN–11APR07
TX1020440
03
First Speed, High Range Forward, Low Range Forward, and 0350
Reverse Clutch 17
KK70125,0000755 –19–09MAY07–3/24
4. Remove washers (8 and 10) and needle bearing (9).
8—Washer
9—Needle Bearing
10—Washer
–UN–11APR07
TX1020441
Washer and Needle Cage Removal

060807
PN=183
13—Snap Ring
–UN–11APR07
TX1020442
03
0350 Snap Ring Remove
18
KK70125,0000755 –19–09MAY07–5/24
6. Remove plate end plate (16), disk and plate assembly

(15), and retainer (16).
14—Retainer
16—End Plate
–UN–11APR07
TX1020443

060807
PN=184
17—Snap Ring
–UN–11APR07
TX1020444
03
Snap Ring 0350
19
KK70125,0000755 –19–09MAY07–7/24
8. Use special tool JDG10510 (18) to remove snap ring

(19).
18—Special Tool JDG10510

19—Snap Ring
–UN–11APR07
TX1020445
Snap Ring Remove

060807
PN=185
9. Remove retainer (21) and compression spring (20).
21—Retainer
–UN–11APR07
03
0350
TX1020446
20
KK70125,0000755 –19–09MAY07–9/24
10. Remove piston (23) from shaft using compressed air

through oil passage (22).
22—Oil Passage
23—Piston
–UN–11APR07
TX1020447

060807
PN=186
11. Remove O-rings (24 and 25) from piston (23).
23—Piston
24—O-ring
25—O-ring
–UN–11APR07
TX1020448
03
Piston O-Ring Remove 0350
21

060807
PN=187
12. Remove seal ring (26).
IMPORTANT: Gear, drum, and shaft are serviced as

an assembly. Do not take apart or
damage will occur.
13. Remove bearing (27).
14. Check all oil passages with compressed air.
–UN–11APR07
26—Seal Ring
27—Bearing
TX1020450
28—Snap Ring
29—Gear
03 30—Clutch Drum
0350 31—Clutch Shaft
22
–UN–11APR07
TX1020451

060807
PN=188
16. Heat bearing (27) to 120°C (248°F).
Specification
248°F
17. Install bearing (27) until contact is made.
–UN–11APR07
26—Snap Ring
27—Bearing
TX1020450
03
0350
23
KK70125,0000755 –19–09MAY07–13/24
NOTE: Inspect O-rings before installing piston. If O-rings

are damaged, leakage in the pack will occur.
19. Apply transmission oil to O-rings (24 and 25).
20. Install O-rings (24 and 25).
23—Piston
24—O-ring
25—O-ring
–UN–11APR07
TX1020448
Piston O-rings Install

060807
PN=189
21. Press piston (23) into place using special tool

JDG10510.
23—Piston
–UN–23APR07
03
0350
TX1021900
24
–UN–23APR07
TX1021903
JDG10510 Assembly Aid

060807
PN=190
22. Install compression spring (20) and retainer (21).
21—Retainer
–UN–11APR07
03
0350
TX1020446
25
KK70125,0000755 –19–09MAY07–16/24
23. Preload compression spring using Assembly Aid

JDG10510 to install snap ring (19).
18—Assembly Aid JDG10510

19—Snap Ring
–UN–11APR07
TX1020445
Snap Ring Install

060807
PN=191
24. Install retainer (14).
14—Retainer
23—Piston
32—Input Shaft
–UN–23APR07
TX1021911
03
0350
26
–UN–10APR07
TX1020528
Cross Section of High Range Forward Clutch
KK70125,0000755 –19–09MAY07–18/24
NOTE: High range forward clutch uses seven plates and

seven disks. Low range forward and reverse
clutch uses ten plates and ten disks.
25. Starting with a plate, alternately install plates (34) and

disks (33).
26. Install end plate (16) with flat side facing down.

–UN–10APR07
28. Check end plate clearance:
33—Disk
TX1020529
34—Plate

060807
PN=192
a. Apply 20 N (4.5 lb) of pressure to end plate (16)

and set dial indicator to zero.
Specification
Applied To Clutch End Plate—
Force .................................................................................................. 20 N
4.5 lb
13—Snap Ring
16—End Plate
–UN–23APR07
TX1021913
03
End Plate Install 0350
27
KK70125,0000755 –19–09MAY07–20/24
b. Using screwdrivers, pry up on end plate and read

the disk clearance.
c. Determine correct thickness of snap ring to be

used to obtain this specification.
Specification
Low Range Forward, High Range
Forward, and Reverse Clutch
Pack Plate—Distance ............................................................ 2.0—2.3 mm
0.079—0.118 in.
–UN–10APR07
NOTE: Snap ring (13) is available in the following
TX1020532
thicknesses:
Specification
End Plate Snap Ring—Thickness .................................................. 2.0 mm End Plate Clearance Measurement
0.079 in.
2.25 mm
.089 in.
2.5 mm
0.098 in.
2.75 mm
0.108 mm
3.0 mm
0.118 in.
3.25 mm
0.128 in.
3.5 mm
0.157 in.

060807
PN=193
29. Apply clean transmission oil to washer (8 and 10) and

needle bearing (9).
30. Install washer (8), needle bearing (9), and washer

(10).
31. Apply clean transmission oil to needle bearings (12).
32. Install needle bearings (12).
–UN–11APR07
8—Washer
9—Needle Bearing
10—Washer
TX1020441
03
0350 Washer and Needle Cage Install
28
KK70125,0000755 –19–09MAY07–22/24
33. Install inner disk carrier (7) until contact is made.
34. Install washer (8), needle bearing (9), and washer

(10).
Specification
248°F
36. Install bearing (11) until contact is made.
37. Install seal ring (5).
7—Inner Disc Carrier

8—Washer
9—Needle Bearing
10—Washer
11—Bearing
–UN–09APR07
TX1020439
Bearings and Inner Disc Carrier Install

060807
PN=194
38. Check closing and opening of clutch by use of

compressed air through oil passage (22).
22—Oil Passage
23—Piston
–UN–11APR07
03
0350
TX1020447
29
KK70125,0000755 –19–09MAY07–24/24
First Speed and Third Speed Clutch

1. Remove sealing ring (1).
1—Sealing Ring
–UN–23APR07
TX1021965
Snap Ring and Bearing Remove

060807
PN=195
4. Remove disk carrier (2).
2—Disk Carrier
3—Bearing
4—Washer
5—Needle Bearing
6—Washer
–UN–23APR07
TX1021966
03
0350
30
–UN–23APR07
TX1021967

060807
PN=196
NOTE: Remove bushing (35) on third speed clutch only.
5.
–UN–23APR07
TX1021968
03
First Speed Clutch 0350
31
KK70125,0000757 –19–05JUN07–3/27
Remove needle bearings (7).
7—Needle Bearing (2 used)

35—Bushing
–UN–23APR07
TX1021883

060807
PN=197
8—Washer
9—Needle Bearing
10—Washer
–UN–23APR07
TX1021969
03
0350
32
KK70125,0000757 –19–05JUN07–5/27
11—Snap Ring
–UN–23APR07
TX1021970
Snap Ring Remove

060807
PN=198
8. Remove end plate (12).
9. Remove disk and plate assembly (13).
NOTE: Pay attention to how bevel spring was assembled.
10. Remove bevel spring (14).
12—End Plate
–UN–23APR07
14—Bevel Spring (14).
TX1021971
03
0350
33
KK70125,0000757 –19–05JUN07–7/27
11. Press compression spring using JDG10510 Assembly

Aid to remove snap rings (15).
–UN–23APR07
TX1021972
Snap Ring Remove

060807
PN=199
12. Remove retainer (16) and compression spring (17).
16—Retainer
–UN–23APR07
TX1021973
03
0350 Retainer and Compression Spring
34 Remove
KK70125,0000757 –19–05JUN07–9/27
13. Remove piston (19) by using compressed air through

oil passage (18).
18—Oil Passage
19—Piston
–UN–23APR07
TX1021974

060807
PN=200
19—Piston
20—O-Ring
21—O-Ring
–UN–23APR07
TX1021975
03
Piston O-Ring Remove 0350
35
KK70125,0000757 –19–05JUN07–11/27
22—Sealing Ring
23—Bearing
–UN–23APR07
TX1021976

060807
PN=201

damage will occur.
24—Gear
25—Drum
–UN–23APR07
26—Shaft
TX1021977
03
0350 Non Serviceable Parts
36
KK70125,0000757 –19–05JUN07–13/27
20. Install bearing (23).
21. Install sealing ring (22).
22—Sealing Ring
23—Bearing
–UN–23APR07
TX1021976

060807
PN=202
19—Piston
20—O-Ring
21—O-Ring
–UN–23APR07
TX1021975
03
Piston O-Ring Install 0350
37
KK70125,0000757 –19–05JUN07–15/27
23. Install piston using Assembly Aid JDG10510.
–UN–23APR07
TX1021978
Piston Install

060807
PN=203
24. Install bevel spring (14).
14—Bevel Spring
19—Piston
26—Input Shaft
–UN–23APR07
TX1021979
03
0350
38
–UN–23APR07
TX1021980
Cross Section of First Speed Clutch

060807
PN=204
NOTE: First speed clutch uses ten plates and ten plates.
Third speed clutch uses nine plates and nine
disks.

disks (27).
27—Disk
28—Plate
–UN–23APR07
03
0350
TX1021981
39
Plate and Disk Install
KK70125,0000757 –19–05JUN07–18/27
26. Install end plate (12) with flat side down on disks and
plate.
11—Snap Ring
12—End Plate
–UN–23APR07
TX1021982
Snap Ring and End Plate Install

060807
PN=205

Specification
Force .................................................................................................. 20 N
4.5 lb
12—End Plate
–UN–23APR07
TX1021984
03
0350 End Plate Clearance Measurement
40
KK70125,0000757 –19–05JUN07–20/27

the disk clearance.

Specification
First Speed Clutch—Distance ............................................... 2.0—2.3 mm
0.079—0.118 in.
Third Speed Clutch—Distance .............................................. 1.8—2.1 mm
0.071—0.083
–UN–23APR07
TX1021986
End Plate Clearance Measurement

060807
PN=206

thicknesses:
Specification
End Plate Snap Ring—Thickness .................................................. 2.0 mm
0.079 in.
2.25 mm
.089 in.
2.5 mm
0.098 in.
2.75 mm
0.108 mm
–UN–23APR07
3.0 mm
0.118 in.
3.25 mm
0.128 in.
TX1021982
3.5 mm
0.157 in.
03
Snap Ring and End Plate Install 0350
11—Snap Ring 41
12—End Plate
KK70125,0000757 –19–05JUN07–22/27
29. Install washers (8 and 10) and needle bearing (9).
8—Washer
9—Needle Bearing
10—Washer
–UN–23APR07
TX1021969

060807
PN=207
NOTE: Install bushing (35) on third speed clutch only.
30.
–UN–23APR07
TX1021968
03
0350 First Speed Clutch
42
KK70125,0000757 –19–05JUN07–24/27
Install needle bearings (7).

35—Bushing
–UN–23APR07
TX1021883

060807
PN=208
31. Install disk carrier (2) until contact is made.
32. Install washer (6), needle bearing (5), and washer (4).
2—Disk Carrier
3—Bearing
4—Washer
5—Needle Bearing
6—Washer
–UN–23APR07
TX1021966
03
0350
43
–UN–23APR07
TX1021967

060807
PN=209
1—Sealing Ring
–UN–23APR07
TX1021965
03
0350 Snap Ring and Bearing Remove
44
KK70125,0000757 –19–05JUN07–27/27
Second Speed Clutch Disassemble and

Assemble
–UN–11APR07
1—Sealing Ring
TX1020533
Snap Ring Remove
Continued on next page JH38101,00002CE –19–16MAY07–1/28

060807
PN=210
4. Remove disc carrier (2).
2—Disc Carrier
3—Bearing
4—Washer
5—Needle Bearing
6—Washer
–UN–10APR07
TX1020537
03
Bearing, Washer, Needle Bearing, and Disc Carrier 0350
Remove 45
–UN–10APR07
TX1020538
Bearing, Washer, Needle Bearing, and Disc Carrier

Remove

060807
PN=211
5. Remove needle bearings (8) and bushing (7).
7—Bushing
–UN–10APR07
TX1020539
03
0350 Needle Bearing and Bushing
46 Remove
JH38101,00002CE –19–16MAY07–3/28
3—Washer
4—Needle Bearing
5—Washer
–UN–11APR07
TX1020541
Needle Bearing and Washer

Remove

060807
PN=212
9—Snap Ring
–UN–10APR07
TX1020542
03
Snap Ring Remove 0350
47
JH38101,00002CE –19–16MAY07–5/28
9. Remove disk and plate assembly (11).
10. Remove bevel spring (10).
10—Bevel Spring
12—End Plate
–UN–10APR07
TX1020543
End Plate, Disks and Plates, and Bevel Spring

Remove

060807
PN=213
13—Snap Ring
–UN–10APR07
TX1020544
03
0350 Snap Ring Remove and Install
48
JH38101,00002CE –19–16MAY07–7/28
12. Remove snap ring (14) using JDG10510 Assembly

Aid.
–UN–10APR07
TX1020545
Snap Ring Remove

060807
PN=214
13. Remove washer (15) and bevel springs (16).
15—Washer
16—Bevel Springs (7 used)
–UN–10APR07
TX1020565
03
Washers Remove 0350
49
JH38101,00002CE –19–16MAY07–9/28
14. Remove piston (17) by using compressed air through

oil passage (18).
17—Piston
18—Oil Passage
–UN–10APR07
TX1020567

060807
PN=215
17—Piston
19—O-ring
20—O-ring
–UN–10APR07
TX1020568
03
0350 Piston O-Rings Remove
50
JH38101,00002CE –19–16MAY07–11/28
16. Remove sealing rings (21).
21—Sealing Ring (2 used)

22—Roller Bearing
–UN–10APR07
TX1020569
Snap Ring and Roller Bearing

Remove

060807
PN=216
IMPORTANT: Gears, drum, and shaft are serviced as

damage will occur.
23—Oil Passage
24—Shaft
–UN–10APR07
25—Gear
26—Gear
27—Hub
TX1020572
03
Non Serviceable Parts 0350
51
JH38101,00002CE –19–16MAY07–13/28
21. Remove sealing rings (21).
23. Install sealing rings (21).
21—Sealing Ring (2 used)

22—Roller Bearing
–UN–10APR07
TX1020569
Snap Ring and Roller Bearing Install

060807
PN=217
17—Piston
19—O-ring
20—O-ring
–UN–10APR07
TX1020568
03
0350 Piston O-Rings Install
52
JH38101,00002CE –19–16MAY07–15/28
–UN–23APR07
TX1021997
Piston Install

060807
PN=218
26. Install bevel springs (14) and spring (15).
15—Washer
16—Bevel Springs (7 used)
–UN–10APR07
TX1020565
03
Washers Install 0350
53
JH38101,00002CE –19–16MAY07–17/28
27. Remove snap ring (14) using JDG10510 Assembly

Aid.
14—Snap Ring
–UN–10APR07
TX1020545
Snap Ring Install

060807
PN=219
13—Snap Ring
–UN–10APR07
TX1020544
03
0350 Snap Ring Install
54
JH38101,00002CE –19–16MAY07–19/28

disks (33).
33—Disks (13 used)

34—Plate (13 used)
–UN–10APR07
TX1020574
Clutch Plate and Disk Install

060807
PN=220
30. Install end plate (12) with flat side down on disks and
plate.
9—Snap Ring
12—End Plate
–UN–23APR07
TX1021999
03
Snap Ring and End Plate Install 0350
55
JH38101,00002CE –19–16MAY07–21/28

Specification
Force .................................................................................................. 20 N
4.5 lb
12—End Plate
–UN–10APR07
TX1020576
End Plate Clearance Measurement

060807
PN=221

the disk clearance.

Specification
First Speed Clutch—Distance ............................................... 2.2—2.5 mm
0.087—0.098 in.
–UN–10APR07
TX1020578
03
0350 End Plate Clearance Measurement
56
JH38101,00002CE –19–16MAY07–23/28

thicknesses:
Specification
End Plate Snap Ring—Thickness .................................................. 2.0 mm
0.079 in.
2.25 mm
.089 in.
2.5 mm
0.098 in.
2.75 mm
0.108 mm
–UN–23APR07
3.0 mm
0.118 in.
3.25 mm
0.128 in.
TX1021982
3.5 mm
0.157 in.
11—Snap Ring Snap Ring and End Plate Install

12—End Plate

060807
PN=222
33. Install washers (3 and 5) and needle bearing (4).
3—Washer
4—Needle Bearing
5—Washer
–UN–11APR07
TX1020541
03
Needle Bearing and Washer 0350
Remove 57
JH38101,00002CE –19–16MAY07–25/28
34. Install needle bearings (8) and bushing (7).
7—Bushing
–UN–10APR07
TX1020539
Needle Bearing and Bushing Install

060807
PN=223
35. Install disk carrier (2) until contact is obtained.
36. Install washer (4), needle bearing (5), and washer (6).
2—Disc Carrier
3—Bearing
4—Washer
5—Needle Bearing
6—Washer
–UN–10APR07
TX1020537
03
0350 Bearing, Washer, Needle Bearing, and Disc Carrier
58 Remove
–UN–10APR07
TX1020538
Bearing, Washer, Needle Bearing, and Disc Carrier

Remove

060807
PN=224
1—Sealing Ring
–UN–11APR07
TX1020533
Snap Ring Remove
03
0350
59
JH38101,00002CE –19–16MAY07–28/28

Clutch Disassemble and Assemble
1—Sealing Ring
2—Bearing
–UN–23APR07
TX1021318
Sealing Ring and Bearing Remove
Continued on next page JH38101,00002CF –19–09MAY07–1/18

060807
PN=225
3. Remove washer (3).
4. Remove inner disk carrier (4).
3—Running Disk
–UN–23APR07
TX1021319
03
0350 Inner Disk Carrier Remove
60
JH38101,00002CF –19–09MAY07–2/18
5—Snap Ring
–UN–23APR07
TX1021320

060807
PN=226
7. Remove plates and disk assembly (6).
7—End Plate
–UN–23APR07
TX1021321
03
End Plate and Disk Assembly 0350
Remove 61
JH38101,00002CF –19–09MAY07–4/18
8. Pre load bevel springs to remove snap ring (8).
8—Snap Ring
9—Pipe
–UN–25APR07
TX1021324
Bevel Spring Snap Ring Remove

060807
PN=227
9. Remove washer (10) and bevel springs (11).
10—Washer
11—Bevel Spring (7 used)
–UN–23APR07
TX1021325
03
0350 Bevel Spring Remove
62
JH38101,00002CF –19–09MAY07–6/18
10. Use compressed air through oil passage (12) to

remove piston (13).
12—Oil Passage
13—Piston
14—Bearing
–UN–23APR07
TX1021326
Piston Remove

060807
PN=228

damage will occur.
15—Shaft
16—Hub
–UN–23APR07
TX1021327
03
Non Serviceable Parts 0350
63
JH38101,00002CF –19–09MAY07–8/18
12—Oil Passage
13—Piston
14—Bearing
–UN–23APR07
TX1021326
Bearing Install

060807
PN=229
–UN–23APR07
TX1022044
Piston Install
03
0350
64
JH38101,00002CF –19–09MAY07–10/18
15. Install washer (10) and bevel springs (11).
10—Washer
17—MFWD Clutch
18—Piston
20—Washer
21—Snap Ring
–UN–23APR07
TX1021325
Bevel Spring Install

–UN–23APR07
TX1021342

060807
PN=230
16. Pre load bevel springs to install snap ring (8).
8—Snap Ring
9—Pipe
–UN–25APR07
TX1021324
03
Bevel Spring Snap Ring Install 0350
65
JH38101,00002CF –19–09MAY07–12/18

disks (22).
22—Disk (12 used)

23—Plate (12 used)
–UN–23APR07
TX1021344
Plate and Disk Install

060807
PN=231
18. Install end plate (7) with flat side facing the disks and
plates.
5—Snap Ring
7—End Plate
–UN–23APR07
TX1022005
03
0350 End Plate and Snap Ring Install
66
JH38101,00002CF –19–09MAY07–14/18

Specification
Apply to End Plate—Pressure ........................................................... 20 N
4.5 lb
7—End Plate
–UN–23APR07
TX1021346

060807
PN=232

the disk clearance.
c. Determine correct thickness of snap rings to be

Specification
MFWD Clutch End Plate
Distance—Distance ............................................................... 2.3—2.8 mm
0.079 in.—
–UN–23APR07
thicknesses.
TX1021351
Specification 03
Snap Ring—Thickness ................................................................... 2.0 mm 0350
0.079 in. End Plate Clearance Measurement
67
2.25 mm
0.089 in.
2.5 mm
0.098 in.
2.75 mm
0.108 in.
3.0 mm
0.118 in.
3.25 mm
0.128 in.
3.5 mm
0.157 in.
3.75
0.168 in.
4 mm
0.179 in.

060807
PN=233
21. Install inner disk carrier (4).
22. Install running disk (3).
Specification
248°F
–UN–23APR07
3—Running Disk
TX1021319
03
0350 Inner Disk Carrier Install
68
JH38101,00002CF –19–09MAY07–17/18
1—Sealing Ring
2—Bearing
–UN–23APR07
TX1021318
Sealing Ring and Bearing Remove
JH38101,00002CF –19–09MAY07–18/18

060807
PN=234
Pump Drive Shaft Install
1. Press bearing (16) until bottomed.
2. Install pump drive shaft (18).
16—Bearing
17—Snap Ring
–UN–04APR07
TX1020115
03
0350
69
–UN–30APR07
TX1022811
Pump Drive Shaft Install
JH38101,00002C4 –19–09MAY07–1/1
Clutch Packs Install
1. Apply petroleum jelly to bearing cups (20).
2. Install bearing cups (20).
3. Install oil suction tube (22).

–UN–04APR07
22—Oil Suction Tube

TX1020118
Torque Converter Side Bearing Outer Rings and Suction Tube

Installation

060807
PN=235
4. Apply petroleum jelly to bearing cups (19).
5. Install bearing cups (19)
NOTE: Use petroleum jelly to hold O-rings in place during

assembly.
–UN–22MAY07
TX1023851
O-ring and Bearing Outer Races
03
0350
70
KK70125,0000762 –19–16MAY07–2/9
7. Apply petroleum jelly to snap O-rings (24 and 25).
8. Install bolts (27) through screen sheet (13).

device.
9. Align bolts (27) with pilot holes (26) to install clutch

packs (9—11) together with screen sheet (13).
Specification
Second, Third, and MFWD Clutch
–UN–23APR07
Pack—Weight (approximate)............................................................. 27 kg
60 lb

TX1021630

Pack
12—Eyebolt (2 used) 2nd, 3rd, and MFWD Installation
13—Screen Sheet
25—Snap Ring
26—Pilot Hole (2 used)
27—Bolts (2 used)

060807
PN=236
10. Apply petroleum jelly to snap rings (28) and install

clutch (8).
8—First Speed Clutch

–UN–23APR07
TX1021690
First Speed Clutch Install
03
0350
71
KK70125,0000762 –19–16MAY07–4/9
11. Apply petroleum jelly to snap rings (29 and 30) and
install clutches (5 and 7) together.
5—Low Range Clutch

7—Reverse Clutch
–UN–23APR07
TX1021688
Reverse and Low Range Clutch Install

060807
PN=237
12. Apply petroleum jelly to snap rings (31) and install

clutch (6).
6—High Range Forward Clutch

31—Snap Ring
–UN–23APR07
TX1021693
High Range Forward Clutch Install
03
0350
72
KK70125,0000762 –19–16MAY07–6/9
NOTE: Bolts (27) must be installed properly before the

transmission halves are installed.
13. Install lifting eyebolts (3) and attach hoist.
14. Clean mating surfaces of transmission case halves

with PM37509 Cure Primer.
15. Apply PM38657 High Flex Form-In-Gasket to mating

surfaces of transmission halves.
–UN–23APR07
3—Eyebolts
27—Bolts
TX1021714
Transmission Case Installation

060807
PN=238

device.
NOTE: Bolts (27) must be installed properly before the

transmission halves are installed.
16. Install lifting eyebolts (3) and attach hoist.
Specification
–UN–23APR07
Transmission Case Half—Weight
(approximate)..................................................................................... 42 kg
93 lb
TX1021714
3—Eyebolts
27—Bolts
03
Transmission Case Installation 0350
73
KK70125,0000762 –19–16MAY07–8/9
17. Install bracket (32).
18. Align the dowel holes.
19. Install dowel pin (1) until flush.
–UN–23APR07
20. Tighten cap screws (2) with a run up torque of 20
N•m (177 lb-in) at a 45° rotation.
TX1021717
Specification
Transmission Case Mounting Cap
Screws—Run Up Torque ............................................................... 20 N•m
177 lb-in
Transmission Case Cap Screws and Pins
21. Tighten cap screws (2). 1—Dowel Pins (2 used)

Specification 32—Bracket
Transmission Case Mounting Cap
Screws—Torque ............................................................................. 65 N•m
48 lb-ft
KK70125,0000762 –19–16MAY07–9/9

060807
PN=239

Assemble
1. Install screen (10).
–UN–09APR07
9—Pin (2 used)
10—Screen
TX1020038
Screen Install
03
0350
74
KK70125,0000763 –19–24MAY07–1/11
2. Install system relief valve assembly (11—15).
11—Plug
12—O-ring
13—Piston
–UN–03APR07
16—System Relief Port
TX1020042
System Relief Valve

060807
PN=240
3. Use JDG10480 driver tool (13) to install converter

safety valve (12).
4. Tighten plug (11).
Specification
–UN–30APR07
System Relief Plug—Torque .......................................................... 50 N•m
37 lb-ft
12—Torque Converter Safety Valve
TX1022772
13—JDG10480 Driver Tool
Torque Converter Safety Valve
03
0350
75
KK70125,0000763 –19–24MAY07–3/11
5. Install M10 guide screws (A).
6. Apply PM38657 high flex form-in-place gasket to

mating surfaces of torque converter bell housing and
transmission case.
–UN–30APR07
A—M10 Guide Screw (2 used)
TX1022770
M10 Guide Screws

060807
PN=241
7. Install torque converter bell housing (6).
6—Plug and O-ring

–UN–09APR07
TX1020036
Torque Converter Bell Housing Install
03
0350
76
KK70125,0000763 –19–24MAY07–5/11
8. Install pins (9).
9—Pin (2 used)
–UN–30APR07
TX1022771
Pin Install

060807
PN=242
Specification
Transmission Bell Housing Cap
Screws—Torque ............................................................................. 46 N•m
34 lb-ft
–UN–02APR07
TX1020034
Transmission Bell Housing Cap Screws Install
03
0350
77
KK70125,0000763 –19–24MAY07–7/11
Specification
Plug—Torque.................................................................................. 25 N•m
221 lb-in
–UN–09APR07
6—Plug and O-ring
TX1020036
Plug and O-Ring Install

060807
PN=243
11. Use JDG10482 driver tool to install mechanical front

wheel drive (MFWD) seal (15).

12—MFWD Shaft
–UN–25APR07
13—Dust Cover
14—Transmission Housing
15—MFWD Seal
TX1022511
MFWD Seal Install
03
0350
78
–UN–25APR07
TX1022512
Cross Section of MFWD

060807
PN=244
12. JDG10482 driver tool (11) to install dust cover (16).

16—Dust Cover
–UN–25APR07
TX1022511
MFWD Dust Cover Install
03
0350
79
–UN–25APR07
TX1022513
Cross Section of MFWD Output
KK70125,0000763 –19–24MAY07–10/11
13. Install torque converter (1).
14. Install flex plate (2).

–UN–02APR07
Specification
Flex Plate Cap Screws—Torque .................................................... 46 N•m
34 lb-ft
TX1020033
1—Torque Converter
2—Flex Plate
Flex Plate Install
KK70125,0000763 –19–24MAY07–11/11

060807
PN=245
Install Outer Components to Assemble

Transmission
Specification
Plug—Torque.................................................................................. 15 N•m
133 lb-in
–UN–02APR07
Specification
Plug—Torque.................................................................................. 28 N•m
21 lb-ft
TX1020013
03
0350 Specification
Plug—Torque.................................................................................... 6 N•m Plugs
80
53 lb-in
18—Plug
19—Plug
4. Install orifices (14—17). 20—Plug
Specification
Orifice—Torque .............................................................................. 10 N•m
89 lb-in
KK70125,0000764 –19–09MAY07–1/6
5. Install solenoids (4—12).
6. Install rear output flange seal using JDG10481 driver

tool.

5—Park Brake Solenoid
6—Differential Lock Solenoid
7—Transmission Forward Direction Solenoid
8—Transmission Reverse Direction Solenoid
–UN–02APR07

12—Mechanical Front Wheel Drive (MFWD) Solenoid
TX1020006

060807
PN=246
7. Press dust cover in place until it is bottomed.
8. Install rear output flange (13).
13—Rear Output Flange
–UN–23APR07
22—Shaft Seal
23—Screen Sheet
24—Cover
25—Flange
TX1022509
Rear Output Flange Instal
03
0350
81
–UN–23APR07
TX1022510
Cross Section of Rear Output
KK70125,0000764 –19–09MAY07–3/6
9. Use JDG10483 driver tool to install dipstick tube (27).
27—Dipstick Tube
–UN–30APR07
TX1022773
Dipstick Tube Install

060807
PN=247
–UN–03APR07
TX1020000
Filter Head O-rings
03
0350
82
KK70125,0000764 –19–09MAY07–5/6
11. Install filter head (1).
Specification
Filter Head Cap Screws—Torque .................................................. 23 N•m
204 lb-in
–UN–03APR07
1—Filter Head
TX1019989
Filter Head
KK70125,0000764 –19–09MAY07–6/6

060807
PN=248
Group 0360
Hydraulic System
Transmission Charge Pump Remove and

Install
NOTE: Transmission pump can not be removed until the

transmission case is separated and the
transmission pump inner cap screws have been
removed.
1. Remove torque converter. See Torque Converter Side

of Transmission Case Disassemble. (Group 0350.)
KK70125,0000765 –19–10MAY07–1/7
NOTE: Mark transmission pump and transmission

housing. 03
0360
2. Remove transmission charge pump cap screws (6). 1
–UN–23APR07
3. Remove torque converter side of transmission case.
See Clutch Packs Remove. (Group 0350.)
TX1022044
Transmission Charge Pump Cap Screws
KK70125,0000765 –19–10MAY07–2/7
4.
IMPORTANT: Transmission charge pump may fall out

of transmission case while removing
cap screws (1 and 2) causing damage
to transmission pump. Hold
–UN–09APR07
transmission pump in place while

removing cap screws.
Remove cap screws (1 and 2).

TX1020123

Transmission Charge Pump Inner Cap Screws

060807
PN=249
Hydraulic System
5. Remove transmission charge pump (3).
3—Transmission Charge Pump
–UN–09APR07
03
0360
TX1020125
2
KK70125,0000765 –19–10MAY07–4/7
7. Install transmission charge pump (3).
4—Transmission Charge Pump

5—Guide Screws
–UN–23APR07
TX1022045

060807
PN=250
Hydraulic System
8. Tighten cap screws (1 and 2).
Specification
Transmision Charge Pump Inner
204 lb-in.
–UN–09APR07
TX1020123
Transmission Charge Pump Inner Cap Screws
03
0360
3
KK70125,0000765 –19–10MAY07–6/7
Specification
Transmision Charge Pump Cap
Screws—Torque ............................................................................. 23 N•m
204 lb-in.
–UN–23APR07
10. Install torque converter housing. See Clutch Packs
TX1022044
11. Install torque converter. See Torque Converter Side
of Transmission Case Disassemble. (Group 0350.)
Transmission Charge Pump Cap Screws
KK70125,0000765 –19–10MAY07–7/7

060807
PN=251
Hydraulic System
Transmission Charge Pump Disassemble and Assemble
03
0360
4
–UN–13DEC06
TX1014801
Transmission Charge Pump


060807
PN=252
Hydraulic System
1—Cap Screw (8 used) 3—Transmission Charge Pump 5—Cap Screw (2 used) 6—Cap Screw (2 used)
2—Seal 4—O-Ring
1. Remove seal (2). 5. Apply PM37509 Cure Primer, then PM38657 High
Flex Form-In-Place Gasket to pump seal (2).
6. Replace seal (2) using Driver Tool JDG10478.
3. Inspect and replace transmission charge pump (3) if
necessary. 7. Fill area between seal lip and dust cover lip with
multi purpose grease.
4. Replace O-ring (4).
KK70125,0000766 –19–10MAY07–2/2
03
0360
5

060807
PN=253
Hydraulic System
03
0360
6

060807
PN=254
Section 04
Engine
Contents
Page

POWERTECH 4.5L (4045) and 6.8L
(6068) John Deere Engines . . . . . . . . . . . .04-0400-1
Engine Remove. . . . . . . . . . . . . . . . . . . . . . .04-0400-1
Engine Install . . . . . . . . . . . . . . . . . . . . . . . .04-0400-7
04

060807
PN=1
Contents
04

060807
PN=2
Group 0400
POWERTECH 4.5L (4045) and 6.8L (6068)

John Deere Engines
For additional engine information on John Deere engines

and components, see the following component technical
manuals (CTM).
–UN–07SEP88
• See POWERTECH 4.5L (4045) and 6.8L (6068) Diesel
Engines—Base Engine. (CTM104.)
• See POWERTECH 4.5L (4045) and 6.8L (6068) Diesel
M44215
Engines—Level 12 Electronic Fuel System with DE10
Pump. (CTM331.)
TF44157,00006AF –19–25APR07–1/1
04
Engine Remove 0400
1
1. Raise loader boom and install locking bar.
2. Open engine hood fully.
3. Switch battery disconnect to off (if equipped) or

disconnect the battery ground cable.
4. Drain transmission. See Change Transmission and

Torque Converter Oil and Replace Filter. (Operator’s
Manual.)
Continued on next page TF44157,00006B0 –19–25APR07–1/12

060807
PN=257
5. Remove cowling (1).
1—Cowling
–UN–25AUG00
T133477B
TF44157,00006B0 –19–25APR07–2/12
04
0400 6. Disconnect air restriction switch connector (1).
2
7. Remove hose clamp (3).
8. Remove cap screws (2) to remove air cleaner and

exhaust pipe assembly (4).
9. Remove cap screw and nut (6).
10. Loosen clamp (7) and remove muffler (5).
–UN–04APR07
11. Remove fan belt, fan, and radiator. See Fan Belt
Remove and Install. (Group 0510.) See Fan Remove
and Install. (Group 0510.) See Radiator Remove and
TX1019607A
1—Air Restriction Switch Connector

3—Hose Clamp
4—Air Cleaner and Exhaust Pipe Assembly
5—Muffler
6—Cap Screw and Nut
7—Clamp
–UN–17AUG00
T133165B

060807
PN=258
12. Tag and disconnect connectors (2,4, and 7).
13. Pull engine wire harness (9) back and out of the way.
14. Disconnect hoses (1, 3, 5, and 8). Close all openings

using caps and plugs.
15. Disconnect coolant heater (if equipped).
16. Remove transmission oil fill tube (6). Close all
–UN–04APR07
1—Vent Hose
2—Air Intake Sensor Wire Connector
TX1019624A
3—Starting Aid Hose (optional)
4—Alternator Connector (3 used)
5—Heater Hose (2 used)
6—Transmission Oil Fill Tube
7—Starting Aid Wire Connector (optional)
8—Fuel Hose
9—Engine Wire Harness
10—Air Intake Tube
04
0400
3
TF44157,00006B0 –19–25APR07–4/12
17. Tag and disconnect items (2 and 3).
18. Tag and disconnect connectors (4, 5, and 6).
1—Starter Motor
2—Ground Strap-to-Starter Motor
3—Power Cables-to-Starter Motor
4—Engine Oil Pressure Switch Connector
5—Engine Control Unit (ECU) Unswitched Battery
Power Connector
–UN–04APR07
6—Engine Control Unit (ECU) Connector
7—Engine Control Unit (ECU)
8—Fuel Injection Pump
TX1019629A

060807
PN=259
19. Tag and disconnect connectors (3, 4, 5, and 6).
20. If equipped with air conditioning:
a. Tag and disconnect air conditioning

compressor-to-engine wire harness connectors (2).
b. Loosen four A/C compressor cap screws and nuts

(1). Remove the two lower cap screws, but do not
remove the two upper cap screws at this time.
–UN–04APR07
1—Air Conditioning Compressor Cap Screw (4 used)
2—Air Conditioning Compressor-to-Engine Wire
Harness Connector (2 used)
TX1019632A
3—Coolant Temperature Sensor Connector
4—Fuel Temperature Sensor Connector
5—Fuel Injection Pump Solenoid Connector
6—Crankshaft Position Sensor Connector
04
0400
4
TF44157,00006B0 –19–25APR07–6/12
21. Disconnect return fuel hose (1).
1—Return Fuel Hose
–UN–04APR07
TX1019633A

060807
PN=260
22. Remove access plate at bottom of flywheel housing.
23. Remove plug (4), located at right front side of

flywheel housing, and insert JDG820 Flywheel
Turning Tool (3).
–UN–11AUG00
24. Remove four flex plate-to-flywheel cap screws (1).
Use flywheel turning tool to rotate flywheel as
necessary.
T133066B
25. Remove six transmission-to-flywheel housing cap
screws (2) located at lower half of flywheel housing.
1—Flex Plate-To-Flywheel Cap Screws (4 used)

2—Transmission-To-Flywheel Housing Cap Screws
3—JDG820 Flywheel Turning Tool
4—Plug
–UN–28AUG00
04
0400
T133480B
5
TF44157,00006B0 –19–25APR07–8/12
26. Stabilize transmission using a floor jack or equivalent.
1—Transmission
2—Floor Jack
–UN–31MAR07
TX1019652A

060807
PN=261
27. Remove cab floor mat and floor access plate (1).
28. Remove the six remaining transmission-to-flywheel

housing cap screws.
IMPORTANT: Hood must be closed before lowering

the loader boom or damage to hood will
result.
–UN–27SEP00
29. Close engine hood.
30. Attach a hoist and lifting strap to loader boom. Put the
boom control lever in float position. Lower loader to
T133998B
the ground using the hoist.
31. Open engine hood. Floor Plates
1—Floor Access Plate

04
0400
6
TF44157,00006B0 –19–25APR07–10/12

device.
Specification
–UN–31MAR07
Engine—Weight (approximate) ...................................................... 404 kg
890 lb
32. Fasten two brackets (1) to engine. TX1019662A
33. Install the D01043A Load Positioning Sling (2) on

brackets (1).
34. If equipped with air conditioning, attach the A/C

compressor to side of boom making sure A/C hoses
and lines are not pinched or kinked. Remove two
remaining cap screws.
–UN–31MAR07
1—Bracket (2 used)
2—D01043A Load Positioning Sling
TX1019663A

060807
PN=262
35. Remove engine mount cap screws, nuts, and

washers (1).
IMPORTANT: Make sure torque converter stays with

the transmission and take care not to
damage the torque converter flex plate
–UN–17AUG00
and the oil cooler as engine is being
removed.
36. Carefully remove engine.
T133169B
1—Cap Screw, Nut, and Washer (2 of each used)
TF44157,00006B0 –19–25APR07–12/12
04
Engine Install 0400
7
1. If removed install engine mount brackets to engine
block and tighten to specifications. 1 2
–UN–31MAR07
Specification
Engine Block Mount Brackets—
Torque .......................................................................................... 320 N•m
235 lb-ft
TX1019673
2. Install engine mount isolators (2 and 3) to engine 3
supports (1). If necessary, use tape to hold isolator TX1019673
mounts in position.
1—Engine Support
2—Upper Half Of Isolator Mount
3—Lower Half Of Isolator Mount
Continued on next page TF44157,00006B1 –19–16MAY07–1/9

060807
PN=263
3. Make sure torque converter is fully seated on

transmission input shaft, then carefully lower engine
into position. Adjust engine height and angle, using
hoist and load-positioning sling, so front of oil pan
clears frame and engine aligns with transmission.
–UN–31MAR07
4. Install several transmission-to-flywheel housing cap
screws.
TX1019663A
2—D01043A Load Positioning Sling
TF44157,00006B1 –19–16MAY07–2/9
04
0400 5. Lower engine so engine rests fully on engine supports.
8 Make sure rubber isolators are in position on mounts.
6. Install cap screws, washers, and nuts (1) at both

mounts. Do final tightening of engine mounts cap
screws after loader boom has been raised.
–UN–17AUG00
7. Disconnect hoist.
8. If equipped with air conditioning, disconnect the A/C
T133169B
compressor from side of boom. Install four cap screws.
IMPORTANT: Engine hood must be closed before

raising the loader boom or damage to 1—Engine Mount Cap Screw, Washer, and Nut (2
of each used)
hood will result.
10. Attach a hoist and lifting strap to loader boom. Put the
boom control lever in float position. Raise loader
boom using the hoist. Install boom lock.
12. Tighten engine mount cap screws to specification.
Specification
Engine Mount Cap Screws—
Torque .......................................................................................... 130 N•m
96 lb-ft

060807
PN=264
13. Remove low lift jack.
14. Install remaining transmission-to-flywheel housing cap

screws (2). Tighten cap screws to specification.
Specification
–UN–11AUG00
Transmission-to-Flywheel
Housing Cap Screws—Torque ....................................................... 73 N•m
54 lb-ft
T133066B
15. Use JDG820 Flywheel Turning Tool (3) to rotate
flywheel and install four flex plate-to-flywheel cap
screws (1). Tighten cap screws to specification.
Specification
Torque Converter Flex
Plate-to-Flywheel Cap Screws—
Torque ............................................................................................ 73 N•m
54 lb-ft
–UN–28AUG00
16. Install flywheel housing access cover. Remove
flywheel turning tool and insert plug (4).
04
1—Flex Plate-To-Flywheel Cap Screws (4 used) 0400
T133480B
2—Transmission-To-Flywheel Housing Cap Screws 9
3—JDG820 Flywheel Turning Tool
4—Plug
TF44157,00006B1 –19–16MAY07–4/9
17. Connect return fuel hose (1).
1—Return Fuel Hose

–UN–04APR07
TX1019633A

060807
PN=265
18. Connect items (2 and 3).
19. Plug in connectors (4, 5, and 6).
1—Starter Motor
2—Ground Strap-to-Starter Motor
3—Power Cables-to-Starter Motor
4—Engine Oil Pressure Switch Connector
5—Engine Control Unit (ECU) Unswitched Battery
Power Connector
–UN–04APR07
6—Engine Control Unit (ECU) Connector
7—Engine Control Unit (ECU)
8—Fuel Injection Pump
TX1019629A
TF44157,00006B1 –19–16MAY07–6/9
04
0400 20. Plug in connectors (3, 4, 5, and 6).
10
21. If equipped with air conditioning, connect air
conditioning compressor-to-engine wire harness
connectors (2).
1—Air Conditioning Compressor Cap Screw (4 used)

2—Air Conditioning Compressor-to-Engine Wire
Harness Connector (2 used)
3—Coolant Temperature Sensor Connector
–UN–04APR07
4—Fuel Temperature Sensor Connector
5—Fuel Injection Pump Solenoid Connector
6—Crankshaft Position Sensor Connector
TX1019632A

060807
PN=266
22. Plug in connectors (2,4, and 7).
23. Install engine wire harness (9) back in its place.
24. Connect hoses (1, 3, 5, and 8).
25. Connect coolant heater (if equipped).
26. Install transmission oil fill tube (6).
–UN–04APR07
27. Install fan belt, fan, and radiator. See Fan Belt
Remove and Install. (Group 0510.) See Fan Remove
and Install. (Group 0510.) See Radiator Remove and
TX1019624A
1—Vent Hose
2—Air Intake Sensor Wire Connector
3—Starting Aid Hose (optional)
4—Alternator Connector (3 used)
5—Heater Hose (2 used)
6—Transmission Oil Fill Tube
7—Starting Aid Wire Connector (optional)
8—Fuel Hose 04
9—Engine Wire Harness 0400
10—Air Intake Tube 11

060807
PN=267
28. Install muffler (5) and cap screw and nut (6). .
29. Install hose clamp (3).
30. Install air cleaner and exhaust pipe assembly (4).
31. Connect air restriction switch connector (1).
32. Install cowling.
–UN–04APR07
33. Install cab floor access plate near front console.
Install cab floor mat.
34. Fill transmission. See Change Transmission and
TX1019607A
Torque Converter Oil and Replace Filter. (Operator’s
Manual.)
35. Switch battery disconnect to on (if equipped) or

connect the battery ground cable.

04
0400 37. Lower loader boom.
12
1—Air Restriction Switch Connector

–UN–17AUG00
3—Hose Clamp
4—Air Cleaner and Exhaust Pipe Assembly
5—Muffler
6—Cap Screw and Nut
7—Clamp
T133165B
TF44157,00006B1 –19–16MAY07–9/9

060807
PN=268
Section 05
Engine Auxiliary Systems
Contents
Page
Group 0505—Cold Weather Starting Aid

Coolant Heater Remove and Install. . . . . . . .05-0505-1
Starting Aid Nozzle Remove and Install . . . .05-0505-3
Starting Aid Solenoid Remove and Install . . .05-0505-4
Group 0510—Cooling System

Fan Remove and Install . . . . . . . . . . . . . . . .05-0510-1
Fan Belt Remove and Install . . . . . . . . . . . . .05-0510-2
Radiator Remove and Install . . . . . . . . . . . . .05-0510-4
Group 0515—Speed Controls

Engine Speed Control Pedal Remove and
Install. . . . . . . . . . . . . . . . . . . . . . . . . . . . .05-0515-1
Group 0520—Intake System

Air Cleaner Remove and Install. . . . . . . . . . .05-0520-2
Group 0530—Exhaust System

05
Muffler with Turbocharger Remove and
Install. . . . . . . . . . . . . . . . . . . . . . . . . . . . .05-0530-2
Group 0560—External Fuel Supply System

Fuel Tank Remove and Install. . . . . . . . . . . .05-0560-2

060807
PN=1
Contents
05

060807
PN=2
Group 0505
Cold Weather Starting Aid
Coolant Heater Remove and Install
1. Drain cooling system. See Draining the Cooling

System. (Operator’s Manual.)
Specification
Cooling System—Capacity .................................................................. 21 L
22 qt
2. Disconnect cord (3) from coolant heater assembly.
3. Loosen lock nut (2).
4. Remove adapter (1) and heater element from engine

block.
CAUTION: TEST COOLANT HEATER IN LIQUID

ONLY. DO NOT plug coolant heater into
electrical power unless heating element is
immersed in coolant. Sheath could burst and
–UN–31MAR07
result in personal injury.
TX1018544A
1—Adapter
2—Lock Nut
3—Cord
05
0505
1

060807
PN=271
6. Install heater element (7) into engine block.
7. Install and tighten the adapter (4).
8. Turn heater element (7) until it comes in contact with

engine casting. Move heater element to the centered
–UN–31MAR07
position.
9. Hold heater element (7) in centered position and

tighten nut (3) to specification.
TX1018543
Specification
Coolant Heater Lock Nut—Torque ................................................. 34 N•m
25 lb-ft
1—Cord
2—Cap
3—Nut
4—Adapter
5—Gasket
6—O-ring
7—Heater Element
TF44157,00006B2 –19–25APR07–2/3
05
0505
2
10. Install cord (3) and secure with plastic tie bands.
11. Refill cooling system. See Filling the Cooling System.

(Operator’s Manual.)
12. Start engine and check for leaks.
1—Adapter
2—Lock Nut
3—Cord
–UN–31MAR07
TX1018544A
TF44157,00006B2 –19–25APR07–3/3

060807
PN=272
Starting Aid Nozzle Remove and Install
CAUTION: Before working on machine with

loader in raised position, install boom lock bar.
1. Raise loader boom and install boom lock bar.
2. Stop engine
3. Open engine hood.

TF44157,00006B3 –19–10MAY07–1/2
5. Disconnect starting aid tube (2).
6. Remove nozzle holder (1) from air inlet.
7. Remove nozzle from holder.
–UN–31MAR07
05
8. Clean or replace nozzle as required. 0505
3
NOTE: Arrow on nozzle holder indicates direction of
TX1018620A
nozzle.
9. Install nozzle holder in air inlet with arrow pointing up.
10. Connect starting aid tube to nozzle holder. 1—Nozzle Holder

2—Starting Aid Tube

13. Disengage boom lock bar and lower loader boom to

ground.
TF44157,00006B3 –19–10MAY07–2/2

060807
PN=273
Starting Aid Solenoid Remove and Install

2. Stop engine
3. Open engine hood.

TF44157,00006B4 –19–25APR07–1/2
5. Remove starting fluid can (2).
6. Disconnect starting aid wire harness (4) and starting

aid hose (3).
–UN–12MAR07
05 7. Remove starting aid solenoid (6).
0505
4
TX1018664A
9. Install starting aid solenoid.
10. Connect starting aid wire harness (4) and starting aid
hose (3).
1—Hose Clamp
2—Starting Fluid Can
11. Install starting fluid can (2).
3—Starting Aid Hose
4—Starting Aid Wire Harness
12. Switch battery disconnect to on (if equipped) or 5—Cap Screw, Washer and Nut (2 each)
connect the battery ground cable. 6—Starting Aid Solenoid
14. Disengage boom lock bar and lower loader boom to

ground.
TF44157,00006B4 –19–25APR07–2/2

060807
PN=274
Group 0510
Cooling System
Fan Remove and Install

2. Stop engine.

TF44157,00006B5 –19–25APR07–1/3
5. Remove right side fan guard (15).
6. If necessary, loosen or remove fan belt. See Fan Belt

05
1—Surge Tank
0510
2—Thermal Bypass Assembly
1
3—Surge Tank Overflow-to-Radiator Hose
4—Horn
5—Surge Tank Mounting Cap Screw (2 used)
6—Horn Wire Harness
7—Radiator
8—Radiator Hoisting Point (2 used)
9—Fan Shroud Cap Screw (4 used)
10—Fan Shroud
11—Thermal Bypass Assembly-to-Radiator Hose
(upper section)
(lower section)
13—Lower Radiator Hose
14—Thermal Bypass Assembly-to-Engine Block Hose –UN–03APR07
15—Right Side Fan Guard
TX1019524A

060807
PN=275
Cooling System
7. Remove fan cap screws (1) and slide fan (3) towards
the engine.
8. Remove spacer cap screws (2) and remove spacer (4)

with fan (3).
–UN–31MAR07
10. Slide fan over spacer and install spacer.
TX1018560A
11. Install fan on spacer.
12. If removed, install fan belt.

1—Fan Cap Screw (4 used)
13. Install right side fan guard. 2—Spacer Cap Screw (4 used)
3—Fan
4—Spacer
16. Remove boom lock bar and lower loader boom.
TF44157,00006B5 –19–25APR07–3/3
05
0510
2
Fan Belt Remove and Install

1. Raise boom and install boom lock bar.
2. Stop engine.


060807
PN=276
Cooling System
1—Surge Tank
2—Thermal Bypass Assembly
4—Horn
7—Radiator
10—Fan Shroud
(upper section)
(lower section)
14—Thermal Bypass Assembly-to-Engine Block Hose
–UN–03APR07
TX1019524A
TF44157,00006B6 –19–25APR07–2/3
05
0510
3
6. Insert a 1/2 in. socket drive in square hole (1) and pull
fan belt tensioner (2) away from belt. Remove fan belt
from the fan and alternator pulleys.
7. Remove belt by sliding belt over fan blades.
–UN–31MAR07
8. Install fan belt. Belt is self-adjusting.
9. Install fan guard.
TX1018587A
10. Install horn wire harness to right side fan guard.

1—Square Hole
12. Disengage boom lock bar and lower loader boom to 2—Fan Belt Tensioner
ground.
TF44157,00006B6 –19–25APR07–3/3

060807
PN=277
Cooling System
Radiator Remove and Install

2. Stop engine.

TF44157,00006B7 –19–25APR07–1/6
CAUTION: Explosive release of fluids from

pressurized cooling system can cause serious
burns.
Stop engine. Remove filler cap only when cool

05
0510 enough to touch with bare hands. Slowly
–UN–23AUG88
4 loosen cap to first stop to relieve pressure
before removing completely.
5. Drain coolant from radiator. See Draining the Cooling
TS281
Specification
Cooling System—Capacity
(approximate)....................................................................................... 21 L
5.5 gal

060807
PN=278
Cooling System
6. Remove left side fan guard (4).
7. Disconnect surge tank overflow-to-upper radiator hose

(2). Cap and plug all openings.
8. Disconnect upper radiator hose (3). Cap and plug all

openings.
9. Disconnect thermal bypass assembly-to-radiator hose

(10). Cap and plug all openings.
10. Disconnect surge tank-to-radiator hose (5) from surge

tank. Cap and plug all openings.
1—Surge Tank
2—Surge Tank Overflow-to-Upper Radiator Hose
3—Upper Radiator Hose
4—Left Side Fan Guard
–UN–03APR07
5—Surge Tank-to-Radiator Hose
8—Radiator
9—Fan Shroud
TX1019523A
05
0510
5

060807
PN=279
Cooling System
12. Disconnect horn wire harness (6).
13. Disconnect surge tank overflow-to-radiator hose (3).

Cap and plug all openings.

(upper section) (11). Cap and plug all openings.

(lower section) (12). Cap and plug all openings.
16. Disconnect lower radiator hose (13). Cap and plug all
openings.
17. Disconnect thermal bypass assembly-to-engine block

hose (14). Cap and plug all openings.
–UN–03APR07
18. Remove fan, if necessary. See Fan Remove and
TX1019524A
19. Remove fan shroud cap screws (9) and slide fan
shroud (10) back towards engine.
CAUTION: Prevent possible injury from heavy 1—Surge Tank

05 object. Use appropriate lifting device. 2—Thermal Bypass Assembly
0510 3—Surge Tank Overflow-to-Radiator Hose
6 4—Horn
20. Attach hoist to radiator hoisting points (8).
Specification
7—Radiator
Radiator—Weight .............................................................................. 25 kg
55 lb
10—Fan Shroud
21. Remove surge tank mounting cap screws (5) and 11—Thermal Bypass Assembly-to-Radiator Hose
surge tank (1). (upper section)
(lower section)
22. Remove radiator (7).
14—Thermal Bypass Assembly-to-Engine Block
23. Repair or replace radiator as necessary. Hose

060807
PN=280
Cooling System
CAUTION: Prevent possible injury from heavy

object. Use appropriate lifting device.
24. Attach hoist to radiator hoisting points.
Specification
Radiator—Weight .............................................................................. 25 kg
55 lb
25. Install radiator (7).
26. Install surge tank (1) and surge tank mounting cap
screws (5).
27. Install fan shroud (10).
28. Install fan, if necessary. See Fan Remove and Install.

(Group 0510.)
–UN–03APR07
29. Connect thermal bypass assembly-to-engine block
hose (14).
TX1019524A
30. Connect lower radiator hose (13).
31. Connect thermal bypass assembly-to-radiator hose

(lower section) (12).
1—Surge Tank
2—Thermal Bypass Assembly 05
32. Connect thermal bypass assembly-to-radiator hose 0510
(upper section) (11). 4—Horn 7
33. Connect surge tank overflow-to-radiator hose (3). 6—Horn Wire Harness
7—Radiator
34. Connect horn wire harness (6).
10—Fan Shroud
35. Install right side fan guard (15). 11—Thermal Bypass Assembly-to-Radiator Hose
(upper section)
(lower section)
14—Thermal Bypass Assembly-to-Engine Block
Hose

060807
PN=281
Cooling System
36. Connect surge tank-to-radiator hose (5) to surge tank.
37. Connect thermal bypass assembly-to-radiator hose

(10).
38. Connect upper radiator hose (3).
39. Connect surge tank overflow-to-upper radiator hose

(2).
40. Install left side fan guard (4).
41. Fill radiator with coolant. See Filling the Cooling


–UN–03APR07
43. Start engine and check cooling system for leaks.
1—Surge Tank
2—Surge Tank Overflow-to-Upper Radiator Hose
TX1019523A
3—Upper Radiator Hose
4—Left Side Fan Guard
5—Surge Tank-to-Radiator Hose
05 8—Radiator
0510 9—Fan Shroud
8 10—Thermal Bypass Assembly-to-Radiator Hose
TF44157,00006B7 –19–25APR07–6/6

060807
PN=282
Group 0515
Speed Controls
Engine Speed Control Pedal Remove and

Install
1. Lower all attachments to the ground and stop engine.

TF44157,00006B8 –19–10MAY07–1/3
3. Remove engine speed control pedal cover (1).
1—Engine Speed Control Pedal Cover

2—Nuts (3 used)
3—Engine Speed Control Pedal
05
–UN–31MAR07
0515
1
TX1018520A

060807
PN=283
Speed Controls
4. Disconnect engine speed control pedal wire harness

(1).
5. Remove engine speed control assembly.
–UN–31MAR07
7. Install engine speed control assembly.
TX1018521A
8. Connect engine speed control pedal wire harness.
9. Install engine speed control pedal cover.
10. Switch battery disconnect to on (if equipped) or 1—Engine Speed Control Pedal Wire Harness
3—Engine Speed Control Pedal
11. Check the operation of the engine speed control

pedal. See Engine Speed Check. (Group 9010-25.)
TF44157,00006B8 –19–10MAY07–3/3
05
0515
2

060807
PN=284
Group 0520
Intake System
05
0520
1

060807
PN=285
Intake System
Air Cleaner Remove and Install
05
0520
2
–UN–20NOV06
TX1012660

060807
PN=286
Intake System
1—Support 6—Cap Screw (3 used) 10—Air Cleaner 14—Air Filter (primary)

2—Washer (2 used) 7—Hose Clamp 11—Valve 15—Air Filter (secondary)
3—Cap Screw (2 used) 8—Hose 12—Cover 16—Fitting
4—Cap Screw (2 used) 9—Hose Clamp 13—Air Restriction Sensor 17—Tie Band
5—Seal
1. Tilt hood. 4. Test air intake system for leaks. See Air Intake
System Leakage Test. (Group 9010-25.)
2. Inspect elements for wear or damage and replace
as necessary.
3. Tighten hose clamps (7 and 9) until air intake hose

deforms around clamp band.
Specification
Air Intake
Hose-to-Turbocharger Inlet
Clamp—Torque ....................................................... 5.6 N•m (50 lb-in.)
Air Intake Hose-to-Air Cleaner
Clamp—Torque .................................................... 5.6.4 N•m (50 lb-in.)
TF44157,00006B9 –19–10MAY07–2/2
05
0520
3

060807
PN=287
Intake System
05
0520
4

060807
PN=288
Group 0530
Exhaust System
05
0530
1

060807
PN=289
Exhaust System
Muffler with Turbocharger Remove and Install
05
0530
2
–UN–04OCT00
TP58067
Continued on next page TF44157,00006BA –19–10MAY07–1/2

060807
PN=290
Exhaust System
1—Muffler Extension 3—Muffler 5—Washer (2 used) 7—Clamp

2—Clamp 4—Cap Screw 6—Nut
1. Remove parts as shown.
2. Repair or replace, and install parts as required.
3. Tighten clamps (2 and 7) to specifications.
Specification
Muffler Clamp-to-Extension and
Muffler Clamp-to-Base—Torque ....................................... 37—50 N•m
27—37 lb-ft
TF44157,00006BA –19–10MAY07–2/2
05
0530
3

060807
PN=291
Exhaust System
05
0530
4

060807
PN=292
Group 0560
External Fuel Supply System
05
0560
1

060807
PN=293
Fuel Tank Remove and Install
05
0560
2
–UN–28OCT06
TX1012682
Continued on next page TF44157,00006BB –19–10MAY07–1/2

060807
PN=294
1—Fuel Tank Assembly 12—Cap Screw (3 used) 21—Angle 30—Hose Clamp

2—Housing 13—Cap Screw (6 used) 22—O-ring 31—Hose
3—Fuel Tank 14—Clamp (2 used) 23—Cap Screw 32—Packing
4—Cap 15—Fuel Sender 24—Cap Screw (6 used) 33—Hose
5—Hose 16—Strainer 25—Washer (6 used) 34—Tie Band
7—Fuel Filter 17—Pipe Plug 26—Bushing 35—Tie Band (2 used)
8—Cap Screw (4 used) 18—Adapter Fitting 27—Clip 36—Line
9—Flange Nut (4 used) 19—Check Valve 28—Clip 37—Support
10—Reflector 20—Gasket 29—Clamp (2 used) 38—Strainer
11—Antiskid Pad
1. Remove pipe plug (17) to drain fuel tank (3). 5. Repair or replace parts as necessary.
Specification 6. Install fuel tank.

Fuel Tank—Capacity
(approximate) .............................................................................. 155 L
41 gal 7. Apply cure primer, then flexible sealant to fuel tank
surface where gasket (20) contacts fuel tank.
2. Disconnect wiring harness from fuel sender (15).
8. Apply cure primer to fuel sender (15) sealing
3. Disconnect hoses (31 and 33) from fuel sender surface.
(15).
9. Apply cure primer, then thread lock and sealer
(medium strength) to threads of pipe plug (17).
CAUTION: Prevent possible injury, use Install pipe plug.
appropriate lifting device.
10. Connect hoses (31 and 33).
4. Remove cap screws and washers (24 and 25).
Remove fuel tank assembly (1) using a hoist. 11. Connect wiring connector to fuel sender (15).
05
Specification
12. Fill fuel tank to proper level with appropriate fuel. 0560
Fuel Tank—Weight 3
(approximate) .............................................................................. 56 kg See Diesel Fuel. See 410J Backhoe Loader Drain
124 lb and Refill Capacities. (Operator’s Manual.)
TF44157,00006BB –19–10MAY07–2/2

060807
PN=295
05
0560
4

060807
PN=296
Section 06
Torque Converter
Contents
Page
Group 0651—Turbine, Gears and Shaft

Torque Converter Remove and Install . . . . . .06-0651-1
Torque Converter Disassemble and
Assemble. . . . . . . . . . . . . . . . . . . . . . . . . .06-0651-2
06

060807
PN=1
Contents
06

060807
PN=2
Group 0651
Turbine, Gears and Shaft
Torque Converter Remove and Install
NOTE: Torque converter has no internal service parts. If

replacement is necessary, install a new torque
converter.
1. Remove torque converter.See Transmission Remove.

(Group 0300.)
2. Install torque converter. See Transmission Install.

(Group 0300.)
KK70125,000077A –19–08MAY07–1/1
06
0651
1

060807
PN=299
Turbine, Gears and Shaft
Torque Converter Disassemble and Assemble
–UN–13DEC06
TX1015943
Torque Converter
1—Cap Screw (4 used) 3—Flex Plate 4—Torque Converter 5—Cap Screw (4 used)
2—Plate (8 used)
1. Disassemble parts as shown. 3. Assemble parts as shown.

06
0651 NOTE: Torque converter has no internal service parts. 4. Apply PM37509 cure primer, then apply PM37477
2
If replacement is necessary, install a new thread lock and sealer (medium strength) to threads
torque converter. of cap screws (1).
2. Inspect torque converter and replace if damaged.
KK70125,000077B –19–14MAR07–1/1

060807
PN=300
Section 09
Steering System
Contents
Page

Steering Column Remove and Install . . . . . .09-0960-1
Standard Steering Wheel and Column
Disassemble and Assemble. . . . . . . . . . . .09-0960-6
Tilt Steering Wheel and Column Disassemble
and Assemble . . . . . . . . . . . . . . . . . . . . . .09-0960-8
Steering Valve Remove and Install . . . . . . . .09-0960-9
Steering Valve Disassemble and
Assemble. . . . . . . . . . . . . . . . . . . . . . . . .09-0960-17
Non-Powered Front Axle Steering Cylinder
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . .09-0960-21
Axle Steering Cylinder Disassemble and
Assemble. . . . . . . . . . . . . . . . . . . . . . . . .09-0960-26
09

060807
PN=1
Contents
09

060807
PN=2
Group 0960
Hydraulic System
Steering Column Remove and Install
1. Park machine on level surface. Lower attachments and

stabilizers to ground.
2. Stop engine and operate all hydraulic controls to
–UN–27SEP00
relieve pressure from hydraulic system.
3. Disconnect batteries negative (–) (ground) cable.
T133991B
4. Remove panels (1 and 2).
1—Vent Panel
2—Switch Panel
KK70125,000077D –19–03MAY07–1/7
5. Tag and disconnect switch connectors (3—6).
3—Front Work Light Wire Harness

4—4-Way Flasher Wire Harness
5—Front Washer Wire Harness
–UN–09APR07
6—Front Wiper Switch Wire Harness
TX1019248A
Panel Switch Connectors
09
0960
1
Continued on next page KK70125,000077D –19–03MAY07–2/7

060807
PN=303
Hydraulic System
6. Remove screws (9 and 10).
7. Disconnect left duct air flow control wire connector (12)

(if equipped).
–UN–09APR07
8. Remove front console cover (11).
9. Open the steering and brake valve access door.
TX1018999A
9—Screw (2 used)
10—Screw (2 used)
11—Front Console Cover
12—Air Flow Control Wire Connector Upper Console Cap Screws
–UN–09APR07
TX1019000A
Lower Console Cap Screws
09
0960
2

060807
PN=304
Hydraulic System
NOTE: Standard steering column shown disassembly of

tilt steering is similar.
10. Disconnect wire harness connectors (1).
11. Support steering valve and spacer.
–UN–11OCT00
12. Remove four cap screws (2). Remove steering
column.
T134330B
13. Check position of adapter on steering valve before
installing steering column.
Standard Steering Column
14. Apply PM37509 cure primer, then apply TY24344
1—Wire Harness Connectors
Adhesive Sealant on lower splines of steering column. 2—Cap Screws (4 used)
15. Install steering column. Wire harness must be above

steering column. Install and tighten cap screws to
specifications.
Specification
Steering Column-to-Valve Cap
Screw—Torque ............................................................................... 30 N•m
22 lb-ft
16. Connect wire harness connectors to steering column.
17. Close the steering and brake valves access door.
09
0960
3

060807
PN=305
Hydraulic System
18. Install front console cover (11) and left air flow duct
wire connector (12) (if equipped).
9—Screw (2 used)
10—Screw (2 used)
–UN–09APR07
12—Air Flow Control Wire Connector
TX1018999A
Upper Console Cap Screws
–UN–09APR07
TX1019000A
KK70125,000077D –19–03MAY07–5/7
19. Connect switch connectors (3—6).
3—Front Work Light Wire Harness

4—4-Way Flasher Wire Harness
5—Front Washer Wire Harness
–UN–09APR07
6—Front Wiper Switch Wire Harness
TX1019248A
09
0960
4

060807
PN=306
Hydraulic System
20. Install vent panel (1) and switch panel (2).
1—Vent Panel
2—Switch Panel
–UN–27SEP00
T133991B
KK70125,000077D –19–03MAY07–7/7
09
0960
5

060807
PN=307
Hydraulic System
Standard Steering Wheel and Column Disassemble and Assemble
09
0960
6
–UN–06DEC06
TX1015716
Continued on next page KK70125,000077E –19–05FEB07–1/2

060807
PN=308
Hydraulic System
1—Cover 3—Nut 5—Steering Wheel 7—Steering Column

2—O-Ring 4—Lock Washer 6—Cap Screw (4 used) 8—Support
1. Remove parts as necessary. 5. Tighten steering wheel nut (3) to specification.
2. Replace as necessary. Specification

Steering Wheel Nut—Torque .................................................. 48 N•m
35 lb-ft
3. Apply PM37509 cure primer, then apply PM37463
RTV Clear Silicone on lower splines of steering
column.
4. Tighten cap screws (7) to specification.
Specification
Screw—Torque ........................................................................ 30 N•m
22 lb-ft
KK70125,000077E –19–05FEB07–2/2
09
0960
7

060807
PN=309
Hydraulic System
Tilt Steering Wheel and Column Disassemble and Assemble
09
0960
8
–UN–01DEC06
TX1013470
Tilt Steering Wheel and Column

Continued on next page KK70125,000077F –19–05FEB07–1/2

060807
PN=310
Hydraulic System
1—Cover 8—Support 15—Cap Screw (4 used) 21—Nut (2 used)

2—O-Ring 9—Plate 16—Screw (4 used) 22—Washer (4 used)
3—Nut 10—Plate 17—Washer (4 used) 23—Cover
4—Lock Washer 11—Isolator (4 used) 18—Washer (4 used) 24—Cover
5—Steering Wheel 12—Nut (8 used) 19—Screw (5 used) 25—Cover
6—Steering Column 13—Cap Screw (4 used) 20—Screw (4 used) 26—Cover Kit
7—Gasket 14—Screw
1. Remove parts as necessary. 5. Tighten cap screws (15) to specification.
2. Replace as necessary. Specification

Screw—Torque ........................................................................ 30 N•m
3. Tighten isolator cap screws (16) to specification. 22 lb-ft
Specification
Steering Column Isolator Cap
6. Tighten steering wheel nut (3) to specification.
Screw—Torque ........................................................................ 41 N•m
30 lb-ft Specification
Steering Wheel Nut—Torque .................................................. 48 N•m
35 lb-ft
4. Tighten plate cap screws (13) to specification.
Specification
Steering Column Plate Cap
Screw—Torque ........................................................................ 30 N•m
22 lb-ft
KK70125,000077F –19–05FEB07–2/2
Steering Valve Remove and Install
CAUTION: To avoid injury from escaping fluid

under pressure, stop engine and relieve the
pressure in the system before disconnecting
hydraulic lines and hoses. Tighten all
1. Stop engine and operate all hydraulic controls to 09

relieve pressure from hydraulic system. 0960
9
3. Remove front floor mat.

060807
PN=311
Hydraulic System
1—Vent Panel
2—Switch Panel
–UN–27SEP00
T133991B
Front Console Panel
KK70125,0000780 –19–03MAY07–2/14
5. Tag and disconnect switch connectors (3).
3—Switch Connector (4 used)
–UN–09APR07
TX1019248A
09
0960
10

060807
PN=312
Hydraulic System
7. Disconnect left duct air flow control wire connector

(12).
–UN–09APR07
TX1018999A
9—Screw (2 used)
10—Screw (2 used)
–UN–09APR07
TX1019000A
KK70125,0000780 –19–03MAY07–4/14
10. Disconnect wire harness connectors (13) from

steering column.

–UN–03APR07
TX1019130A
09
0960
11
Steering Column Wire Connectors and Cap Screws

060807
PN=313
Hydraulic System
NOTE: JDG1385 special tool is mounted on inside of

battery box.
11. Drain hydraulic reservoir or apply a vacuum to the

reservoir. The approximate capacity of reservoir is 37
L (9.8 gal).
–UN–23AUG88
15—Steering Valve-to-Hydraulic Oil Tank
16—Priority Valve-to-Steering Valve
17—Steering Valve-to-Steering Cylinder
X9811
19—Brake Valve-to-Priority Valve
20—Steering Valve
22—Release Sleeve
23—JDG1385 Special Tool
24—Shoulder
–UN–02APR07
TX1019148A
–UN–03APR07
TX1019150A
09 Special Tool JDG1385
0960
12

060807
PN=314
Hydraulic System

–UN–23AUG88
fluids.
X9811
12. Disconnect all hoses from steering valve (20).

Disconnect hoses as follows:
a. Clean area around the STC “quick disconnect”

hose fittings.
IMPORTANT: DO NOT pry against release sleeve (22)

or damage to fitting may result.
DO NOT force release sleeve beyond

normal range of travel, otherwise,
release sleeve may fall off when hose is
disconnected. If this happens and fitting
is connected without the release sleeve
installed, fitting will not be able to be
disconnected again.
NOTE: Cap and plug steering valve and hoses using

special STC plugs, 62H1028 and 62H1029 and
caps 62H1036 and 62H1035. Order caps and 09
plugs through your authorized dealer. 0960
13
b. Insert special tool JDG1385 (23) between release

sleeve (22) and shoulder (24) of fitting.
c. Gently push, DO NOT PRY, release sleeve away

from shoulder to disconnect the fitting.
d. Pull hose to disconnect.

060807
PN=315
Hydraulic System
e. Close all openings with caps and plugs.
13. Mark position of steering cylinder adapter.
14. Remove cap screws (21). Remove steering valve (20)

and steering column.
15. Repair or replace steering valve.
16. Check position of adapter on steering valve before

installing steering column.
17. Apply PM37509 Cure Primer, then apply PM37463

Clear RTV Silicone Adhesive Sealant on lower splines
of steering column.
KK70125,0000780 –19–03MAY07–8/14
CAUTION: If steering valve and steering column

splines do not line up, loss of steering control
will result. Check for proper spline alignment
and engagement.
–UN–03APR07
18. Install steering column. Wire harness must be above
steering column. Install and tighten cap screws (14) to
specifications.
TX1019130A
Specification
Screw—Torque ............................................................................... 30 N•m
22 lb-ft Steering Column Wire Connectors and Cap Screws

19. Connect wire harness connectors to steering column.
09
0960
14

060807
PN=316
Hydraulic System
20. Install fittings (15—19) (if removed) and tighten to

specification.
Steering Valve Fitting—Specification

Return to Reservoir—Torque ......................................................... 73 N•m
54 lb-ft
–UN–02APR07
From Priority Valve (Supply)—
Torque ............................................................................................ 50 N•m
37 lb-ft
Priority Valve Supply Check
TX1019148A
Valve—Torque ................................................................................ 73 N•m
54 lb-ft
To Steering Cylinder (without
adapter)—Torque ........................................................................... 73 N•m
54 lb-ft
To Steering Cylinder (with 15—Blue (to reservoir)
adapter)—Torque ........................................................................... 24 N•m 16—Red (from priority valve, sensing)
212 lb-in 17—Green (to steering cylinder)
To Steering Cylinder Adapter— 18—Orange (to steering cylinder)
Torque ............................................................................................ 73 N•m 19—Yellow (to priority valve, sensing)
54 lb-ft 20—Steering Cylinder
Priority Valve (Sensing)—Torque ................................................... 21 N•m
186 lb-in.
21. Connect hydraulic hoses to the steering valve as

follows:
a. Insert the steering valve hoses identified with

single color bands red, orange, green, and yellow
into the restraint loop at left side of front console
frame.
b. Make sure fitting halves are clean and free from

contaminates.
c. Make sure release sleeve is on male half of fitting

before connecting fitting halves together.
d. Match color coding on hose with appropriate valve

port as shown in illustration.
e. Push fitting halves together until a definite snap 09

0960
and solid stop is felt.
15
f. Pull back on hose to make sure fitting halves are

locked together.
g. To prevent hoses from binding, move component

into position before pressurizing the hydraulic
system.

060807
PN=317
Hydraulic System
KK70125,0000780 –19–03MAY07–11/14
23. Install front console cover (11) and left air flow duct
wire connector (if equipped) (12).
9—Screw (2 used)
10—Screw (2 used)
–UN–09APR07
12—Air Flow Control Wire Connector (if equipped)
TX1018999A
–UN–09APR07
TX1019000A
KK70125,0000780 –19–03MAY07–12/14
24. Connect switch connectors (3).

09
0960 3—Switch Connector (4 used)
16
–UN–09APR07
TX1019248A

060807
PN=318
Hydraulic System
25. Install vent panel (1) and switch panel (2).
26. Fill hydraulic reservoir to proper level or remove

vacuum to the reservoir.See 410J Backhoe Loader
Drain and Refill Capacities. (Operator’s Manual.)
–UN–27SEP00
1—Vent Panel
2—Switch Panel
T133991B
KK70125,0000780 –19–03MAY07–14/14
Steering Valve Disassemble and Assemble
IMPORTANT: Perform all service on steering valve in

a clean isolated work area. Use proper
tools, cleaning material, and lubricants.
NOTE: The manual steering check valve is removed

through gerotor end of valve as indicated in
procedure.
1. Before performing any service on steering valve

components, See Steering Valve Operation. (Group
9025-05.)
KK70125,0000781 –19–05FEB07–1/6
2. Remove cap screws in order (1—3).

09
1—Cap Screw (0.3125 in x 1.875 in) 0960
2—Cap Screw (0.3125 in x 1.750 in) 17
3—Cap Screw (0.3125 in x 1.750 in) 1
–UN–17OCT02
T160385
2 3
Continued on next page KK70125,0000781 –19–05FEB07–2/6

060807
PN=319
Hydraulic System
–UN–17OCT02
T160438B
Steering Valve Assembly
1—Cap Screw 6—Threaded Sleeve 9—Gerotor Meter 12—Thrust Washers and

2—Cap Screws 7—Gerotor Cap 10—Spacer Plate Bearing
4—Steel Ball and Pin 8—Gerotor Star 11—Spool and Drive 13—Housing
5—Steel Balls and Pins
3. Remove manual steering steel ball and pin (4) from 6. Remove remaining four cap screws.
cap screw (1) hole.
IMPORTANT: Spool is not serviceable. Do not
4. Remove anti-cavitation steel balls and pins (5) from disassemble spool.
cap screw (2 and 3) holes by tipping steering valve
upside down or by using a magnet. 7. Remove parts in sequential order (1—13) as shown
in steering valve assembly graphic.
IMPORTANT: To ensure spool, sleeve, and drive
09 pin link does not slip or lock up, IMPORTANT: If components are contaminated or
0960 secure valve with gerotor end facing damaged replace valve.
18 up.
8. Inspect all parts for contamination, nicks and burrs.
5. Mark outside gerotor components (7, 9, 13) to aid
in assembly.

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PN=320
Hydraulic System
IMPORTANT: Lubricate O-rings and seals with 18

Multi-Purpose HD Lithium Complex
grease (TY24416). If petroleum jelly is 20
used for o-ring lubrication use small
enough amount to avoid spreading on
surfaces of other parts. 21
–UN–17OCT02
NOTE: Lubricate spool, sleeve and gerotor star with
hydraulic oil before assembling.
T160387
9. Place new O-rings (18) in gerotor end of housing (13).
10. Install seals in steering input shaft end of housing

(13) with dust seal (21) lip facing out and oil seal (20) 20—Oil Seal
lip facing inward toward spool. 21—Dust Seal
11. Install thrust washers and bearing (12).
09
0960
19

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PN=321
Hydraulic System
12. Mark line (16) on top of drive spline (19) parallel to

8
pin (14) in bottom of spool.
IMPORTANT: Spool must rotate freely inside of

sleeve with torque less than 9
specification. 17
18
13. Install spool (11) into housing (13) sleeve.
Specification
10
Spool—Torque............................................................................. 0.11 N•m
1 lb-in.
18
14. Install spacer plate (10) on top of valve housing (13).
19
IMPORTANT: Timing of drive with respect to gerotor
star is critical. Line on top of drive
spline must be aligned with valley
(inner radius) of gerotor star.
16
15. Install gerotor star (8) on to shaft spline.
–UN–02DEC02
14
16. Install gerotor meter (9) housing over gerotor star.
NOTE: Cap screw (1) is longer than other six cap screws.
T160389
15
17. Install gerotor cap (7) on to assembly.
8—Gerotor Star
NOTE: Manual steering check ball and pin are larger than 9—Gerotor Meter
other two balls and pins. 10—Spacer Plate
14—Pin
18. Insert steering check ball and pin (4) in cap screw 15—Alignment Mark
16—Alignment Mark
hole (1), and anti-cavitation steel balls and pins (5) in 17—Alignment Mark
cap screw holes (2, 3). 18—O-ring (2 used)
19—Drive Spline
19. Install gerotor cap (7) on to assembly.
20. Apply TY9375 John Deere pipe sealant with teflon on

09 bottom side of cap screw heads.
0960
20

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PN=322
Hydraulic System
21. Torque all cap screws evenly to initial specification.

Then torque in sequence to final specification. 7
Specification
Cap screws—Initial Torque ............................................................ 14 N•m 2 5
124 lb-in.
–UN–17OCT02
Specification
Cap screws—Final Torque ............................................................. 27 N•m
4 3
20 lb-ft
T160436
1—Cap Screw 6 1
2—Cap Screw
3—Cap Screw
4—Cap Screw
5—Cap Screw
6—Cap Screw
7—Cap Screw
KK70125,0000781 –19–05FEB07–6/6

Repair
Non-Powered Front Axle Steering Cylinder Remove

and Install
NOTE: Steering cylinder must be removed from machine

for service.
1. Lower all attachments to the ground.
2. Stop engine.

in the hydraulic system.
09
CAUTION: Heavy component; use appropriate 0960
lifting device. 21
Specification
Machine—Weight (approximate) ................................................... 8391 kg
18 500 lb

stands under main frame.

060807
PN=323
Hydraulic System

–UN–23AUG88
fluids.
X9811
–UN–21NOV02
5. Disconnect cylinder lines. Close all openings using
caps and plugs (1).
6. Disconnect tie rod at (3).
T162050B
7. Remove cap screws (2) to remove cylinder.
8. Disassemble and assemble steering cylinder. See 1—Cap/Plug

Non-Powered Axle Steering Cylinder Disassemble and 2—Mounting Cap Screw (6 used)
3—Cylinder Rod
Assemble in this group.
9. Apply PM38654 LOCTITE to threads of cylinder

mounting cap screws (2), and install cylinder. Tighten
cap screws to specification.
Specification
Steering Cylinder Mounting Cap
Screws—Torque ........................................................................... 460 N•m
339 lb-ft
09
10. Connect tie rods. Tighten to specification.
0960
22
Specification
Tie Rod-to-Cylinder Rod
Torque—Torque ........................................................................... 300 N•m
221 lb-ft
11. Connect steering cylinder lines.
LOCTITE is a trademark of Loctite Corp. Continued on next page KK70125,0000782 –19–08MAY07–2/7

060807
PN=324
Hydraulic System
NOTE: If tie rod, spindle assembly, or steering cylinder

are adjusted or serviced, perform the following
procedures.
12. Adjust tracking angle. See Tracking Angle Check and

Adjust toe-in. See Toe-In Check and Adjust. (Group

9020-20.)
Adjust steering angle. See Steering Angle Check and

KK70125,0000782 –19–08MAY07–3/7

1. Remove rod guides (1) from cylinder body (3) and slide
cylinder off of rod (2).
–UN–15NOV02
1—Rod Guide (2 used)
2—Cylinder Rod
3—Cylinder Body
T161850B
KK70125,0000782 –19–08MAY07–4/7
IMPORTANT: To aid in assembly, note location of

each seal before removal.
09
0960
2. Replace seals and rings (4—9) if necessary. –UN–15NOV02 23
4—External Wiper Seal (2 used)

5—Wear Ring (2 used)
6—Backup Ring (2 used)
7—Internal Wiper Seal (2 used)
T161852B
9—Seal Ring (2 used)

10—Groove

060807
PN=325
Hydraulic System
3. Replace rings (11, 13, 14) on cylinder rod piston (12) if

necessary.

12—Cylinder Rod Piston
13—O-Ring
–UN–15NOV02
14—Seal Ring
T161853B
KK70125,0000782 –19–08MAY07–6/7
–UN–21NOV02
T161937
1—Rod Guide (2 used) 5—Wear Ring (2 used) 8—Wear Ring (2 used) 12—Rod Piston
2—Cylinder Rod 6—Backup Ring (2 used) 9—Seal Ring (2 used) 13—O-Ring
3—Cylinder Body 7—Internal Wiper Seal (2 used) 11—Wear Ring (2 used) 14—Seal Ring
09 4—External Wiper Seal (2
0960 used)
24
4. Install seals and rings in rod guides (1) and on
cylinder rod piston (12).
5. Install rod into cylinder body (3).
6. Install rod guides (1) onto rod (2) and into body (3).
KK70125,0000782 –19–08MAY07–7/7

060807
PN=326
Hydraulic System
09
0960
25

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Hydraulic System
Mechanical Front Wheel Drive (MFWD) Axle Steering Cylinder Disassemble and Assemble
09
0960
26
–UN–15DEC06
TX1016365
Steering Cylinder Cross Section


060807
PN=328
Hydraulic System
1—Snap Ring (2 used) 4—Plug 7—Plug (2 used) 10—Snap Ring

2—Snap Ring 5—Rod 8—Hydraulic Cylinder Barrel 11—Hydraulic Cylinder
3—Hydraulic Cylinder 6—Bushing 9—Flange 12—Cap Screw (3 used)
Assembly
KK70125,0000784 –19–15MAY07–2/9

pressure in the system before disconnecting or
connecting hydraulic or other lines. Tighten all
–UN–23AUG88
in hydraulic system.
2. Disconnect hoses from cylinder end cap fittings. Close
X9811
High Pressure Fluid
IMPORTANT: To avoid damaging seals, do not
overheat piston rod. Use a butane torch
with low flame. Stop before heat
reaches seals.
NOTE: Wrench flats on left end of piston rod are covered

by stop collar. Remove left ball joint first if stop
collars are installed on piston rod.
3. Heat right end of piston rod (5) near ball joint to break
down sealant on threads. Hold ball joint on right side of
cylinder to loosen and disconnect right tie rod.
4. Repeat previous step to remove left tie rod.
NOTE: Cylinder is full of oil. Have a container available to

catch oil.
5. Remove cap screws (12) to remove flange (9). 09

0960
27
6. Remove cylinder barrel (8) and piston rod (5) together
from axle housing.
7. Remove snap rings (1 and 2).
8. Pull piston rod assembly from cylinder.
9. Replace parts (3—7) as necessary.

060807
PN=329
Hydraulic System
09
0960
28
–UN–15DEC06
TX1016365
Steering Cylinder Cross Section

060807
PN=330
Hydraulic System
1—Snap Ring (2 used) 4—Plug 7—Plug (2 used) 10—Snap Ring

2—Snap Ring 5—Rod 8—Hydraulic Cylinder Barrel 11—Hydraulic Cylinder
3—Hydraulic Cylinder 6—Bushing 9—Flange 12—Cap Screw (3 used)
Assembly
10.
KK70125,0000784 –19–15MAY07–5/9
NOTE: The piston seal can be made more pliable by

warming it with your hands or by putting seal in
hot water for approximately five minutes. Once
started, install piston seal as quickly as possible
to keep the amount of time the seal is stretched to
a minimum.
–UN–30APR07
Apply clean hydraulic oil to seals to aid in
assembly of rod and plug.
TX1022772
Install seal (13) and scraper (14).
Steering Cylinder Barrel Seal Install

8—Hydraulic Cylinder Barrel
13—Seal
14—Scraper
KK70125,0000784 –19–15MAY07–6/9
11. Install guide rings (15), seal (16), and bushing (6)
6
onto rod (5).
09
5 0960
5—Rod 29
6—Bushing
–UN–16MAY07
15—Guide Ring
16—Seal
15
TX1023773
15 16
Rod Assembly

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PN=331
Hydraulic System
12. Install scraper (17), seal (18), and O-ring (19) onto
plug (4).
13. Install plug (4).
14. Install snap ring (1 and 2) to retain plug (4).
–UN–16MAY07
15. Install flange (9). 20
16. Install snap ring (1) to retain flange (4). 19
TX1023774
18
17
17—Scraper
18—Seal Plug Assembly
19—O-ring
20—Plug
KK70125,0000784 –19–15MAY07–8/9
17. Apply TY24811 Anti-Seize Lubricant to mating parts

of steering cylinder and front axle housing.
–UN–16MAY07
Specification
Steering Cylinder Cap Screws—
Torque .......................................................................................... 240 N•m
177 lb-ft
TX1023775A
19. Apply PM37509 Cure Primer, then PM37418 Thread
Lock and Sealer (medium strength) to threads of tie
rods.
Anti Seize Location
20. Tighten tie rod to piston rod (5).
Specification
09 Tie Rod-to-Piston Rod—Torque ................................................... 300 N•m
0960 221 lb-ft
30
KK70125,0000784 –19–15MAY07–9/9

060807
PN=332
Section 10
Service Brakes
Contents
Page

Service Brake External Inspection . . . . . . . . .10-1011-1
Brake Disk and Pressure Plate Remove
and Install . . . . . . . . . . . . . . . . . . . . . . . . .10-1011-1

Brake Valve Remove and Install . . . . . . . . . .10-1060-1
Brake Valve Disassemble and Assemble . . .10-1060-8
Brake Valve Lines Disassemble and
Assemble. . . . . . . . . . . . . . . . . . . . . . . . .10-1060-14
Brake Pdals
Remove and Install . . . . . . . . . . . . . . . . .10-1060-16
Brake Pedal Adjustment . . . . . . . . . . . . . . .10-1060-17
Brake System Bleeding Procedure . . . . . . .10-1060-17
10

060807
PN=1
Contents
10

060807
PN=2
Group 1011
Active Elements
Service Brake External Inspection
See Service Brakes Inspection. (Group 0250.)
KK70125,0000787 –19–30APR07–1/1
Brake Disk and Pressure Plate Remove and

Install
NOTE: Service brakes are part of rear axle.
Remove and install rear axle for repair of service

brakes.See Rear Axle Remove and Install. (Group 0250.)
KK70125,0000788 –19–08MAY07–1/1
10
1011
1

060807
PN=335
Active Elements
10
1011
2

060807
PN=336
Group 1060
Hydraulic System
Brake Valve Remove and Install

hydraulic lines and hoses. Tighten all

3. Remove front floor mat.
KK70125,0000789 –19–08MAY07–1/10
1—Vent Panel
2—Switch Panel
–UN–27SEP00
T133991B
KK70125,0000789 –19–08MAY07–2/10
3—Wire Switch Connector (4 used)

–UN–09APR07
10
1060
TX1019248A

060807
PN=337
Hydraulic System

(12).
–UN–09APR07
TX1018999A
9—Screw (2 used)
10—Screw (2 used)
–UN–09APR07
TX1019000A
10
1060
2

060807
PN=338
Hydraulic System
10. Disconnect brake light electrical connectors.

reservoir. The approximately capacity of reservoir is
37 L (39 qt).
–UN–23AUG88
X9811
fluids.

–UN–09APR07
TX1019289A
12. Disconnect all hoses from brake valve (16). Brake Valve
Disconnect hoses as follows:

hose fittings.
–UN–03APR07

TX1019150A
is connected without the release sleeve
Special Tool JDG1385
installed, fitting will not be able to be
disconnected again. 14—Cap Screws (4 used)
15—Brake Valve-to-Hydraulic Oil Tank
b. Insert special tool JDG1385 (23) between release 16—Brake Valve
sleeve (22) and shoulder (24) of fitting. Do not 17—Brake Valve-to-Rear Axle (Left Service Brake)
18—Brake Valve-to-Rear Axle (Right Service 10
force the release sleeve away from the shoulder Brake) 1060
by prying. The thickness of the tool will push the 19—Brake Valve-to-Transmission Oil Cooler 3
sleeve sufficiently to disconnect the fitting. 20—Transmission-to-Brake Valve
21—Transmission-to-Brake Valve
22—Release Sleeve
23—JDG1385 Special Tool
24—Shoulder

060807
PN=339
Hydraulic System
c. Pull hose to disconnect.
d. Close all openings with caps and plugs.
13. Remove cap screws (14) and remove brake valve

(16) from pedals.
14. Disassemble and repair valve as needed. See Brake

Valve Disassemble and Assemble. (Group 1060.)
NOTE: Fill brake valve with oil and bleed out air before
installing on machine.
15. Install brake valve to pedals.
16. Install cap screws (14).
KK70125,0000789 –19–08MAY07–6/10
17. Connect lines (15 and 17—21) to brake valve (16) as

follows:
a. Make sure fitting halves are clean and free from

contaminates.
–UN–09APR07
b. Make sure release sleeve is on male half of fitting
before connecting fitting halves together.
TX1019289A
c. Match color coding on hose with appropriate valve
port as shown in illustration.
d. Push fitting halves together until a definite snap Brake Valve

e. Pull back on hose to make sure fitting halves are 16—Brake Valve
locked together. 17—Brake Valve-to-Rear Axle (Left Service Brake)
18—Brake Valve-to-Rear Axle (Right Service
f. To prevent hoses from binding, move component Brake)
19—Brake Valve-to-Transmission Oil Cooler
into position before pressurizing the hydraulic 20—Transmission-to-Brake Valve
system. 21—Transmission-to-Brake Valve
10
1060 18. Install brake light switch wire connectors.
4

060807
PN=340
Hydraulic System
20. Install front console cover and left air flow duct wire
connector (if equipped).
9—Screw (2 used)
10—Screw (2 used)
–UN–09APR07
TX1018999A
–UN–09APR07
TX1019000A
KK70125,0000789 –19–08MAY07–8/10
21. Connect switch connectors (3).
3—Wire Switch Connector (4 used)
–UN–09APR07
TX1019248A
10
1060
5

060807
PN=341
Hydraulic System
22. Install vent pane (1) and switch panel (2).
23. See Brake System Bleeding Procedure. (Group

9020-20.)
24. Fill reservoir with proper oil.See Hydraulic Oil.
–UN–27SEP00
25. Fill reservoir to proper level. See 410J Backhoe

Loader Drain and Refill Capacities. (Operator’s
T133991B
Manual.)
1—Vent Panel
2—Switch Panel
KK70125,0000789 –19–08MAY07–10/10
10
1060
6

060807
PN=342
Hydraulic System
10
1060
7

060807
PN=343
Hydraulic System
Brake Valve Disassemble and Assemble
10
1060
8
–UN–12FEB07
TX1018507
Brake Valve Assembly

Continued on next page KK70125,000078A –19–05FEB07–1/5

060807
PN=344
Hydraulic System
1—Reducer 9—Piston 17—Ball (2 used) 25—Seal (2 used)

2—Fitting Plug 10—Housing 18—Lock Washer (2 used) 26—Snap Ring (2 used)
3—Check Valve (2 used) 11—Retainer (2 used) 19—Snap Ring (2 used) 27—Cap Screw (4 used)
4—O-Ring (4 used) 12—O-Ring (2 used) 20—Piston Ring (2 used) 28—Washer (4 used)
5—Plug (2 used) 13—Spring (2 used) 21—Spring (2 used) 29—O-Ring (2 used)
6—Spring (2 used) 14—Seal (2 used) 22—Push Rod (2 used) 30—Manual Hydraulic Valve
7—Washer (2 used) 15—Ring (2 used) 23—Seal (2 used) 31—O-Ring Kit
8—Ring (2 used) 16—Piston (2 used) 24—Retainer (2 used) 32—Housing
1. Remove seven STC hose fittings. (If not removed.) NOTE: Retainer (24) is held in position by Loctite and
need not be removed to service seals (23 and
2. Remove two brake switches. (If not removed.) 25).
3. Remove valve adapter reducer (1) and fitting plug NOTE: Note direction of seals (23) and wiper seals
(2). (25).
4. Remove O-rings (29) 11. Carefully remove wiper seal (25) by inserting a
small screw driver along the outer parameter of
5. Remove check valves (3) and O-rings (4). wiper seal (25) and prying out. Remove seal (23)
using a dull pointed pick tool being careful not to
6. Housings (10 and 32) are under spring tension, to scratch housing bore.
separate housing halves, position mounting flange
on housing (10) face down and clamp in a vise. 12. Check retainers (24) for wear; if necessary,
Apply downward pressure on housing (30) while remove snap rings (26) and seals (23 and 25).
evenly loosening four cap screws (27) and washers With housing (32) flange face down in a vise, use
(28) while carefully separating housing halves. a plastic or wooden dowel through housing (32)
bore to evenly tap on retainers (24) to remove
7. Remove springs (21), piston (16) assemblies, (using an inside bearing puller from housing (32)
springs (13), O-rings (12) and retainers (11). flange end can also be used to remove retainers
(24).
8. Remove snap ring (19), lock washer (18) and ball
(17) from pistons (16). 13. Remove plugs (5), springs (6) and washers (7).
9. Remove piston ring (20), seal (14) and O-ring (15) 14. Remove O-rings (4).
from pistons (16).
NOTE: Be careful not to scratch or mar spool (9) or
NOTE: Do not remove retaining rings from push rods housing bore.
(22).
15. Use a plastic or wooden dowel to carefully remove
10. Remove push rods (22). piston (9) and O-ring (8).
10
1060
9

060807
PN=345
Hydraulic System
10
1060
10
–UN–23OCT00
T134032

060807
PN=346
Hydraulic System
1—Fitting 9—Spool 17—Ball 24—Retainer

2—O-Ring 10—Housing 18—Lock Washer 25—Wiper Seal
3—Adapter Valve 11—Retainer 19—Snap Ring 26—Snap Ring
4—O-Ring 12—O-Ring 20—Piston Ring 27—Cap Screw
5—Plug 13—Spring 21—Spring 28—Washer
6—Spring 14—Seal 22—Push Rod 29—Valve Assembly
7—Washer 15—Ring 23—Seal 30—Housing
8—Ring 16—Piston
NOTE: When servicing brake valve, install all of the 7. Install piston ring (20) and new O-ring (15) on
brake valve kit parts. pistons (16).
1. Thoroughly clean housings and all parts with clean NOTE: Seals (14) will stretch and become oversized
solvent and allow to dry before proceeding. when being installed. These seals must be
Lubricate all rubber components with clean fluid re-sized before final assembly. To re-size
used in the system. seals (14), lubricate seals (14), pistons (16)
and housing (10) bores with clean type fluid
NOTE: Be careful not to scratch or mar piston (9) or used in the system.
housing bore.
8. Install seal (14) in pistons (16) groove over top
2. Install new O-ring (8) on piston (9). Carefully install O-rings (15). Carefully insert each piston (16)
spool (9). assembly in the proper housing (10) bore being
careful not to extrude seal (14). Allow each piston
3. Install new O-rings (4) on plugs (5). Install washers (14) assembly to remain in the housing bores for at
(7), springs (6) and plugs (5) in housing (10). Be least 10 minutes. Proceed to next step while
sure washers (7) are properly positioned over waiting.
piston (9).
9. Apply clean fluid, type used in the system, on the
4. Tighten plugs (5). outer diameter of push rods (22) and housing (32)
bores. Fully insert push rods (22).
Specification
Brake Valve Plugs—Torque .................................................... 58 N•m 10. Place springs (21) into push rods (22).
43 lb-ft
11. Install retainer (11). Install new O-ring (12) over

NOTE: Note direction of seals (23) and wiper seals
retainers (11).
(25).
NOTE: Be sure the cut on piston rings (20) are
5. Install new seals (23), new wiper seals (25) and
installed with the cut facing the outside when
snap rings (26) in housing (32).
installed into housing (32) bores.
6. If retainers (24) are being replaced, install new
12. Remove piston (16) assemblies from housing (10)
seals (23). Place a thin coat of bearing grease on
and install in housing (30) bores until bottomed on
outside diameter of new retainers (24) and carefully
pistons (22).
tap into place. Install new wiper seals (25) and
retaining rings (26).
13. Install springs (13). 10
1060
NOTE: Be sure the cut on piston rings (20) is position
11
correctly when installed into housing (10)
bores.

060807
PN=347
Hydraulic System
14. Place housing (10) over springs (13) and align 18. Install new O-rings (29) on plug (2) and reducer
housing (10) bores with pistons (16) (be careful (1) in housing (10) and tighten.
not do damage seals (14).)
Specification
15. While applying downward pressure on housing Brake Valve Plugs—Torque .................................................... 71 N•m
53 lb-ft
(10), install two cap screws (27) and washers (28)
diagonal from each other and finger tighten to hold
19. Install seven hose fittings and torque to
the assembly together.
specification.
16. Install the remaining two cap screws (27) and Specification
washers (28). Evenly tighten the four cap screws STC Fitting Connectors—
(27). Torque...................................................................................... 34 N•m
25 lb-ft
Specification
Brake Valve Assemblies Cap 20. Apply PM37509 cure primer and one drop of
screws—Torque ....................................................................... 34 N•m PM37418 Thread Lock and Sealer (medium
24 lb-ft
strength) to each brake light switch and tighten to
specification.
IMPORTANT: Prevent possible damage to adapter
valve assemblies, install push rods Specification
(22) approximately 1/2 in. into bores Brake Light Switch—Torque .................................................... 20 N•m
before installing adapter valve 177 lb-in
assemblies.
21. Install brake valve on the machine. See Brake
17. Install O-ring (4) on adapter valve assemblies (3). Valve Remove and Install (Group 1060.)
While installing valve assemblies (3) in housing
(10), push the push rods (22) in approximately 1/2
in. Tighten adapter valve assemblies (3).
Specification
Brake Adapter Valve
Assemblies—Torque ................................................................ 44 N•m
33 lb-ft
KK70125,000078A –19–05FEB07–5/5
10
1060
12

060807
PN=348
Hydraulic System
10
1060
13

060807
PN=349
Hydraulic System
Brake Valve Lines Disassemble and Assemble
2
1
8
21
9
3
6 17
4
7 10
18
12 11
13
5
14
15 7
20 16
6
19
19
10
1060
14
–UN–03APR07
TX1018808
TX1018808
Brake Valve Lines Disassemble and Assemble
Continued on next page KK70125,000078B –19–10MAY07–1/2

060807
PN=350
Hydraulic System
1—Fitting 5—Brake 9—Cap Screw 15—Clamp

2—Brake Valve-to-Hydraulic Valve-to-Transmission 10—Washer 16—Cap Screw
Oil Tank 6—Right Service Brake 11—Nut 17—Nut
3—Transmission-to-Brake 7—Left Service Brake 12—Washer 18—Washer
Valve 8—Brake Valve-to-Hydraulic 13—Clamp 19—Fitting
4—Transmission-to-Brake Oil Tank 14—Nut 20—Fitting
Valve
2. Inspect for worn or damaged parts.
KK70125,000078B –19–10MAY07–2/2
10
1060
15

060807
PN=351
Hydraulic System
Brake Pedals Remove and Install
10
1060
16
–UN–04APR07
TX1018811
Continued on next page KK70125,000078C –19–09FEB07–1/2

060807
PN=352
Hydraulic System
1—Plate 7—Valve 11—Right Pedal 16—Leaf Spring

2—Cap Screw (4 used) 8—Brake Light Pressure 12—Bushings (2 used) 17—Arm
3—Washer (4 used) Switch (2 used) 13—Washer (2 used) 18—Plate
4—Washer (8 used) 9—Nut (2 used) 14—Left Pedal 19—Pin
5—Cap Screw (8 used) 10—Cap Screw (2 used) 15—Spring Pin 20—Snap Ring (2 used)
6—Right Pedal
KK70125,000078C –19–09FEB07–2/2
Brake Pedal Adjustment
See Brake Pedal Adjustment. (Group 9020-20.)
KK70125,000078D –19–30APR07–1/1
Brake System Bleeding Procedure
See Brake System Bleeding Procedure. (9020-20.)
KK70125,000078E –19–30APR07–1/1
10
1060
17

060807
PN=353
Hydraulic System
10
1060
18

060807
PN=354
Section 11
Park Brake
Contents
Page

Park Brake Remove and Install . . . . . . . . . . .11-1111-1
11

060807
PN=1
Contents
11

060807
PN=2
Group 1111
Active Elements
Park Brake Remove and Install
NOTE: Park brake is part of rear axle.
Remove and install park brake.See Rear Axle Remove

and Install. (Group 0250.)
KK70125,000078F –19–12JAN07–1/1
11
1111
1

060807
PN=357
Active Elements
11
1111
2

060807
PN=358
Section 17
Frame or Supporting Structure 17
Contents
Page
Group 1740—Frame Installation

Welding Repair of Major Structures. . . . . . . .17-1740-1
RIVNUT (KREMNUT) Fasteners Remove
and Install . . . . . . . . . . . . . . . . . . . . . . . . .17-1740-1
Main Frame Bushings Remove and
Install. . . . . . . . . . . . . . . . . . . . . . . . . . . . .17-1740-4
Group 1749—Chassis Weights

Counterweight Remove and Install . . . . . . . .17-1749-2

060807
PN=1
Contents
17

060807
PN=2
Group 1740
Frame Installation
Welding Repair of Major Structures
IMPORTANT: Disconnect battery ground strap or Use one of the following weld processes: 17
1740
turn battery disconnect switch to 1
"OFF" to prevent voltage spikes AWS-E-7018 covered electrode with shielded metal
through alternator or monitor. arc welding (SMAW) process.
Have only a qualified welder do this AWS-ER-70S-3 wire electrode with gas metal arc
job. Connect welder ground clamp welding (GMAW) process.
close to each weld area so electrical
current does not pass through any AWS-E70T-1 or E71T-1 wire electrode with flux core
bearings. arc welding (FCAW) process.
Remove or protect all parts that can Preheat area to be repaired to allow better weld
be damaged by heat or weld splatter. penetration.
If machine is equipped with a To repair weld metal failure, remove failed weld metal
controller (microprocessor) like using arc or grinding equipment. Thoroughly clean
Engine Controller (EC) or Pump and area to be welded. Preheat structural assemblies to a
Valve Controller (PVC) disconnect minimum of 38°C (100°F). Preheat ground engaging
harness connector from controller to tools (cutting edges, skid shoes, and teeth shanks) to
prevent voltage spikes through 177°C (350°F).
microprocessor.
To repair base metal failure remove enough material to
Connect welder ground clamp close allow weld to penetrate to the bottom of crack. Preheat
to each weld area so electrical structural assemblies to a minimum of 38°C (100°F).
current does not arc inside any Preheat ground engaging tools (cutting edges, skid
bearings. shoes, and teeth shanks) to 177°C (350°F).
KK70125,0000797 –19–12JAN07–1/1
RIVNUT (KREMNUT) Fasteners Remove and

Install
1. Remove flange of RIVNUT using a hammer and

chisel. Use care not to damage equipment’s surface
under the flange or the hexagon hole.
–UN–19JUL94
Use a punch to remove threaded portion of fastener.

T8287AJ
RIVNUT is a registered trademark of The BF Goodrich Co. Continued on next page KK70125,0000798 –19–12JAN07–1/4

060807
PN=361
Frame Installation
2. Select the proper length fastener for the thickness of

the material where the fastener will be installed.
17 Fasteners are color-coded as well as stamped on the
1740
2
flange surface. (Coding indicates the nominal plate
thickness for which the fastener can be used.)
–UN–17OCT94
RIVET NUT LENGTH SELECTION
Flange Color Code
Material Thickness Stamp
4.25—5.60 mm (0.167—0.220 in.) 4.5 Silver
T8287AK
5.74—7.09 mm (0.226—0.279 in.) 6 Yellow
7.75—9.09 mm (0.305—0.358 in.) 8 Red
9.75—11.10 mm (0.384—0.437 in.) 10 Black A—Hexagon Hole
11.73—13.08 mm (0.462—0.515 in.) 12 Olive Drab
IMPORTANT: DO NOT force or drive fastener into

hole. Fastener can be damaged and will
not hold securely.
3. Make sure the new fastener fits easily into the existing
hexagon hole (A). If necessary, use a small file to
clean the edges of the hole.
KK70125,0000798 –19–12JAN07–2/4
4. Lubricate the large threads (A) of the JDG894

Installation Tool.
5. Install RIVNUT fastener (C) on tool:
• Small threads (D) of installation tool must extend
–UN–19JUL94
past fastener.
• Flange of fastener must contact shoulder (B) of tool.
A—Large Threads
T8287AL
B—Tool Shoulder
C—Rivnut Fastener
D—Small Threads
RIVNUT is a registered trademark of The BF Goodrich Co. Continued on next page KK70125,0000798 –19–12JAN07–3/4

060807
PN=362
Frame Installation
6. Install fastener with installation tool in hexagon hole.

Make sure flange (C) is flat against mounting surface.
17
1740
IMPORTANT: NEVER turn or tighten JDG894 3
Installation Tool socket head screw.
Damage to threads of fastener can
occur.
7. While holding socket head screw (A) stationary, tighten

large (1-1/16 in.) nut (B) to specifications using a
crowsfoot wrench.
Specification
RIVNUT (KREMNUT)
–UN–17OCT94
Fastener—Torque............................................. 68—74 N•m (50—55 lb-ft)
8. Loosen large nut to remove tool.
T8287AM
A—Socket Head Screw
B—Nut
C—Flange
RIVNUT is a registered trademark of The BF Goodrich Co. KK70125,0000798 –19–12JAN07–4/4

060807
PN=363
Frame Installation
Main Frame Bushings Remove and Install

17
1740
4
–UN–17OCT00
TP69651
1—Nut (10 used) 3—Bushing (2 used) 5—Bushing 7—Nut (15 used)

2—Nut (23 used) 4—Bushing 6—Nut 8—Main Frame Assembly
Inspect bushings, replace if necessary.

KK70125,0000799 –19–12JAN07–1/1

060807
PN=364
Group 1749
Chassis Weights
17
1749
1

060807
PN=365
Chassis Weights
Counterweight Remove and Install

17
1749
2
–UN–10OCT06
TX1012850
Counterweight

060807
PN=366
Chassis Weights
1—Primary Counterweight 3—Bolt (4 used) 5—Washer (4 used) 7— Additional Counterweight

2—Washer (4 used) 4—Nut (2 used) 6—Bolt (2 used) (250 lb.)
17
1. Raise loader boom and install lock bar. 4. Install counterweight. Tighten nut on bolt (3). 1749
3
Specification
CAUTION: Prevent possible crushing injury Front Counterweight Bolts—
from heavy component. Use appropriate Torque.................................................................................... 215 N•m
lifting device. 159 lb-ft
2. Attach hoist to counterweight with straps. 5. Install additional counterweight. Tighten nut (4) on
bolt (6).
Counterweight—Specification
Front Counterweight Specification
(Primary)—Weight .................................................. 204 kg or 440 kg Additional Counterweight Bolts
450 or 970 lb (Used with Additional
Front Counterweight Counterweight)—Torque........................................................ 620 N•m
(Additional)—Weight ................................................................. 107 kg 457 lb-ft
235 lb
3. Remove bolts (3 and 6) to remove counterweight

(1).
KK70125,000079A –19–15FEB07–2/2

060807
PN=367
Chassis Weights
17
1749
4

060807
PN=368
Section 18
Operator’s Station
Contents
Page Page 18
Group 1800—Removal and Installation R134a Compressor Oil Removal

Cab/ROPS Remove and Install . . . . . . . . . . .18-1800-1 Procedure . . . . . . . . . . . . . . . . . . . . . . . . .18-1830-4
Air Conditioning Compressor
Group 1810—Operator Enclosure Disassemble and Assemble
Front Window Wiper and Wiper Motor Compressor Clutch. . . . . . . . . . . . . . . . .18-1830-5
Remove and Install . . . . . . . . . . . . . . . . . .18-1810-1 Check Clutch Hub Clearance. . . . . . . . . . .18-1830-6
Rear Window Wiper and Wiper Motor Inspect Compressor Manifold. . . . . . . . . . .18-1830-7
Remove and Install . . . . . . . . . . . . . . . . . .18-1810-3 Disassemble, Inspect and Assemble . . . . .18-1830-8
Front Cab Windowpane Remove and Heater Core
Install. . . . . . . . . . . . . . . . . . . . . . . . . . . . .18-1810-6 Remove and Install . . . . . . . . . . . . . . . . .18-1830-10
Fixed Windowpanes Remove and Install . . . .18-1810-7 Evaporator
Cab Door and Side Window Disassemble Remove and Install . . . . . . . . . . . . . . . . .18-1830-14
and Assemble . . . . . . . . . . . . . . . . . . . . . .18-1810-8 A/C Freeze Switch
Cab Door Hinges and Latch Adjustment . . .18-1810-10 Remove and Install . . . . . . . . . . . . . . . . .18-1830-18
Cab Door Handle Screw Adjustment . . . . . .18-1810-12 Heater/Blower Assembly
Upper Cab Door and Side Windowpanes Disassemble and Assemble with A/C. . . .18-1830-22
Adjustment. . . . . . . . . . . . . . . . . . . . . . . .18-1810-13 Air Ducts
Upper Cab Door and Side Window Latch Disassemble and Assemble. . . . . . . . . . .18-1830-26
Adjustment. . . . . . . . . . . . . . . . . . . . . . . .18-1810-14 Condenser
Rear Windows Remove and Install . . . . . . .18-1810-16 Disassemble and Assemble. . . . . . . . . . .18-1830-28
Headliner Remove and Install . . . . . . . . . . .18-1810-18 Receiver dryer
Cab Roof Remove and Install . . . . . . . . . . .18-1810-20 Disassemble and Assemble. . . . . . . . . . .18-1830-30
Expansion Valve Remove and Install . . . . .18-1830-32
R134a Component Oil Charge
Group 1821—Seat and Seat Belt Procedure . . . . . . . . . . . . . . . . . . . . . . . .18-1830-33
Seat Assembly Remove and Install . . . . . . . .18-1821-1 R134a Refrigerant Recover, Recycle, and
Seat and Arm Rest Disassemble and Charge Station Installation Procedure . . .18-1830-35
Assemble. . . . . . . . . . . . . . . . . . . . . . . . . .18-1821-2 R134a System Recover Procedure . . . . . . .18-1830-36
Seat Belt Disassemble and Assemble . . . . . .18-1821-4 R134a System Evacuate Procedure . . . . . .18-1830-37
Seat Slide, Lumbar Support, and Adjuster R134a System Charge Procedure . . . . . . . .18-1830-39
Control Levers Disassemble and Air Conditioner System Cleaning
Assemble. . . . . . . . . . . . . . . . . . . . . . . . . .18-1821-6 Procedures . . . . . . . . . . . . . . . . . . . . . . .18-1830-40
Seat Swivel and Swivel Latch Disassemble R134a System Leak Testing . . . . . . . . . . . .18-1830-40
and Assemble . . . . . . . . . . . . . . . . . . . . . .18-1821-8 R134a System Flush Procedure . . . . . . . . .18-1830-41
Seat Suspension and Shock Absorber Purge Air Conditioner System . . . . . . . . . . .18-1830-43
Air Suspension Seat Disassemble and
Assemble—If Equipped . . . . . . . . . . . . . .18-1821-12
Group 1830—Heating and Air Conditioning

Proper Refrigerant Handling . . . . . . . . . . . . .18-1830-1
R134a Refrigerant—Cautions . . . . . . . . . . . .18-1830-1
Refrigerant
Hoses and Tubing Inspection. . . . . . . . . . .18-1830-2
Air Conditioning Compressor
Remove and Install . . . . . . . . . . . . . . . . . .18-1830-3

060807
PN=1
Contents
18

060807
PN=2
Group 1800
Cab/ROPS Remove and Install
NOTE: Cab and ROPS removal and installation are

similar. The cab is shown.
1. Park machine on level surface. Lower attachments and

stabilizers to ground.
18
1800
1
KK70125,000079B –19–10MAY07–1/24

–UN–23AUG88
X9811
High Pressure Fluid
KK70125,000079B –19–10MAY07–2/24
4. Remove front and rear floor mat (2).
5. Remove four cap screws to remove console cover (1).
6. Remove rear floor access plate (3).

–UN–27SEP00
NOTE: If machine is equipped with pilot controls continue

with steps (7 and 8). If machine is not equipped
with pilot controls go to step (9).
T133984B
1—Console Cover
2—Floor Mat

060807
PN=371
7. Disconnect pilot control harness connection (31) from

backhoe hydraulic solenoid valve.
31—Pilot Control Harness
–UN–09APR07
18
1800
TX1019021A
2
Pilot Control Harness

060807
PN=372
18
1800
3
–UN–09APR07
TX1019024A
Pilot Control Lines
4—Hose (right swing) 7—Hose (pressure to left pilot 9—Hose (pressure to right 12—Hose (crowd)
5—Hose (boom up) control) pilot control) 13—Hose (bucket)
6—Hose (to tank from left pilot 8—Hose (to tank from right 10—Hose (crowd in) 14—Hose (boom)
control) pilot control) 11—Hose (bucket dump) 15—Hose (swing)
8. Disconnect hose lines (4—15). (62H1036 and 62H1035) caps. Order caps and
plugs through your authorized dealer.
NOTE: Cap and plug pilot control valve and hoses
using (62H1028 and 62H1029) STC plugs, and

060807
PN=373
9. Remove spring pins (318).
10. Remove retainer clips (17) and remove linkage

cables.
11. Disconnect auxiliary flow control solenoid wire

connector (16) (if equipped).
18
–UN–09APR07
1800 16—Auxiliary Flow Control Solenoid Wire Connector
4 (if equipped)
17—Retainer Clips
18—Spring Pins
TX1019026A
KK70125,000079B –19–10MAY07–6/24
19—Vent Panel
20—Switch Panel
–UN–09APR07
TX1019027A
Front Console Cover

060807
PN=374
21—Wire Connector (4 used)
–UN–09APR07
18
1800
TX1019028A
5
Front Console Wire Connections
KK70125,000079B –19–10MAY07–8/24

(28).
–UN–09APR07
25—Screw (2 used)
26—Screw (2 used)
TX1019029A
Front Console Screws-Upper
–UN–09APR07
TX1019030A
Front Console Screws-Lower


060807
PN=375
17. Remove floor access plates (A and B).

reservoir. The approximately capacity of reservoir is
37 L (39 qt).
–UN–18OCT06
A—Cap Screw (4 used)
18 B—Floor Access Plate
1800
TX1013758A
6
Floor Access Plate

060807
PN=376

–UN–23AUG88
fluids. 18
1800
7
X9811
–UN–09APR07
19. Disconnect all hoses from steering valve (44) and
brake valve (33). Disconnect hoses as follows:
TX1019035A
hose fittings.
Brake Valve
33—Brake Valve
34—Brake Valve-to-Rear Axle (Left Service Brake)
35—Brake Valve-to-Rear Axle (Right Service Brake)
36—Brake Valve-to-Transmission Oil Cooler
39—Steering Valve-to-Hydraulic Oil Tank
–UN–09APR07
40—Priority Valve-to-Steering Valve
43—Brake Valve-to-Priority Valve
TX1019037A
44—Steering Valve
Steering Valve

060807
PN=377


–UN–19OCT02
18 is connected without the release sleeve
1800 installed, fitting will not be able to be
8 disconnected again.
T160617B
b. Insert special tool JDG1385 (7) between release
sleeve (5) and shoulder (6) of fitting. Do not force Seal Tight Connector
the release sleeve away from the shoulder by
5—Release Sleeve
prying. The thickness of the tool will push the 6—Hose Shoulder
sleeve sufficiently to disconnect the fitting. 7—JDG1385 Special Tool
c. Pull hose to disconnect.
d. Close all openings with caps and plugs.

060807
PN=378
18
1800
9
–UN–09APR07
TX1019040A
48—Air Conditioning Line (2 51—Engine 52—Ground Strap 55—Cap Screw and Nut
used) Harness-to-Cab/Canopy 53—Heater Hose (2 used)
49—Wire Harness Connector Station Harness 54—Loader Control Lever
50—Transmission Connector Linkages
Station Harness
Connector
20. Drain radiator or clamp heater hoses (53). 22. Disconnect items (48—54).
Approximate capacity is 21 L (22 qt).
23. Remove cap screw and nut (55) from brake hose
21. Recover R134a refrigerant. See R134a Refrigerant clamp.
Recover, Recycle, and Charge Station Installation
Procedure. (Group 1830.)

060807
PN=379
24. Disconnect boom lock hook (59) from rod (60).
59—Boom Lock Hook

60—Rod
–UN–09APR07
18
1800
TX1019042A
10
Boom Lock
KK70125,000079B –19–10MAY07–14/24

device.
25. Install DFT1101 Lift Bracket (56) using chains and

lifting straps. See DFT1101 Cab and ROPS Lift
Bracket. (Group 9900.)
a. Attach front lifting straps to exterior hand rails (58).
b. Open the rear side windows and attach rear lifting

straps to upper window latch loop (59).
–UN–09APR07
c. Remove slack from chains and lifting straps.
Specification
Cab—Weight ................................................................................... 817 kg
TX1019041A
1800 lb
56—DFT1101 Lift Bracket

57—Lifting Location—Rear
58—Lifting Location—Front

060807
PN=380
NOTE: Remove upper half of rubber isolators (63 and 66)

after cab is lifted from machine frame.
26. Remove items (61—66).
–UN–09APR07
27. Carefully remove cab. Support cab with shop stands.
28. Install cab and rubber isolator mounts. Tighten four 18

cap screws to specifications. 1800
TX1019065A
11
Specification
Cab/ROPS Mount Cap Screws—
Torque .......................................................................................... 420 N•m Cab Mounts-Front
310 lb-ft
62—Washer (2 used)
63—Front Rubber Isolator (2 sets used)
64—Large Washer (2 used)
65—Nut (2 used)
66—Rear Rubber Isolator (2 sets used)
67—Washer
68—Nut
KK70125,000079B –19–10MAY07–16/24
29. Connect boom lock hook (59) to rod (60).
59—Boom Lock Hook

60—Rod
–UN–09APR07
TX1019042A
Boom Lock

060807
PN=381
18
1800
12
–UN–09APR07
TX1019040A
48—Air Conditioning Line (2 51—Engine 52—Ground Strap 55—Cap Screw and Nut
used) Harness-to-Cab/Canopy 53—Heater Hose (2 used)
49—Wire Harness Connector Station Harness 54—Loader Control Lever
50—Transmission Connector Linkages
Station Harness
Connector
30. Fasten brake hose clamp using cap screw and nut 31. Connect items (48—54).
(55).

060807
PN=382
18
1800
13

060807
PN=383
18
1800
14
40
41 42
43
39
32
33
44
34
37
38 35 36
–UN–02APR07
TX1021488
TX1021488
Brake Valve and Steering Valve Line Assembly

060807
PN=384
32—Blue (Brake 36—Blue/Blue (Brake 39—Blue (Steering 42—Orange (Steering

Valve-to-Hydraulic Oil Valve-to-Transmission Oil Valve-to-Hydraulic Oil Valve-to-Steering
Tank) Cooler) Tank) Cylinder)
33—Brake Valve 37—Red/Red 40—Red (Priority 43—Yellow (Brake
34—Green/Green (Brake (Transmission-to-Brake Valve-to-Steering Valve) Valve-to-Priority Valve)
Valve-to-Rear Axle—Left Valve) 41—Green (Steering 44—Steering Valve
Service Brake) 38—Red/Red/Red Valve-to-Steering
35—Orange/Orange (Brake (Transmission-to-Brake Cylinder)
Valve-to-Rear Axle—Right Valve)
Service Brake) 18
1800
15
32. Connect hydraulic hoses (32 and 34—43) to the f. Pull back on hose to make sure fitting halves
steering and brake valves (33 and 44) as follows: are locked together.
a. Insert the steering valve hoses identified with g. To prevent hoses from binding, move
single color bands red, orange, green, and component into position before pressurizing the
yellow into the restraint loop at left side of front hydraulic system.
console frame.
33. Close steering and brake valve access door.
b. Make sure fitting halves are clean and free Fasten with five cap screws and washers.
from contaminates.
34. Install front console cover.
c. Make sure release sleeve is on male half of
fitting before connecting fitting halves together. 35. Connect front console panel switches and air flow
control wire connector.
d. Match color coding on hose with appropriate
valve port as shown in illustration. 36. Install front console switch and vent panels.
e. Push fitting halves together until a definite snap

KK70125,000079B –19–10MAY07–20/24
37. Insert stabilizer valve linkage into support bracket and

install retainer clips (17).
38. Connect linkage to stabilizer valve with pins (18).
39. Connect auxiliary flow control solenoid valve

connector (16) (if equipped)
–UN–09APR07
NOTE: If machine is equipped with pilot controls continue

with steps (40 and 41). If machine is not equipped
with pilot controls go to step (42).
TX1019026A
16—Auxiliary Flow Control Solenoid Wire Connector

(if equipped)
17—Retainer Clips
18—Spring Pins

060807
PN=385
40. Connect pilot control harness connection (31) to

backhoe hydraulic solenoid valve.
31—Pilot Control Harness
–UN–09APR07
18
1800
TX1019021A
16
Pilot Control Harness

060807
PN=386
18
1800
17
–UN–09APR07
TX1019024A
Pilot Control Lines
4—Hose (right swing) 7—Hose (pressure to left pilot 9—Hose (pressure to right 12—Hose (crowd)
5—Hose (boom up) control) pilot control) 13—Hose (bucket)
6—Hose (to tank from left pilot 8—Hose (to tank from right 10—Hose (crowd in) 14—Hose (boom)
control) pilot control) 11—Hose (bucket dump) 15—Hose (swing)
41. Connect hose lines (4—15).

060807
PN=387
42. Install all floor access plates.
43. Install backhoe control lever console cover (1). Make

sure rubber inserts are in position around boom lock
control lever and control pedals (if equipped).
–UN–27SEP00
44. Install floor mat (2).
18
1800 45. Connect batteries negative (–) (ground) cable.
18
T133984B
46. Charge R134a refrigerant to air conditioning
compressor. See R134a Refrigerant Recover,
Recycle, and Charge Station Installation Procedure.
(Group 1830.) 1—Console Cover
2—Floor Mat
47. Fill radiator with proper coolant if drained. See Diesel
Engine Coolant. (Operator’s Manual.) See 410J
Backhoe Loader Drain and Refill Capacities.
48. Fill reservoir, if drained, with proper oil. See

Transmission, Axles, and Mechanical Front Wheel
Drive (MFWD) Oil. (Operator’s Manual.) See 410J
KK70125,000079B –19–10MAY07–24/24

060807
PN=388
Group 1810
Operator Enclosure
Front Window Wiper and Wiper Motor

Remove and Install
Remove vent panel (1).
–UN–27SEP00
1—Vent Panel
2—Switch Panel
18
1810
1
T133991B
Continued on next page KK70125,000079C –19–12JAN07–1/3

060807
PN=389
Operator Enclosure
18
1810
2
–UN–20DEC06
TX1014628
Front Window Wiper and Wiper Motor
Continued on next page KK70125,000079C –19–12JAN07–2/3

060807
PN=390
Operator Enclosure
1—Wiper Motor 3—Cap Screw (2 used) 4—Wiper Arm 5—Wiper Blade

2—Drive Assembly
1. Disconnect wire connectors. Pivot Shaft Jam Nut—Torque.................................................. 20 N•m

177 lb-in.
Wiper Motor Mount Cap
2. Remove parts as shown. Screw—Torque ........................................................................ 10 N•m
88 lb-in.
3. Inspect for worn or damaged parts and replace as
18
necessary. 5. Connect wire connectors. 1810
3
4. Install parts as shown. 6. Install vent panel.
Front Window Wiper Arm and Motor—Specification

Wiper Arm-to-Pivot—Torque ................................................... 18 N•m
160 lb-in.
KK70125,000079C –19–12JAN07–3/3
Rear Window Wiper and Wiper Motor

Remove and Install
1. Remove interior mirror (1) and retainers (2) to remove

headliner.
2. Disconnect wire connectors.
1—Mirror
2—Retainers (9 used)
–UN–19OCT00
T134697B
Continued on next page KK70125,000079D –19–12JAN07–1/3

060807
PN=391
Operator Enclosure
18
1810
4
–UN–04DEC06
TX1014626
Rear Wiper Motor
Continued on next page KK70125,000079D –19–12JAN07–2/3

060807
PN=392
Operator Enclosure
1—Wiper Blade 3—Push Switch 5—Drive Assembly 7—Screw

2—Wiper Arm 4—Wiper Motor 6—Ramp
3. Remove parts as shown. Pivot Shaft Jam Nut—Torque.................................................. 20 N•m

177 lb-in.
Wiper Motor Mount Cap
4. Inspect for worn or damaged parts and replace as Screw—Torque ........................................................................ 10 N•m
necessary. 88 lb-in.
18
5. Install parts as shown. 6. Connect wire connector. 1810
5
Rear Window Wiper Arm And Motor—Specification 7. Install headliner and mirror.
Wiper Arm-to-Pivot—Torque ................................................... 18 N•m
160 lb-in.
KK70125,000079D –19–12JAN07–3/3

060807
PN=393
Operator Enclosure
Front Cab Windowpane Remove and Install
18
1810
6
–UN–11OCT00
T134004

060807
PN=394
Operator Enclosure
1—Front Upper Windowpane 3—Seal (2 used) 4—Front Right Lower 5—Front Left Lower
2—Stand Off
Replace front windowpanes. See Fixed Windowpanes

18
1810
7
KK70125,000079E –19–12JAN07–2/2
Fixed Windowpanes Remove and Install
NOTE: Use this procedure to replace cab front, rear 2. If window frame is removable, remove frame from
side, and lower door windowpanes. cab.
Use Quick Cure Primerless Autoglass Windshield 3. Scrape broken glass off existing adhesive. DO NOT
Sealant or equivalent to hold windowpanes in place. remove adhesive from window frame or cab.
DO NOT use any other type of adhesive other than a
urethane. It is also recommended that an auto glass 4. Trim existing adhesive so it has a smooth surface.
dealer install the windowpanes.
5. Apply a 12.5 mm (1/2 in.) bead of adhesive on top
IMPORTANT: Windowpanes must have an of the existing adhesive.
ultra-violet barrier around the edge
of the glass since ultra-violet rays 6. Put a new windowpane into position. Use light hand
will deteriorate the adhesive. pressure to force windowpane down around the
Windowpanes ordered through John edges until even with metal frame. DO NOT over
Deere Parts have the ultra-violet press adhesive.
barrier. If the windowpane is
purchased through a glass dealer, 7. If windowpane is installed directly on cab, use tape
the dealer must put an ultra-violet to hold it in place while adhesive cures.
barrier on the glass. DO NOT apply
paint to the border of the glass. 8. Allow adhesive to cure for 24 hours before
operating machine.
If an auto glass dealer is not installing the
windowpanes, use the following procedure:
1. Purchase urethane adhesive from your local auto

glass dealer.
KK70125,000079F –19–12JAN07–1/1

060807
PN=395
Operator Enclosure
Cab Door and Side Window Disassemble and Assemble
18
1810
8
–UN–29DEC06
TX1014673
Side Windows and Doors

Continued on next page KK70125,00007A0 –19–12JAN07–1/3

060807
PN=396
Operator Enclosure
1—Link End (2 used) 15—Nut 28—Spacer (2 used) 42—Washer

2—Cylinder 16—Washer 29—Spacer (2 used) 43—Washer (4 used)
3—Washer (4 used) 17—Screw (5 used) 30—Cap Screw (3 used) 44—Bushing (4 used)
4—Lock Nut (8 used) 18—Cap Screw (4 used) 31—Gasket (2 used) 45—Upper Door Windowpane
5—Screw (4 used) 19—Isolator 32—Washer (5 used) (2 used)
6—Self Locking Screw (3 20—Door 33—Washer 46—Bushing
used) 21—Stand-Off (7 used) 34—Lower Door Windowpane 47—Bushing
8—Cover 22—Latch Assembly (4 used) 35—Handle 48—Upper Hinge (2 used)
9—Washer (2 used) 23—Latch (4 used) 36—Isolator 51—Lock Nut
10—Striker (2 used) 24—Dual Lock Fastener (8 37—Washer (4 used) 52—Guard 18
11—Washer (2 used) used) 39—Washer (8 used) 53—Knob 1810
12—Cap Screw (4 used) 25—Latch Base (4 used) 40—Lower Hinge (2 used) 54—Side Windowpane 9
13—Latch 26—Washer (3 used) 41—Washer (8 used) 56—Bumper (2 used)
14—Guard 27—Spacer
1. Disassemble parts as shown. d. Cut end off even with starting point.
2. Remove lower door windowpane.See Fixed 6. Starting at one corner install seal (19) angled lip to
Windowpanes Remove and Install. (Group 1810.) door frame groove.
3. Inspect for worn or damaged parts. Replace as IMPORTANT: Damage to Windowpanes will occur
necessary. unless all sleeves and hardware
passing through glass are in correct
4. To install isolator (36): location before screws are tightened
to specified torque.
a. Clean door frame edge with rubbing alcohol and
wipe dry with clean rag. 7. Windowpanes should have equal spacing between
windowpane and openings.
b. Start at the bottom center of the opening,
remove backing from isolator and apply isolator All hardware which passes through glass should be
to edge of frame all the way around. tighten to 2.93 N•m (26 lb-in.) unless specified
below.
c. Cut end off even with starting point.
Specification
d. Roll entire edge with roller to ensure seal is Through Glass Hardware—
Torque................................................................................... 2.93 N•m
tightly secured and all air gaps are removed. 26 lb-in.
Windowpane Mount Hinge Cap
e. Let cure 4 hours before installing window. Screw—Torque ........................................................................ 25 N•m
220 lb-in.
5. To install isolator (36): Frame Mount Hinge Cap
Screw—Torque ........................................................................ 73 N•m
54 lb-ft
a. Clean cab frame edge and wipe dry with clean
rag. 8. Install windowpane knob (53). Tighten knob to allow
it to turn freely and end play should be kept to a
b. Start at the bottom center of the opening, apply minimum.
isolator to edge of frame opening all the way
around. 9. Install door handle and adjust actuator screw to
specification. See Cab Door Handle Screw
c. Roll corners to ensure seal is tightly secured and Adjustment. (Group 1810.)
all air gaps are removed.

060807
PN=397
Operator Enclosure
Specification Actuator Jamb Nut—Torque ................................................... 8.8 N•m

Door Latch Actuator Screw— 78 lb-in.
Length ....................................................................................... 32 mm
1.26 in.
KK70125,00007A0 –19–12JAN07–3/3
18 Cab Door Hinges and Latch Adjustment

1810
10 1. Adjust cab door frame so door frame is evenly spaced
at front and top of cab frame opening.
NOTE: Hinge mounting holes are slotted to provide

adjustments. Hinges attached to cab frame have
horizontal slotted holes which provide forward and
rearward adjustments. Hinges attached to door
frame have vertical slotted holes for upward and
downward adjustments.
–UN–23OCT00
2. Loosen cap screws (2) connecting hinge to cab frame.
Move door and hinge to position door frame in cab
frame front to rear. Tighten cap screws to specification.
T134771B
Specification
Door Hinge Cap Screws—Torque.................................................. 75 N•m
55 lb-ft 1—Door Frame Cap Screw
2—Cab Frame Cap Screw
3. Loosen cap screws (1) connecting hinge to cab door.
Move door to position door frame in cab frame up and
down. Tighten cap screws to specification.
Specification
Door Hinge Cap Screws—Torque.................................................. 75 N•m
55 lb-ft
4. Check door seal for proper compression. Seal should

be evenly compressed around door to provide a seal
between door frame and cab frame.
5. If excessive clearance exists adjust latch strike pin.

060807
PN=398
Operator Enclosure
NOTE: It may be possible to view latch jaw engagement

with latch cover in place. If not remove cover.
6. Adjust latch and striker pin:
• If gap (C) between latch jaw ends (B) is

approximately 10 mm (0.4 in.), latch is only in first
detent position. Adjust latch to obtain second 18
(primary) detent position. Loosen striker pin (A) and 1810
move it forward approximately 0.8 mm (0.03 in.). 11
Tighten striker pin and check gap to make sure jaws
are in second detent as described below. If
–UN–08APR93
necessary, repeat until second detent engagement is
obtained.
• If gap (C) between latch jaw ends (B) is
approximately 1—2 mm (0.04—0.08 in.), latch is in
T7959AP
second (primary) detent position. To decrease
clearance at door center, loosen striker pin (A) and
move it rearward about 0.8 mm (0.03 in.). Tighten
striker pin and check clearance. If necessary, repeat A—Striker Pin
until clearance of 10—12 mm (0.4—0.5 in.) exists B—Latch Jaw Ends
C—Gap
between cab frame and door frame.
Specification
Cab Frame-to-Door Frame—
Clearance .......................................................... 10—12 mm (0.4—0.5 in.)
• After making adjustment, tighten striker pin nut to

specification.
Specification
Door Latch Striker Pin Nut—
Torque ............................................................................................ 65 N•m
48 lb-ft
KK70125,00007A1 –19–12JAN07–2/2

060807
PN=399
Operator Enclosure
Cab Door Handle Screw Adjustment
NOTE: If door handle is replaced, the door handle screw

will require adjustment.
1. Install adjusting screw (A) and lock nut (B). Install
–UN–15JUL94
screw until the distance (C) from the lock to the top of
18 the screw is to dimension indicated.
1810
12 Specification
T8288BH
Lock-to-Top of Left Door Handle
Adjusting Screw—Distance ............................................................. 32 mm
1.26 in.
A—Adjusting Screw
IMPORTANT: The lock may be permanently damaged B—Lock Nut
if correct procedure is not followed C—Distance Between A and B
when lock nut is tightened.
2. With the lock mechanism unlocked, push button fully.

Tighten lock nut to specification. Check dimension
again after lock nut is tightened.
Specification
Door Handle Adjusting Screw
Lock Nut—Torque ......................................................................... 8.8 N•m
78 lb-in.
3. Install handle and check operation of lock. If further

adjustment is required, push button fully before
loosening lock nut.
KK70125,00007A2 –19–12JAN07–1/1

060807
PN=400
Operator Enclosure
Upper Cab Door and Side Windowpanes

Adjustment
NOTE: Door windowpane must be adjusted prior to

adjusting side window.
1. Unlock latches (1).

18
2. Loosen cap screws (2) and position windowpane 1810
equally in door frame opening. 13
Specification
Windowpane-to-Hinge Cap
Screw—Torque ............................................................................... 25 N•m
221 lb-in.
1—Latch
3—Windowpane Stop
–UN–23OCT00
T134772B

060807
PN=401
Operator Enclosure
4. Unlock latches (2).
5. Loosen cap screws (2) and position windowpane

equally in door frame opening.
Specification
18
Windowpane-to-Hinge Cap
1810
Screw—Torque ............................................................................... 25 N•m
14
221 lb-in.
7. Tighten window open lock knob to allow knob to move

freely.
8. Loosen window open lock knob mount in door

windowpane to and adjust position to knob.
9. Tighten mount to specification.
Specification
–UN–23OCT00
Windowpane Open Lock Mount—
Torque ......................................................................................... 2.93 N•m
26 lb-in.
T134773B
2—Windowpane Latch (2 used)
3—Windowpane Open Lock Knob
KK70125,00007A3 –19–12JAN07–2/2
Upper Cab Door and Side Window Latch

Adjustment
1. Close window and lock using latch (B).
2. Check for even compression of seal (A).

–UN–19APR93
3. Open window. Bend striker (C) to obtain equal

compression of seal.
T7976BD
A—Seal
B—Latch
C—Striker
KK70125,00007A4 –19–12JAN07–1/1

060807
PN=402
Operator Enclosure
18
1810
15

060807
PN=403
Operator Enclosure
Rear Windows Remove and Install
18
1810
16
–UN–28MAY04
T200471
Rear Window Exploded View

Continued on next page KK70125,00007A5 –19–02FEB07–1/2

060807
PN=404
Operator Enclosure
1—Windowpane 7—Weatherstrip (2 used) 13—Lower Fixed Window 18—Label

2—Windowpane 8—Gasket (2 used) 14—Windowpane 19—Label
3—Windowpane 9—Latch (4 used) 15—Windowpane 20—Screw (6 used)
4—Screw (10 used) 10—Seal 16—Stand-Off (22 used) 21—Window
5—Rack Step (2 used) 11—Upper Sliding Window 17—Washer (6 used) 22—Screw (6 used)
6—Frame (2 used) 12—Middle Sliding Window
1. To remove and install fixed window (13). Slide windows (11 and 12). A screw driver may help get
middle and upper sliding windows (11 and 12) to the end started. Cut the rubber approximately 2 18
full up position. inches above the top of the upper and middle 1810
sliding windows. 17
2. Remove two lower rack steps (5) on each side of
window. Each step has three screws (22). 10. Starting with the upper sliding window (11).
Remove one of the latches (9) and raise the upper
3. Raise the lower fixed window (13) until it clears the sliding window until it clears the flocked rubber.
flocked rubber. The lower fixed window can be The upper sliding window can be removed by
removed by guiding it into the deep portion of the guiding the side without the lock into the deep
aluminum channel on one side until the other side portion of the channel until the other side clears
is clear of the frame. the channel and can be removed.
4. Inspect for worn or damaged parts. Repair or 11. Repeat steps 10 and 11 to remove middle sliding
replace as necessary. window (12).
5. Install lower fixed window (13) by sliding into 12. Repair and replace parts as necessary
flocked rubber installed in channel.
13. With lower portion of flocked rubber still in place
6. Install two lower rack steps (5) on each side of install the middle sliding window (12). Move middle
window. Each step has three screws (22). There is sliding window to full down position
a small rubber disk on the bottom of each rack step
to prevent direct contact with glass and rack step. 14. Install flocked rubber in upper portion of middle
channel
7. To remove and install sliding windows (11 and
12) 15. Install latch
8. Move middle sliding window (12) and upper window 16. Repeat steps 14—16 to install upper sliding
(11) to full down position. window (11).
NOTE: When removing and installing middle sliding 17. To remove and install rear side windows (14
window (12) only. Upper sliding window (11) and 15). See Fixed Windowpanes Remove and
should be in full up position. Middle sliding Install. (Group 1810.)
window will start in full down position.
9. Remove old flocked rubber from both sides, to just

above the top of the upper and middle sliding
KK70125,00007A5 –19–02FEB07–2/2

060807
PN=405
Operator Enclosure
Headliner Remove and Install
1. Remove mirror (1).
2. Pull center pin of retainer (2) loose and remove

retainers.
18 3. Remove headliner through rear window.

1810
18 4. Install headliner.
–UN–19OCT00
5. Locate retainers through headliner and cab frame
support and lock retainer with center pin.
6. Install rear view mirror.
T134697B
1—Mirror
Cab Headliner
2—Retainers (9 used)
KK70125,00007A6 –19–12JAN07–1/1

060807
PN=406
Operator Enclosure
18
1810
19

060807
PN=407
Operator Enclosure
Cab Roof Remove and Install
2
2 3
2
3
18 2 3 2
1810
20 3 3
4 4
5 5
–UN–03APR07
TX1019115
TX1019115
Roof
Continued on next page KK70125,00007A7 –19–14FEB07–1/2

060807
PN=408
Operator Enclosure
1—Roof 3—Sealing Washer (8 used) 4—Washer (8 used) 5—Cap Screw (8 used)

2—Lock Nut (8 used)
1. Remove cab roof (1) as shown. Specification

Cab Roof Cap Screw—Torque............................................. 6.78 N•m
60 lb-in.
2. Inspect for worn or damaged parts. Replace if
necessary.
18
3. Install cab roof. Tighten cap screw (5) to 1810
specification. 21
KK70125,00007A7 –19–14FEB07–2/2

060807
PN=409
Operator Enclosure
18
1810
22

060807
PN=410
Group 1821
Seat and Seat Belt
Seat Assembly Remove and Install
2. Disconnect wire harness connector (1).
–UN–17OCT00
3. Remove cap screws (2) from seat base.
18
1821
CAUTION: Prevent possible crushing injury 1
T134650B
device.
Specification
1—Wire Harness Connector
Seat Assembly with Base—
2—Cap screws (4 used)
Weight (approximate) ........................................................................ 54 kg
118 lb
4. Use a lifting device and remove seat assembly with

seat belts through rear of cab. Cab glass must be in
lowest position.
5. Inspect parts. Replace as necessary.
6. Install seat assembly using lifting device through rear

of cab.
7. Tighten cap screws (2) to seat base.
Specification
Seat Base Cap Screw—Torque ..................................................... 50 N•m
37 lb-ft
8. Connect wire harness connector (1).
9. Install floor mat.
KK70125,00007A8 –19–06FEB07–1/1

060807
PN=411
Seat and Seat Belt
Seat and Arm Rest Disassemble and Assemble
18
1821
2
–UN–28DEC06
TX1014249
Seat and Arm Rest

Continued on next page KK70125,00007A9 –19–29MAR07–1/2

060807
PN=412
Seat and Seat Belt
1—Seat Kit 5—Screw 9—Clip 13—Cap Screw

2—Bracket 6—Tie Band 10—Armrest Kit (Left) 14—Washer
3—Bracket 7—Cushion 11—Armrest Kit (Right) 15—Plug
4—Kit 8—Cushion 12—Kit
NOTE: If machine is equipped with Total Machine 2. Disassemble parts as shown.

Control (TMC) start with step 1. If machine is
not equipped with TMC begin with step 2. 3. Inspect for worn or damaged parts.
18
1. Remove joystick controller. 1821
3
KK70125,00007A9 –19–29MAR07–2/2

060807
PN=413
Seat and Seat Belt
Seat Belt Disassemble and Assemble
18
1821
4
–UN–28DEC06
TX1014256
Seat Belt
Continued on next page JH38101,0000271 –19–01FEB07–1/2

060807
PN=414
Seat and Seat Belt
1—Kit 3—Cap Screw 5—Cover (Left) 6—Cover (Right)

2—Seat Belt 4—Washer
1. Disassemble parts as shown. 3. Assemble parts.
18
1821
5
JH38101,0000271 –19–01FEB07–2/2

060807
PN=415
Seat and Seat Belt
Seat Slide, Lumbar Support, and Adjuster Control Levers Disassemble and Assemble
18
1821
6
–UN–28DEC06
TX1014250
Seat Slide, Lumbar Support, and Adjuster Control Levers

Continued on next page KK70125,00007AA –19–12JAN07–1/2

060807
PN=416
Seat and Seat Belt
1—Seat Kit 6—Snap Ring 9—Seat Pan 14—Back Rest Pan

2—Seat Slide Kit 7—Control Lever Kit (Right 10—Spring Pin Kit 15—Electrical Repair Kit
3—Cap Screw Side) 11—Spring Pin 16—Switch
4—Screw 8—Control Lever Kit (Left 12—Paddle Spring Kit 17—Lock Nut
5—Spring Pin Side) 13—Spring Pin
2. Inspect for worn or damaged parts. 18

1821
7
KK70125,00007AA –19–12JAN07–2/2

060807
PN=417
Seat and Seat Belt
Seat Swivel and Swivel Latch Disassemble and Assemble
18
1821
8
–UN–28DEC06
TX1014251
Seat Swivel and Swivel Latch

Continued on next page KK70125,00007AB –19–12JAN07–1/2

060807
PN=418
Seat and Seat Belt
1—Seat Kit 5—Top Swivel Plate Kit 9—Ball 13—Electrical Repair Kit
2—Swivel 6—Swivel Assembly Kit 10—Electrical Repair Kit 14—Switch
3—Snap Ring Kit 7—Washer 11—Switch 15—Lock Nut
4—Snap Ring 8—Lock Nut 12—Lock Nut

18
1821
9
KK70125,00007AB –19–12JAN07–2/2

060807
PN=419
Seat and Seat Belt
Seat Suspension and Shock Absorber Disassemble and Assemble
18
1821
10
–UN–28DEC06
TX1014252
Continued on next page KK70125,00007AC –19–12JAN07–1/2

060807
PN=420
Seat and Seat Belt
1—Seat Kit 8—Knob 14—Boot 21—Cap Screw (2 used)

2—Seat Suspension Assembly 9—Gear 15—Shaft (2 used) 22—Washer (2 used)
3—Bearing Kit 10—Shock Absorber Assembly 16—Washer 23—Washer (2 used)
4—Cap Screw (4 used) 11—Shock Absorber 18—Angle 25—Lock Nut (2 used)
5—Spring 12—Bushing (2 used) 19—Isolator (2 used) 26—Bar (4 used)
6—Adjusting Knob Assembly 13—Bearing/Bushing 20—Tether Belt Assembly
7—Spring Pin (2 used) Assembly
1. Disassemble parts as shown. Specification

Tether Belt-to-Heater/Blower 18
Cover Cap Screw—Torque .................................................... 50 N•m 1821
2. Inspect for worn or damaged parts. 37 ft-lb 11
3. Assemble parts. Tighten cap screw (21) to

specification.
KK70125,00007AC –19–12JAN07–2/2

060807
PN=421
Seat and Seat Belt
Air Suspension Seat Disassemble and Assemble—If Equipped
18
1821
12
–UN–29DEC06
TX1014253
Air Suspension Seat Assembly

Continued on next page KK70125,00007AE –19–30APR07–1/13

060807
PN=422
Seat and Seat Belt
1—Seat Assembly 9—Seat Suspension (2 used) 15—Kit 22—Fitting Kit

2—Air Spring Seat Kit 10—Shaft 16—Housing 23—Bumper
3—Cap Screw (4 used) 11—Seat Bearing Roller 17—Housing 24—Plate
4—Kit Assembly 18—Arm 25—Electrical Repair Kit
5—Electrical Repair Kit 12—Bracket (2 used) 19—Absorber 26—Switch
6—Switch 13—Cylinder (2 used) 20—Seat Suspension Boot 27—Lock Nut (2 used)
7—Lock Nut (2 used) 14—Kit 21—Seat Suspension Boot
8—Toggle Switch Hardware
18
1821
13
KK70125,00007AE –19–30APR07–2/13
NOTE: Repair seat cushion.See Seat and Arm Rest

Disassemble and Assemble. (Group 1821.) Repair
swivel/slider plate.See Seat Slide, Lumbar
Support, and Adjuster Control Levers
Disassemble and Assemble. (Group 1821.)
1. Lift front of seat cushion (2) to access seat base

mounting hardware.
2. Remove nuts and washers (1) to remove seat base

assembly (3).
1—Nuts and Washers (6 used)

2—Seat Cushion
3—Seat Base Assembly
–UN–11FEB99
T120001B

060807
PN=423
Seat and Seat Belt
3. While holding latch (5) down, move plate (1) to

rearmost position.
4. Remove the two front nuts and washers (2). Push latch
(6) and rotate plate (1) to access and remove the two
rear nuts and washers (2).
–UN–14FEB99
18 5. Remove the swivel/slide assembly.
1821
14 6. While holding latch (5) down, move plate (1) forward
T120002B
and remove from swivel/slide assembly.
7. Remove 32 plastic fasteners (3) to remove boot (4).
1—Slide Plate
3—Plastic Fasteners (Plugs) (32 used)
4—Boot
5—Slide Latch
6—Swivel Latch
7—Swivel-Stop Plate
KK70125,00007AE –19–30APR07–4/13
8. Remove wiring connector (1).
9. Remove cap screws (2) and swivel stop plate (3).
1—Air Compressor Wiring Connector
–UN–14FEB99
4—Upper Suspension Tray
T120004B

060807
PN=424
Seat and Seat Belt
10. Disconnect wiring connectors (1).
11. Remove cap screws (2) and switch (3).
12. Disconnect wire harness (9) and remove switch (8).
13. Remove cap screws (6) and switch bracket (7).

18
14. Remove lock nut (10) and upper pivot shaft (11). 1821
15
15. Remove upper tray (12) by lifting and moving the tray
forward until rollers (13) clear roller channel (14).
–UN–14FEB99
1—Wiring Connector (2 used)
3—Seat Position Switch
5—Swivel Stop
T120005B
7—Switch Bracket
8—Air Control Switch
9—Wire Harness
10—Lock Nut
11—Upper Pivot Shaft
13—Roller (4 used)
14—Roller Channel

060807
PN=425
Seat and Seat Belt
16. Remove fitting (4) and elbow (5).
17. Remove upper and lower cap screws (3) and air bag
(10).
18. Remove lock nut (1) and lower pivot shaft (2).
–UN–14FEB99
18 19. Remove scissor frame assembly (9) by turning and
1821 lifting assembly until rollers (6) clear the roller channel
16 (7).
T120006B
1—Lock Nut
2—Lower Pivot Shaft
3—Air Bag Mount Cap Screw (2 used)
4—Fitting
5—Elbow Fitting
6—Roller
7—Roller Channel
8—Lower Suspension Tray
9—Scissor Frame Assembly
10—Air Bag
KK70125,00007AE –19–30APR07–7/13
20. Inspect parts (1—14). Replace if necessary.
21. Clean all bushings, rollers, and pivots. Lubricate with

multi-purpose grease.
22. Assemble parts as shown.
1—Line Fitting
2—Air Line
3—Air Compressor
5—Roller (4 used)
7—Tether Belt (2 used)
8—Shock Absorber
–UN–14FEB99
9—Retainer Clip
10—Spacer/Bushing
11—Spacer
12—Bushing
T120007B
13—Bumper and Cap Screw (2 used)


060807
PN=426
Seat and Seat Belt
23. Install scissor frame assembly (9) onto lower tray (8)
by inserting rollers (6) into roller channel (7).
24. Install lower pivot shaft (2) and lock nut (1).
25. Put a wood block between scissor frame arm and
–UN–14FEB99
lower tray to hold scissor frame in the raised position.
18
26. Install air bag (10) and cap screws (3). Be careful not 1821
to over tighten cap screws. 17
T120006B
27. Install elbow fitting (5) and line fitting (4).
1—Lock Nut
2—Lower Pivot Shaft
3—Air Bag Mount Cap Screw (2 used)
4—Fitting
5—Elbow Fitting
6—Roller
7—Roller Channel
8—Lower Suspension Tray
10—Air Bag

060807
PN=427
Seat and Seat Belt
28. Install upper tray (12) on the scissor frame by

inserting rollers (13) into roller channel (14). Install
pivot shaft (11) and lock nut (10).
29. Install switch bracket (7) and cap screws (6).
30. Install air control switch (8) and connect wire harness
18 (9).
1821
18 31. Install seat position switch (3) and cap screws (2).
32. Connect wiring connectors (1).
–UN–14FEB99
1—Wiring Connector (2 used)
3—Seat Position Switch
5—Swivel Stop
T120005B
7—Switch Bracket
8—Air Control Switch
9—Wire Harness
10—Lock Nut
11—Upper Pivot Shaft
13—Roller (4 used)
14—Roller Channel
KK70125,00007AE –19–30APR07–10/13
33. Install swivel-stop plate (3) and cap screws (2). Be

careful not to crush wires or connectors.
34. Connect air compressor wire connector (1).

–UN–14FEB99
1—Air Compressor Wiring Connector

T120004B

060807
PN=428
Seat and Seat Belt
35. Fasten boot (4) to upper tray using 32 plastic

fasteners (3).
36. While holding latch (5) down, install slide plate (1)
onto swivel plate assembly.
–UN–14FEB99
37. Install swivel/slide assembly to swivel-stop plate (7).
Fasten with four nuts and washers (2). 18
1821
19
T120002B
1—Slide Plate
3—Plastic Fasteners (Plugs) (32 used)
4—Boot
5—Slide Latch
6—Swivel Latch
KK70125,00007AE –19–30APR07–12/13
38. Install cushion base assembly (3) to slide plate using

nuts and washers (1).
39. Install seat cushion (2).

2—Seat Cushion
3—Cushion Base Assembly
–UN–11FEB99
T120001B
KK70125,00007AE –19–30APR07–13/13

060807
PN=429
Seat and Seat Belt
18
1821
20

060807
PN=430
Group 1830
Heating and Air Conditioning
Proper Refrigerant Handling
The U.S. Environmental Protection Agency prohibits intended for use with R12
discharge of any refrigerant into the atmosphere, and refrigerant.
requires that refrigerant be recovered using the
approved recovery equipment. Recovery, recycling and charging stations for R12 and
R134a refrigerants MUST NOT be interchanged.
IMPORTANT: Use correct refrigerant recovery, Systems containing R12 refrigerant use a different oil 18
recycling and charging stations. DO than systems using R134a. Certain seals are not 1830
NOT use refrigerant, hoses, fittings, compatible with both types of refrigerants. 1
components or refrigerant oils
TF44157,00006BC –19–25APR07–1/1
R134a Refrigerant—Cautions
develop high pressure which can burst the

CAUTION: DO NOT allow liquid refrigerant to
container.
contact eyes or skin. Liquid refrigerant will
freeze eyes or skin on contact. Wear
Keep refrigerant containers away from heat
goggles, gloves and protective clothing.
sources. Store refrigerant in a cool place.
If liquid refrigerant contacts eyes or skin, DO
DO NOT handle damp refrigerant container
NOT rub the area. Splash large amounts of
with your bare hands. Skin may freeze to
COOL water on affected area. Go to a
container. Wear gloves.
physician or hospital immediately for
treatment.
If skin freezes to container, pour COOL
water over container to free the skin. Go to a
DO NOT allow refrigerant to contact open
physician or hospital immediately for
flames or very hot surfaces such as electric
treatment.
welding arc, electric heating element and
lighted smoking materials.
DO NOT heat refrigerant over 52°C (125°F) in

a closed container. Heated refrigerant will
TF44157,00006BD –19–10MAY07–1/1

060807
PN=431
Refrigerant Hoses and Tubing Inspection
When a component is disconnected from the system,

special care should be given to inspecting hoses and
tubing for moisture, grease, dirt, rust, or other foreign
material. If such contamination is present in hoses, tubing
or fittings and cannot be removed by cleaning, replace
18 parts.
1830
2 Fittings that have grease or dirt on them should be wiped
clean with a cloth dampened with alcohol. Chlorinated
solvents (such as trichloroethylene) are contaminants, and
must not be used for cleaning.
To assist in making leak-proof joints, use a small amount

of clean, correct viscosity refrigerant oil on all hose and
tube connections. Dip O-rings in correct viscosity oil
before assembling.
IMPORTANT: Hose used for air conditioning systems

contains special barriers in its walls to
prevent migration of refrigerant gas.
DO NOT use hydraulic hoses as

replacement hoses in the air
conditioning system. Use ONLY
certified hose meeting SAE J51B
requirements.
TF44157,00006BE –19–10MAY07–1/1

060807
PN=432
Air Conditioning Compressor Remove and

Install


18
–UN–12SEP00
1830
2. Open engine hood fully. 3
3. Recover refrigerant from the system. See R134a

System Recover Procedure. (Group 1830.)
T133725B
4. Remove fan guard (1).
5. Loosen belt tension to remove fan belt (7) from sheave 1—Fan Guard
of A/C compressor. 2—Ground Wire
3—Suction Line (from expansion valve)
4—Pressure Line (to condenser)
6. Disconnect ground wire (2) and wire connector (6). 5—Cap Screws and Washers (4 used)
6—Wire Connector
7. Disconnect suction and pressure lines (3 and 4). 7—Fan Belt
8. Remove four cap screws (5) and the A/C compressor.

Close all openings using caps and plugs.
9. Repair or replace compressor.
IMPORTANT: If compressor is being replaced due to

an internal failure, flush and purge each
component in air conditioning system
individually. (See Air Conditioner
System Cleaning Procedure in this
group.)
NOTE: If air conditioning system is flushed or purged a

new receiver dryer must be installed.
10. Clean system if needed. See R134a System Cleaning

11. Flush components, if needed. See R134a System

Flush Procedure. (Group 1830.)
12. Purge system, if needed. See R134a System Purge

13. Install compressor. Tighten cap screws (5) to

specification.
Continued on next page TF44157,00006BF –19–10MAY07–1/2

060807
PN=433
Specification
A/C Compressor Mount—Torque ................................................. 120 N•m
89 lb-ft
14. Connect lines (3 and 4).
15. Connect wire connector (6) and ground wire (2).
18 16. Install fan belt (7) and fan guard (1).

1830
4
17. Replace receiver/dryer.
18. Evacuate the system. See R134a System Evacuate

Procedure. (Group 1830.) Charge the system. See
R134a System Charge Procedure. (Group 1830.)
IMPORTANT: Hood must be closed before lowering

the loader boom or damage to hood will
result.
20. Remove boom lock bar and lower loader boom to

ground.
TF44157,00006BF –19–10MAY07–2/2
R134a Compressor Oil Removal Procedure
1. Remove compressor from machine. See Air 4. Record measured oil and discard oil properly.
Conditioning Compressor Remove and Install.
(Group 1830.) 5. Install new oil. See R134a Component Oil Charge
2. Remove inlet/outlet manifold from compressor, and
clutch dust cover. 6. Install compressor. See Air Conditioning
Compressor Remove and Install. (Group 1830.)
3. Drain oil into graduated container while rotating
compressor shaft.
TF44157,00006C0 –19–10MAY07–1/1

060807
PN=434
Air Conditioning Compressor Clutch

18
1830
5
–UN–24JUN92
RW21157
–UN–29APR98
T114965
A—JDG747 Compressor C—Clutch Hub E—Pulley G—Clutch Coil

Clutch Spanner D—Pulley Snap Ring F—Clutch Coil Snap Ring H—Shims
B—Clutch Shaft Bolt
1. Mount compressor on D01006AA Bench Mounted (Group 9900) using two 6 in. x 1/4 in. eye bolts with
Holding Fixture or DFRW20 Compressor Holding nuts as illustrated.
Fixture, see DFRW20 Compressor Holding Fixture
Continued on next page TF44157,00006C1 –19–10MAY07–1/2

060807
PN=435
2. Remove dust cover. 7. Check pulley bearing operation. Replace pulley and
bearing as required.
3. Hold the clutch hub using JDG747 Compressor
Clutch Spanner (A) and remove the clutch shaft bolt 8. Install the clutch coil and new snap ring with flat
(B). side of the snap ring down. Connect the clutch coil
lead wire.
4. Remove the clutch hub (C). Remove the shims (H)
18 from the clutch hub and save for installation. 9. Install the pulley and new snap ring with the flat
1830 side of the snap ring down. Apply grease to the
6 5. Remove and discard snap ring (D). Remove the shims (H) and install to the clutch hub.
pulley (E) using a plastic hammer or JDG220
Puller, JDG748 Jaws and JDG771 Forcing Screw. 10. Install clutch hub and shaft bolt and tighten to
specification.
6. Disconnect the clutch coil lead wire. Remove and
discard the snap ring (F) and remove the clutch coil Specification
(G). Compressor Hub Retaining
Nut—Torque ............................................................................ 14 N•m
120 lb-in.
NOTE: The bearing in the pulley is NOT serviceable.
TF44157,00006C1 –19–10MAY07–2/2
Clutch Hub Clearance Check
NOTE: The clutch coil is NOT polarity sensitive.
1. Check pulley-to-clutch hub clearance using a dial

indicator. Mount the gauge to the pulley as illustrated
and connect a set of jumper wires from the compressor
to a 12V battery.
2. Rotate the pulley and check clearance in three equally

spaced locations around the clutch hub. Correct
clearance is per specification. Add or remove shims as
required.
Specification
Pulley-to-Clutch Hub—Clearance...................................... 0.35—0.65 mm
0.014—0.026 in.
3. Tighten clutch shaft bolt to specification after correct

clearance is obtained.
–UN–24JUN92
Specification
Clutch Shaft Bolt—Torque.............................................................. 14 N•m
120 lb-in.
RW21159
TF44157,00006C2 –19–10MAY07–1/1

060807
PN=436
Air Conditioning Compressor Manifold

Inspection
1. Remove cap screws (A) and the manifold (B).
2. Remove and discard seal (C). Inspect porting surfaces.
3. Lubricate and install a new seal (C). 18

1830
4. Install manifold and tighten cap screws to 7
specifications.
Specification
Manifold Cap Screw—Torque ........................................................ 27 N•m
–UN–24JUN92
20 lb-ft
A—Manifold Cap Screw

B—Manifold
RW21160
C—Manifold Seal
TF44157,00006C3 –19–10MAY07–1/1

060807
PN=437
Air Conditioning Compressor Disassemble and Assemble
18
1830
8
–UN–24JUN92
RW21161
A—Rear Pins G—Rear O-Ring L—Front Gasket Q—Felt Holder
B—Rear Housing H—Front O-Ring M—Snap Ring R—Felt
C—Rear Gasket I—Front Suction Reed Valve N—Lip Seal S—Front Housing
D—Rear Discharge Reed Valve J—Front Valve Plate O—Washer T—Front Pins
E—Rear Valve Plate K—Front Discharge Reed P—Through Bolt
F—Rear Suction Reed Valve Valve
1. Clean the compressor using solvent before NOTE: The valve plates, reed valves, cylinders, and
disassembly. Mount compressor on holding fixture cylinder housings are NOT serviceable. Some
and remove clutch, see Air Conditioning cylinder scuffing (light scratches) is normal.
Compressor Clutch Disassemble and Assemble.
(Group 1830.) 3. Inspect the valves for an even wear pattern and the
cylinders for scoring or excessive wear. Replace
IMPORTANT: When removing front and rear compressor as required.
housing, be careful NOT to damage
the sealing surfaces. 4. Remove the shaft seal snap ring (M). Turn the
housing over and remove the felt holder (Q) and felt
2. Disassemble the compressor as illustrated and (R) from the front housing (S).
discard the O-rings, gaskets, lip seal, snap ring,
and through bolt washers. Replace parts from
service kits.

060807
PN=438
5. Remove the shaft lip seal (N) from the front housing
(S) using a small tool with 5/8 in. OD.
6. Wash all parts in clean solvent and dry before

assembly.
IMPORTANT: Lubricate O-rings, gaskets, and lip seal

using only R134a refrigerant oil during 18
assembly. Other oils could damage the 1830
compressor. 9
7. Apply R134a oil to the bore of the front housing and

install new lip seal (N) to the bottom of the bore using
a socket. Install new snap ring (M) flat side down.
–UN–24JUN92
IMPORTANT: Bushing spacer (U) must be in position
before assembling the compressor.
RW21162
8. Install pins (A) and new O-ring (G) in the rear cylinder.
NOTE: The rear valve plate is marked with an “R” and is

installed face up.
9. Install parts (F—D) over the pins on the rear cylinder.
10. Install a new gasket (C) flat side down and the rear
housing (B) on the rear cylinder. Mount the
compressor onto the holding fixture.
11. Install pins (T) and new O-ring (H) in the front
cylinder.
NOTE: The front valve plate is marked with an “F” and is

installed face up.
–UN–24JUN92
12. Install parts (I—K) over the pins on the front cylinder.
13. Install a new gasket (L) flat side down. Put JDG746
Lip Seal Protector on the shaft and lubricate with
R134a oil. RW21163
14. Install the front housing (S) on the front cylinder and
remove the lip seal protectors. Install through bolts C—Rear Gasket
(P) and new washers (O). D—Rear Discharge Reed Valve
E—Rear Valve Plate
F—Rear Suction Reed Valve
15. Partially tighten the through bolts and then tighten to U—Bushing Spacer
specification.

060807
PN=439
Specification
Compressor Through Bolts—
Torque ............................................................................................ 27 N•m
20 lb-ft
16. Install the felt (R) and felt holder (Q) using the clutch
hub.
18 17. Install the pulley clutch hub and check clearance. See
1830 Clutch Hub Clearance Check. (Group 1830.)
10
TF44157,00006C4 –19–10MAY07–3/3
Heater Core Remove and Install
1. Lower all equipment to ground.
2. With engine off operate all controls to relieve pressure.
–UN–16OCT00
3. Drain radiator.
Specification
Cooling System—Capacity .................................................................. 21 L
T134634B
5.5 gal
4. Disconnect the heater hoses at the heater core

connectors (below the cab floor) and drain heater core. 1—Screws (5 used)
2—Air Filter and Grille
5. Remove floor mat. 3—Lower Console Cover
6. Remove air filter grille and filter (2) from lower console
cover (3).
7. Remove screws (1) and move lower console cover (3).
8. Disconnect wire leads from auxiliary power outlets (if

equipped) and remove lower console cover.

060807
PN=440
9. Remove cap screws (3) and remove air duct (4).
10. Remove heater hoses (1).
11. Remove six screws (2) to remove upper heater core

housing (5).
1—Heater Hoses (2 used) 18

2—Screws (6 used) 1830
3—Cap Screw (2 used) 11
4—Air Duct
–UN–16OCT00
5—Heater Core Upper Housing
T134636B

060807
PN=441
18
1830
12
–UN–19JAN07
TX1017168

060807
PN=442
1—Screw (2 used) 15—O-ring 29—Grommet 42—Clip (2 used)

2—Temperature Switch 16—Expansion Valve 30—Threaded Nipple (2 used) 43— Cap Screw (4 used)
3—Screw (9 used) 17—Cap Screw (2 used) 31—Clamp (2 used) 44—Hose Guard
4—Housing 18—Plate 32—Cap Screw 45—Housing
5—Switch 19—Cap Screw 33—Cap Screw (3 used) 46—Hose Clamp
6—Clip 20—O-ring (3 used) 34—Washer (2 used) 47—Condensate Hose
7—Resistor 21—O-ring (4 used) 35—Bracket 48—Isolator (2 used)
8—Nut (4 used) 22—Coolant Hose 36—Clamp 49—Tie Band (2 used)
9—Heater Core 23—Hose Clamp (4 used) 37—Clamp (2 used) 50—Sheet (2 used)
10—Seal (2 used) 24—Coolant Control Valve 38—Cap Screw (10 Used) 51—Plug 18
11—Screw (4 used) 25—A/C Line 39—Washer (2 used) 52—Hose 1830
12—Evaporator 26—Grommet 40—Blower Motor 53—Hose 13
13—Plate 27—Cable 41—Tie Band 54—Tie Band
14—O-ring 28—Refrigerant Hose
13. Repair or replace heater core.

CAUTION: Wear gloves when removing and
installing heater core to prevent cuts from
14. Install heater core (9).
fins on heater core.
12. Carefully remove the heater core (9).
TF44157,00006C5 –19–08MAY07–4/5
15. Install upper heater core housing and hoses.
16. Install air duct.
17. Position lower console cover and connect wire leads

to auxiliary power outlets (if equipped).
18. Install lower console cover.
19. Connect heater hoses at the heater core connectors

(below the cab floor).
–UN–16OCT00
20. Fill radiator with proper coolant. See Diesel Engine

Coolant. Fill radiator to proper level. See 410J
T134636B
21. Check for leaks.

1—Heater Hoses (2 used)
2—Screws (6 used)
4—Air Duct
TF44157,00006C5 –19–08MAY07–5/5

060807
PN=443
Evaporator Remove and Install
–UN–16OCT00
3. Recover refrigerant from system. See R134a System
18 Recover Procedure. (Group 1830.)
1830
14 4. Remove floor mat.
T134634B
cover (3).
1—Screws (5 used)
3—Lower Console Cover
7. Disconnect wire at auxiliary power outlets (if equipped)

and remove lower console cover.
TF44157,00006C6 –19–08MAY07–1/5
9. Tag and disconnect refrigerant hoses (25 and 28).

Close all openings with caps and plugs.
10. Remove six screws (2) to remove upper housing (5).

2—Screws (6 used)
4—Air Duct
–UN–16OCT00
5—Upper Housing
T134636B

060807
PN=444
18
1830
15

060807
PN=445
18
1830
16
–UN–19JAN07
TX1017168

060807
PN=446

12. Repair or replace evaporator.

CAUTION: Wear gloves when removing and
installing evaporator to prevent cuts from
13. Install evaporator (12).
fins.
11. Carefully remove the evaporator (12).
TF44157,00006C6 –19–08MAY07–4/5
14. Install upper housing and hoses.
16. Position lower console cover and connect wire leads

to auxiliary power outlets (if equipped).
18. Evacuate air conditioner system. See R134a System

Evacuate Procedure. (Group 1830.)
–UN–16OCT00
NOTE: If air conditioning system is flushed or purged a

new receiver dryer must be installed.
T134636B
19. Recharge system. See R134a System Charge

20. Check for leaks.
2—Screws (6 used)
4—Air Duct
TF44157,00006C6 –19–08MAY07–5/5

060807
PN=447
Air Conditioning Freeze Switch Remove and

Install
–UN–16OCT00
18 3. Recover refrigerant from system. See R134a System
1830 Recover Procedure. (Group 1830.)
18
T134634B
1—Screws (5 used)
cover (3).
7. Disconnect wire leads to auxiliary power outlets (if

TF44157,00006C7 –19–10MAY07–1/5
9. Remove six screws (2) to remove upper housing (5).

2—Screws (6 used)
4—Air Duct
5—Upper Housing
–UN–16OCT00
T134636B

060807
PN=448
10. Disconnect wire connector (1).
11. Remove screws (2).
12. Remove A/C freeze switch and temperature sensor.
1—Wire Connector
2—Screws (2 used) 18
3—Temperature Sensor 1830
19
–UN–14NOV00
T135491B

060807
PN=449
13. Install freeze switch to plastic evaporator shroud

using two screws and nuts (2) .
14. Clean sealant from hole in grommet on plastic

housing.
15. Route freeze switch temperature sensor wire (3) in

18 slot of evaporator housing down to evaporator. Install
1830 end of probe halfway into evaporator at given
20 dimensions (4 and 5).
–UN–14NOV00
16. Connect B2 connector (1) to freeze switch.
17. Install temperature sensor and freeze switch with

screws (2).
T135491B
18. Connect wire connector (1).
1—Wire Connector
2—37M7073 Tapping Screw and R50279 Spring Nut (2
used)
3—Temperature Sensor Wire
4—54.6 mm (2.15 in.)
5—56.68 mm (2.23 in.)
–UN–17JAN01
T137433

060807
PN=450
19. Install upper housing (if removed).
21. Connect wire leads to auxiliary power outlets (if

equipped).
22. Install lower console cover. 18

1830
21
–UN–16OCT00
2—Screws (6 used)
4—Air Duct
T134636B
TF44157,00006C7 –19–10MAY07–5/5

060807
PN=451
Heater/Blower Assembly with Air Conditioning and Pressurizer System Disassemble and
Assemble
18
1830
22
–UN–19JAN07
TX1017168

060807
PN=452

TF44157,00006C8 –19–10MAY07–2/4
NOTE: Heater blower with air conditioning and

pressurizer system shown. Standard heater
blower remove and install is similar.
–UN–16OCT00
T134634B
cover (3).
5. Remove screws (1) and move lower console cover (3). 1—Screws (5 used)
6. Disconnect auxiliary power outlet wire leads (if
7. Remove lower console cover (3).

060807
PN=453
8. Remove floor cover at loader control tower.
9. Remove cap screws (4) and move loader control tower

and linkage aside.
10. Disconnect wire connector (1).
–UN–16OCT00
18 11. Remove cap screws (2) and blower motor (3).
1830
24 12. Install blower motor.
T134639B
13. Connect wire harness.
14. Install loader control tower. 1—Wire Harness Connector

3—Blower Motor
15. Install loader control cover. 4—Cap Screw (2 used)
TF44157,00006C8 –19–10MAY07–4/4

060807
PN=454
18
1830
25

060807
PN=455
Air Ducts Disassemble and Assemble
18
1830
26
–UN–31OCT02
T157864
Continued on next page TF44157,00006C9 –19–25APR07–1/2

060807
PN=456
1—Screw (22 used) 8—Washer (4 used) 14—Self Locking Cap Screw (4 19—Air Duct
2—Louver (4 used) 9—Isolator used) 20—Cap Screw (2 used)
3—Cap Screw 10—Clip (3 used) 15—Air Duct 21—Isolator
4—Washer (7 used) 11—Screw (5 used) 16—Clamp (3 used) 22—Air Duct
5—Air Duct 12—Bracket 17—Air Duct 23—Clamp
6—Louver 13—Isolator 18—Air Duct 24—Isolator
1. Disassemble parts (1—24). 2. Inspect and replace parts as necessary. 18

1830
27
TF44157,00006C9 –19–25APR07–2/2

060807
PN=457
Condenser Disassemble and Assemble
18
1830
28
–UN–20JAN07
TX1017829
Continued on next page TF44157,00006CA –19–25APR07–1/2

060807
PN=458
1—Refrigerant Hose 14—Clip 28—Charge Port (high side) 42—Refrigerant Hose

2—Tie Band (3 used) 15—Cap Screw 29—Clamp 43—Grommet
3—Charge Port (low side) 16—Lock Washer 30—O-ring (2 used) 44—Receiver-Dryer
4—Cap 17—Cap Screw (4 used) 31—Nut 45—Cap Screw (2 used)
5—O-ring (8 used) 18—Cap Screw (2 used) 32—Washer (8 used) 46—Cap Screw
6—O-ring 19—Cap Screw 33—Bushing (4 used) 47—Refrigerant Hose
7—O-ring 20—Washer (3 used) 34—Washer (4 used) 48—Bracket
8—Compressor Wiring 21—Bracket 35—Hose Clamp (2 used) 49—O-ring
Harness 22—Clip 36—Cap Screw (4 used) 50—Charge Port (high side)
9—Cap Screw 23—Bracket 37—Vapor Condenser 51—Cap Screw (2 used) 18
10—Washer (11 used) 24—Spring Pin (2 used) 38—Cap Screw 52—Bracket 1830
11—Clamp 25—Compressor 39—Sleeve 53—Cap 29
12—Nut (6 used) 26—Strap 40—Pulley 54—V-belt
13—Cap Screw (4 used) 27—Refrigerant Hose 41—Spacer 55—Kit
IMPORTANT: A new receiver dryer must always be Do a cleaning procedure on the vapor condenser.
install after system is flushed or See R134a System Cleaning Procedure. (Group
purged. DO NOT use a flushed or 1830.)
used receiver dryer. Contamination
of system will cause component 8. Connect lines (27 and 42).
failure.
1. Raise loader boom and install boom lock bar. Procedure. (Group 1830.)
2. Remove grille. 10. Charge the system. See R134a System Charge
IMPORTANT: Hood must be closed before
4. See R134a System Recover Procedure(Group lowering the loader boom or damage
1830.) to hood will result.
5. Disconnect lines (27 and 42). Close all openings 11. Close engine hood.
12. Install grille.
6. Remove vapor condenser (37).
13. Remove boom lock bar and lower loader boom to
7. Repair or replace vapor condenser (37). ground.
NOTE: If air conditioning system is flushed or purged

a new receiver dryer must be installed.
TF44157,00006CA –19–25APR07–2/2

060807
PN=459
Receiver Dryer Remove and Install
18
1830
30
–UN–20JAN07
TX1017829
Continued on next page TF44157,00006CB –19–08MAY07–1/2

060807
PN=460
1—Refrigerant Hose 14—Clip 28—Charge Port (high side) 42—Refrigerant Hose

2—Tie Band (3 used) 15—Cap Screw 29—Clamp 43—Grommet
3—Charge Port (low side) 16—Lock Washer 30—O-ring (2 used) 44—Receiver-Dryer
4—Cap 17—Cap Screw (4 used) 31—Nut 45—Cap Screw (2 used)
5—O-ring (8 used) 18—Cap Screw (2 used) 32—Washer (8 used) 46—Cap Screw
6—O-ring 19—Cap Screw 33—Bushing (4 used) 47—Refrigerant Hose
7—O-ring 20—Washer (3 used) 34—Washer (4 used) 48—Bracket
8—Compressor Wiring 21—Bracket 35—Hose Clamp (2 used) 49—O-ring
Harness 22—Clip 36—Cap Screw (4 used) 50—Charge Port (high side)
9—Cap Screw 23—Bracket 37—Vapor Condenser 51—Cap Screw (2 used) 18
10—Washer (11 used) 24—Spring Pin (2 used) 38—Cap Screw 52—Bracket 1830
11—Clamp 25—Compressor 39—Sleeve 53—Cap 31
12—Nut (6 used) 26—Strap 40—Pulley 54—V-belt
13—Cap Screw (4 used) 27—Refrigerant Hose 41—Spacer 55—Kit
IMPORTANT: A new receiver dryer must always be Clean components, if needed. See R134a System
install after system is flushed or Cleaning Procedure. (Group 1830.)
purged. DO NOT use a flushed or
used receiver dryer. Contamination 6. Install receiver dryer .
of system will cause component
failure. 7. Connect lines (5 and 29).
1. Raise loader boom and install boom lock bar. 8. Evacuate the system.See R134a System Evacuate
9. Charge the system. See R134a System Charge
3. Recover refrigerant from the system. See R134a Procedure. (Group 1830.)
System Recover Procedure. (Group 1830.)
IMPORTANT: Hood must be closed before
4. Disconnect lines (42 and 47). Close all openings lowering the loader boom or damage
using caps and plugs. to hood will result.
5. Remove receiver dryer (44). 10. Close engine hood.
NOTE: If air conditioning system is flushed or purged 11. Remove boom lock bar and lower loader boom to
a new receiver dryer must be installed. ground.
TF44157,00006CB –19–08MAY07–2/2

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PN=461
Expansion Valve Remove and Install
NOTE: Anytime air conditioning system is discharged, a

new receiver-dryer must be installed.
1. Remove floor mat, loader control cover, and side
–UN–09JUL04
console cover.
18
1830 2. Recover R134a from air conditioning system. See
32 R134a System Recover Procedure. (Group 1830.)
T201597A
3. Remove socket head cap screw (2) and disconnect
lines (1 and 3).
1—Expansion Valve Line-to-Receiver/Dryer
2—Socket Head Cap Screw
4. Remove two cap screws and remove expansion valve.
3—Expansion Valve Line-to-Compressor
5. Apply refrigerant oil to new O-rings and connect lines.
6. Install expansion valve and connect lines. Tighten

socket head cap screw (2) to specification.
Specification
Socket Head Cap Screw—Torque ...................................... 9.6—10.7 N•m
85—95 lb-in.
7. Install new receiver-dryer. See Receiver Dryer Remove

8. Add oil. See R134a Component Oil Charge Procedure.

(Group 1830.)
9. Evacuate and charge air conditioning system. See

R134a System Evacuate Procedure and See R134a
System Charge Procedure. (Group 1830.)
TF44157,00006CC –19–08MAY07–1/1

060807
PN=462
R134a Component Oil Charge Procedure
Specification
CAUTION: All new compressors are charged Oil, Used Compressor
with a mixture of nitrogen, R134a refrigerant Installation, Complete System
and TY22025 (R134a) refrigerant oil. Wear Flushed—Volume ................................................................... 438 mL
safety goggles and discharge the 14.8 oz
compressor slowly to avoid possible injury.
18
1830
Compressors can be divided into three categories 33
when determining the correct oil charge for the system. 2. When the complete system was not flushed add the
correct amount of oil for the compressor plus the
• New compressor from parts depot amount of oil for each component that was
• Used compressor removed from operation serviced.
• Compressor internally washed with flushing solvent
• New compressor from parts depot, drain and
Use the following procedure to determine the return 45 mL (1.5 oz) of oil to the compressor.
amount of system oil charge prior to installation of See R134a Compressor Oil Removal Procedure.
compressor on a machine. (Group 1830.)
Specification
1. When the complete system, lines, and components Oil, New Compressor
were flushed add the correct amount of oil as Installation, Complete System
described. Not Flushed—Volume................................. 45 mL (drain and return )
1.5 oz (drain and return )
• New compressor from parts depot contains the
amount of new oil of 210—250 mL (7.0—8.4 oz).
System requires an additional amount of new oil
of 210 mL (7.1 oz) of new oil. • Used compressor removed from operation and oil
drained. See R134a Compressor Oil Removal
Specification Procedure. (Group 1830.) Add 45 mL (1.5 oz) of
Oil, New Compressor new oil.
Installation, Complete System
Flushed—Volume ...................................... 210—250 mL (supplied by
Specification
parts depot)
Oil, Used Compressor
7.0—8.4 oz (supplied by parts
Installation, Complete System
depot)
Not Flushed, Oil Drained—
Volume ...................................................... 210 mL (additional amount
Volume ............................................................................. 45 mL (add)
required)
1.5 oz (add)
7.1 oz (additional amount
required)
• Used compressor removed from operation, oil

• Used compressor removed from operation, oil drained, and flushed add 60 mL (2.0 oz) of new
drained, and flushed requires 438 mL (14.8 oz) of oil.
new oil.
Continued on next page TF44157,00006CD –19–10MAY07–1/2

060807
PN=463
Specification
Oil, Used Compressor CAUTION: DO NOT leave the system or
Installation, Complete System R134a compressor oil containers open. This
Not Flushed, Oil Drained, oil easily absorbs moisture. DO NOT spill
Flushed—Volume ............................................................ 60 mL (add) R134a compressor oil on acrylic or ABS
2.0 oz (add)
plastic. This oil will deteriorate these
materials rapidly. Identify R134a oil
containers and measures to eliminate
18 accidental mixing of different oils.
1830
34 NOTE: Hoses = 3 mL per 0.3 m (0.1 oz per ft).
Components listed below which have been removed,
Approximate total length equals 12.5 m (41.0
drained or flushed, require the removal of the
ft).
compressor to determine the correct oil charge. Use
the following chart as a guide for adding oil to
3. If any section of hose is removed and flushed or
components:
replaced, measure the length of hose and use the
formula to determine the correct amount of oil to be
added.
Item Measurement Specification
Compressor Oil Charge 45 mL

1.5 oz
Evaporator Oil Charge 171.5 mL

5.8 oz
Condenser Oil Charge 133.1 mL

4.5 oz
Receiver/Dryer Oil Charge 30 mL

1.0 oz
Hoses Oil Charge (approximate) 60 mL

2.0 oz
TF44157,00006CD –19–10MAY07–2/2

060807
PN=464
R134a Refrigerant Recover, Recycle, and 2

Charge Station Installation Procedure 8
ESSENTIAL TOOLS
JT02045 R134a Refrigerant Recovery/Recycling and Charging
1
Stationa
a
JT02046 and JT02050 recovery and charging stations can be
substituted for the JT02045 station. 18
1830
35
CAUTION: Do not remove high pressure relief
valve (A). Air conditioning system will 4
3
discharge rapidly causing possible injury.
IMPORTANT: Use correct refrigerant recovery, 5

recycling and charging stations. DO
NOT mix refrigerant, hoses, fittings,
components or refrigerant oils.
1. Close both high and low pressure valves on refrigerant

recovery, recycling and charging station (6). 7
–UN–11AUG00
2. Remove cap from low pressure test port (3). 6
T132733
3. Connect low pressure blue hose (5) from refrigerant
recovery, recycling and charging station (6) to low T132733
pressure test port (3) on compressor.
1—High Pressure Hose
4. Connect high pressure red hose (7) to high pressure 2—High Pressure Test Port
(quick disconnect) test port (2). 3—Low Pressure Test Port
4—Low Pressure Hose
5—Blue Hose
5. Follow the manufacturer’s instructions when using the 6—Refrigerant Recovery/Recycling and Charging
refrigerant recovery, recycling and charging station. Station
7—Red Hose
8—High Pressure Relief Valve
TF44157,00006CE –19–10MAY07–1/1

060807
PN=465
R134a System Recover Procedure 2

8
ESSENTIAL TOOLS
Stationa
a
1
substituted for the JT02045 station.
18
1830
36
valve (A). Air conditioning system will
discharge rapidly causing possible injury. 4
3
IMPORTANT: Use correct refrigerant recovery,
recycling and charging stations. DO 5
NOTE: Run the air conditioning system for three minutes

to help in the recovery process. Turn air
conditioning system off before proceeding with 7
–UN–11AUG00
recovery steps.
6
1. Connect refrigerant recovery, recycling and charging
station. See R134a Refrigerant Recover, Recycle, and
T132733
Charge Station Installation Procedure. (Group 1830.) T132733
2. Follow the manufacturer’s instructions when using the 1—High Pressure Hose
refrigerant recovery, recycling and charging station. 2—High Pressure Test Port
3—Low Pressure Test Port
4—Low Pressure Hose
5—Blue Hose
6—Refrigerant Recovery/Recycling and Charging
Station
7—Red Hose
TF44157,00006CF –19–10MAY07–1/1

060807
PN=466
R134a System Evacuate Procedure 2

8
SPECIFICATIONS
Vacuum Pressure at Sea Level 98 kPa (980 mbar) (29 in. Hg)
Vacuum Pressure Above Sea Subtract 3.4 kPa (34 mbar) (1 in.
1
Level Hg) from 98 kPa (980 mbar) (29
in. Hg) for each 300 m (1000 ft)
elevation
18
1830
ESSENTIAL TOOLS 37
Stationa 4
3
a
substituted for the JT02045 station.
5
discharge rapidly causing possible injury.
IMPORTANT: Use correct refrigerant recovery, 7
–UN–11AUG00
components or refrigerant oils. 6
T132733
Do not run compressor while T132733
evacuating.
1—High Pressure Hose
1. Connect refrigerant recovery, recycling and charging 2—High Pressure Test Port
station. See R134a Refrigerant Recover, Recycle, and 3—Low Pressure Test Port
Charge Station Installation. (Group 1830.) 4—Low Pressure Hose
5—Blue Hose
2. Open low and high pressure valves on refrigerant 6—Refrigerant Recovery/Recycling and Charging
Station
recovery, recycling and charging station. 7—Red Hose
3. Follow the manufacturer’s instructions and evacuate
the system.
NOTE: The vacuum specifications listed are for sea level

conditions. Subtract 3.4 kPa (34 mbar) (1 in. Hg)
from 98 kPa (980 mbar) (29 in. Hg) for each 300
m (1000 ft) elevation above sea level.
4. Evacuate system until low pressure gauge registers 98

kPa (980 mbar) (29 in. Hg) vacuum.
Continued on next page TF44157,00006D0 –19–10MAY07–1/2

060807
PN=467
If 98 kPa (980 mbar) (29 in. Hg) vacuum cannot be

obtained in 15 minutes, test the system for leaks. See
R134a System Leak Testing. (Group 1830.) Correct
any leaks.
Specification
Vacuum—Pressure at Sea Level .................................................... 98 kPa
980 mbar
18 29 in. Hg
1830 Pressure Above Sea Level ................... Subtract 3.4 kPa (34 mbar) (1 in.
38 Hg) from 98 kPa (980 mbar) (29
in. Hg) for each 300 m (1000 ft)
elevation
5. When vacuum is 98 kPa (980 mbar) (29 in. Hg), close

low-side and high-side valves. Turn vacuum pump off.
6. If the vacuum decreases more than 3.4 kPa (34 mbar)

(1 in. Hg) in 5 minutes, there is a leak in the system.
7. Repair leak.
8. Start to evacuate.
9. Open low-side and high-side valves.
10. Evacuate system for 30 minutes after 98 kPa (980

mbar) (29 in. Hg) vacuum is reached.
11. Close low-side and high-side valves. Stop evacuation.
12. Charge the system. See R134a System Charge

TF44157,00006D0 –19–10MAY07–2/2

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PN=468
R134a System Charge Procedure 2

8
SPECIFICATIONS
Refrigerant Weight 3.062 Kg (6.75 lbs)
1
ESSENTIAL TOOLS
Stationa 18
a
JT02046 and JT02050 recovery and charging stations can be 1830
substituted for the JT02045 station. 39
3 4
discharge rapidly causing possible injury. 5
IMPORTANT: Use correct refrigerant recovery,

7
–UN–11AUG00
1. Connect JT02045 R134a refrigerant recovery, recycling
and charging station. See R134a Refrigerant Recover, 6
Recycle, and Charge Station Installation Procedure.
T132733
(Group 1830.)
T132733
Procedure. (Group 1830.) 1—High Pressure Hose
2—High Pressure Test Port
NOTE: Before beginning to charge air conditioning 3—Low Pressure Test Port
system, the following conditions must exist: 4—Low Pressure Hose
5—Blue Hose
Engine STOPPED, the pump must be capable of 6—Refrigerant Recovery/Recycling and Charging
pulling at least 28.6 in. Hg vacuum (sea level). Station
Subtract 3.4 kPa (34 mbar) (1 in. Hg) from 98 kPa 7—Red Hose
(980 mbar) (29 in. Hg) for each 300 m (1000 ft) 8—High Pressure Relief Valve
elevation above sea level.
3. Follow the manufacturer’s instructions and charge the

system.
4. Add refrigerant until system is charged with 3.062 Kg

(6.75 lbs).
Specification
Refrigerant—Weight ..................................................................... 3.062 Kg
6.75 lbs
TF44157,00006D1 –19–10MAY07–1/1

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PN=469
R134a System Cleaning Procedure
Flushing: Flushing the system or component is a • TY16134 Air Conditioning System Flushing Solvent
cleaning process using a liquid solvent to remove oil
and debris. Purging is always necessary after flushing Purging: Purging the system or a component is a
to remove solvent from the system or component. cleaning process using a gas to force liquid from the
system. Purging alone will not remove refrigerant oil
18 Following is a list of situations that require a flushing from the system.
1830 procedure be done:
40 Following is a list of situations that require a purging
1. The compressor has an internal failure. procedure be done:
2. No oil remains in used compressor.
3. Oil drained from compressor appears or smells • After flushing system with solvent, to prevent oil
overheated. dilution
4. System was contaminated with a mixture of • System was contaminated with nitrogen or two
refrigerant oils. refrigerants.
5. System was left open to the atmosphere long • System was left open to the atmosphere and
enough for dirt, moisture, or debris to enter the flushing could not be performed.
tubing or components. • Installation of new lines, condenser, or evaporator
6. System has an internal blockage. was required.
The following solvent is recommended for flushing air Evacuating: Evacuating the system is a process to
conditioner systems. Use only solvents with an remove air and moisture from the system, creating a
equivalent MSDS. vacuum.
TF44157,00006D2 –19–10MAY07–1/1
R134a System Leak Testing
1. Inspect all lines, fittings, and components for oily or 3. If a leak detector is used, move the leak detector
dusty spots. When refrigerant leaks from the probe under the hoses and around the connections
system, a small amount of oil is carried out with it. at a rate of 25 mm (1 in.) per second.
2. A soap and water solution can be sprayed on the 4. Some refrigerant manufacturers add dye to
components in the system to form bubbles at the refrigerant to aid in leak detection.
source of the leak.
TF44157,00006D3 –19–10MAY07–1/1

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PN=470
R134a System Flush Procedure
SPECIFICATIONS Specification
Compressor Flushing Solvent—
Compressor Flushing Solvent 240 mL
Quantity (in discharge port) .................................................... 120 mL
Quantity (in suction port) 8 oz
4 oz
Compressor Flushing Solvent 120 mL
Quantity (in discharge port) 4 oz
Flusher Tank Capacity 4L 18
1 gal 1830
b. Turn compressor end for end and roll it side to
Regulated Air Pressure 620 kPa 41
side.
(minimum) 6.2 bar
90 psi
c. Remove both plugs from manifold ports and
Condenser Purging Time 10—12 Minutes
drain solvent from compressor.
ESSENTIAL TOOLS
d. Connect battery power to compressor clutch coil.
JT02075 Air Conditioning Flusher Rotate pulley at least five revolutions to move
JT02098 Fitting Kit solvent out of cylinders.
JT02099 and JT02100 with JT03194 Cap
JT02102 Adapter e. Invert compressor, roll end for end, and side to
side. Drain thoroughly.
SERVICE EQUIPMENT AND TOOLS
JT03188 Adapter
f. Let compressor sit inverted for three to five
minutes.
JT02101 Adapter
g. Repeat previous two steps at least three times.

Add flushing solvent to system with JT02075 Air
Conditioning Flusher and JT02098 Fitting Kit. 4. Remove and discard receiver-dryer.
NOTE: Flushing can be performed on vehicle. 5. Divide system into two circuits:
1. Recover refrigerant. See R134a System Recover a. Condenser, including inlet and outlet hoses.
Procedure. (Group 1830.) (Steps 6—12)
2. Remove compressor and measure oil drained from b. Evaporator, including inlet and outlet hoses.
both manifold ports. (Steps 13—26)
3. Clean compressor as follows: IMPORTANT: DO NOT attempt to flush through

compressor or receiver-dryer.
a. Pour specified amount of flushing solvent into Flushing through expansion valve is
suction port and Specified amount of flushing acceptable if refrigerant oil has
solvent into discharge port. Plug both ports in normal odor and appearance.
compressor manifold, using Caps.
6. To Flush/Purge Condenser:
Specification
Compressor Flushing Solvent—
Quantity (in suction port) ......................................................... 240 mL Connect flusher outlet hose to inlet end of
8 oz compressor discharge line using JT02102 Adapter.

060807
PN=471
7. Attach a return hose and aerator nozzle to outlet expansion valve, if oil appears normal. Remove
end of receiver-dryer inlet hose using JT03197 evaporator. See Evaporator Remove and Install.
Adapter. Put nozzle in container to collect flushing (Group 1830.)
solvent.
14. Force flushing solvent through evaporator inlet
8. Fill flusher tank with 4 L (1 gal) of solvent and with compressed air.
fasten all connections.
18 15. Purge system until dry.
1830 Specification
42 Flusher Tank—Capacity ................................................................. 4 L 16. Reinstall evaporator.
1 gal
17. Go to Step 22.

NOTE: Air pressure must be at least 620 kPa (6.2
bar) (90 psi) for flushing and purging.
18. To Flush Evaporator Through Expansion
Valve:
9. Connect a supply line of moisture-free compressed
air or dry nitrogen to flusher air valve. Adjust
Connect flusher outlet hose to connection of
regulator to specification.
receiver-dryer outlet hose using JT03188 Adapter.
Specification
Regulated Air—Pressure 19. Attach a hose and aerator nozzle to compressor
(minimum) ............................................................................... 620 kPa inlet line using JT02101 Adapter. Put nozzle in a
6.2 bar container to collect solvent.
90 psi
20. Repeat Steps 8, 9 and 10 to flush evaporator.
10. Open air valve to force flushing solvent into
condenser circuit. Flusher tank is empty when NOTE: Purging the evaporator circuit takes 12—15
hose pulsing stops. Additional flushing cycles are minutes to thoroughly remove solvent.
required if system is heavily contaminated with
burned oil or metal particles. 21. Disconnect hose from aeration nozzle to check
circuit for solvent. Hold hose close to a piece of
NOTE: Purging the condenser circuit takes 10—12 cardboard. Continue purging until cardboard is dry.
minutes to thoroughly remove solvent.
22. Install a new receiver-dryer compatible with R134a
Specification
Condenser Purging—Time ......................................... 10—12 Minutes
refrigerant. Tighten connections and mounting
bracket.
11. Disconnect hose from aeration nozzle to check
circuit for solvent. Hold hose close to a piece of 23. Add required oil. See R134a Component Oil
cardboard; continue purging until cardboard is dry. Charge Procedure. (Group 1830.)
12. Go to Step 13 to flush evaporator. Go to Step 22 if 24. Install compressor, and connect refrigerant lines to
evaporator does not require flushing. manifold.
13. To Flush Evaporator: 25. Connect clutch coil wire. Install drive belt.
If system is contaminated with burned refrigerant 26. Purge system. See R134a System Purge
oil or debris, remove and bench flush evaporator. Procedure. (Group 1830.)
Go to Step 18 to flush evaporator through
TF44157,00006D4 –19–08MAY07–2/2

060807
PN=472
R134a System Purge Procedure
SPECIFICATIONS 3. Connect gauge manifold discharge hose to

Nitrogen Purge Pressure (for 275 kPa compressor discharge post, and open valve.
two minutes) 2.75 bar Disconnect discharge hose from gauge manifold to
40 psi allow purging nitrogen to atmosphere.
4. Open nitrogen tank valve and adjust regulator to
IMPORTANT: Air compressors used for purging Specification. Purge system for two minutes. 18
systems require a water separator. Disconnect nitrogen supply. 1830
Purging without a separator adds 43
moisture, creating hydrofluoric acid Specification
when combined with refrigerant oil. Nitrogen Purge—Pressure (for
two minutes) ........................................................................... 275 kPa
Acid is corrosive to metal tubing.
2.75 bar
40 psi
1. Connect dry nitrogen hose to gauge manifold center
hose. 5. Evacuate system. See R134a System Evacuate
2. Connect gauge manifold suction hose to Procedure. (Group 1830.)
compressor suction port, and open valves.
TF44157,00006D5 –19–10MAY07–1/1

060807
PN=473
18
1830
44

060807
PN=474
Section 19
Sheet Metal and Styling
Contents
Page
Group 1910—Hood and Engine Enclosure

Hood and Engine Enclosure Disassemble
and Assemble . . . . . . . . . . . . . . . . . . . . . .19-1910-2
Group 1913—Miscellaneous Shields 19

Battery Box Disassemble and Assemble . . . .19-1913-2
Group 1921—Grille and Grille Housing

Grille and Grille Housing Disassemble and
Assemble. . . . . . . . . . . . . . . . . . . . . . . . . .19-1921-2
Group 1927—Fenders
Fenders and Cab Skirts Remove and
Install—If Equipped . . . . . . . . . . . . . . . . . .19-1927-1

060807
PN=1
Contents
19

060807
PN=2
Group 1910
Hood and Engine Enclosure
19
1910
1

060807
PN=477
Hood and Engine Enclosure Disassemble and Assemble
19
1910
2
–UN–09DEC06
TX1013669
Continued on next page KK70125,00007CA –19–08FEB07–1/2

060807
PN=478
1—Right Side Panel Assembly 14—Bracket 28—Compression Spring 42—Gas Operated Cylinder
2—Left Side Panel Assembly 15—Right Louver 29—Hood 43—Striker
3—Hood 16—Left Louver 30—Angle 44—Washer (2 used)
4—Nut (28 used) 17—Bracket 31—Guide 45—Washer (10 used)
5—Cap Screw (8 used) 18—Left Louver 32—Latch 46—Washer (3 used)
6—Cap Screw (4 used) 19—Nut (4 used) 33—Washer (28 used) 47—Washer (2 used)
7—Screw (8 used) 20—Grommet 34—Washer (4 used) 48—Screw (6 used)
8—Screw (16 used) 21—Bracket 35—Cap Screw (8 used) 49—Cap Screw (4 used)
9—Washer (40 used) 22—Snap Ring (2 used) 36—Cap Screw (2 used) 50—Cap Screw (2 used)
10—Bushing (2 used) 23—Washer 37—Cap Screw (2 used) 51—Cap Screw (2 used)
11—Right Louver 24—Bolt (2 used) 38—Cap Screw (4 used) 52—Cap Screw (2 used)
12—Insert 25—Right Guide 39—Nut (16 used) 53—Flange Nut (2 used)
13—Protective Coating 26—Left Guide 40—Support 54—Nut
Material (2 used) 27—Extension Spring (2 used) 41—Prop Rod
1. Raise loader and install boom lock bar. Stationary Hood—Torque ..................................................... 36.5 N•m 19
27 lb-ft 1910
Hood Latch and Strike Pin— 3
2. Remove grille. Torque................................................................................... 11.3 N•m
100 lb-in
3. Move hood to full open position. Side Panel Louver—Torque
Turn....................................................................... Snug Plus 1/4 Turn
4. Disconnect extension springs (27) at upper hook. Pivot Bracket-to-Side Panel—
Torque................................................................................... 11.3 N•m
100 lb-in.
5. Remove end cap at upper cylinder (42) mount and M5 Hood and Side Panel
disconnect cylinder. Screw—Torque ...................................................................... 5.6 N•m
50 lb-in
6. Remove lock ring (22), washers (46), and M6 Hood and Side Panel
Screw—Torque ....................................................................... 7.9 N•m
compression spring (28) at bar (41) . 70 lb-in
IMPORTANT: Second person should hold hood 13. Position hood (3) and prop rod (41) with second
assembly before hood pivot cap person and install pivot cap screws (24). Torque
screw is removed. nut (53) to specifications.
7. Remove nut and washer (53 and 44). With second Specification
person holding hood remove pivot cap screw (24). Hood and Engine Enclosure
Nut—Torque ............................................................................ 65 N•m
8. Disconnect hood prop rod (41) and remove hood. 48 lb-ft
9. Disassemble parts as shown. .
10. Inspect parts and replace if necessary. 14. Install lock ring (22), washers (46), and spring (28)
at rod (41) .
11. Tape prop rod and cylinder to cover to aid
assembly. 15. Install cylinder and end cap lock.
12. Tighten components to specification. 16. Install extension springs (27).
Hood and Side Shields—Specification

Hood-to-Side Shield—Torque................................................. 7.9 N•m
70 lb-in
KK70125,00007CA –19–08FEB07–2/2

060807
PN=479
19
1910
4

060807
PN=480
Group 1913
Miscellaneous Shields
19
1913
1

060807
PN=481
Battery Box Disassemble and Assemble
19
1913
2
–UN–18DEC06
TX1015821
Battery Box
Continued on next page KK70125,00007CB –19–08FEB07–1/2

060807
PN=482
1—Anti-Skid Pad 4—Latch 7—Cap Screw (4 used) 10—Washer

2—Tool Box 5—Angle 8—Washer (6 used) 11—Reflector
3—Rivet (5 used) 6—Battery Box 9—Cap Screw (4 used) 12—JDG1385 Tool
Inspect for worn or damaged parts and replace if

necessary.
KK70125,00007CB –19–08FEB07–2/2
19
1913
3

060807
PN=483
19
1913
4

060807
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Group 1921
Grille and Grille Housing
19
1921
1

060807
PN=485
Grille and Grille Housing Disassemble and Assemble
19
1921
2
–UN–16NOV06
TX1013701
Grill and Grill Housing

Continued on next page KK70125,00007CC –19–08FEB07–1/2

060807
PN=486
1—Frame 5—Cap Screw (4 used) 9—Screen Assembly 13—Nut (4 used)

2—Grille 6—Washer (4 used) 10—Screen 14—Cap Screw (4 used)
3—Bumper (2 used) 7—Nut (4 used) 11—Isolator 15—Washer (8 used)
4—Washer (4 used) 8—Cap Screw (4 used) 12—Guard Assembly 16—Bumper (2 used)
1. Raise loader and install boom lock bar. 4. Assemble parts.
2. Disassemble parts as shown. 5. Remove boom lock bar.
3. Inspect parts and replace if necessary.
KK70125,00007CC –19–08FEB07–2/2
19
1921
3

060807
PN=487
19
1921
4

060807
PN=488
Group 1927
Fenders
Fenders and Cab Skirts Remove and Install—If Equipped
19
1927
1
–UN–17OCT00
T134034
1—Left Fender 4—Cap Screw (12 used) 6—Left Shirt (if equipped) 8—Washer (4 used)
2—Washer (24 used) 5—Right Fender 7—Right Skirt (if equipped) 9—Cap Screw (4 used)
3—Lock Nut (12 used)
1. Disassemble parts as shown. 2. Inspect parts and replace as necessary.
KK70125,00007CD –19–08FEB07–1/1

060807
PN=489
Fenders
19
1927
2

060807
PN=490
Section 20
Safety, Convenience and Miscellaneous
Contents
Page
Group 2001—Radio
Radio Remove and Install . . . . . . . . . . . . . . .20-2001-1
Antenna Remove and Install . . . . . . . . . . . . .20-2001-2
Radio Speakers and Antenna Remove
and Install . . . . . . . . . . . . . . . . . . . . . . . . .20-2001-4
Group 2004—Horn and Warning Devices

Horn Remove and Install. . . . . . . . . . . . . . . .20-2004-1
Backup Alarm Remove and Install. . . . . . . . .20-2004-2
Backup Alarm Volume Adjustment . . . . . . . .20-2004-3 20

060807
PN=1
Contents
20

060807
PN=2
Group 2001
Radio
Radio Remove and Install
1. Remove rear view mirror (1).
2. Release center pin on retainer (2) to remove retainer

and headliner.
1—Mirror
2—Retainer (9 used)
–UN–19OCT00
T134697B
20
KK70125,00007CE –19–07FEB07–1/2 2001
1
3. Disconnect antenna coaxial cable (3) and radio wiring

harness connector (2).
4. Remove cap screws (1) to remove radio mounting

bracket (4) and radio.
–UN–19OCT00
5. Remove radio from mounting bracket.
6. Install radio with mounting bracket.
T134695B
7. Connect antenna coaxial cable and radio wiring
harness.
8. Install headliner and rear view mirror. 1—Cap Screw

2—Wire Harness Connector
3—Antenna Coaxial Cable
KK70125,00007CE –19–07FEB07–2/2

060807
PN=493
Radio
Antenna Remove and Install
1. Loosen screw (2) and move antenna to horizontal

position.
2. Remove nut (3) and slide over antenna to remove

antenna base from bracket.
3. Remove headliner.
4. Disconnect antenna cable from radio.
5. From outside cab pull cable through grommet in cab.
6. Install cable through grommet in cab and connect to

radio.
7. Install headliner.
20
8. Install antenna, lock washers and nuts.
–UN–12MAR07
2001
2
9. Move antenna to upright position and tighten screw to
specification.
TX1018659A
Specification
Antenna Pivot Screw—Torque ...................................................... 1.3 N•m
12 lb-in.
Antenna
1—Antenna Mast
2—Pivot Screw
3—Nut and Washer
KK70125,00007CF –19–07FEB07–1/1

060807
PN=494
Radio
20
2001
3

060807
PN=495
Radio
Radio Speakers and Antenna Remove and Install
20
2001
4
–UN–18DEC06
TX1014614
Radio Speakers and Antenna

Continued on next page KK70125,00007D0 –19–07FEB07–1/2

060807
PN=496
Radio
1—Antenna 6—Wire Harness 11—Radio 16—Radio Assembly

2—Bracket 7—Bracket 12—Cap Screw (2 used) 17—Plug (9 used)
3—Headliner 8—Nut (6 used) 13—Washer (2 used) 18—Washer
4—Cap Screw (6 used) 9—Speaker (2 used) 14—Bracket 19—Lamp
5—Grommet 10—Screw (6 used) 15—Bracket 20—Cap Screw
1. Disassemble parts as shown. 2. Inspect parts and replace as necessary.
KK70125,00007D0 –19–07FEB07–2/2
20
2001
5

060807
PN=497
Radio
20
2001
6

060807
PN=498
Group 2004
Horn and Warning Devices
Horn Remove and Install
NOTE: Horn is located in the front and center above

radiator in engine compartment.
1. Open hood.
2. Disconnect wire leads.
KK70125,00007D4 –19–07FEB07–1/2
20
2004
1
–UN–29APR02
T154411
Horn
1—Nut 2—Washer 3—Bolt 4—Horn
3. Remove nut and bolt (1 and 3) to remove horn (4). 5. Connect wire leads.
4. Install horn and tighten nut.

KK70125,00007D4 –19–07FEB07–2/2

060807
PN=499
Backup Alarm Remove and Install
20
2004
2
–UN–01OCT02
T160036
Backup Alarm
Continued on next page KK70125,00007D5 –19–07FEB07–1/2

060807
PN=500
1—Backup Alarm 4—Lock Nut 6—Cap Screw (2 used) 8—Cap Screw

2—Lock Nut (2 used) 5—Bracket 7—Washer 9—Lock Washer (2 used)
3—Washer (2 used)
NOTE: Backup alarm is located on inside of left rear 3. Install backup alarm using cap screws.
of main frame.
4. Connect wire leads.
1. Disconnect wire leads.
2. Remove two cap screws (6) to remove backup

alarm (1).
KK70125,00007D5 –19–07FEB07–2/2
Backup Alarm Volume Adjustment
IMPORTANT: The backup alarm is set on high volume

at the factory. It may be necessary to
adjust the volume to meet local 20
regulations. 2004
–UN–20MAY91
3
1. To change alarm to low volume, leave ground wire

attached to ground terminal (—NEG) (A). Remove nut
(B) and disconnect wire from high terminal (+HI) (F).
T7530AV
2. Remove nut (C) and shorting bar (E).
3. Attach wire to low terminal (+LO) (D). Install nut (C) A—Ground Terminal (—NEG)
B—Nut
and tighten securely. Save shorting bar (E) for future
C—Nut
use. D—Low Terminal (+LO)
E—Shorting Bar
F—High Terminal (+HI)
KK70125,00007D6 –19–25JAN07–1/1

060807
PN=501
20
2004
4

060807
PN=502
Section 21
Main Hydraulic System
Contents
Page

Hydraulic Pump Remove and Install . . . . . . .21-2160-1
Hydraulic Pump Disassemble and
Assemble. . . . . . . . . . . . . . . . . . . . . . . . . .21-2160-6
Hydraulic Pump Control Disassemble and
Assemble. . . . . . . . . . . . . . . . . . . . . . . . . .21-2160-8
Power Limiting Valve Remove and Install . . .21-2160-9
Hydraulic Filter Assembly Remove and
Install. . . . . . . . . . . . . . . . . . . . . . . . . . . .21-2160-11
Hydraulic Reservoir Remove and Install . . .21-2160-13
Hydraulic Reservoir Disassemble and
Assemble. . . . . . . . . . . . . . . . . . . . . . . . .21-2160-18
Hydraulic and Transmission Oil Coolers
21

060807
PN=1
Contents
21

060807
PN=2
Group 2160
Hydraulic System
Hydraulic Pump Remove and Install
IMPORTANT: Do pump flow test before removing

hydraulic pump for repair. See
Hydraulic Pump Flow Test. (Group
9025-25.) If pump does not meet test
specification, replace it. Do not rebuild
pump.
NOTE: The only serviceable parts are seal kits and

O-rings.
1. Lower all attachments to the ground.
2. Stop engine

21
2160
1
TF44157,00006D6 –19–10MAY07–1/5

–UN–23AUG88
4. Drain hydraulic reservoir.
Specification
Hydraulic Reservoir—Capacity
X9811
(approximate)....................................................................................... 37 L
9.8 gal

060807
PN=505
Hydraulic System
5. Remove cab floor mat and floor access plate (2).
6. Remove rear drive shaft. See Drive Shaft Remove and


–UN–27SEP00
T133998B
21
2160
2

060807
PN=506
Hydraulic System
1
5
4
8
9
12
7
21
2160
3
11 7
–UN–15JUN05
10 4 6
T211317
T211317
Hydraulic Pump Removal
1—Power Limiting Valve 6—Quick Coupler Test Fitting 8—Hydraulic 10—Attachment Coupler Valve
2—Main Hydraulic Pump on Hydraulic Pump-to-Backhoe Control (optional)
3—Hydraulic Pump Case Pump-to-Attachment Valve (or attenuator if 11—Hydraulic
Drain-to-Hydraulic Coupler Valve Hose (if equipped with a cab) Reservoir-to-Hydraulic
Reservoir Hose equipped) 9—Hydraulic Pump-to-Power Pump Suction Hose
4—Hydraulic Pump Mounting 7—Four Bolt Flange Cap Limiting Valve Hose 12—Clamp
Cap Screws (2 used) Screws (4 used)
5—Hydraulic
Pump-to-Attachment
Coupler Valve Hose (if
equipped)
7. Remove four bolt flange cap screws (7) and 9. Disconnect hydraulic pump-to-attachment coupler
hydraulic reservoir-to-hydraulic pump suction hose valve hose (optional) (5). Cap or plug all openings.
(11). Cap or plug all openings.
10. Disconnect hydraulic pump-to-power limiting valve
8. Disconnect hydraulic pump case drain-to-hydraulic hose (9). Cap or plug all openings.
reservoir hose (3). Cap or plug all openings.

060807
PN=507
Hydraulic System
11. Remove hydraulic pump-to-backhoe control valve 20. Install hydraulic reservoir-to-hydraulic pump
line (8). Cap or plug all openings. suction hose (11) with four bolt flange cap screws
(7).
12. Attach lifting strap and hoist to hydraulic pump.
IMPORTANT: Applies to 410J and 710J only.
Whenever main hydraulic pump or
hydraulic reservoir have been
from heavy object. Use an appropriate lifting
drained, refill hydraulic pump case
device.
before start up. See Hydraulic Oil.
13. Remove hydraulic pump mounting cap screws (4)
and remove main hydraulic pump (2).
21. Fill hydraulic pump case with hydraulic oil through
Specification hydraulic pump case drain-to-hydraulic reservoir
Hydraulic Pump—Weight..................................... 36 kg (approximate) fitting.
80 lb (approximate)
22. Install hydraulic pump case drain-to-hydraulic
14. Repair or replace main hydraulic pump (2) as reservoir hose (3).
necessary. See Hydraulic Pump Disassemble and
Assemble. (Group 2160.) 23. Refill hydraulic reservoir. See Check Hydraulic
Reservoir Oil Level. (Operator’s Manual.)
15. Install new O-ring between main hydraulic pump
and transmission. 24. Install rear drive shaft. See Drive Shaft Remove
16. Install main hydraulic pump (2) with hydraulic
21 pump mounting cap screws (4). 25. Switch battery disconnect to on (if equipped) or
2160
4
17. Install hydraulic pump-to-backhoe control valve
line (8). 26. Start engine and check for leaks.
18. Install hydraulic pump-to-power limiting valve hose

(9).
19. Install hydraulic pump-to-attachment coupler valve

hose (optional) (5).
TF44157,00006D6 –19–10MAY07–5/5

060807
PN=508
Hydraulic System
21
2160
5

060807
PN=509
Hydraulic System
Hydraulic Pump Disassemble and Assemble
2
1 3
21
2160
6
17 18
16
15
11
8 10
9
14
12
–UN–28JUN05
13
T212068
T212068
Pump Assembly Exploded View

060807
PN=510
Hydraulic System
1—Snap Ring 6—Drive Shaft 11—Bearing 15—Cap Screw (4 used)

2—Seal 7—Rotate Group 12—O-ring (4 used) 16—Gasket
3—Pump Housing 8—Bias Piston 13—Control Piston 17—Pump Control
4—O-ring 9—Seal 14—Valve End Plate 18—Cap Screw (4 used)
5—Bearing 10—Shim
NOTE: Internal components of the hydraulic pump and IMPORTANT: Mark orientation of valve end plate
rotate group are not serviced individually. before disassembly.
Entire pump and rotate group are serviced as
one assembly. Service parts available are the 2. Mount pump on D01006AA Bench Mounted Holding
following: complete pump, control valve for Fixture. Remove cap screws (15) and pump valve
pump, pump seal kit and pump control seal kit. end plate (14). Inspect valve plate for cracks or
scratches. Remove O-rings (4 & 12).
NOTE: Drive shaft seal (2) can be removed without
disassembling pump and shaft. Remove snap 3. Remove and replace O-rings (4 and 12).
ring. Using a small screw driver tap edge of
seal to allow removal. 4. Replace cap screws (15) and pump valve end plate
(14).
5. Remove snap ring (1) and seal (2).
from heavy object. Use an appropriate lifting
device.
Specification
Hydraulic Pump—Weight
(approximate) .............................................................................. 33 kg
73 lb 21
2160
7
1. Remove four cap screws (18), pump control (17)
and gasket (16). See Hydraulic Pump Control
TF44157,00006D7 –19–10MAY07–2/2

060807
PN=511
Hydraulic System
Hydraulic Pump Control Disassemble and 1

Assemble
1
2
NOTE: Pump control is serviced as complete assembly or
a seal kit only. 22
2
IMPORTANT: When removing adjusting screws and 3
O-rings make note to retain current
settings.
23
1. Remove complete adjustment screw assemblies by 4
removing fittings (4 and 23) with all adjusting parts in
place. Replace O-ring (5 and 21). Install adjustment 5
assemblies in housing. Tighten in housing (14) port. 21
20 19
2. Remove adjustment covers (1) for load sense and high
pressure cut off screws (3). 6
18
7
3. Remove lock nuts (22) and O-rings (2) being careful
17
not to lose current settings. Replace O-rings.
8
4. Install lock nuts, O-rings and adjustment covers. 16
9
5. Install control on hydraulic pump housing.
21
2160 1—Cap (adjustment screw) 15
10
8
3—Adjustment Screw (2 used)
4—Fitting
5—O-ring
6—Spring 11
7—Spring 14
8—Guide
9—Spool (load sense)
10—Plug
11—Plug
13—Plug (2 used)
–UN–23JUN05
14—Control Housing
15—Spool (high pressure cut-off) 12
16—Guide
17—Spring
18—Spring
13
T211883
19—Spacer
13 12
20—Spacer
21—O-ring Pump Control Exploded View
22—Hex Nut (2 used)
23—Fitting
TF44157,00006D8 –19–10MAY07–1/1

060807
PN=512
Hydraulic System
Power Limiting Valve Remove and Install
NOTE: Failure of the power limiting valve will cause loss

of hydraulic power or engine stalling when
applying hydraulic load. The power limiting valve
is serviced as a complete valve assembly which
–UN–23AUG88
includes the solenoid cartridge. If power limiting
function is not working properly due to solenoid
failure replace complete valve with solenoid.
X9811
1. Lower all equipment to the ground.
2. Stop engine.
3. Release hydraulic pressure. See Hydraulic Circuit

Pressure Release. (Group 9025-25.)
4. Switch battery disconnect to off (if equipped) or 21

disconnect the battery ground cable. 2160
9

060807
PN=513
Hydraulic System
1
4
2
6
3
–UN–10JUN05
T211318
21 T211318
2160 Power Limiting Valve Removal
10
1—Power Limiting 3—Power Limiting 5—Attachment Coupler 6—Quick Coupler Test Fitting
Valve-to-Loader Control Valve-from-Pump Control Valve-to-Power Limiting
Valve Hose (load sense in) Hose (load sense out) Valve Hose (optional)
2—Power Limiting Valve 4—Power Limiting
Valve-to-Hydraulic
Reservoir Hose
5. Pinch off power limiting valve-to-hydraulic reservoir 11. Connect wire lead to solenoid.
hose (4) and remove hose. Cap or plug all
openings. 12. Connect hoses (1,2,3,4 and 5).
6. Disconnect hoses (1,3 and 5) and cap or plug all 13. Remove device used to pinch off power limiting
openings valve-to-hydraulic reservoir hose (4).
7. Disconnect wire lead from solenoid on power 14. Switch battery disconnect on (if equipped) or
limiting valve (2). install battery ground cable.
8. Remove power limiting valve (2). 15. Check hydraulic reservoir oil level. See Check
Hydraulic Reservoir Oil Level. (Operator’s
9. Repair or replace power limiting valve (2). Manual.)
10. Install power limiting valve (2). 16. Start the machine and check for leaks.
TF44157,00006D9 –19–10MAY07–2/2

060807
PN=514
Hydraulic System
Hydraulic Filter Assembly Remove and

Install

–UN–23AUG88
X9811
2. Stop engine. Release pressure in hydraulic system.
See Hydraulic Circuit Pressure Release. (Group
9025-25.)

21
2160
11
Continued on next page TF44157,00006DA –19–10MAY07–1/2

060807
PN=515
Hydraulic System
4. Rotate hydraulic filter (5) counterclockwise to remove.
5. Disconnect lines (1, 3, 4, and 6).

7 2
6. Tag all lines. Close all openings with caps and plugs. 2 4
7. Disconnect wire lead from pressure switch (7). 3
1
8. Remove cap screws (2) and remove hydraulic filter
assembly. 6
5
–UN–07MAR07
9. Inspect and replace parts as necessary .
10. Install filter assembly and cap screws (2).
TX1018209
11. Install wire lead for pressure switch (7).
12. Connect lines (1, 3, 4, and 6).

1—Backhoe Control Valve-to-Filter Hydraulic
Hose
13. Apply clean hydraulic oil to filter seal. Turn hydraulic 2—Cap Screws (4 used)
filter (5) clockwise until seal touches base and tighten 3—Hydraulic Filter-to-Hydraulic Oil Cooler
additional 3/4 turn. Hydraulic Hose
4—Hydraulic Filter-to-Hydraulic Reservoir
14. Check hydraulic oil level. See Check Hydraulic Hydraulic Hose
21 5—Hydraulic Filter
Reservoir Oil Level. (Operator’s Manual) 6—Loader Control Valve-to-Hydraulic Filter
2160
12 Hydraulic Hose
15. Switch battery disconnect to on (if equipped) or 7—Pressure Switch
TF44157,00006DA –19–10MAY07–2/2

060807
PN=516
Hydraulic System
Hydraulic Reservoir Remove and Install
1. Lower all attachments to the ground. Stop engine.
2. Release pressure in hydraulic system. See Hydraulic

Circuit Pressure Release. (Group 9025-25.)

4. Remove cab. See Cab/ROPS Remove and Install.

(Group 1800.)
5. Drain hydraulic reservoir.
Specification
Hydraulic Reservoir—Capacity............................................................ 21 L
5.5 gal
21
2160
13
TF44157,00006DB –19–10MAY07–1/5
6. Remove cowling.
7. Disconnect vent hose (1) from hydraulic reservoir fill

tube.
–UN–15SEP00
1—Vent Hose
T133790B
Continued on next page TF44157,00006DB –19–10MAY07–2/5

060807
PN=517
Hydraulic System
8. Remove hydraulic level gauge (2).
9. Remove isolator (1)
1—Isolator
2—Hydraulic Level Gauge
3—Plugs (5 each)
–UN–31MAR07
TX1018462
21
2160
14

060807
PN=518
Hydraulic System

–UN–23AUG88
10. Disconnect hoses (4—8, 10,11). Close all openings
11. If necessary, remove hoses (9 and 12). Close all
X9811
CAUTION: The approximate weight of reservoir

is 27 kg (60 lb).
Specification
Hydraulic Reservoir—Weight
(approximate)..................................................................................... 27 kg
–UN–31MAR07
60 lb
12. Install JT01748 Lifting Bracket (2) and a hoist.
TX1018476
21
14. Remove hydraulic reservoir with bottom of reservoir 2160
tilted toward rear of machine. 1—Cap Screw (3 used) 15
2—JT01748 Lifting Bracket
15. Repair or replace as necessary. 3—Cap Screw, Washer, and Spacer
4—Hydraulic Reservoir-to-Hydraulic Pump Hose
5—Hydraulic Reservoir-to-Power Limiting Valve
16. Move hydraulic reservoir into position with bottom of Hose
reservoir tilted toward rear of machine. 6—Hydraulic Reservoir-to-Ride Control Valve
Hose (optional)
17. Install cap screws (1 and 3). 7—Hydraulic Reservoir-to-Hydraulic Pump Case
Drain Hose
8—Hydraulic Reservoir-to-Backhoe Control Valve
18. Remove hoist and lifting bracket. Hose
9—Hydraulic Reservoir-to-Brake Valve Hose
19. If necessary, install hoses (9 and 12). 10—Hydraulic Reservoir-to-Hydraulic Oil Filter
Hose
11—Hydraulic Reservoir-to-Hydraulic Oil Cooler
20. Install hoses (4—8, 10,11).
Hose
12—Hydraulic Reservoir Drain Line
21. Install isolator.
22. Connect vent hose to hydraulic reservoir fill tube.
23. Install cowling.
24. Install cab. See Cab/ROPS Remove and Install.

(Group 1800.)

060807
PN=519
Hydraulic System
25. Fill hydraulic reservoir. See Check Hydraulic


TF44157,00006DB –19–10MAY07–5/5
21
2160
16

060807
PN=520
Hydraulic System
21
2160
17

060807
PN=521
Hydraulic System
Hydraulic Reservoir Disassemble and Assemble
21
2160
18
–UN–20DEC06
TX1014897
Continued on next page TF44157,00006DC –19–10MAY07–1/2

060807
PN=522
Hydraulic System
1—Cap Screw (4 each) 5—Air Filter 9—Hydraulic Reservoir 12—Fitting (3 each)

2—Washer 6—Strainer 10—Filler Cap 13—Vent Hose
3—Washer (3 each) 7—Level Gauge 11—O-ring (3 each) 14—Spacer
4—Hose Clamp (2 each) 8—Clamp (2 each)
Remove and replace parts as necessary.
TF44157,00006DC –19–10MAY07–2/2
Hydraulic and Transmission Oil Coolers

Remove and Install
Lower Hydraulic Oil Cooler Remove
–UN–23AUG88
connections before applying pressure. 21
X9811
2160
19

9025-25.)
Continued on next page TF44157,00006DD –19–10MAY07–1/11

060807
PN=523
Hydraulic System
2
4 3
8
2
8
5
21
6 7
2160
20
8
8
6
3
8 7 5 8
–UN–07MAR07
TX1018194
TX1018194

060807
PN=524
Hydraulic System
1—Hydraulic 3—Hydraulic Oil Cooler 5—Coolant Hose 8—Cap Screws and

Hose-to-Hydraulic (upper), Hydraulic Oil 6—Coolant Hose-to-Radiator Nuts-to-Mounting Plate (9
Reservoir Cooler (lower) (410J, 410J 7—Mounting Plate Cap Screws each)
2—Transmission TMC and 710J only) (3 each) 9—Transmission Oil Cooler
Hose-to-Transmission (2 4—Hydraulic Oil Hose
used)
3. Disconnect hydraulic hose (4) on hydraulic cooler. 3. Connect coolant hoses-to-hydraulic cooler (5).
Cap and plug all openings.
4. Connect hydraulic hose-to-hydraulic cooler (4).
4. Clamp off and disconnect coolant hoses (5) on
hydraulic cooler. Cap and plug all openings. 5. Check hydraulic and coolant levels. See Check
Hydraulic Reservoir Oil Level. See Check Coolant
5. Loosen mounting plate cap screws (7) and unhook Level. (Operator’s Manual.)
mounting plate from cap screws.
6. Operate machine to check for leaks.
6. Remove cap screws and nuts (8) from hydraulic
cooler. Upper Hydraulic Cooler Remove
7. Remove hydraulic cooler (4) from mounting plate. 1. Lower all equipment to ground.
8. Repair or replace as necessary. 2. Stop engine. Release pressure in hydraulic system.

Lower Hydraulic Oil Cooler Install 9025-25.)
1. Install hydraulic cooler (4) with cap screws and 3. Remove front floor mat. 21
2160
nuts-to-mounting plate (8). 21
2. Hook mounting plate back on cap screws (7).

Tighten cap screws.
TF44157,00006DD –19–10MAY07–3/11
4. Remove floor access plates (1) and (2).

2—Floor Access Plate –UN–27SEP00
T133998B

060807
PN=525
Hydraulic System
5. Remove cap screws-to-park brake line clamp (1).
1—Cap Screw-to-Park Brake Line Clamp (2 used)

2—Park Brake Line
3—Park Brake Line-to-Park Brake
–UN–07MAR07
TX1018199
TF44157,00006DD –19–10MAY07–5/11

–UN–23AUG88
6. Disconnect park brake line-to-park brake (3) and move
away from upper hydraulic cooler.
21
X9811
2160
22

060807
PN=526
Hydraulic System
21
2160
23

060807
PN=527
Hydraulic System
2
4 3
8
2
8
5
21
6 7
2160
24
8
8
6
3
8 7 5 8
–UN–07MAR07
TX1018194
TX1018194

060807
PN=528
Hydraulic System

used)
7. Disconnect hydraulic hoses (1,4) on hydraulic 3. Connect coolant hoses-to-hydraulic cooler (5,6).
cooler. Cap and plug all openings.
4. Connect hydraulic hoses-to-hydraulic cooler (1,4).
8. Clamp off and disconnect coolant hoses (5,6) on
hydraulic cooler. Cap and plug all openings. 5. Connect transmission-to-park brake line at the park
brake.
9. Loosen mounting plate cap screws (7) and unhook
mounting plate from cap screws. 6. Install park brake line clamp.
10. Remove cap screws and nuts (8) from hydraulic 7. Install floor access plates.
cooler.
8. Replace front floor mat.
11. Remove hydraulic cooler (3) from mounting plate.
9. Check hydraulic and coolant levels. See Check
12. Repair or replace as necessary. Hydraulic Reservoir Oil Level. See Check Coolant
Level. (Operator’s Manual.)
Upper Hydraulic Cooler Install
1. Install hydraulic cooler (3) with cap screws and 21
2160
nuts-to-mounting plate (8). 25
2. Hook mounting plate back on cap screws (7).

Tighten cap screws.
TF44157,00006DD –19–10MAY07–8/11
Transmission Oil Cooler Remove and Install

–UN–23AUG88

X9811

9025-25.)

060807
PN=529
Hydraulic System
2
4 3
8
2
8
5
21
6 7
2160
26
8
8
6
3
8 7 5 8
–UN–07MAR07
TX1018194
TX1018194

060807
PN=530
Hydraulic System

used)
3. Disconnect transmission hoses (2) on transmission 10. Hook mounting plate back on cap screws (7).
cooler (9). Cap and plug all openings. Tighten cap screws.
4. Clamp off and disconnect coolant hoses (5,6) on 11. Connect coolant hoses on transmission cooler
transmission cooler. Cap and plug all openings. (5,6).
5. Loosen cap screws (7) on mounting plate and 12. Connect transmission hoses (2) on transmission
unhook mounting plate from cap screws. cooler (9).
6. Remove cap screws and nuts-to-mounting plate (8). 13. Check transmission and coolant levels. See Check
Transmission Oil Level. See Check Coolant Level.
7. Remove transmission cooler (9) from mounting (Operator’s Manual.)
plate.
8. Repair or replace as necessary.
9. Install transmission cooler (9) with cap screws and

nuts-to-mounting plate (8).
21
2160
27
TF44157,00006DD –19–10MAY07–11/11

060807
PN=531
Hydraulic System
21
2160
28

060807
PN=532
Section 31
Loader
Contents
Page Page
Group 3100—Loader Loader Auxiliary Circuit Relief Valve

Loader Boom Remove and Install . . . . . . . . .31-3100-1 Disassemble and Assemble. . . . . . . . . . .31-3160-13
Loader Auxiliary Shutoff Plug Disassemble
Group 3102—Bucket and Assemble . . . . . . . . . . . . . . . . . . . . .31-3160-14
Loader Bucket Remove and Install . . . . . . . .31-3102-1 Loader Bucket Cylinder Remove and
Loader Bucket Install. . . . . . . . . . . . . . . . . . . . . . . . . . . .31-3160-15
Repair Cracked Cutting Edge . . . . . . . . . .31-3102-1 Loader Bucket Cylinder Disassemble and
Remove and Install Cutting Edge. . . . . . . .31-3102-2 Assemble. . . . . . . . . . . . . . . . . . . . . . . . .31-3160-16
Loader Multi-Purpose Bucket and Lines Loader Multi-Purpose Bucket Cylinder
Disassemble and Assemble. . . . . . . . . . . .31-3102-8 Disassemble and Assemble. . . . . . . . . . .31-3160-16
Loader Boom Cylinder Remove and
Install. . . . . . . . . . . . . . . . . . . . . . . . . . . .31-3160-17
Group 3104—Attachment Coupler
Loader Boom Cylinder Disassemble and
Attachment Coupler Remove and Install . . . .31-3104-1
Assemble. . . . . . . . . . . . . . . . . . . . . . . . .31-3160-18
Attachment Coupler Cylinder Remove and
Ride Control Valve Remove and Install . . . .31-3160-18
Install. . . . . . . . . . . . . . . . . . . . . . . . . . . . .31-3104-3
Ride Control Valve Disassemble and
Attachment Coupler Cylinder Disassemble
Assemble. . . . . . . . . . . . . . . . . . . . . . . . .31-3160-22
and Assemble . . . . . . . . . . . . . . . . . . . . . .31-3104-4
Ride Control Valve Solenoid Disassemble
and Assemble . . . . . . . . . . . . . . . . . . . . .31-3160-24
Group 3115—Control Linkages Ride Control Accumulator Remove and
Loader Control Valve Linkage Remove Install. . . . . . . . . . . . . . . . . . . . . . . . . . . .31-3160-25 31
and Install . . . . . . . . . . . . . . . . . . . . . . . . .31-3115-1
Third Function Loader Control Valve
Linkage Remove and Install. . . . . . . . . . . .31-3115-3
Stabilizer Linkage Remove and Install. . . . . .31-3115-5
Loader Bucket Linkage Remove and
Install. . . . . . . . . . . . . . . . . . . . . . . . . . . . .31-3115-7

Loader and Stabilizer Control Valve Remove
and Install . . . . . . . . . . . . . . . . . . . . . . . . .31-3160-1
Loader and Stabilizer Control Valve
Disassemble and Assemble. . . . . . . . . . . .31-3160-3
Loader and Stabilizer Control Valve Relief
Valves Remove and Install . . . . . . . . . . . .31-3160-8
Loader and Stabilizer Control Valve Load
Sense Relief Valve Disassemble and
Assemble. . . . . . . . . . . . . . . . . . . . . . . . .31-3160-10
Loader Boom Raise and Bucket Curl
Circuit Relief Valve Disassemble and
Assemble. . . . . . . . . . . . . . . . . . . . . . . . .31-3160-11
Bucket Dump Circuit Relief Valve With
Anti-Cavitation
Disassemble and Asemble. . . . . . . . . . . .31-3160-12
Anti-Cavitation Valve

060807
PN=1
Contents
31

060807
PN=2
Group 3100
Loader
Loader Boom Remove and Install
Loader Boom Remove
1. Lower all equipment to ground. Stop engine.

3. Remove loader bucket, if necessary. See Loader

Bucket Remove and Install. (Group 3102)
4. Remove loader bucket linkage, if necessary. See

Loader Bucket Linkage Remove and Install. (Group
3115.)
TF44157,00006DE –19–10MAY07–1/6

device.
Specification
–UN–31MAR07
Loader Boom Cylinder—Weight
(approximate)..................................................................................... 37 kg
81 lb
31
TX1018830A
NOTE: Remove loader boom cylinders if necessary. See 3100
1
Loader Boom Cylinder Remove and Install.
(Group 3160)
5. On both sides of the machine, support the weight of 1—Loader Boom Cylinder (2 each)
the loader boom cylinders (1). 2—Pin (2 each)
3—Cap Screw (2 each)
6. Remove pin (2) and lower rod end of loader boom

cylinder. Repeat this procedure for the other loader
boom cylinder.
Continued on next page TF44157,00006DE –19–10MAY07–2/6

060807
PN=535
Loader
7. Install lifting straps at locations (1 and 3). Make sure

lifting straps are installed as follows:
• Attach rear lifting straps to each boom arm using

choker method.
• Attach front lifting straps around each boom arm just
in front of cross tube (2).
1—Location (rear lifting point)

2—Cross Tube
3—Location (front lifting point)
–UN–15SEP00
T133793B
31
3100
2

060807
PN=536
Loader
8. Disconnect return-to-dig switch connector (7).

–UN–23AUG88
9. Tag and disconnect hydraulic hoses (5 and 6). Close

all openings using caps and plugs.
X9811
10. Remove yoke pin (2) and washers to disconnect
bucket self-leveling linkage (3). Fasten linkage rod to
loader arm using a tie band or piece of wire.
11. Remove cowling (8).
–UN–31MAR07
device.
TX1018865A
Specification
Loader Boom—Weight
(approximate)................................................................................... 317 kg
700 lb
1—Actuator
12. On both sides of the machine, remove loader boom 2—Yoke Pin
pivot pin (4) and actuator (1). 3—Bucket Self-Leveling Linkage
4—Loader Boom Pivot Pin
5—Bucket Hydraulic Hoses (2 used)
13. Lift and remove loader boom using the hoist. 6—Auxiliary Hydraulic Hoses (optional) (2 used)
31
3100
7—Return-to-Dig Switch Connector
3
14. Repair or replace loader boom as necessary. 8—Cowling
Loader Boom Install

device.
Specification
Loader Boom—Weight
(approximate)................................................................................... 317 kg
700 lb
1. Lower loader boom into position and align loader boom

with pivot pin boss holes.

060807
PN=537
Loader
2. Install loader boom pivot pin (4) with actuator (1).
3. Connect bucket self-leveling linkage (3) to actuator (1).
4. Connect return-to-dig switch connector (7).
–UN–31MAR07
5. Connect hydraulic hoses (5 and 6).
1—Actuator
TX1018865A
2—Yoke Pin
3—Bucket Self-Leveling Linkage
4—Loader Boom Pivot Pin
5—Bucket Hydraulic Hoses (2 used)
6—Auxiliary Hydraulic Hoses (optional) (2 used)
7—Return-to-Dig Switch Connector
8—Cowling
TF44157,00006DE –19–10MAY07–5/6

device.
Specification
–UN–31MAR07
Boom Cylinder—Weight
(approximate)..................................................................................... 37 kg
81 lb
31
TX1018830A
3100 NOTE: Install loader boom cylinders, if completely
4
removed from machine. See Loader Boom
Cylinder Remove and Install. (Group 3160.)
6. Install loader boom cylinder (1) rod end. Repeat this 1—Loader Boom Cylinder (2 each)
procedure for the other loader boom cylinder. 2—Pin (2 each)
3—Cap Screw (2 each)
7. Install loader bucket linkage, if necessary. See Loader

Bucket Linkage Remove and Install. (Group 3115.)
8. Install loader bucket, if necessary. See Loader Bucket

9. Adjust bucket self-leveling linkage. See Loader Bucket

Self-Leveling Linkage and Return-To-Dig Switch
Adjustment. (Group 9025-20.)
TF44157,00006DE –19–10MAY07–6/6

060807
PN=538
Group 3102
Bucket
Loader Bucket Remove and Install

device. Be careful when removing bucket
linkage pins. Bucket cylinder and links will fall
forward and cause bodily injury. If necessary,
support bucket linkage using blocks.
1. Put bucket on floor.
2. Remove pin (3). Lift and rotate bucket links (2) until
links rest against the machine.
3. Attach a hoist and lifting strap to bucket cylinder (1).

Remove pin (4). Allow cylinder to rest against the
machine while being careful not to damage hose fitting
at top of cylinder.
–UN–03MAY06
4. Remove pins (5). Remove bucket.
5. Repair or replace bucket as needed.
TX1007151A
6. Move bucket into position. Align loader arms with
bucket pin bosses and install pins (5).
7. Align bucket cylinder rod with bucket. Install pin (4).

1—Bucket Cylinder
2—Bucket Link (2 used)
8. Align links (2) with bucket and install pin (3). 3—Bucket Link-to-Bucket Pin
4—Cylinder-to-Bucket Pin 31
5—Boom-to-Bucket Pin (2 used) 3102
1
TF44157,00006E0 –19–10MAY07–1/1
Loader Bucket Cutting Edge Crack Repair
1. If cutting edge has any cracks, clean the area to find

end of crack.
2. Drill a small hole at end of crack to prevent spreading.
3. Grind V-grooves along crack on top and bottom of

cutting edge.
4. Fill the V-grooves with weld. Use E7018 electrodes.

Extend the weld approximately 13 mm (0.5 in.) beyond
end of crack.
TF44157,00006E1 –19–25APR07–1/1

060807
PN=539
Bucket
Loader Bucket Cutting Edge Remove and Install
–UN–15MAY91
T7513AQ
31 A—Weld
3102
2 1. Lower bucket onto shop stands. 3. Remove top weld using cutting torch or air arc
equipment. Remove weld on side stiffener to cutting
2. Tack weld a straight edge along weld (A) joining edge joint.
bucket to cutting edge to use as a guide.
Continued on next page TF44157,00006E2 –19–10MAY07–1/6

060807
PN=540
Bucket
–UN–15MAY91
T7513AR
A—51 mm (2.0 in.) long x 12 C—40 mm (1.6 in.) long x 8 D—140 mm (5.5 in.) long x 8 E—76 mm (3.0 in.) long x 8
mm (0.5 in.) fillet weld mm (0.3 in.) fillet weld mm (0.3 in.) fillet weld mm (0.3 in.) fillet weld
B—51 mm (2.0 in.) long x 8 (also wrap corners)
31
mm (0.3 in.) fillet weld
3102
3
IMPORTANT: Cutting edge overlaps bucket at 4. Put bucket into dump position. Remove all bottom
bottom welds. Be careful not to cut welds (A—E) with cutting torch or air arc
into bucket when removing weld. equipment.
NOTE: Weld sequence on cutting edge is

symmetrical. Use left side notations to guide
you to cut welds on the right side.

060807
PN=541
Bucket
5. Smooth rough surfaces with grinder.
6. Position new cutting edge and hold in place with

clamps.
IMPORTANT: Disconnect battery ground strap or turn
–UN–07FEB90
battery disconnect switch to "OFF".
Have only a certified or qualified welder

do this work. Connect welder ground
T92453
clamp close to each weld area so
electrical current does not pass through
any bearings.
Remove or protect all parts that can be

damaged by heat or weld splatter.
High carbon cutting edges must be

preheated to 176°C (350°F), then welded
with low hydrogen E-7018 dry rods or
A.W.S. E-70T-4 flux core process.
NOTE: Weld sequence on cutting edge is symmetrical.

Use left side notations to weld right side.
7. Tack weld cutting edge to bucket. Remove clamps.
31
3102
4

060807
PN=542
Bucket
–UN–15MAY91
T7513AR
A—51 mm (2.0 in.) long x 12 C—40 mm (1.6 in.) long x 8 D—140 mm (5.5 in.) long x 8 E—76 mm (3.0 in.) long x 8
mm (0.5 in.) fillet weld mm (0.3 in.) fillet weld mm (0.3 in.) fillet weld mm (0.3 in.) fillet weld
B—51 mm (2.0 in.) long x 8 (also wrap corners)
31
mm (0.3 in.) fillet weld
3102
5
8. Weld bottom of cutting edge at A, B, C, D and E.
Use weld instructions on drawing.

060807
PN=543
Bucket
–UN–15MAY91
T7513AQ
A—Weld
31 9. Put bucket flat on shop stands. Weld floor of bucket and weld continuous to end. Weld both halves
3102 to cutting edge (A) with a 5 mm (0.2 in.) high by 9 before welding side stiffener to cutting edge.
6 mm (0.36 in.) wide fillet weld. Start weld in center

060807
PN=544
Bucket
10. Weld both sides and front of each side stiffener to

cutting edge using a 12 mm (0.5 in.) fillet weld (A).
Wrap weld around corners.
A—Fillet Weld
–UN–05JUN91
T7513AS
TF44157,00006E2 –19–10MAY07–6/6
31
3102
7

060807
PN=545
Bucket
Loader Multi-Purpose Bucket and Lines Disassemble and Assemble
31
3102
8
–UN–10APR02
T153162

060807
PN=546
Bucket
1—Complete Multi-Purpose 8—Lock Nut (2 used) 16—Hydraulic Hose (2 used) 23—Clamp

Bucket Assembly 9—Hydraulic Hose (2 used) 17—Pin Fastener (2 used) 24—Washer
2—Bushing (2 used) 10—O-ring (As Required) 18—Washer (2 used) 25—Cap Screw
3—Hydraulic Cylinder (2 used) 11—Line (2 used) 19—Cotter Pin (2 used) 26—Hydraulic Hose (2 used)
4—Lubrication Fitting (2 used) 12—Clamp (6 used) 20—Plate (3 used) 27—Bushing
5—Cap Screw (2 used) 13—Elbow Fitting (2 used) 21—Cap Screw (3 used) 28—O-ring
6—Pin (2 used) 14—O-ring (4 used) 22—Elbow Fitting 29—Label
7—Washer (2 used) 15—Elbow Fitting (2 used)
Inspect all parts for wear. Replace if necessary.
TF44157,00006E3 –19–10MAY07–2/2
31
3102
9

060807
PN=547
Bucket
31
3102
10

060807
PN=548
Group 3104
Attachment Coupler
Attachment Coupler Remove and Install
1. Remove loader bucket or front attachment. See

Operating Loader Coupler—If Equipped. (Operator’s
Manual.)
2. Place attachment coupler in horizontal position.
3. Stop engine.
4. Release all hydraulic system pressure. See Hydraulic

31
3104
1

060807
PN=549
Attachment Coupler

–UN–23AUG88
5. Disconnect loader auxiliary hydraulic hoses (1).
6. Disconnect attachment coupler hoses (3).
X9811
7. Remove bucket cylinder linkage, if necessary. See
3115.)
8. Remove bucket cylinder, if necessary. See Loader

Bucket Cylinder Remove and Install. (Group 3160.)
CAUTION: Prevent possible injury from falling

linkage. Bucket cylinder and links will fall when
pins are removed. Support or block linkage and
cylinder before removing pins.
–UN–03APR07
9. Remove bucket cylinder linkage pin (6).
Specification
Loader Bucket Cylinder—Weight
TX1019370A
(approximate)..................................................................................... 45 kg
100 lb
31 10. Remove bucket cylinder rod end pin (4).

3104 1—Loader Auxiliary Hydraulic Hose (2 used)
2 2—Bucket Cylinder
11. Remove loader arm attachment pins (5).
3—Attachment Coupler Hydraulic Hose (2 used)
4—Bucket Cylinder Rod End Pin
12. Remove attachment coupler (7). 5—Loader Arm Attachment Pin (2 used)
6—Bucket Cylinder Linkage Pin
13. Repair or replace attachment coupler as necessary. 7—Attachment Coupler
14. Install loader arm attachment pins.
15. Install bucket cylinder rod end pin.
16. Install bucket cylinder linkage pin.
17. Connect attachment coupler hydraulic hoses.
18. Connect loader auxiliary hydraulic hoses.

060807
PN=550
Attachment Coupler
19. Check hydraulic fluid level. See Check Hydraulic

20. Start the machine and check for leaks.
21. Install loader bucket or front attachment. See

Manual.)
TF44157,00006E4 –19–10MAY07–3/3
Attachment Coupler Cylinder Remove and

Install
1. Remove loader bucket or front attachment. See

Manual.)
2. Stop engine.
3. Release all hydraulic system pressure. See Hydraulic

31
3104
3

060807
PN=551
Attachment Coupler

–UN–23AUG88
4. Disconnect attachment coupler cylinder hydraulic
hoses (2). Cap and plug all openings.
5. Remove attachment coupler cylinder.
X9811
6. Repair or replace attachment coupler cylinder as
necessary.
7. Install attachment coupler cylinder.
8. Connect attachment coupler cylinder hydraulic hoses.
–UN–03APR07
9. Check hydraulic fluid level. See Checking Hydraulic
TX1019405A
11. Install loader bucket or front attachment. See

Manual.) 1—Attachment Coupler Cylinder
2—Attachment Coupler Hydraulic Hoses (2 used)
3—Attachment Coupler Cap Screw, Nut, and
Washer (2 used)
31
3104
4
TF44157,00006E5 –19–10MAY07–2/2
Attachment Coupler Cylinder Disassemble

and Assemble
For attachment coupler cylinder repair information, see

100 Series Hydraulic Cylinders. (TM-H100A.)
–UN–17JAN89
TS225
TF44157,00006E6 –19–10MAY07–1/1

060807
PN=552
Group 3115
Control Linkages
Loader Control Valve Linkage Remove and

Install
1. Remove access panel (1).
1—Access Panel
2—Loader Control Lever
3—Auxiliary Control Lever
–UN–31MAR07
TX1018901A
31
3115
1

060807
PN=553
Control Linkages
31
3115
2
–UN–06DEC06
TX1015656

060807
PN=554
Control Linkages
1—Cap Screw (2 used) 6—Washer 10—Lever 14—Cover

2—Cap Screw (2 used) 7—Cap Screw (2 used) 11—Switch 15—Insert
3—Washer (2 used) 8—Ball Joint 12—Control Support 16—Spacer
4—Washer (2 used) 9—Knob 13—Tie Band (2 used) 17—Plate
5—Nut (2 used)
2. Remove and install parts as shown.
TF44157,00006E7 –19–10MAY07–3/3
Third Function Loader Control Valve Linkage

Remove and Install
1. Remove access panel (1).
1—Access Panel
2—Loader Control Lever
3—Auxiliary Control Lever
–UN–31MAR07
31
3115
TX1018901A
3

060807
PN=555
Control Linkages
31
3115
4
–UN–28DEC06
TX1015652

060807
PN=556
Control Linkages
1—Cap Screw (2 used) 6—Washer (2 used) 11—Auxiliary Lever 16—Knob

2—Cap Screw (2 used) 7—Screw (2 used) 12—Bushing 17—Cover
3—Washer (2 used) 8—Ball Joint 13—Switch 18—Insert
4—Washer (2 used) 9—Knob 14—Control Support 19—Spacer
5—Nut (2 used) 10—Loader Lever 15—Tie Band (2 used) 20—Plate
TF44157,00006E8 –19–10MAY07–3/3
Stabilizer Linkage Remove and Install
1. Remove stabilizer linkage access cover (1).
1—Stabilizer Linkage Access Cover

2—Stabilizer Lever (2 used)
–UN–31MAR07
31
3115
TX1018907A
5

060807
PN=557
Control Linkages
31
3115
6
–UN–29DEC06
TX1016046

060807
PN=558
Control Linkages
1—Cap Screw (2 used) 8—Washer 14—Lever 20—Screw (2 used)

2—Washer (2 used) 9—Washer (2 used) 15—Bearing (2 used) 21—Knob (2 used)
3—Bracket 10—Push Pull Cable (2 used) 16—Bracket 22—Swivel (2 used)
4—Cap Screw 11—Nut (2 used) 17—Washer (2 used) 23—Plate
5—Cap Screw 12—Lever 18—Snap Ring (4 used) 24—Tie Band
6—Cotter Pin (2 used) 13—Bearing (2 used) 19—Snap Ring (2 used) 25—Seal
7—Washer (2 used)
2. Disassemble and assemble parts as shown.
TF44157,00006E9 –19–10MAY07–3/3
Loader Bucket Linkage Remove and Install
1. Lower all equipment to ground and stop the engine.


3. Support or block linkage from falling when

disconnecting the linkage. 31
3115
7
Continued on next page TF44157,00006EA –19–10MAY07–1/2

060807
PN=559
Control Linkages
4. Disconnect self-leveling rod (1) by removing snap ring

(2).

5. Remove two bucket links (6) by removing snap rings

and washers (3) and snap rings, washers, and pin (7).
Specification
Loader Bucket Cylinder—Weight
(approximate)..................................................................................... 45 kg
100 lb
6. Slowly remove bucket links (4) by removing snap rings,

washers, and pin (5).
7. Inspect links. Repair or replace as needed. Remove
–UN–06OCT00
and install bushings using Seal Driver Set.
IMPORTANT: Do not use a graphite based grease on

the synthetic bushings when
T134325B
assembling. The graphite will
deteriorate the synthetic bushings.
8. Apply multipurpose grease to inside of all bushings 1—Self-Leveling Rod

before assembly. 2—Snap Ring
3—Snap Ring and Washer (2 used)
31
9. Attach bucket links (6) to loader boom using pin, 4—Bucket Links (2 used)
3115
washers, and snap rings (7). 5—Snap Rings, Washers, and Pin
8
6—Bucket Links (2 used)
7—Snap Rings, Washers, and Pin
10. Attach bucket links (4) to bucket using pin, washers,
and snap rings (5).
11. Align bucket links (4 and 6) with cylinder and attach

links to cylinder using washers and snap rings (3).
Shim as required to reduce looseness on bucket links
and bucket links to cylinder.
12. Attach self-leveling rod (1) using snap ring (2).
TF44157,00006EA –19–10MAY07–2/2

060807
PN=560
Group 3160
Hydraulic System
Loader and Stabilizer Control Valve Remove

and Install
2. Stop engine. Place transmission control lever (TCL) in

neutral and set park brake.
3. Remove right rear wheel. Perform Remove Right

Wheel. (Group 0110.)

5. Drain or apply vacuum to hydraulic reservoir.
Specification
5.5 gal
TF44157,00006EC –19–25APR07–1/3
6. Remove loader and stabilizer control valve cover (1).

31
3160
7. Remove floor panel above loader and stabilizer control 1
valve.
8. Remove loader and stabilizer control linkage. See
–UN–12OCT00
3115.) See Stabilizer Linkage Remove and Install.
(Group 3115.)
1—Loader and Stabilizer Control Valve Cover T134605B
Continued on next page TF44157,00006EC –19–25APR07–2/3

060807
PN=561
Hydraulic System

–UN–23AUG88
9. Tag and disconnect hydraulic hoses on loader and
stabilizer control valve. Close all openings using caps
and plugs.
X9811
10. Remove loader and stabilizer control valve.
11. Repair or replace loader and stabilizer control valve,

as necessary.
12. Install loader and stabilizer control valve.
13. Connect hydraulic hoses on loader and stabilizer

control valve.
14. Install loader and stabilizer control linkage. See

3115.) See Stabilizer Linkage Remove and Install.
(Group 3115.)
15. Install floor panel above loader and stabilizer control
–UN–10APR03
valve.
16. Install loader and stabilizer control valve cover

31
T189526B
3160
2
17. Fill hydraulic reservoir, if drained.
Specification
5.5 gal
18. Install right rear wheel. See Rear Wheel Assembly

Remove and Install. (Group 0110.) –UN–10APR03
T189526C
TF44157,00006EC –19–25APR07–3/3

060807
PN=562
Hydraulic System
Loader and Stabilizer Control Valve

Disassemble and Assemble 5
NOTE: Left Stabilizer thermal relief valve (if equipped) is

located in top of valve. Right stabilizer thermal
4
relief valve (if equipped) is located in bottom of
valve.
3
2
Wiper rings and seals are only serviceable parts
on loader and stabilizer valve.
1. Clean valve assembly to remove any dirt and debris.

1
2. Remove two socket head cap screws (5) and retainer
–UN–22AUG05
plate (4) from top of valve section.
3. Use an O-ring pick to remove spool wiper ring (3) and

lip seal (2).
T213604
1—Spool Wiper Ring and Lip Seal
2—Lip Seal
3—Spool Wiper Ring
4—Retainer Plate
5—Socket Head Cap Screw (2 used)
31
3160
3
Continued on next page TF44157,00006ED –19–10MAY07–1/5

060807
PN=563
Hydraulic System
4. Remove two screws (6) and cap (14) from bottom of

valve section.
5. Remove spool end screw (12) to remove spring seats 7 11

(13), spring (9), and retainer plate (10).
8
10
lip seal (7).
9
13
7—Lip Seal
9—Spring 12
10—Retainer Plate
14
–UN–22AUG05
11—Spool
12—Spool End Screw
13—Spring Seat (2 used)
14—Cap 6
T213605
Valve Spool Seal Repair
31
3160
4

060807
PN=564
Hydraulic System
IMPORTANT: Do not damage OD or ID of new seal

during installation. Installation tool
JDG374 must be used to install lip seal.
15
Lube seals with hydraulic oil prior to
installation.
16
7. Use JDG734 Hydraulic Valve Seal Replacer to install
new lip seal at each end of spool.
8. Place lip seal (16) on end of tool driver (17) with open
side of seal away from tool driver. 17
NOTE: Lip end of sleeve ID is cone-shaped to compress
–UN–22AUG05
lip seal for installation.
9. Carefully slide sleeve (15) over lip seal (16) and tool
driver (17) with raised lip of sleeve away from driver.
T213606
Do not push lip seal (16) through sleeve (15).
Installation Tool
10. Place tool assembly over end of spool with raised lip
into counterbore of valve section. 15—Tool Sleeve
16—Lip Seal
11. Push tool driver (17) to install lip seal (16) into valve 17—Tool Driver
housing.
12. Spin tool driver 180 degrees and hold down for
several seconds. This will allow air to escape and
seal will seat in valve counter bore.
31
3160
5

060807
PN=565
Hydraulic System
13. Install spool wiper ring (8).
14. Repeat steps (7 —13) for opposite end of spool.

7 11
15. Install retainer plate (10), spring seats (13) and spring
8
(9). 10
16. Torque Spool End Screw (12) to specification.

9
Specification
13
Spool End Screw—Torque ............................................................ 9.5 N•m
84 lb-in.
12
17. Install cap (14) and cap screws (6). Torque screws to
14
–UN–22AUG05
specification.
Specification
Retaining Screw (2 used)—
6
Torque ........................................................................................... 9.5 N•m
T213605
84 lb-in.

7—Lip Seal
9—Spring
10—Retainer Plate
11—Spool
14—Cap
31
3160
6

060807
PN=566
Hydraulic System
18. Install retainer plate (4) and screws (5). Tighten

screws to specification. 5
Specification
84 lb-in. 4
19. Check for correct installation of seals by pushing 3

down on spool (1). Spool must return to neutral 2
position.
1—Spool
2—Lip Seal 1
3—Spool Wiper
–UN–22AUG05
4—Retainer Plate
5—Screw (2 used)
T213604
Wiper Ring and Lip Seal
TF44157,00006ED –19–10MAY07–5/5
31
3160
7

060807
PN=567
Hydraulic System
Loader and Stabilizer Control Valve Relief

Valves Remove and Install
1. To aid in assembly, put identification marks on the

relief valve and the control valve.
2. Remove relief valves.
3. Repair or replace relief valves as necessary. See

Loader and Stabilizer Control Valve Load Sense Relief
Valve Disassemble and Assemble. See Loader Boom
Raise and Bucket Curl Circuit Relief Valve
Disassemble and Assemble. See Loader Bucket Dump
Circuit Relief Valve with Anticavitation Disassemble
and Assemble. See Loader Anticavitation Valve
Disassemble and Assemble. See Loader Auxiliary
Circuit Relief Valve Disassemble and Assemble. See
Loader Auxiliary Shutoff Plug Disassemble and
Assemble. (Group 3160.)
–UN–27SEP00
4. Remove and inspect O-rings and backup rings for
damage. If damaged, check housing for cause.
5. Install new O-rings and backup rings.
T134012
IMPORTANT: Relief valves must be installed in the
correct ports for proper valve function.
1—Auxiliary Circuit Relief with Anticavitation
IMPORTANT: Relief valve installation torque is port 2—Boom Raise
3—Bucket Curl Circuit Relief
31 size specific. Verify diameter of port
4—Auxiliary Plug
3160 with specifications listed below. 5—Boom Lower Circuit Relief
8
6—Load Sense Relief
6. Install relief valves. Tighten relief valves to
specification.
Relief Valve Torque—Specification

Relief Valve without Anticavitation
22.35 mm (0.88 in.)—Torque ......................................................... 45 N•m
33 lb-ft
Relief Valve without Anticavitation
26 mm (1.06 in.)—Torque .............................................................. 61 N•m
45 lb-ft
Relief Valve with Anticavitation
22.35 mm (0.88 in.)—Torque ......................................................... 45 N•m
33 lb-ft
Relief Valve with Anticavitation 26
mm (1.06 in.)—Torque ................................................................... 61 N•m
45 lb-ft
Continued on next page TF44157,0000743 –19–10MAY07–1/2

060807
PN=568
Hydraulic System
IMPORTANT: Relief valves MUST be adjusted anytime

they are disassembled or replaced.
Failure to do so could cause damage to
hydraulic system.
7. Adjust circuit relief valve pressures. See Circuit Relief

Valve Test With Remote Pump. (Group 9025-25.)
8. Adjust load sense relief valve. See Backhoe, Loader,

and Steering Load Sense Relief Valve Pressure Test.
(Group 9025-25.)
TF44157,0000743 –19–10MAY07–2/2
31
3160
9

060807
PN=569
Hydraulic System
Loader and Stabilizer Control Valve Load

Sense Relief Valve Disassemble and
Assemble
1. Disassemble and inspect parts for wear and damage.

Replace as necessary.
NOTE: Parts (1—4) are available for service. If parts (5—

13) need service replace entire assembly.
NOTE: If seals are damaged, inspect port on control

valve for wear or damage.
2. Put clean hydraulic oil on all parts before assembly.
3. Install relief valve.
Specification
Circuit Relief Valve without
Anticavitation 22.35 mm (0.88
in.)—Torque .................................................................................... 45 N•m
–UN–28APR03
33 lb-ft
1—O-ring
2—Back-Up Ring
T189943
3—O-ring
4—O-ring
5—Lock Nut
6—Adjustment Screw
7—Spring
8—Poppet
31 9—Relief Valve Body
3160 10—Spring
10 11—Pilot Poppet
12—Back-Up Ring
13—Snap Ring
TF44157,00006EE –19–10MAY07–1/1

060807
PN=570
Hydraulic System
Loader Boom Raise and Bucket Curl Circuit

Relief Valve Disassemble and Assemble

NOTE: Parts (5—10) are available for service. If parts

(1—4) need service replace entire assembly.


IMPORTANT: Relief valve installation torque is port

size specific. Verify diameter of port
with specifications listed below.
–UN–28APR03
Specification
Circuit Relief Valve 26 mm (1.06
T189942
in.)—Torque (installation) ........................................................ 58—72 N•m
43—53 lb-ft
1—Relief Valve Body

2—Poppet
3—Adjustment Screw
31
4—Lock Nut
3160
5—O-ring
11
6—Spring
7—O-ring
8—O-ring
9—Back-Up Ring
10—O-ring
TF44157,00006EF –19–10MAY07–1/1

060807
PN=571
Hydraulic System
Loader Bucket Dump Circuit Relief Valve

with Anticavitation Disassemble and
Assemble

NOTE: Parts (1—5, 8) are available for service. If parts

(6, 7, 9—17) need service replace entire
assembly.


–UN–04APR07
IMPORTANT: Relief valve installation torque is port
size specific. Verify diameter of port
with specifications listed below.
TX1019735
Specification
Circuit Relief Valve with 1—O-ring
Anticavitation 26 mm (1.06 in.)— 2—Backup Ring
Torque (installation) ................................................................. 58—72 N•m 3—O-ring
43—53 lb-ft 4—Backup Ring
31 5—O-ring
3160 6—Nut
12 7—Adjustment Screw
8—O-ring
9—Pilot Spring
10—Pilot Poppet
11—Valve Body
12—Anticavitation Spring
13—Main Spring
14—Piston
15—Poppet
16—Main Poppet
17—Valve Body
TF44157,00006F0 –19–26APR07–1/1

060807
PN=572
Hydraulic System
Loader Anticavitation Valve Disassemble and

Assemble

NOTE: Parts (1—3) are available for service. If part (4)

needs service replace entire assembly.
–UN–31MAR07
TX1019747
3. Install relief valve. Anticavitation valve installation
torque.
Specification
Anticavitation Valve—Torque 1—O-ring
(installation) ............................................................................. 58—72 N•m 2—Backup ring
43—53 lb-ft 3—O-ring
4—Valve Body
TF44157,00006F1 –19–10MAY07–1/1
Loader Auxiliary Circuit Relief Valve

31
Disassemble and Assemble 3160
13
1. Disassemble and inspect parts for wear or damage.
3. Install loader auxiliary circuit relief valve and torque to

specification.
Specification
Loader Auxiliary Circuit Relief
Valve—Torque (installation) .................................................... 58—72 N•m
43—53 lb-ft
1—O-ring
2—Seal Kit
3—Backup Ring
–UN–29MAR07
4—O-ring
5—Spring
6—Valve Body
TX1019765
TF44157,00006F2 –19–25APR07–1/1

060807
PN=573
Hydraulic System
Loader Auxiliary Shutoff Plug Disassemble

and Assemble
1. Remove seal, if necessary.
2. Put clean hydraulic oil on seal before assembly.
–UN–05JAN00
3. Install seal using JDG1328 Seal Installer.
4. Plug (1) installation torque.
T127068
Specification
Shut-Off Plug—Torque
(installation) ............................................................................. 58—72 N•m 1—Shut-Off Plug
43—53 lb-ft 2—Seal
TF44157,00006F3 –19–10MAY07–1/1
31
3160
14

060807
PN=574
Hydraulic System
Loader Bucket Cylinder Remove and Install

–UN–23AUG88
X9811
4. Tag and disconnect hydraulic lines (1) from bucket

cylinder (3). Close all openings with caps and plugs.
5. Remove clamp (2).

6. Attach a hoist and lifting strap to bucket cylinder.

Remove slack from lifting strap.
31
Specification 3160
Bucket Cylinder—Weight 15
(approximate).................................................................................... 45 kg
–UN–15SEP00
100 lb
7. At both sides of cylinder:
T133798B
a. Remove snap rings (5, 8, and 10).
b. Remove bucket links (4 and 7).

1—Hydraulic Hose (2 used)
8. Remove pin (6). 2—Clamp
3—Bucket Cylinder
9. Remove bucket cylinder. 4—Bucket Front Link (2 used)
5—Snap Ring
6—Bucket Cylinder-To-Bucket Pin
10. Apply multipurpose grease to inside of all bushings 7—Bucket Rear Link (2 used)
before assembly. 8—Snap Ring
9—Bucket Cylinder Pivot Pin
11. Move bucket cylinder into position and install pin (6). 10—Snap Ring (2 used)
Continued on next page TF44157,00006F4 –19–25APR07–1/2

060807
PN=575
Hydraulic System
12. At both sides, install bucket links (4 and 7) and snap

rings (5, 8, and 10).
13. Remove hoist and lifting strap.
14. Connect hydraulic hoses (1).
15. Install clamp (2).
TF44157,00006F4 –19–25APR07–2/2
Loader Bucket Cylinder Disassemble and

Assemble
For loader bucket cylinder repair information, see 120

Series Hydraulic Cylinders. (TM-H120A.)
–UN–17JAN89
TS225
TF44157,00006F5 –19–10MAY07–1/1
Loader Multi-Purpose Bucket Cylinder

31
3160
16
For loader multi-purpose bucket cylinder repair
information, see 120 Series Hydraulic Cylinders.
(TM-H120A.)
–UN–17JAN89
TS225
TF44157,00006F6 –19–10MAY07–1/1

060807
PN=576
Hydraulic System
Loader Boom Cylinder Remove and Install

–UN–23AUG88
Circuit Pressure Release. (9025-25.)
X9811
4. Tag and disconnect hydraulic lines (4 and 7) from

boom cylinder. Close all openings with caps and plugs.
–UN–24OCT00
5. Remove clamp (6).
6. Remove snap ring (1) and washer (3).
T133830C
CAUTION: Avoid personal injury, use
appropriate lifting device. 1—Snap Ring
2—Pin
7. While supporting rod end of boom cylinder, remove pin 3—Washers
(8). Lower rod end of cylinder away from loader arm 4—Hydraulic Hose (to cylinder head end)
5—Boom Cylinder
and slide boom cylinder off pin (2). 6—Clamp 31
7—Hydraulic Hose (to cylinder rod end) 3160
Specification 8—Pin 17
Boom Cylinder—Weight
(approximate)..................................................................................... 37 kg
81 lb
8. Apply multipurpose grease to inside of all bushings

before installing cylinder.
9. Slide head end of boom cylinder onto pin (2). Align

hole in rod end of boom cylinder with pin boss holes in
loader arm. Install pin (8).
10. Install washers (3) and snap ring (1).
11. Attach hydraulic hoses (4 and 7).
12. Fasten hoses to cylinder using clamp (6).
TF44157,00006F7 –19–25APR07–1/1

060807
PN=577
Hydraulic System
Loader Boom Cylinder Disassemble and

Assemble
For loader bucket cylinder repair information, see 120

–UN–17JAN89
TS225
TF44157,00006F8 –19–25APR07–1/1
Ride Control Valve Remove and Install
NOTE: Before preforming service on ride control valve.

See Ride Control Hydraulic Circuit Component
Location and Valve Operation. (Group 9025-05.)
CAUTION: Prevent possible injury from

unexpected boom or bucket movement when
equipped with ride control. Ride control
accumulator energy must be discharged when
working on hydraulic components. Turn key
switch to ON position and move the loader
control lever into the float position.
31
1. Relieve pressure in ride control system. See Ride
3160 Control Accumulator Discharge Procedure. (Group
18 9025-20.)
NOTE: Ride control accumulator is located inside battery

box attached to left frame rail.
2. Access ride control valve. See Battery Box

Continued on next page TF44157,00006F9 –19–10MAY07–1/3

060807
PN=578
Hydraulic System
–UN–23AUG88
X9811
31
3160
19
–UN–20NOV02
T161303F
1—Accumulator Mounting Nut 3—Ride Control Valve 5—Solenoid Valve 7—Ride Control Valve
(4 used) Mounting Bolts (2 used) 6—Hydraulic Hose-to-Loader 8—Ride Control Accumulator
2—Return Hose-to-Hydraulic 4—Solenoid Valve Boom Cylinder (2 used)
Reservoir
3. Remove connectors on ride control valve solenoids 4. Tag and disconnect return hose-to-reservoir (2) and
(4, 5). hydraulic hose-to-loader boom cylinders (6). Close
all opening with caps and plugs.
CAUTION: To avoid injury from escaping
5. Tag and disconnect hydraulic hose from ride control
fluid under pressure, stop engine and relieve
valve-to-accumulator. Close all opening with caps
the pressure in the system before
and plugs.
disconnecting or connecting hydraulic or
other lines. Tighten all connections before
6. Remove ride control valve (7).
applying pressure.
Continued on next page TF44157,00006F9 –19–10MAY07–2/3

060807
PN=579
Hydraulic System
7. Repair or replace ride control valve as necessary. Specification

Ride Control Valve Hydraulic
Hoses—Torque ........................................................................ 50 N•m
8. Install ride control valve. Tighten to specification. 37 lb-ft
Specification
Ride Control Valve Cap 10. Connect wire connector to ride control valve
Screws—Torque ...................................................................... 37 N•m solenoids (4, 5).
27 lb-ft
11. Assemble battery box. See Battery Box
9. Connect hydraulic hoses and tighten hoses to Disassemble and Assemble. (Group 1913.)
specification.
TF44157,00006F9 –19–10MAY07–3/3
31
3160
20

060807
PN=580
Hydraulic System
31
3160
21

060807
PN=581
Hydraulic System
Ride Control Valve Disassemble and Assemble
31
3160
22
–UN–28DEC06
TX1016014
Continued on next page TF44157,00006FA –19–10MAY07–1/2

060807
PN=582
Hydraulic System
1—Nut (4 used) 10—O-ring (2 used) 22—Plate 37—Tie Band (8 used)

2—Cap Screw (4 used) 11—Adapter Fitting 23—Ride Control Valve 38—Nut (4 used)
3—Cap Screw (2 used) 12—Tee Fitting (6 used) 30—Hydraulic Hose (2 used) 39—Grommet
4—Washer (2 used) 15—Hydraulic Accumulator 31—Toggle/Rocker Switch 41—Bracket
5—Washer (4 used) 17—Hydraulic Hose (2 used) 32—Wiring Harness 42—Channel (2 used)
6—Elbow Fitting (2 used) 18—Hydraulic Hose 33—Tie Band (8 used) 43—Clamp
7—O-ring (4 used) 19—Hydraulic Hose 34—Clamp 44—Label
8—Elbow Fitting (3 used) 20—Hydraulic Hose 35—Wiring Harness 90—Field Installation Kit
9—O-ring (6 used) 21—Hydraulic Hose 36—Plug (6 used)
1. Disassemble parts as shown. Inspect parts for wear 3. Install solenoids on ride control valve (23).
or cracks in O-ring (9).
2. Remove solenoids from ride control valve (23). See

Ride Control Valve Solenoid Disassemble and
Assemble. (Group 3160.)
TF44157,00006FA –19–10MAY07–2/2
31
3160
23

060807
PN=583
Hydraulic System
Ride Control Valve Solenoid Disassemble and Assemble
–UN–22NOV02
T162075B
1—Ride Control Valve 4—Solenoid Valve Spool (2 5—Solenoid Coil (2 used) 7—Slotted Nut (2 used)
2—O-ring (2 used) used) 6—Wire Connector (2 used) 8—Orifice
3—O-ring (2 used)
NOTE: Before preforming service on ride control 5. Remove O-rings (3) and replace.
valve. See Ride Control Hydraulic Circuit
Component Location and Valve Operation. 6. Inspect and clean all orifices (8).
31 (Group 9025-05.)
3160
24
7. Install new O-ring (3).
NOTE: Ride control valve removed for clarity only.
Solenoid can be serviced when ride control 8. Install solenoid valve spool (4) in ride control valve
valve is installed on machine. (1).
1. Disconnect wire connector (6). 9. Install nut (7) to specification.
2. Remove slotted nuts (7). Specification

Ride Control Valve—Torque
(slotted nut) ................................................................................ 7 N•m
3. Slide solenoid coil (5) off of solenoid valve spool 60 lb-in.
(4).
10. Connect wire connector (6).
4. Remove solenoid valve spool (4) from ride control
valve (1).
TF44157,00006FB –19–08MAY07–1/1

060807
PN=584
Hydraulic System
Ride Control Accumulator Remove and

Install

unexpected boom or bucket movement when
equipped with ride control. Ride control
accumulator energy must be discharged when
working on hydraulic components.
1. Relieve pressure in ride control system as follows. See

Ride Control Accumulator Discharge Procedure.
(Group 9025-20.)
NOTE: Ride control accumulator is located inside battery

box attached to left frame rail.
2. Disconnect battery cables and remove battery box.

See Battery Box Disassemble and Assemble. (Group
1913.)
Continued on next page TF44157,00006FC –19–08MAY07–1/2
31
3160
25

060807
PN=585
Hydraulic System

–UN–23AUG88
3. Disconnect hydraulic hose (6) from accumulator (1).
NOTE: The ride control valve does not have to be

removed from the lower mounting strap (4).
X9811
4. Remove upper and lower mounting straps (2 and 4) to
remove accumulator (1).
5. Install accumulator. Fasten with mounting straps (2 and

4). Tighten mounting strap cap screws (3 and 5) to
specification.
Specification
Ride Control Accumulator Clamp
54 lb-ft
6. Connect hydraulic hose (6) and tighten to specification.
Specification
Ride Control Accumulator
Hydraulic Line—Torque ................................................................. 37 N•m
27 lb-ft
31 7. Install battery box and connect battery cables. See

3160 Battery Box Disassemble and Assemble. (Group 1913.)
26
8. Charge ride control accumulator. See Ride Control
–UN–21SEP00
Accumulator Charge Procedure. (Group 3160.)
T133847B
1—Accumulator
2—Upper Mounting Strap
4—Lower Mounting Strap
6—Hydraulic Hose
TF44157,00006FC –19–08MAY07–2/2

060807
PN=586
Section 33
Backhoe
Contents
Page Page
Group 3302—Bucket Backhoe Control Valve Relief Valves Remove

Backhoe Bucket and Bucket Links Remove and Install . . . . . . . . . . . . . . . . . . . . . . . .33-3360-13
and Install . . . . . . . . . . . . . . . . . . . . . . . . .33-3302-1 Backhoe Inlet Section Disassemble and
Backhoe Bucket Tooth Tips Remove and Assemble. . . . . . . . . . . . . . . . . . . . . . . . .33-3360-16
Install. . . . . . . . . . . . . . . . . . . . . . . . . . . . .33-3302-2 Backhoe Flow Control Section Disassemble
Backhoe Bucket Tooth Shank Remove and Assemble . . . . . . . . . . . . . . . . . . . . .33-3360-18
and Install . . . . . . . . . . . . . . . . . . . . . . . . .33-3302-2 Backhoe Swing Section Disassemble and
Backhoe Bucket Cutting Edge Remove Assemble. . . . . . . . . . . . . . . . . . . . . . . . .33-3360-20
and Install . . . . . . . . . . . . . . . . . . . . . . . . .33-3302-4 Backhoe Boom Section Disassemble and
Assemble. . . . . . . . . . . . . . . . . . . . . . . . .33-3360-22
Group 3315—Control Linkage Backhoe Bucket Section Disassemble and
Backhoe Control Valve Linkage—Two Assemble. . . . . . . . . . . . . . . . . . . . . . . . .33-3360-24
Lever Remove and Install . . . . . . . . . . . . .33-3315-2 Backhoe Crowd Section Disassemble and
Backhoe Control Valve Linkage—Three Assemble. . . . . . . . . . . . . . . . . . . . . . . . .33-3360-26
Lever Remove and Install . . . . . . . . . . . . .33-3315-4 Backhoe Extendible Dipperstick Section
Backhoe Fifth Function Pedal Remove
and Install . . . . . . . . . . . . . . . . . . . . . . . . .33-3315-6
Backhoe Outlet Section Disassemble and
Backhoe Sixth Function Pedal Remove
Assemble. . . . . . . . . . . . . . . . . . . . . . . . .33-3360-30
and Install . . . . . . . . . . . . . . . . . . . . . . . .33-3315-10
Pilot Control Manifold Valve Remove and
Backhoe Pilot Control Valve Remove and
Install. . . . . . . . . . . . . . . . . . . . . . . . . . . .33-3360-32
Install. . . . . . . . . . . . . . . . . . . . . . . . . . . .33-3315-13
Pilot Control Manifold Valve Disassemble and
Backhoe Pilot Control Valve Disassemble
and Assemble . . . . . . . . . . . . . . . . . . . . .33-3315-16 Assemble. . . . . . . . . . . . . . . . . . . . . . . . .33-3360-33
Backhoe Pilot Control Tower Remove and Pattern Select Valve Remove and Install. . .33-3360-34
Install. . . . . . . . . . . . . . . . . . . . . . . . . . . .33-3315-19 Pattern Select Valve Disassemble and
Backhoe Pilot Control Tower Disassemble Assemble. . . . . . . . . . . . . . . . . . . . . . . . .33-3360-38
and Assemble . . . . . . . . . . . . . . . . . . . . .33-3315-22 Backhoe Bucket Cylinder Remove and 33
Backhoe Boom Lock Control Lever and Install. . . . . . . . . . . . . . . . . . . . . . . . . . . .33-3360-39

Linkage Remove and Install. . . . . . . . . . .33-3315-24 Backhoe Bucket Cylinder Disassemble and
Backhoe Boom Lock Remove and Assemble. . . . . . . . . . . . . . . . . . . . . . . . .33-3360-40
Install. . . . . . . . . . . . . . . . . . . . . . . . . . . .33-3315-26 Backhoe Crowd Cylinder Remove and
Install. . . . . . . . . . . . . . . . . . . . . . . . . . . .33-3360-41
Group 3340—Frames Backhoe Crowd Cylinder Disassemble and
Dipperstick Remove and Install . . . . . . . . . . .33-3340-1 Assemble. . . . . . . . . . . . . . . . . . . . . . . . .33-3360-42
Boom Remove and Install . . . . . . . . . . . . . . .33-3340-4 Backhoe Boom Cylinder Remove and
Swing Frame Remove and Install . . . . . . . . .33-3340-6 Install. . . . . . . . . . . . . . . . . . . . . . . . . . . .33-3360-43
Extendible Dipperstick Extension Remove Backhoe Boom Cylinder Disassemble and
and Install . . . . . . . . . . . . . . . . . . . . . . . . .33-3340-8 Assemble. . . . . . . . . . . . . . . . . . . . . . . . .33-3360-44
Backhoe Swing Cylinder Remove and
Group 3360—Hydraulic System Install. . . . . . . . . . . . . . . . . . . . . . . . . . . .33-3360-44
Backhoe Control Valve Remove and Backhoe Swing Cylinder Disassemble and
Install. . . . . . . . . . . . . . . . . . . . . . . . . . . . .33-3360-1 Assemble. . . . . . . . . . . . . . . . . . . . . . . . .33-3360-47
Backhoe Control Valve Disassemble and Backhoe Stabilizer Cylinder Remove and
Assemble. . . . . . . . . . . . . . . . . . . . . . . . . .33-3360-6 Install. . . . . . . . . . . . . . . . . . . . . . . . . . . .33-3360-48
Backhoe Control Valve Spool Seals Remove
and Install . . . . . . . . . . . . . . . . . . . . . . . . .33-3360-9 Continued on next page

060807
PN=1
Contents
Page
Backhoe Stabilizer Cylinder Disassemble and

Assemble. . . . . . . . . . . . . . . . . . . . . . . . .33-3360-49
Backhoe Extendible Dipperstick Cylinder
33

060807
PN=2
Group 3302
Bucket
Backhoe Bucket and Bucket Links Remove

and Install
1. Lower bucket to ground.
2. Remove bucket cap screw, cotter pins, and special

washers (1—5) and remove bucket links and linkage
pins.
3. Inspect bushings and replace as necessary. For ease

of removing bushings weld three straight beads the
inside length of the bushing. Allow bushing to cool
before removing with a punch. Install new bushings
even with outside surface of bucket using D01072AA
seal driver set.
4. Install links and linkage pins.
5. Install bucket cap screw, cotter pins and special

washers (1—5).
–UN–06OCT00
6. Align bucket with pin boss holes. Install bucket pins.
1—Dipperstick-to-Bucket Link Snap Ring and Special
T134346B
Washers
2—Dipperstick-to-Bucket Cotter Pins and Special
Washers
3—Link-to-Bucket Cotter Pins and Special Washers
4—Link Snap Ring and Special Washers
5—Bucket Cylinder Rod End Cap Screw and Washer
33
3302
1
TF44157,00006FD –19–25APR07–1/1

060807
PN=589
Bucket
Backhoe Bucket Tooth Tips Remove and

Install

accidental lowering of bucket. Use shop stands
–UN–07OCT00
under the bucket.
1. Put shop stands under the bucket.
T134353
2. To remove tooth tip, drive pin (3) out using DO1030AA
pin master tool.
3. Drive pin (3) in tooth shank using DO1030AA pin 1—Tooth Shank
master tool. 2—Tooth Tip
3—Flex Pin
TF44157,00006FE –19–25APR07–1/1
Backhoe Bucket Tooth Shank Remove and

Install
1. Remove top and bottom welds using air arc equipment

or cutting torch.
–UN–07JUN91
T7535AG
33
3302
2
–UN–07JUN91
T7535AF
Continued on next page TF44157,00006FF –19–25APR07–1/4

060807
PN=590
Bucket
2. Grind smooth all surfaces.
IMPORTANT: Shanks and cutting edge must be

preheated to 177°C (350°F) to prevent
under bead cracking in shank and
brittleness in cutting edge. Preheat
–UN–31OCT88
each shank and cutting edge area just
before welding. Use low hydrogen
E-7018 dry rods or E-70T-4 flux core
process.
T92511
3. Position shanks on cutting edge. Preheat area to be
welded just before welding to 177°C (350°F).
TF44157,00006FF –19–25APR07–2/4
4. Start welds on top of shank, the long part. On corner

shanks, weld area (A) with a bevel weld. Penetrate 3
mm (0.12 in.) and leave a 5 mm (0.20 in.) face. Fill
entire area between shank and side cutter level with
top of shank. Cap this area with a 9 mm (0.35 in.) fillet
weld. Weld all the way to edge of cutting edge.
5. Weld area (B) of corner shank with an angle weld 6

mm (0.24 in.) deep and 11 mm (0.43 in.) across face.
6. Weld area (C) of corner shank with a bevel weld.

Penetrate 3 mm (0.12 in.) and leave a 5 mm (0.20 in.)
face. Cap that weld with a 11 mm (0.43 in.) fillet weld.
Leave area (D) free of weld for 19 mm (0.75 in.). 33
3302
7. On center shanks, weld areas (E) with a bevel weld. 3
face. Cover with a 9 mm (0.35 in.) fillet weld.
8. Weld area (F) with an angle weld 6 mm (0.24 in.) deep

–UN–07JUN91
and 11 mm (0.43 in.) across face.
A—Bevel Weld and Fillet Weld

B—Angle Weld
T7552AA
C—Bevel Weld
D—Weld Free Area
E—Bevel Weld and Fillet Weld
F—Angle Weld
Continued on next page TF44157,00006FF –19–25APR07–3/4

060807
PN=591
Bucket
9. Turn bucket over and weld bottom of shank to cutting

edge. On corner shank, weld area (A) with bevel weld.
face. Cover with 11 mm (0.43 in.) fillet weld. Weld all
the way to edge of cutting edge.
10. Weld area (B) with bevel weld. Penetrate 3 mm (0.12

in.) and leave a 5 mm (0.20 in.) face. Cover with 9
mm (0.35 in.) fillet weld.
11. Weld area (C) of corner shank with bevel weld.

Penetrate 3 mm (0.12 in.) and leave a 5 mm (0.20
in.) face. Cover with 11 mm (0.43 in.) fillet weld.
Leave area (D) free of weld for 19 mm (0.75 in.).
12. On center shanks, weld areas (E) with bevel weld.

Penetrate 3 mm (0.12 in.) and leave a 5 mm (0.20
in.) face. Cover with a 9 mm (0.35 in.) fillet weld.
Leave area (D) free of weld for 19 mm (0.75 in.).
–UN–07JUN91
13. Weld area (F) with angle weld. Penetrate 6 mm (0.24
in.) and leave a 11 mm (0.43 in.) face.
A—Bevel Weld and Fillet Weld
T7552AB
B—Bevel Weld and Fillet Weld
C—Bevel Weld and Fillet Weld
D—Weld Free Area
E—Bevel Weld and Fillet
F—Angle Weld
TF44157,00006FF –19–25APR07–4/4
33
3302 Backhoe Bucket Cutting Edge Remove and
4
Install
1. Remove tooth shanks in corners. Remove all shanks if

they are to be reused. (See procedure in this group.)
Continued on next page TF44157,0000700 –19–25APR07–1/5

060807
PN=592
Bucket
2. Use air arc equipment or cutting torch to remove

welds. Remove all welds from cutting edge to side
cutters.
3. Remove weld from cutting edge to bottom joint.
–UN–07JUN91
T7535AL
TF44157,0000700 –19–25APR07–2/5
4. Turn bucket over and remove weld from cutting edge

to bottom. Do not blow through bottom.
5. Cut new cutting edge to proper length for bucket,

approximately 11 mm (0.43 in.) protruding beyond side
cutter on each side.
–UN–07JUN91
T7535AK
TF44157,0000700 –19–25APR07–3/5
IMPORTANT: Cutting edge must be preheated to

177°C (350°F) to prevent brittleness in
cutting edge. Preheat area just before
welding. Use low hydrogen E-7018 dry
rods or E-70T-4 flux core process.
–UN–07JUN91
6. Set bucket on bottom and weld top first. Position 33
cutting edge and clamp. Preheat cutting edge to 177°C 3302
(350°F). Start at center of cutting edge and weld 5
toward side cutters. Use a 6 mm (0.24 in.) fillet weld.
T7535AL
7. Make 11 mm (0.43 in.) fillet weld outside bucket at
cutting edge to side cutter joint. Continue weld down
back edge.

060807
PN=593
Bucket
8. Turn bucket over and weld cutting edge to bottom with

6 mm (0.24 in.) fillet weld.
9. Install shanks. (See procedure in this group).
–UN–07JUN91
T7535AK
TF44157,0000700 –19–25APR07–5/5
33
3302
6

060807
PN=594
Group 3315
Control Linkage
33
3315
1

060807
PN=595
Control Linkage
Backhoe Control Valve Linkage—Two Lever Remove and Install
33
3315
2
–UN–25OCT06
TX1013148
Continued on next page TF44157,0000701 –19–07JUN07–1/2

060807
PN=596
Control Linkage
1—Knob (2 used) 8—Grommet (2 used) 14—Yoke (4 used) 20—Cover

2—Lever 9—Spacer (2 used) 15—Retainer (4 used) 21—Washer (2 used)
3—Lever 10—Ball Joint (4 used) 16—Pin Fastener (4 used) 22—Lock Nut (2 used)
4—Lock Nut (4 used) 11—Nut (4 used) 17—Link End (2 used) 23—Label
5—Dust Shield (2 used) 12—Rod (4 used) 18—Nut 24—Cap Screw (4 used)
6—Spring (2 used) 13—Nut (4 used) 19—Cap Screw (2 used) 25—Linkage
7—Nut (2 used)
1. Remove rear floor mat, console cover (20) and cab 4. Adjust backhoe valve linkage. See Backhoe Control
floor access plate. Lever to Valve Linkage (Two Lever) Adjustment.
(Group 9025-20.)
3. Assemble yokes to valve spools, adjust yokes so

lever base is parallel to ground.
TF44157,0000701 –19–07JUN07–2/2
33
3315
3

060807
PN=597
Control Linkage
Backhoe Control Valve Linkage—Three Lever Remove and Install
33
3315
4
–UN–15JUL03
T193127
Continued on next page TF44157,0000702 –19–07JUN07–1/2

060807
PN=598
Control Linkage
1—Link End (2 used) 15—Bellcrank 29—Lubrication Fitting 42—Spring Locking Pin (3

2—Ball Joint (4 used) 16—Rod 30—Pedal used)
3—Nut (5 used) 17—Rod 31—Grommet (2 used) 43—Pin Fastener (5 used)
4—Rod (2 used) 18—Spacer (2 used) 32—Seal (2 used) 44—Washer (4 used)
5—Nut (4 used) 19—Spacer 33—Cap Screw (2 used) 45—Spring
6—Yoke (4 used) 20—Support 34—Washer 46—Cover
7—Pin Fastener (4 used) 21—Nut (2 used) 35—Hook Bolt 47—Knob (3 used)
8—Bracket 22—Lock Nut (2 used) 36—Ring (2 used) 49—Cover
9—Bearing (6 used) 23—Nut 37—Pin 50—Label
10—Lock Nut (7 used) 24—Cap Screw (2 used) 38—Control Lever 51—Cover
11—Washer (5 used) 25—Washer (10 used) 39—Control Lever 52—Screw (4 used)
12—Cap Screw 26—Spring Washer (6 used) 40—Control Lever 53—Retainer (4 used)
13—Washer 27—Bushing (2 used) 41—Link 54—Kit
14—Spacer 28—Cap Screw (2 used)
1. Remove rear floor mat, console cover and cab floor 5. Measure perpendicular distance from floor plate to
access plate. top of pedal toe flange.
2. Remove and install parts as shown. Specification

Floor Plate-to-Top of Pedal Toe
Flange—Distance .......................................................... 138—148 mm
3. Apply cure primer and then thread lock and sealer 5.4—5.8 in.
to thread of cap screw (33).
6. Apply instant gel adhesive to threads of backhoe
4. Compress washers (26) to give an approximate control knobs (47).
endplay of 1.5 mm (0.06 in.).
7. Adjust backhoe valve linkage. See Backhoe Control
Specification
Pedal-to-Bracket Washers—
Lever to Valve Linkage (Four Lever) Adjustment—If
End Play ................................................................................. 1.5 mm Equipped. (Group 9025-20.)
0.06 in.
TF44157,0000702 –19–07JUN07–2/2
33
3315
5

060807
PN=599
Control Linkage
Backhoe Fifth Function Pedal Remove and Install
33
3315
6
–UN–16JUL03
T193181

060807
PN=600
Control Linkage
1—Pedal 7—Spring Washer (2 used) 13—Retainer 19—Ball Joint

2—Bushing (2 used) 8—Nut (2 used) 14—Lock Nut 20—Cover
3—Cap Screw 9—Angle 15—Yoke 21—Label
4—Washer 10—Nut (2 used) 16—Nut 22—Label
5—Grommet 11—Cap Screw (2 used) 17—Stud 23—Kit
6—Label 12—Pin Fastener 18—Nut
Backhoe Fifth Function Pedal (Two Lever) Remove 4. Compress spring washers (7) to specific clearance.
and Install
Specification
1. Remove rear floor mat, console cover and cab floor Spring Washer—Clearance ..................................................... 1.5 mm
0.06 in.
access plate.
3. Tighten balljoint (19) to foot control locknut (14).
Specification
Balljoint-to-Foot Control
Locknut—Torque ..................................................................... 25 N•m
18 lb-ft
33
3315
7

060807
PN=601
Control Linkage
33
3315
8
–UN–25FEB03
T165817

060807
PN=602
Control Linkage
1—Label 7—Cover 13—Pin Fastener 18—Lock Nut

2—Label 8—Ball Joint 14—Cap Screw 19—Washer
3—Pedal 9—Nut 15—Yoke 20—Lock Nut
4—Lock Nut (4 used) 10—Stud 16—Bushing (2 used) 21—Bracket
5—Cap Screw (4 used) 11—Nut 17—Pivot 21—Kit
6—Grommet 12—Retainer
Backhoe Fifth Function Pedal (Pilot Control) 4. Install yoke (15) to valve spool using pin (13).
Remove and Install Install retaining clip (12) to pin.
1. Remove console cover, rear floor mat, boom lock 5. Install cab floor access plate, rear floor mat,
control lever knob, and cab floor access plate. console cover from kit, and boom lock control lever
knob. Apply LOCTITE TY9370 medium strength
2. Inspect and install parts as shown. thread locker to boom lock control lever knob.
3. Attach pedal assembly to existing machine frame 6. Install pedal (3) to pivot using hardware (4, 5).
holes using hardware (4 and 5). Tighten to Tighten to specification.
specification.
Specification
Specification Cap Screw—Torque ................................................................ 28 N•m
Cap Screw—Torque ................................................................ 28 N•m 20.5 lb-ft
20.5 lb-ft
LOCTITE is a trademark of Henkel Corporation TF44157,0000703 –19–25APR07–4/4
33
3315
9

060807
PN=603
Control Linkage
Backhoe Sixth Function Pedal Remove and Install
33
3315
10
–UN–21JUL03
T193198

060807
PN=604
Control Linkage
1—Ball Joint 7—Pin Fastener 13—Bushing (2 used) 19—Grommet

2—Nut 8—Cap Screw (2 used) 14—Pedal 20—Cover
3—Stud 9—Angle 15—Washer 21—Label
4—Nut 10—Nut (2 used) 16—Cap Screw 22—Screw (4 used)
5—Yoke 11—Nut (2 used) 17—Lock Nut 23—Kit
6—Retainer 12—Spring Washer (2 used) 18—Label
Backhoe Sixth Function Pedal Remove and Install 2. Remove and install parts as shown.
(Two Lever)
3. Compress washers (12) to give an approximate
1. Remove rear floor mat, console cover and cab floor endplay of 1.5 mm (0.06 in.).
access plate.
33
3315
11

060807
PN=605
Control Linkage
33
3315
12
–UN–25FEB03
T165820

060807
PN=606
Control Linkage
1—Pedal 7—Ball Joint 12—Pin Fastener 17—Bracket

2—Cap Screw (4 used) 8—Nut 13—Yoke 18—Pivot
3—Lock Nut (4 used) 9—Stud 14—Cap Screw 19—Washer
4—Label 10—Nut 15—Bushing (2 used) 20—Lock Nut
5—Grommet 11—Spring Locking Pin 16—Lock Nut 21—Kit
6—Cover
Backhoe Sixth Function Pedal (Pilot Control) 4. Install yoke to valve spool using pin (12). Install
Remove and Install retaining clip (11) to pin.
1. Remove console cover, rear floor mat, boom lock 5. Install cab floor access plate, rear floor mat,
control lever knob, and cab floor access plate. console cover from kit, and boom lock control lever
knob. Apply LOCTITE TY9370 medium strength
2. Install parts as shown. thread locker to boom lock control lever knob.
3. Attach pedal assembly to existing machine frame 6. Install pedal (1) to pivot using hardware (2, 3).
holes using hardware (2 and 3). Tighten to Tighten to specifications.
specification.
Specification
Specification Cap Screw—Torque ................................................................ 28 N•m
Cap Screw—Torque ................................................................ 28 N•m 20.5 lb-ft
20.5 lb-ft
LOCTITE is a trademark of Henkel Corporation TF44157,0000704 –19–25APR07–4/4
Backhoe Pilot Control Valve Remove and

Install
1. Park machine on level surface. Lower all attachments.
2. Stop engine, place transmission control lever (TCL) in

neutral and set park brake. 33
3315
13
3. Release hydraulic system pressure. See Hydraulic
4. Drain or apply vacuum to hydraulic reservoir. See

Change Hydraulic Reservoir Oil. (Operator’s Manual.)

060807
PN=607
Control Linkage
5. Remove pilot control tower cover (3).
3—Pilot Control Tower Cover
33
–UN–14APR03
3315
14 T189533
Pilot Control Tower

060807
PN=608
Control Linkage

–UN–23AUG88
7. Tag and disconnect all hydraulic hoses (2). Close all

X9811
8. Remove pilot control valve (4).
9. Repair or replace pilot control valve, if necessary.
10. Install pilot control valve.
11. Install all hydraulic hoses.
12. Install cap screws.
13. Install pilot control tower cover.
14. Fill or release vacuum to hydraulic reservoir. See


2—Hydraulic Hose (6 used)
4—Pilot Control Valve
–UN–10APR03
33
3315
T189534B
15
Pilot Control Valve
TF44157,0000705 –19–07MAY07–3/3

060807
PN=609
Control Linkage
Backhoe Pilot Control Valve Disassemble and Assemble
33
3315
16
–UN–18MAR03
T188654
Left Side

060807
PN=610
Control Linkage
1—Hydraulic Pilot Control 5—Plunger (4 used) 10—Return Spring (4 used) 15—Adapter (3 used)
Valve (Left Hand) 6—Seal (4 used) 11—O-ring 16—O-ring (6 used)
2—Handle 7—O-ring (4 used) 12—Cap Screw (2 used) 17—Orifice (used only in port
3—Wobble Plate Assembly 8—Kit (4 used) 13—O-ring (6 used) 4, boom down function)
4—Socket Head Cap Screw (3 9—Metering Spring (4 used) 14—Adapter (3 used) 18—Seal Kit
used)
33
3315
17

060807
PN=611
Control Linkage
33
3315
18
–UN–18MAR03
T188655
Right Side

060807
PN=612
Control Linkage
1—Hydraulic Pilot Control 5—Kit (4 used) 10—Return Spring (4 used) 14—O-ring (6 used)
Valve (Right Hand) 6—Seal (4 used) 11—O-ring 15—Adapter (6 used)
2—Handle 7—O-ring (4 used) 12—Cap Screw (2 used) 16—O-ring (6 used)
3—Wobble Plate Assembly 8—Kit (4 used) 13—Orifice (only used in port 17—Seal Kit
4—Socket Head Cap Screw (3 9—Metering Spring (4 used) 2, crowd out function)
used)
Disassemble and assemble as shown.
TF44157,0000706 –19–25APR07–4/4
Backhoe Pilot Control Tower Remove and

Install
1. Park machine on level surface. Lower all attachments.
2. Stop engine, place transmission control lever (TCL) in



TF44157,0000707 –19–08MAY07–1/3
33
5. Remove rear floor mat (43). 3315
19
6. Remove foot pedal (45).
7. Remove boom lock control lever knob (48).

–UN–08APR03
8. Remove console cover (46).
9. Remove cab floor access plate (44).

T189398B
43—Floor Mat
44—Floor Plate
45—Foot Pedals (if equipped)
46—Console Cover
47—Backhoe Boom Lock Lever
48—Knob

060807
PN=613
Control Linkage

–UN–23AUG88
10. Tag and disconnect pilot control hydraulic hoses (41).
Close all openings using caps and plugs.
11. Remove pilot control tower (28).
X9811
12. Repair or replace parts, as necessary.
13. Install pilot control tower.
14. Connect pilot control hydraulic hoses.
15. Install cab floor access plate.
–UN–07APR03
16. Install console cover.
17. Install boom lock control lever knob.
T189359B
18. Install foot pedal.
Pilot Control Tower Removal
19. Install rear floor mat
28—Pilot Control Tower Mounting Hardware
41—Pilot Control Hydraulic Hose (6 per side)
20. Fill or release vacuum to hydraulic reservoir. See
33
3315
20
TF44157,0000707 –19–08MAY07–3/3

060807
PN=614
Control Linkage
33
3315
21

060807
PN=615
Control Linkage
Backhoe Pilot Control Tower Disassemble and Assemble
33
3315
22
–UN–07APR04
T199111

060807
PN=616
Control Linkage
1—Cover 10—Lever 20—Cap Screw 30—Isolator

2—Self-Locking Screw 11—Bracket 21—Cap Screw 31—Cover
3—Washer (5 used) 12—Pin 22—Spacer 32—Support
4—Self-Locking Screw (4 13—Sleeve 23—Snap Ring 33—Link End (2 used)
used) 14—Bushing 24—Washer 34—Nut (6 used)
5—Isolator 15—Cap Screw (2 used) 25—Strap 35—Plug (2 used)
6—Spring Washer 16—Spacer 26—Ball Bearing (2 used) 36—Guide
7—Washer 17—Washer (14 used) 27—Washer (5 used) 37—Washer (2 used)
8—Washer (2 used) 18—Nut (4 used) 28—Cap Screw (4 used) 38—Safety Sign
9—Cap Screw (3 used) 19—Gas Operated Cylinder 29—Arm 39—Label
TF44157,0000708 –19–25APR07–2/3
NOTE: Gas shock should be orientated with rod end (42)

down to extend shock life.
Disassemble and assemble parts as shown.
42—Rod End of Gas Shock
–UN–08APR03
33
3315
23
T189397B
Gas Shock
TF44157,0000708 –19–25APR07–3/3

060807
PN=617
Control Linkage
Backhoe Boom Lock Control Lever and Linkage Remove and Install
33
3315
24
–UN–03OCT02
T160156

060807
PN=618
Control Linkage
1—Knob 6—Grommet 11—Spring Locking Pin (2 15—Spring

2—Cap Screw (4 used) 7—Spring Washer used) 16—Clamp (2 used)
3—Washer (4 used) 8—Snap Ring 12—Bumper 17—Washer (2 used)
4—Pillow block 9—Washer (3 used) 13—Pivot Rod 18—Cap Screw (2 used)
5—Lever 10—Pin (2 used) 14—Link
TF44157,0000709 –19–25APR07–2/2
33
3315
25

060807
PN=619
Control Linkage
Backhoe Boom Lock Remove and Install
33
3315
26
–UN–28DEC06
TX1017103
Continued on next page TF44157,000070A –19–22MAY07–1/2

060807
PN=620
Control Linkage
1—Nut (2 used) 4—Rod 7—Snap Ring (4 used) 9—Lock

2—Yoke (2 used) 5—Spring Pin (2 used) 8—Lock 10—Pin Fastener (2 used)
3—Spring (2 used) 6—Pin
1. Disassemble and assemble parts as shown.
2. After assembly of backhoe boom lock, see Check

and Adjust Backhoe Boom Lock. (Operator’s
Manual.)
TF44157,000070A –19–22MAY07–2/2
33
3315
27

060807
PN=621
Control Linkage
33
3315
28

060807
PN=622
Group 3340
Frames
Dipperstick Remove and Install
1. Extend boom and dipperstick straight out. Put a floor

stand under outer end of boom. Support dipperstick
with a hoist.


4. Remove backhoe bucket and bucket links. See

Backhoe Bucket and Bucket Links Remove and Install.
–UN–27FEB97
(Group 3302.)
A—Bucket Cylinder Line (2 used)

B—Boom-to-Dipperstick Pin
T107574
C—Crowd Cylinder-to-Dipperstick Pin
Continued on next page TF44157,000070B –19–25APR07–1/3
33
3340
1

060807
PN=623
Frames

–UN–23AUG88
5. Tag and remove bucket cylinder lines (A). Close all
6. Remove crowd cylinder-to-dipperstick pin (C).
X9811
device.
NOTE: If bucket links are removed, fasten rod end of

bucket cylinder to dipperstick.
7. Remove boom-to-dipperstick pin (B) and remove

dipperstick using a hoist.
Specification
Dipperstick with Bucket Cylinder
and Links—Weight (approximate) ................................................... 204 kg
450 lb
33
3340
2

060807
PN=624
Frames
–UN–12NOV01
T148086
1—Bolt 3—Shim (As Required) 5—Washer (not serviced) 7—Outer Plate
2—Washer 4—Shim (As Required) 6—Pin
8. Adjust dipperstick and boom: 10. Align crowd cylinder and install pin.
• Use shims (4) if pin (6) does not extend to 11. Connect bucket cylinder lines.
surface of outer plate (7). Shim until flush with
outer plate surface. 12. Install backhoe bucket and bucket links. See
• Use shims (3) if pin (7) extends beyond surface Backhoe Bucket and Bucket Links Remove and 33
3340
of outer plate. Shim until flush with end of pin. Install. (Group 3302.)
3
9. Tighten pin cap screw (1) to specifications.
Specification
Dipperstick-to-Boom
Connecting Pin Cap Screw—
Torque.................................................................................... 620 N•m
460 lb-ft
TF44157,000070B –19–25APR07–3/3

060807
PN=625
Frames
Boom Remove and Install


3. Remove dipperstick. See Dipperstick Remove and


device.
4. Support boom with a hoist.
Specification
Boom with Cylinders—Weight
(approximate)................................................................................... 385 kg
850 lb
Continued on next page TF44157,000070C –19–25APR07–1/2
33
3340
4

060807
PN=626
Frames

–UN–23AUG88
5. Tag and disconnect hydraulic hoses (A). Close all
openings with caps and plugs.
6. Remove pivots (E) and boom cylinder rod end pin.
X9811
7. Remove cap screws (F) and remove boom pivot pins.
8. Remove boom.
9. Repair or replace boom, as necessary.
10. Install boom and boom pivot pins.
11. Install pivots and boom cylinder rod end pin.
12. Connect hydraulic hoses to backhoe control valve.
13. Install dipperstick to boom. See Dipperstick Remove

and Install. (Group 3340)
A—Hydraulic Hose (4 used)

B—Collar (2 used)
C—Pin
D—Snap Ring (2 used)
E—Pivot (2 used)
F—Cap Screw (2 used)
–UN–06MAR97
33
3340
5
T107582
TF44157,000070C –19–25APR07–2/2

060807
PN=627
Frames
Swing Frame Remove and Install
1. Remove dipperstick. See Dipperstick Remove and

2. Remove boom. See Boom Remove and Install. (Group

3340.)

device.
3. Connect swing frame to hoist using a lift strap (A).
Specification
Swing Frame—Weight
(approximate)................................................................................... 123 kg
272 lb
4. Remove swing cylinder pivot pins (D).
–UN–27FEB97
5. Remove lower pivot pin (H).
6. Remove upper pivot pin (B).
T107577
7. Remove swing frame repair or replacement.
NOTE: Weight of backhoe is supported at the lower pivot.

There must be clearance between upper main
frame pivot boss and the ears of the swing frame.
8. Install thrust washer on top of lower pivot boss.
NOTE: Install swing frame pins so that cross-drilled holes

align with holes in swing frame to ease hardware
33 installation.
3340
–UN–27FEB97
6
9. Position swing frame and install pin (B) even with top
surface. Secure in position with cap screw (C) and nut.
10. Install pin (H) even with top surface of swing frame.
T107578
Make sure pin is through thrust washer. Secure in

position with cap screw (E) and nut.
A—Lift Strap
11. Align swing cylinders and install pins (D) from the B—Upper Pivot Pin
bottom. Top of pins should be even with casting. C—Upper Pivot Locking Cap Screw
Secure in position with rod and snap ring. D—Swing Cylinder Pivot Pin (2 used)
E—Lower Pivot Locking Cap Screw
F—Swing Cylinder Locking Snap Ring and Rod
G—Thrust Washer
H—Lower Pivot Pin
Continued on next page TF44157,000070D –19–07MAY07–1/2

060807
PN=628
Frames
12. Install boom. See Boom Remove and Install. (Group

3340.)
13. Install dipperstick. See Dipperstick Remove and

TF44157,000070D –19–07MAY07–2/2
33
3340
7

060807
PN=629
Frames
Extendible Dipperstick Extension Remove and Install
33
3340
8
–UN–24JAN07
TX1017918
Continued on next page TF44157,000070E –19–07MAY07–1/7

060807
PN=630
Frames
1—Lock Nut (18 used) 18—Pin 36—Lubrication Fitting (3 49—Washer

2—Cap Screw (6 used) 20—Wear Plate used) 50—Washer
3—Cap Screw (22 used) 22—Dipperstick (internal) 37—Bushing (2 used) 51—Washer
5—Washer (2 used) 23—Wear Plate 38—Bushing (2 used) 52—Snap Ring
8—Washer (10 used) 25—Dipperstick (external) 39—Bushing 53—Snap Ring
10—Spring Pin 30—Nut 41—Shim (8 used) 54—Pin
13—Snap Ring (2 used) 31—Pin 42—Shim (4 used) 55—Pin
14—Snap Ring (2 used) 33—Wear Plate (2 used) 43—Shim (8 used) 56—Washer
15—Hydraulic Cylinder 34—Shim (4 used) 44—Wear Plate (8 used) 57—Kit
17—Quick Lock Pin 35—Spacer
Extendible Dipperstick Extension Remove
33
3340
9

060807
PN=631
Frames
1. Park machine on level surface. Extend boom and

extendible dipperstick to maximum reach with bucket
dumped and lowered to the ground.

–UN–23AUG88
X9811
4. Remove bucket and bucket links. See Backhoe Bucket
and Bucket Links Remove and Install. (Group 3302.)

5. Tag and disconnect hydraulic hoses from bucket

cylinder. Close all openings using caps and plugs.
6. Remove wear plates (20,23) and shims (34,42), if

equipped.

device.
7. Install proper lifting device (3) to dipperstick extending

member (1).
–UN–04MAY06
Specification
Dipperstick Extension—Weight
33 (approximate)................................................................................... 385 kg
850 lb
TX1007204A
3340
10
8. Remove extending cylinder rod end pin (4).
Dipperstick Extension in Vertical Position
9. Extend stabilizers fully, raise boom and put dipperstick
extension in vertical position on the ground. 1—Dipperstick (Extending Member)
2—Bucket Cylinder
10. Raise the boom, with extension supported, and 3—Lifting Strap
4—Extending Cylinder Rod End Pin
moving dipperstick toward machine raise boom until
5—Dipperstick (Stationary Member)
extension can be removed.

060807
PN=632
Frames
11. Inspect internal dipperstick wear plates (33, 44).

Replace if necessary.
12. Inspect extendible dipperstick cylinder. Repair or

replace if necessary. See Backhoe Extendible
Dipperstick Cylinder Remove and Install. See
Backhoe Extendible Dipperstick Cylinder Disassemble
and Assemble. (Group 3360.)
33
3340
11

060807
PN=633
Frames
33
3340
12
–UN–24JAN07
TX1017918

060807
PN=634
Frames
1—Lock Nut (18 used) 18—Pin 36—Lubrication Fitting (3 49—Washer

2—Cap Screw (6 used) 20—Wear Plate used) 50—Washer
3—Cap Screw (22 used) 22—Dipperstick (internal) 37—Bushing (2 used) 51—Washer
5—Washer (2 used) 23—Wear Plate 38—Bushing (2 used) 52—Snap Ring
8—Washer (10 used) 25—Dipperstick (external) 39—Bushing 53—Snap Ring
10—Spring Pin 30—Nut 41—Shim (8 used) 54—Pin
13—Snap Ring (2 used) 31—Pin 42—Shim (4 used) 55—Pin
14—Snap Ring (2 used) 33—Wear Plate (2 used) 43—Shim (8 used) 56—Washer
15—Hydraulic Cylinder 34—Shim (4 used) 44—Wear Plate (8 used) 57—Kit
17—Quick Lock Pin 35—Spacer
Extendible Dipperstick Extension Install

from heavy component. Use appropriate
IMPORTANT: It is important to maintain running
lifting device.
clearance between pad and inner
member of extension. Specification
Dipperstick Extension—
Do not damage shims. Only put in Approximate Weight ................................................................. 385 kg
enough shims to fill clearance and 850 lb
then remove one shim.
5. Using proper lifting device, lift extension to vertical
Locking nuts should be replaced if position. With stabilizers fully extended raise boom
removed to prevent loosening. and install dipperstick into the extension.
1. Install shims (34), as required, to fill clearance and 6. Install extendible dipperstick cylinder rod end pin
then remove one shim. If wear pads are replaced, (18) through dipperstick (25) and cylinder (15) rod
install new lock nuts (1) with flat face of nut mating end.
to dipperstick.
7. Install upper wear plates (20, 23) and shims (34,42)
NOTE: Do not over tighten cap screws or wear plate as required. For every three shims added, remove
deformation may result. a washer (8) from under the head of cap screws (2)
to allow adequate thread engagement.
2. Tighten hex socket cap screws (3) to specification.
8. Apply cure primer, then thread lock and sealer
Specification (medium strength) to threads of cap screws (2).
Extendible Dipperstick Hex Tighten cap screws (2).
Socket Cap Screws for Internal
Wear Plates—Torque ....................................................... 22—27 N•m Specification 33
16—20 lb-ft Extendible Dipperstick Hex 3340
Socket Cap Screws for Outer 13
3. Apply a light film of grease on wear pads. Pads—Torque ................................................................... 47—54 N•m
35—40 lb-ft
4. Tighten cylinder head end 90° fitting to
specifications.
Specification
Extendible Cylinder Head End
90° Fitting—Torque................................................................ 104 N.m
76 lb.-ft

060807
PN=635
Frames
9. Connect hydraulic hoses to bucket cylinder.
10. Install bucket and bucket links. See Backhoe Bucket

and Bucket Links Remove and Install. (Group 3302.)
11. Cycle extension in and out to ensure proper
–UN–27FEB02
operation.
1—O-Ring (2 Used)
2—Fitting
T151963
3—Hose, Rod End
4—Hose, Head End
5—O-Ring
6—Elbow Fitting
7—O-Ring
8—Extendible Cylinder
TF44157,000070E –19–07MAY07–7/7
33
3340
14

060807
PN=636
Group 3360
Hydraulic System
Backhoe Control Valve Remove and Install
1. Park machine on level surface. Lower backhoe bucket

on the floor with dipperstick extended straight out.
Lower stabilizers to ground.
–UN–29SEP00
T134098B
hydraulic lines or hoses. Tighten all
2. Stop engine and release hydraulic system pressure.

9025-25.)
3. Drain hydraulic reservoir or attach vacuum pump to

retain hydraulic oil in reservoir.
Specification
9.8 gal
Continued on next page TF44157,000070F –19–07MAY07–1/5
33
3360
1

060807
PN=637
Hydraulic System
–UN–29SEP00
–UN–29SEP00
T134077B
T134076B
Backhoe Valve Hose Connections—Left View Backhoe Valve Hose Connections—Right View
4. Disconnect auxiliary flow control solenoid wire leads

(17).

–UN–23AUG88
5. Tag and disconnect hoses (1—16). On machines with
X9811
pilot controls, remove all pilot lines to backhoe valve.
Close all openings with caps and plugs.
1—Hose (auxiliary tool return, if equipped)
2—Hose (to head end of extendible dipperstick
cylinder)
3—Hose (to rod end of extendible dipperstick
cylinder)
4—Hose (to rod end of crowd cylinder)
5—Hose (to head end of crowd cylinder)
33 6—Hose (to head end of bucket cylinder)
3360 7—Hose (to rod end of bucket cylinder)
2 8—Hose (to head end of boom cylinder)
9—Hose (to rod end of boom cylinder)
10—Hose (swing cylinder—left)
11—Hose (swing cylinder—right)
12—Hose (auxiliary, if equipped)
13—Hose (auxiliary, if equipped)
14—Hose (auxiliary tool, if equipped)
15—Hose (to steering valve—supply pressure)
16—Hose (to steering valve—load sense)
17—Auxiliary Flow Control Solenoid Wire Leads
(if equipped)

060807
PN=638
Hydraulic System
6. Remove cab rear windows. See Rear Windows

7. Remove rear floor mat (2).
8. Remove four cap screws to remove console cover (1).
–UN–01NOV00
9. Remove cab floor access plate (3).
10. Remove backhoe control levers (5). See Backhoe
T133984C
Control Valve Linkage Two Lever Remove and Install.
(Group 3315.)
11. Remove foot pedals (4), if equipped. See Backhoe

Fifth Function Pedal Remove and Install. See
Backhoe Sixth Function Pedal Remove and Install.
(Group 3315.)
–UN–14MAR03
1—Console Cover
2—Rear Floor Mat
3—Floor Plate
4—Foot Pedals
5—Backhoe Control Levers
T188535B
7—Floor Plate
8—Boom Lock Control Lever Knob
9—Boom Lock Control Lever
Boom Lock Control Lever—Pilot Controls
33
3360
3

060807
PN=639
Hydraulic System

disconnecting hydraulic lines and hoses.
Tighten all connections before applying
pressure.
12. Tag and disconnect hoses (10—17). Close all

openings with caps and plugs.
–UN–21FEB03
13. Remove lower pilot lines from backhoe valve, if
equipped.
IMPORTANT: Check to verify all hoses have been
T165760B
disconnected from backhoe valve.
Hydraulic Hoses—Manual Controls

CAUTION: Avoid personal injury from heavy
component. Use appropriate lifting device.
14. Connect lifting strap and hoist to backhoe valve

mounting bracket to remove backhoe valve.
Specification
Backhoe Control Valve—Weight
(approximate)..................................................................................... 61 kg
135 lb
15. Remove four mounting bracket cap screws. Move

backhoe valve mounting bracket assembly forward
–UN–21FEB03
and carefully remove assembly.
16. Repair backhoe valve as necessary. See Backhoe

Control Valve Disassemble and Assemble. (Group
T165764B
3360)
33 Hydraulic Hoses—Pilot Controls
3360 NOTE: When installing the backhoe valve, leave the
4 valve bolts loose until after torquing the valve to 10—Hydraulic Hose
the mounting plate. This will insure the valve will 11—Hydraulic Hose
not be twisted if the mounting plate is slightly 12—Hydraulic Hose
warped. 13—Hydraulic Hose
14—Hydraulic Hose
15—Hydraulic Hose
17. Install backhoe valve mounting bracket assembly. 16—Hydraulic Hose
Tighten cap mounting bracket cap screws. 17—Hydraulic Hose
Specification
Backhoe Control Valve Mounting
Bracket Cap Screws—Torque ........................................................ 46 N•m
34 lb-ft

060807
PN=640
Hydraulic System
18. Connect all hydraulic hoses.
19. Connect hose retainers to lower corners of mounting

bracket.
20. Install backhoe control lever assembly and foot

pedals.
21. Connect backhoe valve linkage.
22. Connect auxiliary flow control solenoid wire

connector, if equipped.
23. Install cab floor access plate.
24. Install backhoe control lever console and floor mat.
25. Install cab rear windows.
26. Check hydraulic oil level. See Check Hydraulic

27. Start the machine and check for leaks.
TF44157,000070F –19–07MAY07–5/5
33
3360
5

060807
PN=641
Hydraulic System
Backhoe Control Valve Disassemble and Assemble
12
11
10
–UN–06OCT00
1 8
T134369
3 4 5 6 7
T134369
1—Outlet Section 6—Swing Section 10—Orifice (one in each 12—O-Ring (one between each
2—Auxiliary Flow Section 7—Electro-Hydraulic Auxiliary section except the section)
3—Crowd Section Section auxiliary flow section)
4—Bucket Section 8—Inlet Section 11—Compensator Valve (one
5—Boom Section 9—Nut and Tie Rod Assembly in each section except the
(3 used) auxiliary flow section)
33
IMPORTANT: Keep all components for each valve 2. To aid in assembly, identify each section with a
3360
6 section together as a set. mark.
3. Remove nuts and tie rods (9).

heavy object. Use appropriate lifting device.
4. Carefully remove sections (1—8) so as not to lose
Specification or damage O-rings (12), orifices (10), compensators
Backhoe Control Valve— (11) and load sense logic check. Keep
Weight (approximate) ................................................................. 64 kg compensators and valve sections together as a set.
140 lb
5. Inspect O-rings between each section for wear or
1. Set control valve assembly vertically on a work damage. Replace as necessary.
bench with the inlet section on the bottom.

060807
PN=642
Hydraulic System
6. Inspect compensator parts (1 and 4), springs (3),

orifices (2 and 5), and load sense logic checks (7) for
scoring, wear, or damage. Replace as necessary.
7. Apply clean hydraulic oil to all internal parts.
1—Upper Compensator
2—Orifice
3—Spring
4—Lower Compensator
5—Orifice Set Screw
6—Compensator Bore
7—Load Sense Logic Check
–UN–14APR07
TX1020800A
33
3360
7

060807
PN=643
Hydraulic System
8. Remove and inspect the anti-drift poppet parts (1—4)

used on the boom, crowd, and extendible dipperstick
sections only.
9. Assemble sections making sure load sense logic
–UN–14APR07
checks, compensators, spring and O-ring remain in
position. Install the tie rods in so the shorter threaded
length end is on the bottom. Fully screw on the nuts on
the shorter threaded end.
TX1020799A
10. Install nuts on other end of tie rods and snug tight; do
not make final torque.
IMPORTANT: Tighten tie rod evenly and at several 1—Plug with O-Ring
intervals to prevent valve spool binding 2—Spring Guide
3—Spring
or leakage between sections. 4—Anti-Drift Poppet
11. Lay valve assembly horizontally on bench supported

by blocks under the mounting feet. Tighten tie rod
nuts to specification.
Specification
Backhoe Control Valve Tie Rod
Nuts (1/2-20 Threads)—Torque ................................................... 100 N•m
74 lb-ft
Specification
Backhoe Control Valve Tie Rod
Nuts (7/16-20 Threads)—Torque ................................................... 65 N•m
48 lb-ft
TF44157,0000710 –19–25APR07–3/3
33
3360
8

060807
PN=644
Hydraulic System
Backhoe Control Valve Spool Seals Remove

and Install 5
1. Clean valve assembly to remove any dirt and debris.

4
2. Remove two socket head cap screws (5) and retainer
plate (4) from top of valve section.
3
2
lip seal (2).
1—Spool 1
2—Lip Seal
–UN–22AUG05
4—Retainer Plate
5—Socket Head Cap Screw (2 used)
T213604
TF44157,0000711 –19–25APR07–1/5
4. Remove two screws (6) and cap (14) from bottom of

valve section.
5. Remove spool end screw (12) to remove spring seats 7 11

(13), spring (9), and retainer plate (10).
8
10
6. Use an O-ring pick to remove spool wiper ring (8) and 33
lip seal (7). 3360
9 9
13
7—Lip Seal
9—Spring 12
10—Retainer Plate
14
–UN–22AUG05
11—Spool
14—Cap 6
T213605

060807
PN=645
Hydraulic System
IMPORTANT: Do not damage OD or ID of new seal

during installation. Installation tool
JDG374 must be used to install lip seal.
15
Lube seals with hydraulic oil prior to
installation.
16
7. Use JDG734 Hydraulic Valve Seal Replacer to install
new lip seal at each end of spool.
8. Place lip seal (16) on end of tool driver (17) with open
side of seal away from tool driver. 17
NOTE: Lip end of sleeve ID is cone-shaped to compress
–UN–22AUG05
lip seal for installation.
9. Carefully slide sleeve (15) over lip seal (16) and tool
driver (17) with raised lip of sleeve away from driver.
T213606
Do not push lip seal (16) through sleeve (15).
Installation Tool
10. Place tool assembly over end of spool with raised lip
into counterbore of valve section. 15—Tool Sleeve
16—Lip Seal
11. Push tool driver (17) to install lip seal (16) into valve 17—Tool Driver
housing.
12. Spin tool driver 180 degrees and hold down for
several seconds. This will allow air to escape and
seal will seat in valve counter bore.
33
3360
10

060807
PN=646
Hydraulic System
13. Install spool wiper ring (8).
14. Repeat steps (7 —13) for opposite end of spool.

7 11
15. Install retainer plate (10), spring seats (13) and spring
8
(9). 10
16. Torque Spool End Screw (12) to specification.

9
Specification
13
84 lb-in.
12
17. Install cap (14) and cap screws (6). Torque screws to
14
–UN–22AUG05
specification.
Specification
Retaining Screw (2 used)—
6
Torque ........................................................................................... 9.5 N•m
T213605
84 lb-in.

7—Lip Seal
9—Spring
10—Retainer Plate
11—Spool
14—Cap
33
3360
11

060807
PN=647
Hydraulic System
18. Install retainer plate (4) and screws (5). Tighten

screws to specification. 5
Specification
84 lb-in. 4
19. Check for correct installation of seals by pushing 3

down on spool (1). Spool must return to neutral 2
position.
1—Spool
2—Lip Seal 1
3—Spool Wiper
–UN–22AUG05
4—Retainer Plate
5—Screw (2 used)
T213604
TF44157,0000711 –19–25APR07–5/5
33
3360
12

060807
PN=648
Hydraulic System
Backhoe Control Valve Relief Valves Remove and Install
–UN–09OCT00
T134375
1—System Relief Valve Outlet 4—Bucket Curl Circuit Relief 7—Auxiliary Flow Circuit Relief 10—Boom Raise Circuit Relief
Section Valve with Anticavitation Valve without 11—Bucket Dump Circuit
2—Extendible Dipperstick 5—Boom Lower Circuit Relief Anticavitation Relief Valve Without
Shut-off Plugs (2 used) Valve 8—Load Sense Relief Valve Anticavitation
3—Crowd Out Circuit Relief 6—Swing Left Circuit Relief 9—Swing Right Circuit Relief 12—Crowd In Circuit Relief
Valve without Valve with Anticavitation Valve with Anticavitation Valve With Anticavitation
Anticavitation
33
3360
1. To aid in assembly, put identification marks on the IMPORTANT: Relief valve installation torque is 13
relief valves and the valve section. port size specific. Verify diameter of
port with specifications listed below.
2. Remove relief valves.
5. Install relief valves. Tighten relief valves to
3. Remove and inspect O-rings and backup rings for specification.
damage. If damaged, check housing for cause.
Relief Valve Torque—Specification
4. Install new O-rings and backup rings. Relief Valve without
Anticavitation 22.35 mm (0.88
in.)—Torque ............................................................................. 45 N•m
IMPORTANT: Relief valves must be installed in the 33 lb-ft
correct ports for proper valve
function.

060807
PN=649
Hydraulic System
Relief Valve without IMPORTANT: Relief valves MUST be adjusted

Anticavitation 26 mm (1.06
when valves are disassembled or
in.)—Torque ............................................................................. 61 N•m
45 lb-ft replaced. Failure to do so could
Relief Valve with Anticavitation cause damage to hydraulic system.
22.35 mm (0.88 in.)—Torque .................................................. 45 N•m
33 lb-ft 6. Circuit Relief Valve Test With Remote Pump.
Relief Valve with Anticavitation
(Group 9025-25.)
26 mm (1.06 in.)—Torque ....................................................... 61 N•m
45 lb-ft
TF44157,0000712 –19–26APR07–2/2
33
3360
14

060807
PN=650
Hydraulic System
33
3360
15

060807
PN=651
Hydraulic System
Backhoe Inlet Section Disassemble and Assemble
33
3360
16
–UN–12DEC06
TX1014524

060807
PN=652
Hydraulic System
1—Valve Section Body 7—Seal (2 used) 16—Snap Ring 21—O-ring (5 function valve)
2—Load Sense Pressure Relief 8—Fitting Plug (6 and 7 17—O-ring 22—Seal Kit (22.35 mm relief
Valve function) 18—Fitting (5 function valve) valve seal kit) (0.88 in.
4—Nut 12—O-ring 19—O-ring (5 function valve) relief valve seal kit)
5—O-ring (2 used) 13—O-ring 20—Fitting Plug (5 function
6—Nut 15—Spring valve)
1. Inspect all parts for wear or damage. Replace Specification

O-rings. Replace all seals. See Backhoe Control Backhoe Inlet Section Plug—
Torque............................................................................... 22—27 N•m
Valve Spool Seals Remove and Install. (Group 16—20 lb-ft
3360.)
5. Torque load sense pressure relief valve to
2. Inspect all orifices. Orifices must be clear of any specification. See Backhoe Control Valve Relief
debris. Valves Remove and Install. (Group 3360.)
3. Put clean hydraulic oil on all internal parts.
4. Install spring and plug assembly (8 or 18 and 20).

Tighten plug to specification.
TF44157,0000713 –19–25APR07–2/2
33
3360
17

060807
PN=653
Hydraulic System
Backhoe Flow Control Section Disassemble and Assemble
33
3360
18
–UN–18DEC06
TX1016705

060807
PN=654
Hydraulic System
1—Flow Control Hydraulic 11—Compression Spring 22—Adjuster 33—O-ring

Valve 12—Poppet 23—Sleeve 34—O-ring
2—Electro-Hydraulic Poppet 13—Disk 24—Plunger 35—O-ring
Solenoid with Connector 14—O-ring 25—Nut 36—Backup Ring
3—Screw (2 used) 15—Drain Plug 26—Spacer 37—Seal Kit (22.35 mm Relief
5—O-ring 16—O-ring 27—Nut Valve Seal) (0.88 in. Relief
6—Screw 17—Cap Screw 28—Kit (Spool Stop) Valve Seal)
7—Washer 18—O-ring 29—Pressure Relief Valve 38—O-ring
8—Spring 19—O-ring 30—O-ring 39—O-ring (2 used)
9—Housing 20—Housing 31—O-ring 40—Seal Kit (Electro-Hydraulic
10—Poppet 21—Nut 32—Backup Ring Seal Kit)
1. Inspect all parts for wear or damage. Replace all Specification

Backhoe Flow Control Section
seals. See Backhoe Control Valve Spool Seals
Electro-Hydraulic Valve Block
Remove and Install. (Group 3360.) Screws—Torque ..................................................................... 9.5 N•m
84 lb-in
IMPORTANT: Spool must be installed in the valve
housing the same way spool was 4. Install parts (15 and 16) and tighten plug (15) to
removed for proper operation of the specification.
hydraulic function.
Specification
2. Put clean hydraulic oil on spool. Install spool in Backhoe Flow Control Section
housing. Plug—Torque ........................................................................... 65 N•m
48 lb-ft
3. Apply thread lock and sealer (medium strength) to

5. Torque pressure relief valve to specification. See
threads of screws (3). Install electro-hydraulic valve
Backhoe Control Valve Relief Valves Remove and
block assembly and tighten screws (3 to
specification.
TF44157,0000714 –19–25APR07–2/2
33
3360
19

060807
PN=655
Hydraulic System
Backhoe Swing Section Disassemble and Assemble
33
3360
20
–UN–12DEC06
TX1014553

060807
PN=656
Hydraulic System
1—Swing Section Valve 10—Housing 20—Washer 29—Spring

2—Screw (2 used) 11—Retainer (2 used) 21—Screw 30—O-ring
3—Plate (2 used) 12—Extension Spring 22—O-ring 31—Washer
4—Spool 13—Screw 23—Backup Ring 32—Washer
5—Seal (2 used) 14—Cap 24—O-ring 33—Poppet
6—Seal (2 used) 16—Screw (2 used) 25—Spring 34—Seal Kit (Relief Valve)
7—Compression Spring 17—Relief Valve (2 used) 26—Housing 35—Seal Kit (Spool Seal)
8—O-ring 18—Sleeve 27—Retainer 36—Seal Kit (26 mm, 1.06 in.
9—Disk 19—Washer 28—Backup Ring (2 used) Relief Valve Seal Kit)
1. Inspect parts for wear or damage. Replace lip and 4. Install plate (3), end cap (14) and tighten screws
wiper seals. See Backhoe Control Valve Spool (16) to specification.
Seals Remove and Install. (Group 3360.)
Specification
IMPORTANT: Spool must be installed in the valve Backhoe Swing, Boom, Bucket,
Crowd and Extendible Section
housing the same way spool was End Cap Screws—Torque ...................................................... 9.5 N•m
removed for proper operation of the 84 lb-in
hydraulic function.
5. Install and tighten screws (2) to specification.
2. Apply clean hydraulic oil on spool and install spool
into valve housing. Specification
Backhoe Swing, Boom, Bucket,
3. Clean threads of spool and spool end screw (13) Crowd and Extendible Section
Seal Plate Screws—Torque ................................................... 5.5 N•m
with cure primer. Install parts (5, 6, 11 and 12) on 48 lb-in
spool. Apply thread lock and sealer (high strength)
on spool end screw (13) and spool tang. Tighten to 6. Torque relief valves (17) to specification. See
specification. Backhoe Control Valve Relief Valves Remove and
Specification
Spool End Screw—Torque ..................................................... 9.5 N•m
84 lb-in.
NOTE: Torque specification for end cap screws

(manual controls) and pilot cap screws (pilot
controls) is the same.
33
3360
21
TF44157,0000715 –19–07MAY07–2/2

060807
PN=657
Hydraulic System
Backhoe Boom Section Disassemble and Assemble
33
3360
22
–UN–12DEC06
TX1014538

060807
PN=658
Hydraulic System
1—Boom Section Valve 8—Kit (Relief Valve Cartridge) 19—Plug (2 used) 34—Backup Ring (2 used)
2—Pressure Relief Valve (2150 9—O-ring 20—O-ring 35—O-ring (2 used)
psi Anticavitation) 10—Backup Ring 21—Retainer (2 used) 36—O-ring
4—Pressure Relief Valve (26 11—O-ring 22—Extension Spring 37—Spring
mm, 1.06 in. port) (5500 psi 12—Screw (2 used) 23—Screw 38—O-ring
Not Anticavitation) 13—Plate (2 used) 24—Cap 39—Seal Kit (Spool Seal)
5—Pressure Relief Valve (26 14—Seal (2 used) 25—Screw (2 used) 40—Seal Kit (Relief Valve Seal
mm, 1.06 in. port) (5500 psi 15—Seal (2 used) 27—Spring and Spring)
Anticavitation) 16—Compression Spring 28—Seal Kit (Drift Check) 41—Seal Kit (26 mm, 1.06 in.
6—Housing 17—Disk 33—O-ring (2 used) Relief Valve Seal Kit)
7—Spring 18—O-ring
1. Inspect parts for wear or damage. Replace lip and 4. Install plate (13), end cap (24) and tighten screws
wiper seals. See Backhoe Control Valve Spool (25) to specification.
Specification
IMPORTANT: Spool must be installed in the same Backhoe Swing, Boom, Bucket,
valve section as was removed for End Cap Screws—Torque ...................................................... 9.5 N•m
proper operation of the hydraulic 84 lb-in.
function.
with cure primer. Install parts (14, 15, 21 and 22) 48 lb-in
on spool. Apply thread lock and sealer (high
strength) on spool end screw (23). Tighten to 6. Install plugs (19) to specification.
specification.
Specification
Specification Backhoe Boom Crowd and
Backhoe Swing, Boom, Bucket, Extendible Section Plug—
Crowd and Extendible Section Torque....................................................................... 65 N•m (48 lb-ft)
84 lb-in.
7. Torque relief valves (2,4, and 5) to specification.
See Backhoe Control Valve Relief Valves Remove
(manual controls) and pilot cap screws (pilot 33
controls) is the same. 3360
23
TF44157,0000716 –19–25APR07–2/2

060807
PN=659
Hydraulic System
Backhoe Bucket Section Disassemble and Assemble
33
3360
24
–UN–12DEC06
TX1014549

060807
PN=660
Hydraulic System
1—Bucket Section Valve 7—Fitting Plug (26 mm, 1.06 15—Seal (2 used) 25—Seal
2—Pressure Relief Valve (26 in. port) (4 and 5 function) 16—Compression Spring 26—O-ring (2 used)
mm, 1.06 in. port) (4600 8—Backup Ring 17—Disk 27—Nut
psi) (6 and 7 function) 9—O-ring 18—O-ring 28—Nut
(anticavitation) 10—O-ring (2 used) 19—Retainer (2 used) 32—Seal
3—Pressure Relief Valve 11—Backup Ring 20—Extension Spring 34—O-ring (4 used)
(22.35 mm, 0.88 in. port) (6 12—Screw (2 used) 21—Screw 35—Seal Kit (26 mm, 1.06 in.
and 7 function) (not 13—Plate (2 used) 22—Cap relief valve seal kit)
anticavitation) 14—Seal (2 used) 23—Screw (2 used) 36—Seal Kit (spool seal)
6—Fitting Plug (22.35 mm, 0.88
in. port) (4 and 5 function)
1. Inspect parts for wear or damage. Replace lip and Specification

wiper seals. See Backhoe Control Valve Spool
Seals Remove and Install. (Group 3360.) End Cap Screws—Torque ...................................... 9.5 N•m (84 lb-in.)
IMPORTANT: Spool must be installed in the valve 5. Install and tighten screws (12) to specification.
housing the same way spool was
removed for proper operation of the Specification
hydraulic function. Backhoe Swing, Boom, Bucket,
2. Apply clean hydraulic oil on spool and install spool Seal Plate Screws—Torque ................................................... 5.5 N•m
48 lb-in.
into valve housing.
6. Torque relief valves (2,4, and 5) to specification.
3. Clean threads of spool and spool end screw (21)
See Backhoe Control Valve Relief Valves Remove
with cure primer. Install parts (14, 15, 19 and 20)
strength) on spool end screw (21) and spool tang.
7. Install plug (6), if using a five function backhoe
Tighten to specification.
control valve. Torque to specification.
Specification
Backhoe Swing, Boom, Bucket, Specification
Crowd and Extendible Section 22.35 mm (0.88 in.) Plug—
Spool End Screw—Torque ..................................................... 9.5 N•m Torque...................................................................................... 45 N•m
84 lb-in. 33 lb-ft
NOTE: Torque specification for end cap screws 8. Install plug (7), if using a five function backhoe
(manual controls) and pilot cap screws (pilot control valve. Torque to specification.
33
Specification
26 mm (1.06 in.) Plug—Torque ............................................... 65 N•m 25
4. Install plate (13), cap (22) and tighten screws (23) 48 lb-ft
to specification.
TF44157,0000717 –19–25APR07–2/2

060807
PN=661
Hydraulic System
Backhoe Crowd Section Disassemble and Assemble
33
3360
26
–UN–12DEC06
TX1014552

060807
PN=662
Hydraulic System
1—Crowd Section Valve 12—O-ring 23—Seal (2 used) 34—Kit (relief valve cartridge)
3—Pressure Relief Valve (26 13—O-ring 24—Compression Spring 35—Backup Ring
mm, 1.06 in. port) (4750 14—Backup Ring (2 used) 25—Disk 36—O-ring
psi) (not anticavitation) 15—O-ring (2 used) 26—O-ring 37—Spring
4—Pressure Relief Valve (26 16—Screw (2 used) 27—Retainer (2 used) 38—Housing
mm, 1.06 in. port) (4750 17—Plate (2 used) 28—Extension Spring 39—Seal Kit (26 mm, 1.06 in.
psi) (anticavitation) 18—Seal Kit (drift check) 29—Screw relief valve seal kit)
5—Pressure Relief Valve (3800 19—Plug (2 used) 30—Cap 40—Seal Kit (spool seal)
psi) 20—O-ring (2 used) 31—Screw (2 used) 41—Seal Kit (relief valve seal
10—O-ring 21—Spring 33—O-ring and spring)
11— 22—Seal (2 used)
1. Inspect parts for wear or damage. Replace lip and 4. Install plate (17), cap (30) and tighten screws (31)
wiper seals. See Backhoe Control Valve Spool to specification.
Specification
IMPORTANT: Spool MUST be installed in the same Backhoe Swing, Boom, Bucket,
valve section as was removed for End Cap Screws—Torque ...................................................... 9.5 N•m
proper operation of the hydraulic 84 lb-in.
function.
with cure primer. Install parts (22, 23, 27 and 28) 48 lb-in.
strength) on spool end screw (29) and spool tang. 6. Install parts (19—21) and tighten plug (18) to
Tighten to specification. specification.
Specification
Specification
Backhoe Boom, Crowd and
Extendible Section Plug—
Spool End Screw—Torque ..................................................... 9.5 N•m Torque...................................................................................... 65 N•m
84 lb-in. 48 lb-ft

(manual controls) and pilot cap screws (pilot 33
27
TF44157,0000718 –19–25APR07–2/2

060807
PN=663
Hydraulic System
Backhoe Extendible Dipperstick Section Disassemble and Assemble
33
3360
28
–UN–12DEC06
TX1014554

060807
PN=664
Hydraulic System
1—Extendible Dipperstick 7—Compression Spring 13—Screw 20—Spring

Section Valve 8—Disk 14—Cap 21—Poppet
2—Screw (2 used) 9—O-ring 16—Screw (2 used) 22—Fitting Plug (2 used)
3—Plate (2 used) 10—Housing 17—Plug (2 used) 23—Seal (2 used)
4—Spool Valve 11—Retainer (2 used) 18—O-ring (2 used) 24—Seal Kit (drift check)
5—Seal (2 used) 12—Extension Spring 19—Washer 25—Seal Kit (spool seal)
6—Seal (2 used)
1. Inspect parts for wear or damage. Replace lip and Specification

wiper seals. See Backhoe Control Valve Spool
Seals Remove and Install. (Group 3360.) End Cap Screws—Torque ...................................................... 9.5 N•m
84 lb-in.
IMPORTANT: Spool MUST be installed in the same
valve section as was removed for 5. Install and tighten screws (2) to specification.
proper operation of the hydraulic
function. Specification
2. Apply clean hydraulic oil on spool and install spool Crowd and Extendible Section
into valve housing. 48 lb-in.
3. Clean threads of spool and spool end screw (13) 6. Install parts (18—21, 23) and tighten plugs (17, 22)
with cure primer. Install parts (5, 6, 11 and 12) on to specification.
spool. Apply thread lock and sealer (high strength)
on spool end screw (13) and spool tang. Tighten to Specification
specification. Backhoe Boom, Crowd and
Extendible Section Plug—
Specification Torque...................................................................................... 65 N•m
Backhoe Swing, Boom, Bucket, 48 lb-ft
84 lb-in.
4. Install plate (3), cap (14) and tighten screws (16) to

specification.
33
3360
29
TF44157,0000719 –19–25APR07–2/2

060807
PN=665
Hydraulic System
Backhoe Outlet Section Disassemble and Assemble
33
3360
30
–UN–19DEC06
TX1014589
Continued on next page TF44157,000071A –19–25APR07–1/2

060807
PN=666
Hydraulic System
1—Outlet Section 2—Fitting Plug 3—Seal
1. Remove and install seal, if necessary. See Backhoe

Control Valve Spool Seals Remove and Install.
(Group 3360.)
2. Put clean hydraulic oil on seal before assembly.
3. Plug (1) installation torque.
Specification
Shut-Off Plug (Installation)—
Torque...................................................................................... 65 N•m
48 lb-ft
TF44157,000071A –19–25APR07–2/2
33
3360
31

060807
PN=667
Hydraulic System
Pilot Control Manifold Valve Remove and

Install
1. Park machine. Lower all attachments and set park

brake.
–UN–23AUG88
X9811
3. Tag and disconnect hydraulic lines (2, 5-7) from PCMV

(4). Close all openings using caps and plugs.
4. Disconnect pilot enable solenoid harness (3).
5. Remove PCMV cap screws (1).
6. Repair or replace PCMV.
7. Connect pilot enable solenoid harness (3).
–UN–09APR03
8. Connect hydraulic lines (2, 5-7) from PCMV (4).
9. Fill or remove vacuum to hydraulic reservoir.
T189439B
10. Start engine and test for leaks.
1—Pilot Control Manifold Valve Cap Screw (2

used)
33
2—Hydraulic Return Line to Tank
3360
3—Pilot Enable Solenoid Harness
32
4—Pilot Control Manifold Valve (PCMV)
5—Hydraulic Supply Line From PCMV to Pilot
Control Valves
6—Hydraulic Return Line From Pilot Control
Valves to PCMV.
7—Hydraulic Supply Line From Backhoe Valve to
PCMV
8—PCMV Accumulator
9—Pilot Control Pressure Reducing Adjustment
TF44157,000071B –19–07MAY07–1/1

060807
PN=668
Hydraulic System
Pilot Control Manifold Valve Disassemble and Assemble
–UN–22MAR04
T198598
1—Pneumatic Accumulator 5—Washer (2 used) 9—Cap Screw (2 used) 13—Check Valve
2—O-ring 6—Cap Screw (2 used) 10—Backup Ring 14—Fitting Plug
3—Pressure Reducing 7—Nut (2 used) 11—O-ring 15—Fitting Plug (6 used)
Cartridge Valve 8—Solenoid Valve 12—O-ring 16—Seal Kit
4—Flow Control Hydraulic
Valve
33
1. Disassemble parts as shown. 2. Replace parts as necessary. 3360
33
TF44157,000071C –19–25APR07–1/1

060807
PN=669
Hydraulic System
Pattern Select Valve Remove and Install
1. Stop engine and set park brake.

–UN–23AUG88
X9811
3. Remove rear cab windows. See Rear Windows

4. Remove auxiliary function pedals from pivot shaft, if

equipped. See Backhoe Fifth Function Pedal Remove
and Install. See Backhoe Sixth Function Pedal Remove
5. Remove boom lock control lever knob, console cover,

and floor mat.
6. Remove floor plate exposing backhoe control valve.

33
3360
34

060807
PN=670
Hydraulic System
–UN–25APR03
T189897A
Pattern Select Valve Plumbing
2—Retaining Hardware 3—Hydraulic Hose
NOTE: Tag and mark all hoses prior to removal. Cap 10. Remove cap screws (2) from hose connection
and plug all openings. bracket.
8. Disconnect hoses (3) from fittings on bracket. 11. Remove hose connection bracket.
9. Disconnect wiring harness to pattern select 12. Remove pattern select valve from hose connection 33
solenoids on pattern select valve. bracket. 3360
35

060807
PN=671
Hydraulic System
–UN–17MAR03
T188601
Pattern Select Valve Fittings
1—Nut 3—Washer 5—Fitting (2 used) 7—45 ORFS Fitting (2 used)

2—Mounting Bolt 4—Washer 6—Fitting (2 used)
NOTE: Install washer (4) between valve and bracket. 17. Install boom lock control lever console cover.
13. Mount pattern select valve to hose bracket using 18. Apply LOCTITE medium strength threadlock to
hardware (1—4). boom lock control lever knob and install boom lock
33 control lever knob.
3360 14. Tighten bracket hardware to specification.
36 19. Install auxiliary function pedals.
Specification
Cap Screw—Torque ............................................................. 11.5 N•m 20. Fill hydraulic reservoir, if needed. See Change
102 lb-in.
Hydraulic Reservoir Oil. (Operator’s Manual.)
15. Install all hoses to proper ports.
16. Remove vacuum, if used. Install rear floor plate

and floor mat.
LOCTITE is a trademark of Henkel Corporation TF44157,000071D –19–07MAY07–3/3

060807
PN=672
Hydraulic System
33
3360
37

060807
PN=673
Hydraulic System
Pattern Select Valve Disassemble and Assemble
33
3360
38
–UN–23DEC06
TX1017075

060807
PN=674
Hydraulic System
1—Nut (2 used) 3—Washer (2 used) 4—Cap Screw (2 used) 5—Pattern Select Valve
2—Washer (4 used) (solenoid coil 2 each)
(cartridge valve 2 each)
TF44157,0000737 –19–25APR07–2/2
Backhoe Bucket Cylinder Remove and Install
1. Park the machine and set the park brake.
2. Turn engine off and release hydraulic system

pressure. See Hydraulic Circuit Pressure Release.
(Group 9025-25.)

3. Attach backhoe bucket cylinder to a hoist.
Specification
Backhoe Bucket Cylinder—
75 lb
33
3360
39

060807
PN=675
Hydraulic System

–UN–23AUG88
4. Tag and disconnect hydraulic hoses to bucket cylinder
(B). Close all openings with caps and plugs. Remove
hose clamps on cylinder.
X9811
5. Remove pin (A) from bucket linkage.
6. Remove pin (C) from head end of bucket cylinder and

remove bucket cylinder.
7. Repair or replace bucket cylinder as necessary.
8. Install pin (C) at head end of bucket cylinder.
–UN–15FEB97
9. Install pin (A) through bucket linkage and bucket
cylinder rod.
T107239
10. Connect lines and install hose clamps.
TF44157,000072B –19–25APR07–2/2
33
3360 Backhoe Bucket Cylinder Disassemble and
40
Assemble
For backhoe bucket cylinder repair information, see 120

–UN–17JAN89
TS225
TF44157,000072C –19–25APR07–1/1

060807
PN=676
Hydraulic System
Backhoe Crowd Cylinder Remove and Install
1. Park the machine and set the park brake.
2. Turn engine off and release hydraulic system

pressure. See Hydraulic Circuit Pressure Release.
(Group 9025-25.)

3. Attach crowd cylinder to a hoist.
Specification
Backhoe Crowd Cylinder—Weight
(approximate)..................................................................................... 59 kg
130 lb
TF44157,000072D –19–25APR07–1/2

–UN–23AUG88
4. Tag and disconnect hydraulic hoses to crowd cylinder
(B). Close all openings with caps and plugs.
5. Remove pin (A) from dipperstick and crowd cylinder
X9811
rod end.
6. Remove pin (C) from head end of crowd cylinder and

remove crowd cylinder. 33
3360
41
7. Repair or replace crowd cylinder as necessary.
8. Install pin (A) at head end of crowd cylinder. –UN–15FEB97
9. Install pin (C) through dipperstick and crowd cylinder

rod end.
T107236
10. Connect hydraulic hoses.
TF44157,000072D –19–25APR07–2/2

060807
PN=677
Hydraulic System
Backhoe Crowd Cylinder Disassemble and

Assemble
For backhoe crowd cylinder repair information, see 125

–UN–17JAN89
TS225
TF44157,000072E –19–25APR07–1/1
33
3360
42

060807
PN=678
Hydraulic System
Backhoe Boom Cylinder Remove and Install
1. Lower boom to the ground.
2. Stop engine and set the park brake.
–UN–23AUG88
CAUTION: Avoid personal injury from lifting
X9811
heavy object. Use an appropriate lifting device.
4. Attach boom cylinder (B) to hoist using a lifting strap.
Specification
Backhoe Boom Cylinder—Weight
(approximate) ................................................................................... 82 kg
180 lb
–UN–15FEB97
T107234
5. Tag and disconnect hydraulic hoses from boom

cylinder. Close all openings with caps and plugs.
6. Remove pin (A) from boom cylinder head end and

boom.
7. Remove pins (D and F) to remove boom lock pivot (E).
8. Remove boom cylinder rod end pin (C) to remove

boom cylinder. 33
3360
9. Repair or replace boom cylinder as necessary. 43
10. Position boom cylinder in place and install pins (A

and C).
11. Install pins (D and F) and boom lock pivot (E).

A—Boom Cylinder Head End Pin
B—Boom Cylinder
C—Boom Cylinder Rod End Pin
D—Pin
–UN–15FEB97
E—Boom Lock Pivot

F—Pin
T107235

060807
PN=679
Hydraulic System
12. Connect boom cylinder hydraulic hoses.
13. Maneuver backhoe to check out boom cylinder

operation.
TF44157,000072F –19–07MAY07–2/2
Backhoe Boom Cylinder Disassemble and

Assemble
For backhoe boom cylinder repair information, see 125

–UN–17JAN89
TS225
TF44157,0000730 –19–25APR07–1/1
Backhoe Swing Cylinder Remove and Install
1. Swing backhoe to one side and lower backhoe bucket

to ground.

TF44157,0000731 –19–25APR07–1/5
33
3360
44 CAUTION: To avoid injury from escaping fluid
–UN–23AUG88
4. Tag and disconnect hydraulic hoses from swing

cylinder. Close all openings with caps and plugs.
X9811

060807
PN=680
Hydraulic System
5. Remove trunnion cap screws (A) and trunnion (B).

6. Attach cylinder to a hoist using a lifting strap.
–UN–15FEB97
Specification
Swing Cylinder—Weight
(approximate) ................................................................................... 48 kg
T107238
106 lb
7. Remove swing cylinder rod end pin (C) through swing

frame.
8. Remove swing cylinder.
9. Repair or replace swing cylinder as necessary.
TF44157,0000731 –19–25APR07–3/5
10. Inspect swing cylinder bushings (A). Remove if

replacement is necessary.
11. Install new bushings even with trunnion using 49 mm

and 59 mm disks.
–UN–25MAY89
33
3360
45
T6131AK

060807
PN=681
Hydraulic System
12. Inspect upper and lower trunnion block bushings.

Remove if replacement is necessary using 60 mm
and 69 mm disks.
13. Install new bushings with 60 mm and 69 mm disks.

Align grease passages in trunnion block and frame
–UN–15MAY91
with passage in bushing. Be sure lower trunnion
bushing is pushed into seat flange.
Press upper bushing even with top of trunnion block.
T7531CA
IMPORTANT: Be sure hydraulic fittings in swing
cylinder are tightened to specification.
Cylinder movement and hydraulic
pressure can loosen fittings and cause
a leak.
14. If hydraulic fittings were removed from cylinder, install

and tighten fittings to specification.
Specification
Swing Cylinder Hydraulic
Fittings—Torque ............................................................................. 34 N•m
25 lb-ft
15. Install lower trunnion spacer washer.
16. Install swing cylinder into lower trunnion.
17. Install pin through swing frame and cylinder rod end.
18. Install trunnion over upper swing cylinder bushings.
19. Install trunnion cap screws and tighten.
33
20. Connect hydraulic hoses to cylinder.
3360
46 21. Maneuver backhoe to test swing cylinder operation.
TF44157,0000731 –19–25APR07–5/5

060807
PN=682
Hydraulic System
Backhoe Swing Cylinder Disassemble and

Assemble
For backhoe swing cylinder repair information, see 120

–UN–17JAN89
TS225
TF44157,0000732 –19–25APR07–1/1
33
3360
47

060807
PN=683
Hydraulic System
Backhoe Stabilizer Cylinder Remove and

Install
1. Lower stabilizer to ground. On machines equipped with

reversible feet, remove the foot before lowering
stabilizer arm to ground.
–UN–23AUG88
X9811

–UN–11OCT00
4. Tag and disconnect hydraulic hoses on stabilizer
cylinder (2). Close all openings with caps and plugs.
5. Remove hose clamp.
T134570B
object. Use appropriate lifting device. 1—Stabilizer Rod End Pin
2—Stabilizer Cylinder
6. Attach stabilizer cylinder (2) to a hoist with a lifting 3—Stabilizer Head End Pin
strap.
Specification
Stabilizer Cylinder—Weight
(approximate)..................................................................................... 39 kg
86 lb
33 7. Remove stabilizer cylinder rod end pin (1).

3360
48 8. Remove stabilizer cylinder head end pin (3) and
remove stabilizer cylinder (2).
9. Repair or replace stabilizer cylinder as necessary.
10. Install stabilizer cylinder and pins (1 and 3).
11. Connect hydraulic hoses and hose clamp.
12. Maneuver stabilizer up and down to check operation

of stabilizer cylinder.
TF44157,0000733 –19–07MAY07–1/1

060807
PN=684
Hydraulic System
Backhoe Stabilizer Cylinder Disassemble and

Assemble
For backhoe stabilizer cylinder repair information, see 120

–UN–17JAN89
TS225
TF44157,0000734 –19–25APR07–1/1

Remove and Install
1. Remove extendible dipperstick extension. See

Extendible Dipperstick Extension Remove and Install.
(Group 3340.)
2. Extend arm out.

33
3360
49

060807
PN=685
Hydraulic System

–UN–23AUG88
5. Tag and disconnect extendible dipperstick cylinder
hydraulic hoses.
X9811
6. Attach a hoist to extendible dipperstick cylinder.
Specification
Extendible Dipperstick Cylinder—
95 lb
7. Remove extendible dipperstick cylinder head end pin

and slowly remove cylinder.
8. Repair or replace extendible dipperstick cylinder as

necessary.
9. Position extendible dipperstick cylinder in place and

install extendible dipperstick cylinder head end pin.
10. Torque elbow fitting to head end of extendible

dipperstick cylinder.
Specification
Elbow Fitting-to-Extendible
Dipperstick Cylinder Head End—
Torque ............................................................................................ 73 N•m
33 54 lb-ft
3360
50 11. Connect extendible dipperstick cylinder hydraulic
hoses.
12. Install extendible dipperstick extension. See

Extendible Dipperstick Extension Remove and Install.
(Group 3340.)
TF44157,0000735 –19–07MAY07–2/2

060807
PN=686
Hydraulic System

For backhoe extendible dipperstick cylinder repair

information, see 120 Series Hydraulic Cylinders.
(TM-H120A.)
–UN–17JAN89
TS225
TF44157,0000736 –19–25APR07–1/1
33
3360
51

060807
PN=687
Hydraulic System
33
3360
52

060807
PN=688
Section 99
Dealer Fabricated Tools
Contents
Page
Group 9900—Dealer Fabricated Tools

DFRW20 Compressor Holding Fixture. . . . . .99-9900-1
DFT1101 Cab and ROPS Lift Bracket . . . . . .99-9900-2
DFT1285 Engine Support Bracket . . . . . . . . .99-9900-3
DFT1286 Backlash Measurement Tool . . . . .99-9900-5
99

060807
PN=1
Contents
99

060807
PN=2
Group 9900
DFRW20 Compressor Holding Fixture
–UN–20SEP89
RW13619
A—102 mm (4 in.) D—6.4 mm (0.25 in.) G—254 mm (10 in.) J—Fillet Weld
B—76 mm (3 in.) E—19 mm (0.75 in.) H—114 mm (4.5 in.) K—Two Holes
C—70 mm (2.75 in.) F—152 mm (6 in.) I—178 mm (7 in.)
This tool is used to hold the air conditioning • Two pieces of threaded rod, 13 mm (1/2 in.) threads
compressor during disassembly and assembly. x 178 mm (7 in.) long
• Four lock washers and nuts
MATERIALS:
• Two pieces of steel plate, approximately 70 x 120

mm (2-3/4 x 4 in.) and 152 x 254 mm (6 x 10 in.)
JH38101,00003C3 –19–04MAY07–1/1
99
9900
1

060807
PN=691
DFT1101 Cab and ROPS Lift Bracket
–UN–23SEP98
T117366
A—Drill Six Holes (0.625 in.) B—Weld C—U46161 Lift Eyes Welded to
Tube with 0.25 in. Fillet
Weld
Used to remove and install cab or ROPS. • U46161 U-Bolts (4 used)

• JT01748 Lift Brackets (2 used)
Material: • 0.625 in. x 3.00 in. "F" Grade Cap Screws (2 used)
• 2.0 in. x 2.0 in. x 0.250 in. Square Tube
99 JH38101,00003C4 –19–04MAY07–1/1
9900
2

060807
PN=692
DFT1285 Engine Support Bracket
63.3 mm
(2.49 in)
13 mm 2 1 1 2
(0.51 in)
30 mm 63.3 mm
(1.18 in) (2.49 in)
101.6 mm
(4.0 in)
790 mm
119 mm (31.10 in)
(4.69 in) 552 mm 8.153 mm
(21.73 in) (0.32 in)
41.53 mm
(1.64 in)
R4.48 mm
–UN–16APR07
(0.18 in)
5 mm
(0.2 in)
706.94 mm 43.713 mm
TX1020774
(27.83 in) 8.153 mm
(1.72 in) (0.32 in)
TX1020774
DFT1285 Cross Bar
Continued on next page JH38101,00003C5 –19–04MAY07–1/3
99
9900
3

060807
PN=693
99
9900
4
–UN–16APR07
TX1020775
DFT1285 Spacers
Continued on next page JH38101,00003C5 –19–04MAY07–2/3

060807
PN=694
Used to support engine during while transmission is • C Channel Steel (C4 x 7.25)
being removed and installed. • 4 Cap Screws (10 mm x 1.5 mm x 80 mm)
MATERIALS:
JH38101,00003C5 –19–04MAY07–3/3
DFT1286 Backlash Measurement Tool
95 mm
(3.74 in)
25.4 mm
(1 in)
Dia. 15.875 mm Dia. 15.875 mm

(.625 in) (.625 in)
178 mm
(7 in)
–UN–30APR07
TX1022775
TX1022775
DFT1286 Backlash Measurement Tool
Used to measure backlash between ring gear and • 2 Cap Screws (7/16 x 30)
pinion. • 3/8 in. 1020 Steel
MATERIALS:
JH38101,00003C6 –19–04MAY07–1/1
99
9900
5

060807
PN=695
99
9900
6

060807
PN=696
Index
Page Page
A Remove and install . . . . . . . . . . . . . . . .33-3360-43

Backhoe boom lock
Air cleaner Remove and install . . . . . . . . . . . . . . . .33-3315-26
Remove and install . . . . . . . . . . . . . . . . .05-0520-2 Backhoe boom lock control lever and linkage
Air conditioning compressor Remove and install . . . . . . . . . . . . . . . .33-3315-24
Disassemble and assemble . . . . . . . . . .18-1830-8 Backhoe boom section
Remove and install . . . . . . . . . . . . . . . . .18-1830-3 Disassemble and assemble . . . . . . . . .33-3360-22
Air conditioning compressor clutch Backhoe bucket and bucket links
Disassemble and assemble . . . . . . . . . .18-1830-5 Remove and install . . . . . . . . . . . . . . . . .33-3302-1
Air conditioning compressor manifold Backhoe bucket cylinder
Inspect . . . . . . . . . . . . . . . . . . . . . . . . . .18-1830-7 Disassemble and assemble . . . . . . . . .33-3360-40
Air conditioning freeze switch Remove and install . . . . . . . . . . . . . . . .33-3360-39
Remove and install . . . . . . . . . . . . . . . .18-1830-18 Backhoe bucket section
Air ducts Disassemble and assemble . . . . . . . . .33-3360-24
Disassemble and assemble . . . . . . . . .18-1830-26 Backhoe bucket tooth shank
Air suspension seat Remove and install . . . . . . . . . . . . . . . . .33-3302-2
Disassemble and assemble . . . . . . . . .18-1821-12 Backhoe bucket tooth tips
Antenna Remove and install . . . . . . . . . . . . . . . . .33-3302-2
Remove and install . . . . . . . . . . . . . . . . .20-2001-2 Backhoe control valve
Anticavitation valve Spool seals, remove and install. . . . . . . .33-3360-9
Loader, disassemble and assemble . . .31-3160-13 Backhoe control valve inlet section
Arm rest Disassemble and assemble . . . . . . . . .33-3360-16
Disassemble and assemble . . . . . . . . . .18-1821-2 Backhoe control valve linkage three lever
Attachment coupler Remove and install . . . . . . . . . . . . . . . . .33-3315-4
Remove and install . . . . . . . . . . . . . . . . .31-3104-1 Backhoe control valve linkage two lever
Attachment coupler cylinder Remove and install . . . . . . . . . . . . . . . . .33-3315-2
Disassemble and assemble . . . . . . . . . .31-3104-4 Backhoe control valve relief valves
Remove and install . . . . . . . . . . . . . . . . .31-3104-3 Remove and install . . . . . . . . . . . . . . . .33-3360-13
Attachments Backhoe control valve section
Adding safely . . . . . . . . . . . . . . . . . . . .00-0001-12 Disassemble and assemble . . . . . . . . . .33-3360-6
Operating safely . . . . . . . . . . . . . . . . . .00-0001-12 Backhoe coupler
Auxiliary flow section, backhoe Safety signs . . . . . . . . . . . . . . . . . . . . .00-0001-19
Disassemble and assemble . . . . . . . . .33-3360-18
Backhoe crowd cylinder
Axle
Rear, assemble. . . . . . . . . . . . . . . . . . .02-0250-40
Remove and install . . . . . . . . . . . . . . . .33-3360-41
Rear, disassemble . . . . . . . . . . . . . . . . .02-0250-7
Backhoe crowd section
Rear, remove and install . . . . . . . . . . . . .02-0250-3
Axle, front, MFWD
Backhoe extendible dipperstick
Remove and install . . . . . . . . . . . . . . . . .02-0240-1
Use CTM4687. . . . . . . . . . . . . . . . . . . . .02-0240-4
Axle, rear Backhoe extendible dipperstick cylinder
Gear tooth contact pattern, check . . . . .02-0250-62 Disassemble and assemble . . . . . . . . .33-3360-51
Backhoe fifth function pedal (two lever)
Indx
B Backhoe outlet section
1
Backhoe auxiliary flow section Backhoe stabilizer cylinder
Disassemble and assemble . . . . . . . . .33-3360-18 Disassemble and assemble . . . . . . . . .33-3360-49
Backhoe boom Remove and install . . . . . . . . . . . . . . . .33-3360-48
Remove and install . . . . . . . . . . . . . . . . .33-3340-4 Backhoe swing cylinder
Backhoe boom cylinder Disassemble and assemble . . . . . . . . .33-3360-47
Disassemble and assemble . . . . . . . . .33-3360-44 Remove and install . . . . . . . . . . . . . . . .33-3360-44
TM10147 (08JUN07) Index-1 410J Backhoe Loader

060807
PN=1
Index
Page Page
Backhoe swing section C

Backhoe valve Cab
Remove and install . . . . . . . . . . . . . . . . .33-3360-1 Remove and Install . . . . . . . . . . . . . . . . .18-1800-1
Backover accidents Cab door and side window latch
Avoid . . . . . . . . . . . . . . . . . . . . . . . . . .00-0001-11 Adjust . . . . . . . . . . . . . . . . . . . . . . . . . .18-1810-14
Backup alarm Cab doors
Remove and install . . . . . . . . . . . . . . . . .20-2004-2 Disassemble and assemble . . . . . . . . . .18-1810-8
Volume adjustment . . . . . . . . . . . . . . . . .20-2004-3 Cab roof
Battery Remove and install . . . . . . . . . . . . . . . .18-1810-20
Explosions, prevent. . . . . . . . . . . . . . . . .00-0001-6 Cab skirts
Battery box Remove And install . . . . . . . . . . . . . . . . .19-1927-1
Disassemble and assemble . . . . . . . . . .19-1913-2 Cab upper door and side windowpanes
Boom Adjust . . . . . . . . . . . . . . . . . . . . . . . . . .18-1810-13
Backhoe, Remove and install . . . . . . . . .33-3340-4 Cautions
Loader, remove and install . . . . . . . . . . .31-3100-1 R134a Refrigerant. . . . . . . . . . . . . . . . . .18-1830-1
Boom cylinder, backhoe Charge pump
Disassemble and assemble . . . . . . . . .33-3360-44 Disassemble and assemble . . . . . . . . . .03-0360-4
Remove and install . . . . . . . . . . . . . . . .33-3360-43 Remove and install . . . . . . . . . . . . . . . . .03-0360-1
Boom cylinder, loader Chemical products
Remove and install . . . . . . . . . . . . . . . .31-3160-17 Handling . . . . . . . . . . . . . . . . . . . . . . . . .00-0001-7
Boom section, backhoe Circuit relief valve
Disassemble and assemble . . . . . . . . .33-3360-22 Loader auxiliary, disassemble and
Brake assemble . . . . . . . . . . . . . . . . . . . . . .31-3160-13
Bleeding . . . . . . . . . . . . . . . . . . . . . . . .10-1060-17 Loader boom raise and bucket curl, disassemble
Pedal adjustments . . . . . . . . . . . . . . . .10-1060-17 and assemble . . . . . . . . . . . . . . . . . .31-3160-11
Brake disk Circuit relief valve with anticavitation
Loader bucket dump, disassemble and
assemble . . . . . . . . . . . . . . . . . . . . . .31-3160-12
Brake pedal
Clutch hub
Clearance check . . . . . . . . . . . . . . . . . . .18-1830-6
Brake valve
Clutch packs
Disassemble and assemble . . . . . . . . . .10-1060-8
First and third speed clutch disassemble and
Brake Valve
assemble . . . . . . . . . . . . . . . . . . . . . .03-0350-29
Lines, disassemble and assemble. . . . .10-1060-14
High range forward, low range forward, and
Brake valve reverse disassemble and
Remove and install . . . . . . . . . . . . . . . . .10-1060-1 assemble . . . . . . . . . . . . . . . . . . . . . .03-0350-15
Bucket Install . . . . . . . . . . . . . . . . . . . . . . . . . .03-0350-69
Loader, remove and install . . . . . . . . . . .31-3102-1 Mechanical front wheel drive (MFWD) disassemble
Bucket cutting edge and assemble . . . . . . . . . . . . . . . . . .03-0350-59
Loader, crack repair . . . . . . . . . . . . . . . .31-3102-1 Remove . . . . . . . . . . . . . . . . . . . . . . . . .03-0350-8
Loader, remove and install . . . . . . . . . . .31-3102-2 Second speed disassemble and
Remove and install . . . . . . . . . . . . . . . . .33-3302-4 assemble . . . . . . . . . . . . . . . . . . . . . .03-0350-44
Bucket cylinder Clutch,
Indx Loader multi-purpose, disassemble and Air conditioning compressor, disassemble and
2
assemble . . . . . . . . . . . . . . . . . . . . . .31-3160-16 assemble . . . . . . . . . . . . . . . . . . . . . . .18-1830-5
Loader, disassemble and assemble . . .31-3160-16 Component oil
Loader, remove and install . . . . . . . . . .31-3160-15 R134a, charge procedure . . . . . . . . . . .18-1830-33
Bucket cylinder,backhoe Compressor
Remove and install . . . . . . . . . . . . . . . .33-3360-39 Air conditioning, disassemble and
Bucket section, backhoe assemble . . . . . . . . . . . . . . . . . . . . . . .18-1830-8
Disassemble and assemble . . . . . . . . .33-3360-24 Air conditioning, remove and install. . . . .18-1830-3

060807
PN=2
Index
Page Page
Compressor oil E
R134a, removal procedure . . . . . . . . . . .18-1830-4
Condenser Emergencies
Disassemble and assemble . . . . . . . . .18-1830-28 Prepare for . . . . . . . . . . . . . . . . . . . . . . .00-0001-7
Coolant heater Engine
Remove and install . . . . . . . . . . . . . . . . .05-0505-1 Install . . . . . . . . . . . . . . . . . . . . . . . . . . .04-0400-7
Counterweight Remove . . . . . . . . . . . . . . . . . . . . . . . . .04-0400-1
Remove and install . . . . . . . . . . . . . . . . .17-1749-2 Engine speed control pedal
Crowd cylinder, backhoe Remove and install . . . . . . . . . . . . . . . . .05-0515-1
Disassemble and assemble . . . . . . . . .33-3360-42 Engine support bracket
Remove and install . . . . . . . . . . . . . . . .33-3360-41 DFT1145. . . . . . . . . . . . . . . . . . . . . . . . .99-9900-3
Crowd section, backhoe Equipment, protective
Disassemble and assemble . . . . . . . . .33-3360-26 Wear . . . . . . . . . . . . . . . . . . . . . . . . . . . .00-0001-3
Cylinder Evaporator
Attachment coupler, disassemble and Remove and install . . . . . . . . . . . . . . . .18-1830-14
assemble . . . . . . . . . . . . . . . . . . . . . . .31-3104-4 Expansion valve
Attachment coupler, remove and Remove and install . . . . . . . . . . . . . . . .18-1830-32
install. . . . . . . . . . . . . . . . . . . . . . . . . .31-3104-3 Extendible dipperstick cylinder, backhoe
Loader bucket, disassemble and Disassemble and assemble . . . . . . . . .33-3360-51
assemble . . . . . . . . . . . . . . . . . . . . . .31-3160-16 Remove and install . . . . . . . . . . . . . . . .33-3360-49
Loader bucket, remove and install . . . .31-3160-15 Extendible dipperstick extension
Loader multi-purpose bucket, disassemble and Remove and install . . . . . . . . . . . . . . . . .33-3340-8
assemble . . . . . . . . . . . . . . . . . . . . . .31-3160-16 Extendible dipperstick section, backhoe
Cylinder, bachoe bucket Disassemble and assemble . . . . . . . . .33-3360-28
Cylinder, loader boom
F
Fan
D Remove and install . . . . . . . . . . . . . . . . .05-0510-1
Fan belt
Decals Remove and install . . . . . . . . . . . . . . . . .05-0510-2
Safety . . . . . . . . . . . . . . . . . . . . . . . . . .00-0001-17 Fenders
DFT1145 Remove and install . . . . . . . . . . . . . . . . .19-1927-1
Engine support bracket . . . . . . . . . . . . . .99-9900-3 Filter assembly
DFT1286 Hydraulic, remove and install . . . . . . . .21-2160-11
Backlash measurement tool . . . . . . . . . .99-9900-5 Fires, prevent . . . . . . . . . . . . . . . . . . . . . . .00-0001-6
Dipperstick Fixed front cab windows
Remove and install . . . . . . . . . . . . . . . . .33-3340-1 Disassemble and assemble . . . . . . . . . .18-1810-6
Dipperstick,extendible extension Freeze switch
Remove and install . . . . . . . . . . . . . . . . .33-3340-8 Air conditioning, remove and install. . . .18-1830-18
Disassemble and assemble Front axle
Air suspension seat. . . . . . . . . . . . . . . .18-1821-12 Non-powered, steering cylinder disassemble and
Indx
Door latches and hinges assemble . . . . . . . . . . . . . . . . . . . . . .09-0960-23 3
Adjust . . . . . . . . . . . . . . . . . . . . . . . . . .18-1810-10 Non-powered, steering cylinder remove and
Drive shaft install. . . . . . . . . . . . . . . . . . . . . . . . .09-0960-21
Remove and install . . . . . . . . . . . . . . . . .02-0225-2 Non-powered, steering cylinder
Drive shaft U-joints repair. . . . . . . . . . . . . . . . . . . . . . . . .09-0960-21
Remove and install . . . . . . . . . . . . . . . . .02-0225-4 Front axle, MFWD
Driveshaft Remove and install . . . . . . . . . . . . . . . . .02-0240-1
Pump, install . . . . . . . . . . . . . . . . . . . . .03-0350-69 Use CTM4687. . . . . . . . . . . . . . . . . . . . .02-0240-4

060807
PN=3
Index
Page Page
Front wheel Hydraulic oil cooler

Front window wiper Hydraulic pump
Front wiper motor . . . . . . . . . . . . . . . . . .18-1810-1 Disassemble and assemble . . . . . . . . . .21-2160-6
Fuel tank Remove and install . . . . . . . . . . . . . . . . .21-2160-1
Remove and install . . . . . . . . . . . . . . . . .05-0560-2 Hydraulic pump control
Fumes, exhaust Disassemble and assemble . . . . . . . . . .21-2160-8
Beware . . . . . . . . . . . . . . . . . . . . . . . . . .00-0001-5 Hydraulic reservoir
G
I
Gear tooth contact pattern
Check . . . . . . . . . . . . . . . . . . . . . . . . . .02-0250-62
Inch bolt and cap screw
Grille
Torque value. . . . . . . . . . . . . . . . . . . . . .00-0003-4
Inch series four bolt flange fitting
Grille housing
Service recommendation, torque value for high
pressure . . . . . . . . . . . . . . . . . . . . . .00-0003-20
Inspection
External, service brakes . . . . . . . . . . . . .10-1011-1
H Refrigerant hoses and tubing . . . . . . . . .18-1830-2
Instructions, follow
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . .00-0001-2
Handholds
Use correctly. . . . . . . . . . . . . . . . . . . . . .00-0001-8
Headliner
Remove and install . . . . . . . . . . . . . . . .18-1810-18 L
Heater core
Remove and install . . . . . . . . . . . . . . . .18-1830-10 Linkage
Heater/blower assembly with air conditioning and Loader bucket, remove and install . . . . .31-3115-7
pressurizer system Loader control valve, remove and
Disassemble and assemble . . . . . . . . .18-1830-22 install. . . . . . . . . . . . . . . . . . . . . . . . . .31-3115-1
High-pressure fluids Stabilizer, remove and install . . . . . . . . .31-3115-5
Avoid . . . . . . . . . . . . . . . . . . . . . . . . . . .00-0001-5 Third function loader control valve, remove and
Hood and engine enclosure install. . . . . . . . . . . . . . . . . . . . . . . . . .31-3115-3
Disassemble and assemble . . . . . . . . . .19-1910-2 Load sense relief valve
Horn Loader and stabilizer control valve, disassemble
Remove and install . . . . . . . . . . . . . . . . .20-2004-1 and assemble . . . . . . . . . . . . . . . . . .31-3160-10
Hub Loader and stabilizer control valve
Non-powered front axle, remove and Disassemble and assemble . . . . . . . . . .31-3160-3
install. . . . . . . . . . . . . . . . . . . . . . . . . .02-0230-1 Remove and install . . . . . . . . . . . . . . . . .31-3160-1
Hydraulic Loader and stabilizer control valve load sense relief
Fittings, 30° cone seat. . . . . . . . . . .00-0003-5 valve
Fittings, 37° flare . . . . . . . . . . . . . . .00-0003-5 Disassemble and assemble . . . . . . . . .31-3160-10
Indx
4
Hydraulic and transmission oil coolers Loader and stabilizer control valve relief valves
Remove and Install . . . . . . . . . . . . . . . .21-2160-19 Remove and install . . . . . . . . . . . . . . . . .31-3160-8
Hydraulic filter assembly Loader anticavitation valve
Remove and install . . . . . . . . . . . . . . . .21-2160-11 Disassemble and assemble . . . . . . . . .31-3160-13
Hydraulic fitting Loader auxiliary circuit relief valve
Flared connections . . . . . . . . . . . . . . . .00-0003-10 Disassemble and assemble . . . . . . . . .31-3160-13
Non-restricted banjo (adjustable). . . . . .00-0003-21 Loader auxiliary shutoff plug
O-ring boss with shoulder . . . . . . . . . . .00-0003-23 Disassemble and Assemble . . . . . . . . .31-3160-14

060807
PN=4
Index
Page Page
Loader boom N
Loader boom cylinder Non powered front axle
Disassemble and assemble . . . . . . . . .31-3160-18 Remove and install . . . . . . . . . . . . . . . . .02-0230-7
Remove and install . . . . . . . . . . . . . . . .31-3160-17 Non-powered front axle
Loader boom raise and bucket curl circuit relief valve Steering cylinder disassemble and
Disassemble and assemble . . . . . . . . .31-3160-11 assemble . . . . . . . . . . . . . . . . . . . . . .09-0960-23
Loader bucket Steering cylinder remove and install . . .09-0960-21
Remove and install . . . . . . . . . . . . . . . . .31-3102-1 Steering cylinder repair . . . . . . . . . . . . .09-0960-21
Loader bucket cutting edge Nozzle
Crack repair . . . . . . . . . . . . . . . . . . . . . .31-3102-1 Starting aid, remove and install . . . . . . . .05-0505-3
Loader bucket cylinder
O
Loader bucket dump circuit relief valve with
anticavitation O-ring boss fitting in aluminum housing—excavators
Torque value, service
recommendation . . . . . . . . . . . . . . . . .00-0003-8
Loader bucket linkage
O-ring boss fittings . . . . . . . . . . . . . . . . . . .00-0003-6
O-ring face seal fitting
Loader control valve linkage
Inch hex nut and stud end for high pressure torque
values . . . . . . . . . . . . . . . . . . . . . . . .00-0003-12
Loader multi-purpose bucket and lines Metric hex nut and stud end for high pressure
Disassemble and asssemble. . . . . . . . . .31-3102-8 torque values. . . . . . . . . . . . . . . . . . .00-0003-16
Loader multi-purpose bucket cylinder Metric hex nut and stud end for standard pressure
Disassemble and assemble . . . . . . . . .31-3160-16 torque values. . . . . . . . . . . . . . . . . . .00-0003-14
Lower rear windowpane O-ring seal, metric 24°
Remove and install . . . . . . . . . . . . . . . . .18-1810-7 Service recommendation. . . . . . . . . . . .00-0003-26
Operating
Use Special Care . . . . . . . . . . . . . . . . .00-0001-12
Operation qualification . . . . . . . . . . . . . . . .00-0001-3
M Operator convenience features. . . . . . . . . .00-0001-1
Outlet section, backhoe
Machine tipover Disassemble and assemble . . . . . . . . .33-3360-30
Avoid . . . . . . . . . . . . . . . . . . . . . . . . . .00-0001-11
Machine, inspect . . . . . . . . . . . . . . . . . . . .00-0001-4
Main frame bushings P
Manifold Park brake
Air conditioning compressor, inspect . . . .18-1830-7 Disassemble and assemble . . . . . . . . .02-0250-22
Metric bolt and cap screw Remove and install . . . . . . . . . . . . . . . . .11-1111-1
Torque value. . . . . . . . . . . . . . . . . . . . . .00-0003-1 Parts, moving
MFWD axle Stay clear . . . . . . . . . . . . . . . . . . . . . . . .00-0001-4 Indx
Remove and install . . . . . . . . . . . . . . . . .02-0240-1 Pattern select valve 5
Use CTM4687. . . . . . . . . . . . . . . . . . . . .02-0240-4 Disassemble and assemble . . . . . . . . .33-3360-38
Muffler with turbocharger Remove and install . . . . . . . . . . . . . . . .33-3360-34
Remove and install . . . . . . . . . . . . . . . . .05-0530-2 Pedal
Multi-purpose bucket and lines Engine speed control, remove and
Loader, disassemble and assemble . . . .31-3102-8 install. . . . . . . . . . . . . . . . . . . . . . . . . .05-0515-1
Multi-purpose bucket cylinder Pedal, sixth function
Loader, disassemble and assemble . . .31-3160-16 Remove and install . . . . . . . . . . . . . . . .33-3315-10

060807
PN=5
Index
Page Page
Pilot control manifold valve Relief valve, backhoe

Disassemble and assemble . . . . . . . . 33-3360-32, Remove and install . . . . . . . . . . . . . . . .33-3360-13
33-3360-33 Relief valves
Pins, metal Loader and stabilizer control valve, remove and
Drive safely . . . . . . . . . . . . . . . . . . . . . .00-0001-16 install. . . . . . . . . . . . . . . . . . . . . . . . . .31-3160-8
Power limiting valve Remove and install
Remove and install . . . . . . . . . . . . . . . . .21-2160-9 Brake pedal . . . . . . . . . . . . . . . . . . . . .10-1060-16
Pressure plate Rear window wiper . . . . . . . . . . . . . . . . .18-1810-3
Remove and install . . . . . . . . . . . . . . . . .10-1011-1 Seat assembly . . . . . . . . . . . . . . . . . . . .18-1821-1
Pump Spindle assembly . . . . . . . . . . . . . . . . . .02-0230-2
Driveshaft install . . . . . . . . . . . . . . . . . .03-0350-69 Reservoir
Hydraulic, disassemble and assemble. . .21-2160-6 Hydraulic, disassemble and
Hydraulic, remove and install . . . . . . . . .21-2160-1 assemble . . . . . . . . . . . . . . . . . . . . . .21-2160-18
Pump control Hydraulic, remove and install . . . . . . . .21-2160-13
Hydraulic, disassemble and assemble. . .21-2160-8 Ride control
Pump drive shaft remove Valve, disassemble and assemble . . . .31-3160-22
Transmission. . . . . . . . . . . . . . . . . . . . .03-0350-12
Valve, remove and install . . . . . . . . . . .31-3160-18
Ride control accumulator
Ride control valve
R Disassamble and assemble . . . . . . . . .31-3160-22
Radiator Ride control valve solenoid
Radio Riders
Remove and install . . . . . . . . . . . . . . . . .20-2001-1 Keep off Machine . . . . . . . . . . . . . . . . .00-0001-10
Radio, speakers, antenna Roads
Remove and install . . . . . . . . . . . . . . . . .20-2001-4 Operating or traveling . . . . . . . . . . . . . .00-0001-13
Rear axle ROPS
Assemble . . . . . . . . . . . . . . . . . . . . . . .02-0250-40 Inspect . . . . . . . . . . . . . . . . . . . . . . . . .00-0001-13
Disassemble . . . . . . . . . . . . . . . . . . . . . .02-0250-7 Maintain . . . . . . . . . . . . . . . . . . . . . . . .00-0001-13
Gear tooth contact pattern, check . . . . .02-0250-62
Park brake, disassemble and
R134a component oil
assemble . . . . . . . . . . . . . . . . . . . . . .02-0250-22
Charge procedure . . . . . . . . . . . . . . . . .18-1830-33
R134a compressor oil
Rear wheel
Removal procedure. . . . . . . . . . . . . . . . .18-1830-4
Rear window wiper R134a refrigerant
Remove and install . . . . . . . . . . . . . . . . .18-1810-3 Cautions . . . . . . . . . . . . . . . . . . . . . . . . .18-1830-1
Rear windows R134a refrigerant recover, recycle, and charge
remove and install. . . . . . . . . . . . . . . . .18-1810-16 station
Receiver dryer Installation procedure . . . . . . . . . . . . . .18-1830-35
Disassemble and assemble . . . . . . . . .18-1830-30 R134a system
Recognize Charge procedure . . . . . . . . . . . . . . . . .18-1830-39
Indx Cleaning procedures . . . . . . . . . . . . . . .18-1830-40
Safety, information . . . . . . . . . . . . . . . . .00-0001-2
6
Refrigerant Evacuate procedure . . . . . . . . . . . . . . .18-1830-37
R134a, cautions . . . . . . . . . . . . . . . . . . .18-1830-1 R134a System
Refrigerant handling . . . . . . . . . . . . . . . . . .18-1830-1 Flush Procedure . . . . . . . . . . . . . . . . . .18-1830-41
Refrigerant hoses and tubing R134a system
Inspection . . . . . . . . . . . . . . . . . . . . . . . .18-1830-2 Leak testing . . . . . . . . . . . . . . . . . . . . .18-1830-40
Refrigerant recover, recycle, and charge station Purge procedure . . . . . . . . . . . . . . . . . .18-1830-43
R134a, installation procedure . . . . . . . .18-1830-35 Recover procedure . . . . . . . . . . . . . . . .18-1830-36

060807
PN=6
Index
Page Page
S Spindle assembly
Safety Spool seals, remove and install
Instructions, follow . . . . . . . . . . . . . . . . .00-0001-2 Backhoe control valve . . . . . . . . . . . . . . .33-3360-9
Operator’s seat . . . . . . . . . . . . . . . . . . . .00-0001-8 Stabilizer cylinder, backhoe
Park and prepare for service safely. . . .00-0001-14 Disassemble and assemble . . . . . . . . .33-3360-49
Safety features . . . . . . . . . . . . . . . . . . . . . .00-0001-1 Remove and install . . . . . . . . . . . . . . . .33-3360-48
Safety signs . . . . . . . . . . . . . . . . . . . . . . .00-0001-17 Stabilizer linkage
Backhoe coupler . . . . . . . . . . . . . . . . . .00-0001-19 Remove and install . . . . . . . . . . . . . . . . .31-3115-5
Safety, information Standard steering wheel and column
Recognize. . . . . . . . . . . . . . . . . . . . . . . .00-0001-2 Disassemble and assemble . . . . . . . . . .09-0960-6
Seat Starting aid nozzle
Disassemble and assemble . . . . . . . . . .18-1821-2 Remove and install . . . . . . . . . . . . . . . . .05-0505-3
Seat assembly Starting aid solenoid
Remove and install . . . . . . . . . . . . . . . . .18-1821-1 Remove and install . . . . . . . . . . . . . . . . .05-0505-4
Seat Belt Steering column
Steering cylinder
Seat belt
Non-powered front axle, disassemble and
Use and maintain . . . . . . . . . . . . . . . . . .00-0001-8
assemble . . . . . . . . . . . . . . . . . . . . . .09-0960-23
Seat latch
Non-powered front axle, remove and
install. . . . . . . . . . . . . . . . . . . . . . . . .09-0960-21
Seat shock absorber
Non-powered front axle, repair . . . . . . .09-0960-21
Steering valve
Seat slide, swivel, lumbar control levers
Disassemble . . . . . . . . . . . . . . . . . . . . .09-0960-17
Seat suspension
Steering wheel and column
Standard, disassemble and assemble. . .09-0960-6
Seat swivel Tilt, disassemble and assemble . . . . . . .09-0960-8
Disassemble and assemble . . . . . . . . . .18-1821-8 Steps
Service brakes Use correctly. . . . . . . . . . . . . . . . . . . . . .00-0001-8
External inspection . . . . . . . . . . . . . . . . .10-1011-1 Swing cylinder, backhoe
Service Brakes Disassemble and assemble . . . . . . . . .33-3360-47
Inspect . . . . . . . . . . . . . . . . . . . . . . . . . .02-0250-1 Remove and install . . . . . . . . . . . . . . . .33-3360-44
Service recommendation Swing frame
Inch series four bolt flange fitting for high Remove and install . . . . . . . . . . . . . . . . .33-3340-6
pressure . . . . . . . . . . . . . . . . . . . . . .00-0003-20 Swing section, backhoe
O-ring boss fitting in aluminum housing— Disassemble and assemble . . . . . . . . .33-3360-20
excavators . . . . . . . . . . . . . . . . . . . . . .00-0003-8
O-ring face seal fittings with inch hex nut and
stud end for high pressure. . . . . . . . .00-0003-12
O-ring face seal fittings with metric hex nut and T
stud end for high pressure. . . . . . . . .00-0003-16
O-ring face seal fittings with metric hex nut and Third function loader control valve linkage
stud end for standard pressure . . . . .00-0003-14 Remove and install . . . . . . . . . . . . . . . . .31-3115-3 Indx
O-ring seal, metric 24° . . . . . . . . . . . . .00-0003-26 Tie rod 7
Shutoff plug Remove and install . . . . . . . . . . . . . . . . .02-0230-5
Loader auxiliary, disassemble and Tilt steering wheel and column
Assemble . . . . . . . . . . . . . . . . . . . . .31-3160-14 Disassemble and assemble . . . . . . . . . .09-0960-8
Sixth function pedal Tire
Remove and Install . . . . . . . . . . . . . . . .33-3315-10 Remove and install . . . . . . . . . . . . . . . . .01-0110-4
Solenoid Torque converter
Starting aid, remove and install . . . . . . . .05-0505-4 Remove and install . . . . . . . . . . . . . . . . .06-0651-1

060807
PN=7
Index
Page Page
Torque value V
Flared connections . . . . . . . . . . . . . . . .00-0003-10
Flat face O-ring seal fitting . . . . . . . . . .00-0003-11 Valve
Inch SAE four bolt flange fitting. . . . . . .00-0003-19 Loader and stabilizer control valve load sense,
Inch series four bolt flange fitting for high disassemble and assemble . . . . . . . .31-3160-10
pressure . . . . . . . . . . . . . . . . . . . . . .00-0003-20 Loader and stabilizer control, disassemble and
Metric bolt and cap screw . . . . . . . . . . . .00-0003-1 assemble . . . . . . . . . . . . . . . . . . . . . . .31-3160-3
Metric cap screw. . . . . . . . . . . . . . . . . . .00-0003-2 Loader and stabilizer control, remove and
Metric four bolt flange fitting . . . . . . . . .00-0003-18 install. . . . . . . . . . . . . . . . . . . . . . . . . .31-3160-1
Non-restricted banjo fittings. . . . . . . . . .00-0003-21 Loader anticavitation, disassemble and
O-Ring boss fitting . . . . . . . . . . . . . . . . .00-0003-6 assemble . . . . . . . . . . . . . . . . . . . . . .31-3160-13
O-ring boss fitting in aluminum housing— Loader auxiliary circuit relief, disassemble and
excavators . . . . . . . . . . . . . . . . . . . . . .00-0003-8 assemble . . . . . . . . . . . . . . . . . . . . . .31-3160-13
O-ring boss fittings with shoulder . . . . .00-0003-23 Loader boom raise and bucket curl circuit relief,
O-ring face seal fittings with inch hex nut and disassemble and assemble . . . . . . . .31-3160-11
stud end for high pressure. . . . . . . . .00-0003-12 Loader bucket dump circuit relief, disassemble and
O-ring face seal fittings with metric hex nut and assemble . . . . . . . . . . . . . . . . . . . . . .31-3160-12
stud end for high pressure. . . . . . . . .00-0003-16 Power limiting, remove and install. . . . . .21-2160-9
O-ring face seal fittings with metric hex nut and Steering, disassemble . . . . . . . . . . . . . .09-0960-17
stud end for standard pressure . . . . .00-0003-14 Valve, backhoe
O-ring seal, metric 24° . . . . . . . . . . . . .00-0003-26 Remove and install . . . . . . . . . . . . . . . . .33-3360-1
Unified inch bolt and cap screw . . . . . . .00-0003-4 Valve, backhoe boom section
30° cone seat hydraulic fittings . . . .00-0003-5 Disassemble and assemble . . . . . . . . .33-3360-22
37° flare hydraulic fittings . . . . . . . .00-0003-5 Valve, backhoe bucket section
Transmission Disassemble and assemble . . . . . . . . .33-3360-24
Charge pump disassemble and Valve, backhoe control
assemble . . . . . . . . . . . . . . . . . . . . . . .03-0360-4 Disassemble and assemble . . . . . . . . . .33-3360-6
Charge pump remove and install . . . . . .03-0360-1 Valve, backhoe crowd section
Converter side of case, assemble . . . . .03-0350-74 Disassemble and assemble . . . . . . . . .33-3360-26
Outer components, install . . . . . . . . . . .03-0350-80 Valve, backhoe inlet section
Power shift, install. . . . . . . . . . . . . . . . . .03-0300-8 Disassemble and assemble . . . . . . . . .33-3360-16
Power shift, remove . . . . . . . . . . . . . . . .03-0300-1 Valve, backhoe swing section
Pump disassemble and assemble . . . . .03-0350-14 Disassemble and assemble . . . . . . . . .33-3360-20
Pump drive shaft remove . . . . . . . . . . .03-0350-12 Valve, pattern select
Torque converter side of transmission Disassemble and assemble . . . . . . . . .33-3360-38
case . . . . . . . . . . . . . . . . . . . . . . . . . .03-0350-5 Remove and install . . . . . . . . . . . . . . . .33-3360-34
Transmission oil cooler Valve, pilot control manifold
Remove and install . . . . . . . . . . . . . . . .21-2160-19 Disassemble and assemble . . . . . . . . .33-3360-33
Transmission pump Valves
Disassemble and Assemble . . . . . . . . .03-0350-14 Loader and stabilizer control valve relief, remove
Transmisssion and install . . . . . . . . . . . . . . . . . . . . . .31-3160-8
Remove outer components to
disassemble . . . . . . . . . . . . . . . . . . . .03-0350-1
Traveling
W
Indx On public roads. . . . . . . . . . . . . . . . . . .00-0001-13
8
Waste
Dispose of properly . . . . . . . . . . . . . . . . .00-0001-7
Welding repair of major structures . . . . . . .17-1740-1
U Welding repairs
Make safely . . . . . . . . . . . . . . . . . . . . .00-0001-15
Upper and lower door windowpanes Wheel
Remove and install . . . . . . . . . . . . . . . . .18-1810-7 Front, remove and install . . . . . . . . . . . .01-0110-3

060807
PN=8
Index
Page
Rear, remove and install . . . . . . . . . . . . .01-0110-1

Windows
Rear, remove and install . . . . . . . . . . . .18-1810-16
Wiper motor
Front . . . . . . . . . . . . . . . . . . . . . . . . . . . .18-1810-1
Wipers
Indx
9

060807
PN=9
Index
Indx
10

060807
PN=10

TM10147 Reparacion 410J

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TM10147 (08JUN07) 410J Backhoe Loader

Technical Information Feedback Form

We need your help to continually improve our technical

SEND TO: John Deere Dubuque Works

FAX NUMBER: 563-589-5800

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TM10147 (08JUN07) 410J Backhoe Loader

TM10147 (08JUN07) 410J Backhoe Loader

SECTION 01—Wheels SECTION 18—Operator’s Station

All information, illustrations and specifications in this manual are based on

TM10147 (08JUN07) i 410J Backhoe Loader

TM10147 (08JUN07) ii 410J Backhoe Loader

TM10147 (08JUN07) iii 410J Backhoe Loader

TM10147 (08JUN07) iv 410J Backhoe Loader

Group 0001—Safety Information Additional Metric Cap Screw Torque

Group 0003—Torque Values

TM10147 (08JUN07) 00-1 410J Backhoe Loader

TM10147 (08JUN07) 00-2 410J Backhoe Loader

TM10147 (08JUN07) 00-0001-1 410J Backhoe Loader

This is the safety alert symbol. When you see this

Follow the precautions and safe operating practices

A signal word — DANGER, WARNING, or CAUTION — is

Follow Safety Instructions

Read the safety messages in this manual and on the

Be sure all operators of this machine understand every

TM10147 (08JUN07) 00-0001-2 410J Backhoe Loader

Wear Protective Equipment

Guard against injury from flying pieces of metal or debris;

Wear close fitting clothing and safety equipment

Avoid Unauthorized Machine Modifications

TM10147 (08JUN07) 00-0001-3 410J Backhoe Loader

Inspect machine carefully each day by walking around it

Keep all guards and shields in good condition and

Stay Clear of Moving Parts

Stop engine before examining, adjusting or maintaining

Avoid High-Pressure Fluids

Escaping fluid under pressure can penetrate the skin

Avoid the hazard by relieving pressure before

Search for leaks with a piece of cardboard. Protect hands

and body from high pressure fluids.

If an accident occurs, see a doctor immediately. Any fluid

TM10147 (08JUN07) 00-0001-4 410J Backhoe Loader

This machine uses a high-pressure hydraulic system.

Beware of Exhaust Fumes

Prevent asphyxiation. Engine exhaust fumes can cause

TM10147 (08JUN07) 00-0001-5 410J Backhoe Loader

Keep A Fire Extinguisher Available: Always keep a

Prevent Battery Explosions

Battery gas can explode. Keep sparks, lighted matches,

Never check battery charge by placing a metal object

Do not charge a frozen battery; it may explode. Warm –UN–23AUG88

TM10147 (08JUN07) 00-0001-6 410J Backhoe Loader

Exposure to hazardous chemicals can cause serious

Dispose of Waste Properly

Improper disposal of waste can threaten the environment.

Never pour waste onto the ground, down a drain, or into

Air conditioning refrigerants can damage the atmosphere.

If uncertain about the safe disposal of waste, contact your

Prepare for Emergencies