John Deere 450C Crawler Service Manual 1973

John Deere
JD450-C
Crawler
TM-1102
Litho in U.S.A. (T) New

1
J 0450-C Crawler
Technical Manual
TM-11 02 (Nov-73)
CONTENTS
Section 10 - GENERAL Section 50 - HYDRAULIC SYSTEM
Group 5 Specifications Group 5 Transmission Pump
Group 10 Predelivery, Delivery, and After-Sale Group 10 Main Hydraulic Pump
Services Group 15 Winch Hydraulic Pump
Group 15 Lubrication Group 20 Reverser Clutch Control Valve
Group 25 Steering Valve
Section 20 - ENGINE Group 30 Loader Control Valve
Group 5 Engine Removal and Installation Group 35 Dozer Control Valve
Group 10 Basic Engine Group 40 Backhoe Control Valve
Group 15 Engine Lubrication System Group 45 Winch Control Valve
Group 20 Engine Cooling System Group 50 Cylinders
Group 25 Fuel System Group 55 Miscellaneous Hydraulic Components
Group 30 Speed Control Linkage Group 60 Specificiations and Special Tools
Group 35 Air Intake System
Group 40 Specifications and Special Tools Section 60 - MISCELLANEOUS COMPONENTS
Group 5 Tracks
Section 30 - ELECTRICAL SYSTEM Group 10 Track Carrier Assembly
Group 5 Batteries Group 15 Winch
Group 10 Charging System Group 20 Winch Fairlead Assembly
Group 15 Starting System Group 25 Loader Frame, Boom and Buck-
Group 20 Gauges and Switches Group 30 Dozer Frames and Blades
Group 25 Specifications and Special Tools Group 35 Backhoe Frame, Boom and Bucket
Group 40 Specificiations and Special Tools
Section 40 - POWER TRAIN
Group 5 Engine Clutch Assembly Section 70 - SYSTEM TESTING
Group 10 Transmission Group 5 General Information
Group 15 Steering Clutch and Brake Assembly Group 10 Engine
Group 20 Final Drive Assembly Group 15 Electrical System
Group 25 Power Take-Off and Winch Drive Group 20 Power Train
Group 30 Specifications and Special Tools Group 25 Hydraulic System
Group 30 Miscellaneous Components
Group 35 Specifications and Special Tools
The specifications and design information con-

tained in this manual were correct at the time this
machine was manufactured. It is John Deere's policy
to continually improve and update our machines.
Therefore, the specifications and design information
are subject to change without notice. Wherever appli-
cable, specifications and design information are in
accordance with SAE and IEMC standards.
Litho in U.S.A.
Crawler - JD450-C
2 T~-1102 (Nov-73)
INTRODUCTION
Use FOS Manuals for Reference Use Technical Manuals for Actual Service
This technical manual is part of a twin concept of This technical manual was planned and written for
service: you-a journeyman mechanic. Keep it in a perma-
nent binder in the shop where it is handy. Refer to it
The two kinds of manuals work as a team to give whenever in doubt about correct service procedures
you both the general background and technical de- or specifications.
tails of shop service.
Some features of this manual:
•FOS Manuals-for reference
• Inside front cover - "Table of Contents" and
Fundamentals of Service (FOS) Manuals cover ba- "Maintenance Without Accident".
sic theory of operation, fundamentals of trouble
• Section 10 - General specifications and ser-
shooting, general maintenance, and basic types of
vices.
failure and their causes. FOS Manuals are for train-
ing new men and for reference by experienced men. • Sections 20 through 60 - Removal, repair, test-
ing (components removed), installation, and ad-
When a serviceman should refer to a FOS justment.
Manual for more information , a FOS symbol
• Section 70 - Detailed explanation of system
like the one at the left is used in the TM to
operation, diagnosis, visual inspection , testing,
identify the reference.
and adjustments.
•Technical Manuals-for actual service • Specifications grouped and illustrated at the end
of each section.
Technical Manuals are concise service guides for
a specific machine. Technical manuals are on-the-
job guides containing only the vital information need-
ed by a journeyman mechanic.
Litho in U.S.A.
Crawler - JD450-C
TM- 11 02 (Nov-73) 3
MAINTENANCE WITHOUT ACCIDENT

WORK SAFELY
T27999N
A This safety alert symbol identifies important

..-. safety messages in this manual and on the
T2 7502N
crawler. When you see this symbol, be alert to the
possibility of personal injury and carefully read the
ALWAYS AVOID loose clothing or any accesso-
message that follows.
ry-flopping cuffs, dangling neckties and scarves, or
rings and wrist watches-that can catch in moving
EVERY EMPLOYER HAS A
parts and put you out of work.
SAFETY PROGRAM. KNOW
WHAT IT IS!
T31961
BE ALERT!
Plan ahead - work safely -
avoid accidental damage and
injury . If a careless moment
does cause an accident or fire,
react quickly with the tools and
skills at hand - know how to
use a first aid kit and a fire ex-
tinguisher - and where to get
aid and assistance. In an emer-
Consult your shop foreman for specific instructions gency, spl it-second action is
on a job. and the safety equipment required. the key to safety.
For instance. you may need : Hard hat , safety
shoes, safety goggles, heavy gloves, reflector vests.
ear protectors. respirators.
Litho in U.S.A.
Crawler - JD450-C
4 TM-1102 (Nov- 73)

Specific safety procedures should always be · ob- UNDER ALL MAINTENANCE
served, whether servicing the equipment or making CONDITIONS-
the repairs. Remembering these-in time!- can pre-
Do not perform any work on the equipment unless
vent an injury . . . or save your life . . .
authorized to do so. Then be sure you know what
you're doing. Follow recommended procedures.
AVOID FIRE HAZARDS -
Fuel Is Dangerous! Never service the equipment while it is being oper-
Don't smoke while refueling. ated .
Don't smoke while handling highly flammable ma-
terial.
Engine should be shut off when refueling.
Use care in refueling if the engine is hot.
Don't use open pans of gasoline or diesel fuel for
cleaning parts. Good commercial , nonflammable sol-
vents are preferred.
Avoid working on equipment with the engine run-

ning. If it is necessary to make checks with the en-
gine running, ALWAYS USE TWO MEN-one, the
T J1962 operator. at the controls, the other checking where
Battery Gas Is Highly Flammable! the operator can see him. Also, put the transmission
in neutral, set the parking brake. and apply any safe-
Provide adequate ventilation when charging bat- ty locks provided. KEEP HANDS AWAY FROM
teries. MOVING PARTS.
Don't check battery charge by placing metal ob-
jects across the posts.
Don't allow sparks or open flame near batteries.
Don't smoke near battery.
Flame Is Not a Flashlight!

Never check fuel. battery electrolyte or coolant lev-
els with an open flame.
Never use an open flame to look for leaks any-
where on the equipment.
Never use an open flame as a light anywhere on
or around the equipment.
KNOW WHERE FIRE EXTINGUISHERS ARE
KEPT!
<'::: ~ ;::* ;·, '*

'.>f
Litho in U.S.A.
Crawler - JD450-C
TM- 1102 (Nov-73) 5
Before serv1cmg, adjusting, or repa1nng crawlers Make sure the maintenance area is adequately
which have attachments such as dozers, blades, vented.
etc.-LOWER attachments to the ground- or, if nec-
essary to raise them for access to certain parts, SE- Keep maintenance area CLEAN AND DRY. Oily
CURELY SUPPORT by external means. DO NOT and wet floors are slippery; greasy rags are a fire
rely on controls to support or position attachments for hazard ; wet spots are dangerous when working with
maintenance. electrical equipment.
Never allow ANYONE to walk under equipment Store starting aids in a cool and well-ventilated
that is raised and not properly blocked. place, out of the reach of unauthorized personnel.
Avoid working directly under raised and blocked SERVICING PRECAUTIONS

equipment unless absolutely necessary.
Stop the engine before cleaning or lubricating the
equipment.
Lower mounted equipment and tools to the ground

carefully.
Engine coolant gets hot! Don't remove the radiator

cap until coolant temperature is below the boiling
point. Then turn cap slightly to relieve pressure be-
fore removing .
. \'=--
/'/ (
T 3 1 964
T 31966
Exhaust gases are dangerous! Periodically check

exhaust system for excessive leakage.
Don't forget a hydraulic system may be pressur-

ized! To relieve pressure, follow the technical man-
If the machine is on an incline, block it securely.
ual.
Use hoisting equipment for lifting heavy parts.
When checking hydraulic pressure, be sure to use
TAKE CARE! WATCH OUT FOR OTHER PEOPLE
the correct test gauge for the pressure in the particu-
IN THE VICINITY.
lar system.
Use extreme caution in removing radiator caps,
drain plugs, grease fittings, or hydraulic pressure
caps.
Wear safety glasses when drilling, grinding, or

hammering metal.
Litho in U.S.A.
Crawler - JD450-C
6 TM- 1102 (Nov-73)
Keep ALL equipment free of dirt and oil. This at-

tention will minimize fire hazards and facilitate spot-
ting of loose or defective parts.
When preparing engine for storage, remember that
inhibitor is volatile and therefore dangerous. Seal and
tape openings after adding the inhibitor. Keep con-
tainer tightly closed when not in use.
TJ 1 96 9
Before removing any housing covers, stop engine.

Take all objects from your pockets which could fall
into the opened housings. Don't let adjusting wrench-
es fall into opened housings.
ADJUSTING PRECAUTIONS
.. . . for Maintenance Adjustments
... . for Operating Adjustments
Don't attempt to check belt tension while the en-
Keep clutch and brake control units properly ad- gine is running.
justed at all times. Before making adjustments, stop
engine. Don't ad just the fuel system while the machine is
in motion.
ALWAYS WEAR GLOVES WHEN HANDLING
CABLE.
T 3 1970
Litho in U.S.A.
Crawler - JD450-C
TM-11 02 (Nov-73) 7
PRECAUTIONS DURING When changing cutting edges on blade-

REPAIR
Stop the engine and securely block the blade.
Before working on the engine fuel system-close
fuel shutoff valve.
Never let your bare hands come in contact with the
sharp edges. WEAR GLOVES.
Before working on hydraulic system-make sure
engine is not running and the system pressure is re-
lieved by working the control levers in all directions
with the engine shut off.
TJ1972
Before repairing the electrical system, or perform-

ing a major overhaul, make sure the batteries are
disconnected.
Litho in U.S.A.
Crawler - JD450-C
8 TM-11 02 (Nov- 73)
KNOW EQUIPMENT IS READY!

Check guards, canopies, safety bars- all protec-
ti ve devices instal led on the craw ler. Every one
should be in place and secure.
CHECK IT OUT!
0 GUARDS
o CANOPIES
0 SHIELDS
0 PROTECTIVE DEVICES
0 ROLL-OVER PROTECTIVE STRUCTURES 1' 31 9 ?5
0 SEAT BELTS, ETC.
Be sure to clean any oil, grease or mud accumula-

tion from floor of operator's compartment, stepping
points, and grab rai ls to minimize the danger of
slipping.
In freezing weather beware of snow or ice deposits

on stepping points, grab rails, and floor.
Remove loose bolts, tools, or other objects from

Carefully inspect equipment for visual defects- floor of operator's compartment.
leaks in fuel, lubrication, and hydraulic systems. Do
not search for press urized f luid leaks with your Although it is impractical to try to cover every pos-
hands. Use cardboard or wood to search for leaks. sible maintenance situation, the safety precautions
Check levels of fuel, coolant, hydraulic fluid, and recommended here should serve to develop and pro-
lubricating oil. If fuel must be added- FIRST, PUT mote safe maintenance procedures.
OUT THAT CIGARET.
Check and secure all caps and filler plugs for fuel, The information contained in this manual is not in-
oils, radiator, etc. tended to replace safety codes, insurance require-
ments, federal, state, and local laws, rules and
regulations. In particular, your service area or jobsite
activities may be subject to state safety rules and/or
federal regulation under the Occupational Safety and
Health Act (OSHA). Familiarize yourself with all regu-
lations applicable to your situation in order to avoid
possible safety violations.
Illustrations and copy reproduced in part by per-

mission of Construction Industry Manufacturers' as-
sociation (CIMA).
T319?4
Litho in U.S.A.
Crawler - JD450-C General 10
TM-11 02 (Nov-73) Specifications 5-1
Section 10
GENERAL
CONTENTS OF THIS SECTION
Page Page
GROUP 5 - SPECIFICATIONS GROUP 15 - LUBRICATION
General Machine Specifications ......................... 5-1 General Information .......................................... 15-1
Crawler Periodic Service Chart ....................... 15-1
GROUP 10 - PREDELIVERY, DELIVERY, AND Engine Lubricating Oil ...................................... 15-3
AFTER SALE SERVICES Transmission, Steering and
Temporary Crawler Storage ............................. 10-1 Hydraulic System Oils ................................... 15-3
Predelivery Service ........................................... 10-1 Greases ............................................................. 15-3
Delivery Service .............................................. 10-23
After-Sale lnspection ....................................... 10-23
Group 5
GENERAL MACHINE SPECIFICATIONS
(Specifications and design subject to change without notice. Wherever applicable, specifications are in accor-
dance with IEMC and SAE standards. Except where otherwise noted, these specifications are based on a unit
3
equipped with 1-1 I 4 cu. yd. [0. 93 m 1 digging bucket w/teeth, roll-over protective structure and standard equip-
ment.)
Horsepower Cooling ....................... Pressurized w/thermostat and

((iu 2,500 engine rpm): SAE DIN fixed bypass
Gross 70 Fan .................................................................... Blower
Net 65 69.1 PS Air cleaner w/restriction indicator. ........................ Dry
Drawbar (Dozers) 48.6 51.5 PS Electrical system .......................... 12-volt w I alternator
Battery ...................... Reserve capacity: 150 minutes
*Net engine flywheel horsepower is for an engine
equipped with fan, air cleaner, water pump, lubricat- TRANSMISSION:
ing oil pump, fuel pump, alternator and muffler. The H-L-R 4 speed ranges; with high, low and reverse
gross engine horsepower is without fan. Gross and speeds shifted hydraulically without clutching in each
net flywheel horsepower ratings are under SAE stan- range.
dard conditions of 500-ft. altitude and 85°F. tempera-
ture and DIN 70 020 standard conditions of 760 mm CLUTCH ......................... 11-in. [279 mm] single-disk
Hg barometer (sea level) and 20°C temperature.
STEERING:
ENGINE: Steering clutches and brakes are controlled by a sin-
John Deere, 4-cylinder, diesel, 4-stroke cycle gle lever for each track. A pedal provides braking
and lockdown for parking.
Bore and stroke .... .4.02 x 4.33 in. [102 x 110 mm] Clutches ..... Oil-cooled hydraulically-actuated, mul-
Piston displacement... ............ 219 cu. in. [3588 cm 3] tiple-disk 11-in. [279 mm] disk; 16 friction surfaces
Compression ratio ........................................ 16.2 to 1 per clutch
Maximum torque @ 1,400 rpm ................. 164.5 lb-ft Brakes ..... Self-adjusting, self energizing, oil-cooled
[22.74 kg-mJ contracting band with bonded lining.
NACC or AMA (U.S. Tax) horsepower ............ 23.84
Lubrication ............. Pressure system w/full-flow filter
Main bearings ............................................................ 5
Litho in U.S.A.
10 General Crawler - JD450-C
5-2 Specifications TM-11 02 (Nov-73)
Gear: Travel Max. Drawbar Pull Tracks (5-roller track frames w/rock guards):
Speeds: (Dozer) (with Grouser (Dozer) ................................ 16-in. [406 mm]
adequate weight
Triple semi-grouser open-center
and traction)
(loader) ........................................... 14-in. l356 mm]
mph km/h lb. kg Track shoes each side (Dozer) ............................. 36
Track shoes, each side (Loader) ........................... 37
Range 1 Ground contact area
Low 1.3 2.1 18,050 8188 (Dozer) ........................... 2,328 sq. in. [15019 cm 2 ]
High 1.8 2.9 12,600 5715 Ground contact area
Reverse 1.7 2.7 (Loader) ......................... 2,128 sq. in. [13729 cm 2 ]
Range 2 Ground pressure (Dozer) ...... 6.1 psi [0.429 kg/cm 2 ]
Low 2.0 3.2 10,050 4559 Ground pressure (Loader) .... 7.8 psi [0.548 kg/cm ]
2
High 2.8 4.5 7,050 3197 Length of track on ground (Dozer) .. 72.75 in. [1.85 m]
Reverse 2.7 4.3 Length of track on ground (Loader) ..... 76 in. [1.93 m]
Range 3 Track gauge ....................................... 52 in. [1.32 m]
Low 3.0 4.8 6,400 2903 Carrier roller ............................................................... 1
High 4.3 6.9 4,250 1928 Adjustment. .................................................... Hydraulic
Reverse 4.1 6.6 Clearance at rear crossbar ........ 14.25 in. [362 mm]
Range 4
Low 4.7 7.6 3,500 1588 Bulldozer Blade: Reinforced, box-welded
High 6.7 10.8 2,350 1066 Cutting edge ............. 3-piece reversible, replaceable
Reverse 6.4 10.3 Center section ................................. 0.75 in. [19 mm]
End bits, cast steel ........................ 0.75 in. [19 mm]
DOZER HYDRAULIC SYSTEM:
Control ............ Single-lever, double hydraulic system C-Frame ................................ Reinforced, box-welded
Pump ............... Gear, 15 or 23 gpm (57 or 87 lpm)
2
Pressure ............................. 1,750 psi [123.0 kg/cm ] LOADER SPECIFICATIONS
LOADER HYDRAULIC SYSTEM: SAE Heaped

Controi ............... Single-lever, triple hydraulic system Buckets: Capacity Width
Pump .................................. Gear, 28 gpm [1 06 lpm] Digging 1-1/4 cu. yd. 72.25 in.
2
Pressure ............................. 2,250 psi [158.2 kg/cm ] [0.96 m3 ] [1.84 m]
Oil lines ............ Seamless steel tubing; double-wire- Light Materials 1-3/4 cu. yd. 78.25 in.
braid hose [1.34 m3 ] [1.99 m]
Filter ............. Dual filtration, micronic and wire mesh Multipurpose 1-1/4 cu. yd. 73 in.
3
[0.96 m ] [1.85 m]
LOADER HYDRAULIC
CYLINDERS: Bore Stroke Operating Information:
Boom, two .. 4.25-in. [108 mm] 28.25-in. [718 mm] Breakout force ................ , .......... 14,360 lb. [6513 kg]
Bucket, two .... 3.5-in. [89 mm] 31.1-in. [790 mm] Lifting capacity, full height.. ........ 9,000 lb. [ 4082 kg]
Cylinder rods ... Ground, heat-treated, chrome-plated, Maximum dumping angle ............................... 50 deg.
polished Raising time .................................................... 7.0 sec.
Boom cylinder rods ................. 2.25-in. [57 mm] dia. Dumping time .................................................. 1.6 sec.
Bucket cylinder rods ..................... 2-in. [51 mm] dia. Lowering time ........................................ :....... .4.0 sec.
BULLDOZER HYDRAULIC Loader SAE operating weight .. 16, 700 lb. [7582 kg]
CYLINDERS: Bore Stroke SAE operating weight (6405 and
Lift, two .......... 3.5-in. [89 mm] 15-in. [381 mm] 6415) ....................................... 14,500 lb. [6571 kg]
Tilt, one ......... .4.5-in. [114 mm] 3-in. [76 mm] SAE operating weight (641 0) ... 14,250 lb. [6463 kg]
Cylinder rods ... Ground, heat-treated, chrome-plated,
polished NOTE: The 6405, 6410, and 6415 Bulldozers fit all
Cylinder pivot pins ........ Hardened steel (replaceable JD450-Series Crawlers.
bushings)
Litho in U.S.A.
TM-11 02 (Nov-73) Specifications 5-3
CAPACITIES u.s. Litres SPECIAL EQUIPMENT:
Cooling system ...................... . 4 gal. 15.1 Tachometer

Fuel tank ................................ . 31 gal. 117.3 Ether starting aid
Crankcase including filter ...... . 9 qt. 8.5 PTO (1 ,000 rpm)
Transmission .......................... . 8 gal. 30.3 Upper and lower front idler shields
Final drive (each) .................. . 6.5 qt. 6.2 Spark-arresting muffler
Hydraulic reservoir (loader) ... . 7 gal. 26.5 Altitude compensator
Hydraulic reservoir (dozer) .... . 6.4 gal. 24.5 ROPS w/canopy and seat belt
Hydraulic system (loader) ..... . 13 gal. 49.2 16-in. [ 406 mm] open-center grouser shoes
Hydraulic system (641 0 16-in. [ 406 mm] triple semi-grouser, open-center
and 6415) ........................... . 10 gal. 37.8 shoes
Hydraulic system (6405) ....... . 12.25 gal. 46.4 Auxiliary hydraulic system w/breakaway couplings
Steering clutch housing Swinging drawbar
(each side) ......................... . 14 qt. 13.2 Remote hydraulic cylinder
Radiator sand shield (bulldozer)
ADDITIONAL STANDARD EQUIPMENT: Cap (includes ROPS)
Winch drive
Front bottom guard, rear bottom guard (dozer) Two batteries
Front hitch Return to dig
Deluxe cushion seat w/arm rests Rear counterweight for multipurpose bucket or log
Key switch w/push-button safety start loader
Precleaner Winch drive
Electric hourmeter
Cigaret lighter
Vandal protection
Grease gun
Bottom guard counterweight w/fixed drawbar (loader)
Bucket level indicator (loader)
Radiator sand shield (loader)
Sprocket weights (loader)
Lights
Trash-resistant radiator (dozer)
Outer sprocket shields (dozer)
Litho in U.S.A
10 General Crawler - J0450-C
5-4 Specifications TM-1102 (Nov-73)
Litho in U.S.A.
TM-1102 (Nov-73) Predelivery, Delivery, and After-Sale Services 10-1
Group 10
PREDELIVERV, DELIVERY, AND AFTER-SALE SERVICES
TEMPORARY UNIT STORAGE PREDELIVERY SERVICE
After receiving your crawler from the factory and Because of the shipping factors involved, plus ex-
before putting the machine into temporary storage, tra finishing touches that are necessary to promote
perform the following checks. customer satisfaction, proper predelivery service is of
prime importance to the dealer and the customer.
For long term storage (over 30 days) information,
consult your JD450-C operator's manual. Use the following list when preparing a unit for de-
livery to the customer.
1. Check battery electrolyte level and charge the
battery, if necessary. 1. Air Cleaner
2. Check the level of coolant in the radiator. The
coolant should be maintained at a level midway be-
tween the radiator core and filler neck.
3. Fill the fuel tank.
4. Check crankcase oil level. Oil should be at top

mark of dipsticK after machine has been shut down
for 10 minutes.
5. Relieve hydraulic pressure by stopping engine,

lowering all equipment and operating control levers
until system fails to respond.
1- Restrlctlon Indicator 3-filter Element

2-Safety Filter Element 4-Baffle
Fig. 1-Air Cleaner
Check air filter restriction indicator, if equipped. If

red signal locks in full view, remove air filter and
clean. Replace air filter if necessary.
Litho in U.S.A.
10-2 Predelivery, Delivery, and After-Sale Services TM-11 02 (Nov-73)
2. Fuel Filter 4. Fuel Tank
Fig. 2-Fuel Filter

Fig. 4-Fuel Tank
Check fuel filter for sediment and drain, if neces-
sary.
Check the fuel tank level. If fuel level is low, add
Sediment present in filter Yes No sufficient fuel to fill the fuel tank. Fuel tank capacity
is 31 gals. [117.3 II.
3. Batteries Full
Fuel tank level 112-Full Empty
5. Radiator
Fig. 3-Batteries
Check battery electrolyte level. If distilled water is Fig. 5-Radiator Filler Cap
not available. use clean soft water. Avoid use of hard
water. Remove foreign material from top of battery
and coat terminals with petroleum jelly. Clean vent h CAUTION : Do not remove radiator filler
holes in battery caps. . . cap until the coolant temperature is below
its boiling point. Then loosen cap slowly to the
IMPORTANT: Never add water to battery in stop to relieve any excess pressure before re-
freezing weather unless engine is to be run long moving cap completely.
enough (2 or 3 hours) to assure mixing of water
and electrolyte. Check the level of coolant in the radiator. Coolant
should be maintained at a level midway between the
Punch date code on battery. radiator core and filler neck. Add permanent type an-
tifreeze if cold weather is anticipated.
Water added Yes No Radiator coolant level checked Yes No
Coolant or antifreeze added Yes No
Litho in U.S.A.
TM-11 02 (Nov- 73) Predelivery, Delivery. and After-Sale Services 10-3
6. Crankcase Oil Level Check alternator belt tension. Loosen the alterna-
tor bracket and adjusting cap screws and apply out-
ward force to the FRONT alternator frame until a firm
KfE i' OIL lE VEl
B ETWH~ HAH!':S pull (20 pound [9.07 kg] force) on the belt midway
between the pulleys will deflect the belt 3/ 4 inch
-------
--
~:~
\ :.-_~ [ 19.05 mm). If belt gauge is used, tighten fan belt to
100-110 lb. [ 45.36-49.89 kg] strand tension. After 3
minutes of machine operation, tension should be 80
lb. [36.29 kg) minimum.
IMPORTANT: Do not pry on the rear half of the

alternator housing as this may misalign the com -
plete alternator assembly.
Belt tension lbs {kg] tension

inch [mm) flex
8. Check Air Intake Hoses

'1'~~ .7 9 8 :!N '{
Check clamps on hoses which connect air cleaner
and engine. Tighten hose clamps where necessary
1- Dipsti ck 2-0il Filler Cap
to prevent dirt from entering engine. Inspect hoses
Fig. 6-Crankcase Oil Level for cracks.
Check crankcase oil level with unit on level Loose connections Yes No
ground. If oil level is at or below bottom mark on dip-
stick, add sufficient oil of the proper viscosity and Hydraulic Reservoir Oil Level
type specified on page 10-15-3 to bring oil level to
Check oil level in loader hydraulic system. Oil level
between marks on dipstick. Do not operate engine
should be halfway up in oil level window with the
with oil level below the bottom mark.
bucket rolled back or. the ground.
Crankcase oil level checked Yes No
Oil added Yes No
7. Alternator Belt Tension
Fig. 8-Hydraulic System Oil Level Window and Latch
Fig. 7-Adjusting Alternator Belt Tension
Litho in U.S.A.
10-4 Predelivery, Delivery, and After-Sale Services TM-1102 (Nov-73)
To add oil, turn latch and lift reservoir cover. Turn

pressure cap slowly and remove it. Add John Deere
Type 303 Special-Purpose Oil or an equivalent until
oil level reaches half circle on window.
NOTE: The hydraulic pump on crawlers not

equipped with auxiliary equipment must be disen-
gaged at all times. In order to protect the hydraulic
pump in case it is accidently engaged, the reservoir
should be kept full. When operating hydraulic auxilia-
ry equipment, refer to the appropriate equipment op-
erator's manual for hydraulic system oil capacity.
IMPORTANT: Do not operate crawler without

oil in reservoir. Doing so will damage the hydrau-
lic pump if engaged.
Fig. 10-Transmission Oil Dipstick
Hydraulic oil level at proper level Yes No Oil level checked
Oil added, if any. qts. [I]
10. Pre-Cleaner
12. Winch Housing Oil Level
Fig. 9-Pre-Cieaner Attachment
Check the pre-cleaner and empty it if the accumu-

lation of foreign material is up to the mark on the
plastic bowl.
NOTE: Under extremely dusty conditions, it will be

necessary to remove and clean the unit more often.
Never allow the precleaner to become clogged with
foreign material.
1- Filler Plug 2- 011 Level Plug
Pre-cleaner cleaned out Yes No Fig. 11-Winch Oil Level
11. Transmission Oil Level Check the oil level of the winch housing by remov-
ing the oil level plug on the lower right side. If oil is
The transmission dipstick is located under the not up to the hole, remove the filler plug and add oil
seat. The oil level should be between the marks on as specified on page 10-15-3.
the dipstick with threads resting on filler tube and the
engine off. Add sufficient John Deere Type 303 Spe- Oil level checked
cial-Purpose Oil or an equivalent to bring oil to this Oil added, if any qts. [I}
level.
Litho in U.S.A.
13. Fuel Tank Sump 15. Steering Reservoir Oil Level
Fig. 12-Fuel Tank Sump
Drain fuel tank sump in the morning or after the 1-Fill Plug 2-Level Plug
machine has been idle for a long period of time.
Open drain cock under seat and allow approximately Fig. 14-Steering Reservoir Fill and Level Plugs
one cup of fluid to drain out This will insure that all
moisture has been removed from the sump.
Check the steering reservoir oil level. Remove oil
Fuel sump drained level plug . Oil should be to the level of the oil level
plug. If necessary to add oil, replace oil level plug,
14. Final Drives remove fill plug and add sufficient John Deere Type
303 Special-Purpose Oil or an equivalent to bring oil
level to bottom of oil level plug.
Oil level checked
Oil added, if any qts. [I]
16. Lights
1- 0il Level Plug 2-Drain Plug
Fig. 13-Final Drive
The oil supply in the final drives should be main-

tained at the level of the oil level hole. Check oil level
and, if necessary, add the amount of lubricant re-
Fig. 15-Light Switch
quired to bring oil to this level. Use John Deere Type
303 Special-Purpose Oil or an equivalent.
All lights are controlled by the "push-pull" light
Oil level checked switch. To turn on lights, pull out switch knob. To
Oil added. if any qts. [I} turn off lights, push in switch knob.
Lights operational Yes No
Litho in U.S.A.
17. Check Engine Speed Controls
T20 940N
1- Hand Throttle Lever &-Adjustable Yoke a- Adjustable Yoke

2- Lever-to-Bell Crank Link 6-Speed Control Cable 9-Pump Slow-Idle Stop Screw
3-Friction Adjusting Nut 7-Bracket 1G-Pump Fast-Idle Stop Screw
4--Bell Crank
Fig. 16-Speed Control Unkage
Check the engine speeds. If any ad justment is 3. Lightly rotate pump throttle arm to slow-idle po-
needed. follow the exact order listed below. Refer to sition. Engine speed should be at slow idle of 800
Fig. 16 as a guide to adjusting points. rpm. If not, adjust slow-idle stop screw (9) on top of
injection pump.
IMPORTANT:. Be sure engine is at operating
temperature before making speed adjustments. 4. With speed control cable disconnected, move
Use a master tachometer. All speeds given are hand lever forward to the high idle position. Adjust
for engine at no load. cable yoke (8) to provide for 1/8-inch [3. 175 mm]
overtravel of the pump arm. (For more travel, adjust
1. Disconnect speed control cable from injection
cable at yoke (5) under dash.) Check slow idle .
pump arm. Loosen cable clamp (7).
5. Move hand throttle fully rearward and turn off
2. Run engine and rotate pump throttle arm until
ignition .
fast-idle stop screw (10) contacts its stop. Engine
speed should be at fast idle of 2650 rpm. If not, ad- 6. Move hand throttle back and forth to check fric-
just pump stop screw (10) to correct. Lock screw with tion on lever. Check for 5 to 11 lbs. [2.3 to 5.0 kg]
sealing wire. drag with a spring scale. Adjust, if necessary, at nut
(3).
Engine speeds checked
Litho in U.S.A.
TM-11 02 (Nov-73) ?redelivery, Delivery, and After-Sale Services 10-7
18. Check Transmission Shifting 19. Gauge Operation

When operating the crawler, check the engine oil
pressure gauge, transmission oil temperature gauge,
engine coolant temperature gauge and the ammeter.
LI GHT
Ll GHT 160oF G EN
EEN 22 4o F
BL REO
ANGE
Fig. 18-Ammeter Fig. 19-Engine Coolant

Temperature Guage
If the indicator hand of the engine coolant temper-

1- H-L-R Neutral Lock 3-Shift Lever ature gauge goes into the red-orange zone, check
2-H-L-R Lever the cooling system.
Fig. 17-Transmission Shifting If the ammeter needle is in the red-orange zone

while the engine is running, the alternator is dis-
Check the transmission operation.
charging. Shut off the engine immediately and trou-
ble shoot the electrical system.
The shift lever has four shift stations. These shift
stations correspond to the four ranges provided .
Within each of these ranges are high, low, and re-
verse gears which are selected by the H-L-R lever
located on the battery box. By using the H-L-R lever,
the operator can "down-shift" from high to low in or-
der to gain additional power, or can shift from low to
high to increase travel speed. Shifting is also con-
venient between forward and reverse when " shut-
tling" the crawler.
The H-L-R lever is used to shift into high, low, or

reverse gear within the range set by the shift lever.
Note the shift pattern . This lever is used for fast
" down-shift" or "shuttling" of the crawler as during
loading and dozer work.
Fig. 20-Engine Oil Pressure Gauge
The H-L-R lever may be locked in neutral by en-
gaging the H-L·R neutral lock lever. The engine oil pressure gauge indicates the pres-
sure of the engine lubricating oil. Oil pressure will
Transmission operational vary slightly with wear, but with recommended oil,
the gauge indicator hand should be in the operating
range (indicated by green zone on the dial). If oil
pressure drops into the orange zone on the dial, stop
crawler immediately and check the crankcase oil lev-
el. If oil level is not low. check for restrictions in oil
lines or incorrect viscosity oil.
Litho in U.S.A.
10-8 ?redelivery, Delivery, and After-Safe Services TM-11 02 (Nov- 73)
After starting the engine do not accelerate or apply 21. Steering

a load until the engine oil pressure gauge indicates
Check steering levers for proper adjustment and
pressure. In cold weather. or after the engine has
operation .
been idle for several weeks, idle the engine for sev-
eral minutes at speeds below 1000 rpm before accel-
erating or operating engine under load.
ll GHT
GR EE N
T31 99 0N
Fig. 21-Transmission Temperature Gauge
The transmission temperature gauge indicates the TJ1992!1

temperature of the lubricating oil in the transmission.
If hand enters the red-orange zone, operate in a low- 1-Steering Brake Rods 2-Steering Valve Rods
er gear. If hand remains in the red-orange zone,
check transmission oil level. Do not continue crawler Fig. 23-Steering Levers and Rods Adjustment
operations with hand in the red-orange zone.
All gauges operational Yes No Refer to Fig. 23 and adjust the steering brake rod
yokes. Adjust so that the top of the steering levers
20. Hydraulic Brakes move 10 inches [254.00 mm] when the brake lever
(4, Fig. 7, page 40-15-7) contacts the brake lever
adjusting screw (1 ). Tighten steering brake rod yoke
jam nuts (Fig. 23).
Refer to Fig. 24 and adjust steering valve spool

eyebolts. Bottom spools in the steering valve housing
(4). Adjust eyebolts (2) so that the steering valve
rods (1) will just slip through the eyebolts. Tighten
one additional turn and tighten jam nuts (3).
Adjust brake pedal with pedal back against the

stop. Pull brake rods forward to take up pin clear-
ance. Adjust brake rods to align holes and install
1-Brake Pedal 2-Parking Brake l ock pins. Tighten jam nuts.
Fig. 22-Brakes Reach through the access hole in the side of

steering clutch housing. Tighten the brake adjusting
Check the brake pedal for adjustment and proper nuts until 60 lbs. [27.2 kg] pull at the base of the
operation. Apply parking brake lock. Parking brake steering lever hand grip will just move the lever to
lock should hold crawler from moving. the stop.
Brakes operational Yes No
Litho in U.S.A.
TM-1102 (Nov-73) Predelivery, Delivery, and After-Sale Services 10·9
If the operator releases the control lever at any

time during normal operation, it will automatically re-
turn to neutral , holding the boom in the position
reached at that time.
Bucket Control
Moving the control lever right or left operates either
the bucket or fork. Pushing the lever to the right
dumps and pulling it to the left retracts the bucket or
fork.
When released, the control lever will always return

to neutral, holding the bucket or fork in the position
The speed of dumping or retracting can be con-

trolled by the distance the control lever is moved.
Moving the lever all the way right dumps the bucket
or fork in the shortest possible time.
1-Steerlng Valve Rods 3-Jam Nuts
2-Steerlng Valve Spool 4-Steerlng Valve
For most accurate control and maximum power,
Eye Bolts
move the control lever only partially to the right.
Fig. 24-Steering Valve Spool Adjustment
When retracting, maximum power is obtained by
moving the lever all the way left.
22. Loader Control Lever
Loader control lever operational Yes No
23. 6410 and 6415 Bulldozer Control Le-

ver
1-Lower Boom 3-Raise Boom

2- Bucket Dump 4-Bucket Retract
F~g. 25-Loader Control Lever
1-Raise 3-Lower
Check loader control lever operation. 2- Neu1ral 4-Fioat
Boom Control Fig. 26-6410 and 6415 Bulldozer Control Lever
The boom is operated by moving the control lever

either forward or rearward. Pushing the lever forward Check bulldozer control lever operation.
lowers the boom and pulling it rearward raises the
boom. Raise the blade by pulling the lever all the way
back.
Litho in U.S.A.
10-10 Predelivery, Delivery, and After-Sate Services TM-11 02 (Nov-73)
Lower the blade by pushing the lever forward, but The 6405 Bulldozer blade may be angled 25 de-
not to the extreme forward position. grees to the left or right.
When the control lever is pushed to the extreme

forward position (detent), the blade is in float posi-
tion. In this position, the blade will follow the contour
of the ground.
The control lever will return to neutral position au-

tomatically when the lever is released from all posi-
tions except float position. Heturn lever to neutral
manually from the float position.
Bulldozer control lever operational Yes No
24. 6405 Bulldozer Control Lever
1- Angle Left 2- Angle Right
Fig. 28-8/ade Angling
Angle the blade to the right by twisting the control

lever to the right.
Angle the blade to the left by twisting the control

lever to the left.
1-Ralse Blade 3-Lower Blade The 6405 Bulldozer blade may be tilted 14 inches
2- Neutral 4-Fioat Blad e
down.
Fig. 27-6405 Bulldozer Control Lever
Check bulldozer control lever operation.
The control lever is set to return to neutral auto-

matically when the lever is released from all positions
except float position . Return lever to neutral manually
from float position .
Raise the blade by pulling the control lever to the

full rear position.
Lower the blade by pushing the control lever for-

ward, but not to the extreme forward position.
Push the lever to the extreme forward position-

this is the blade float position. The lever must be
manually returned to neutral position from float.
1-Tilt Left 2-Tilt Right
Fig. 29-81ade Tilting
Litho in U.S. A.
Tilt the left side of the blade up by pushing the 26. Backhoe Stabilizer Control Levers
control lever to the far right position.
Tilt the left side of the blade down by pulling the

control lever to the far left position.
25. Attachment Control Lever

Check attachment control lever for correct opera-
tion.
Fig. 31-Stabilizer Control Levers
Check the operation of stabilizer control levers.
To lower the stabilizers for backhoe operation,

move the control levers forward. To raise them, pull
the levers rearward.
Backhoe stabilizer control levers operational Yes No

1- Forward 2-Rearward
Fig. 30-Attachment Control Lever 27. Backhoe Boom and Swing Control
Lever
The attachment control lever (outside) controls op-
eration of all hydraulic attachments other than loader
and dozer operations. This control is operated by
moving it either forward or rearward.
Attachment control lever operational Yes No
1-Down 3--Up
2-Right 4-Left
Fig. 32-Boom and Swing Control Lever
Check the boom and swing control lever operation.
Lower the boom by moving the control lever for-

ward. Raise the boom by moving the lever rearward.
Swing left by moving the lever to the left and swing
right by moving lever to the right.
Litho in U.S.A.
10-12 Predelivery, Delivery, and After-Sale Services T~- 1102 (Nov-73)
By moving the lever to one of the intermediate po- By moving the lever to one of the intermediate po-
sitions, the boom can be swung to the left or right at sitions, the dipperstick can be extended or retracted
the same time it is being raised or lowered, perform- at the same time the bucket is being loaded or
ing two opercniv n:> ~;n'lt..l ta , leously . dumped.
Swing left and lower the boom by moving the con- Extend and dump the bucket by moving the lever
trol lever rearward and to the left forward and to the right.
Swing left and raise the boom by moving the con- Retract and dump the bucket by moving the lever
trol lever rearward and to the left rearward and to the right.
Swing right and lower the boom by moving the Extend and load the bucket by moving the lever
control lever forward and to the right. forward and to the left.
Swing right and raise the boom by moving the Retract and load the bucket by moving the lever
control lever rearward and to the right. rearward and to the left.
A swing brake, built into the swing cylinder, auto- Bucket and dipperstick control
matically slows the boom before it strikes the stops lever operational Yes No
on the main frame,
29. PTO Operation
Boom and swing control
lever operational Check the PTO operation.
Yes no.
Your crawler may be equipped with a 1000 rpm

28. Bucket and Dipperstick Control Lever power take-off which allows for the operation of rear-
Check the bucket and dipperstick control lever op- driven tools.
eration.
1-Bucket Out 3-Bucket In

2-Dump 4-Load
Fig. 34-PTO Control Lever
Fig, 33-Bucket and Oipperstick Control Lever
The power take-off shaft is engaged by a control

Extend dipperstick (move bucket out) by moving
lever located on the platform under the air cleaner.
the control lever forward and retract it (move bucket
To engage the powershaft, depress engine clutch
in) by moving the lever rearward.
pedal, shift PTO control lever rearward , and slowly
release clutch pedal.
Dump the bucket by moving the control lever to
the right and load it by moving the lever to the left.
Litho in U.S.A.
A CAUTION : Never dismount from the

. . crawler without first disengaging the PTO
shaft and stopping the engine. Never engage the
PTO when the engine is stopped.
PTO operational Yes No
30. Winch Control and Operation
1- PTO Master Shield 2- PTO Shaft Guard
Fig. 35-PTO
When attaching short-coupled equipment, it may

be necessary to remove the PTO master shield at
the rear of the crawler. To do so, remove the four
shield retaining cap screws and lift off the shield.
A CAUTION : Remove the master shield only

. . when necessary. Be sure that the shield
is in place any time the PTO guard is removed.
1-Wind 3-Unwind
2- Hold
The PTO guard should always be installed on the
PTO shaft except when operating PTO-driven equip- Fig. 36-Winch Control Lever
ment. T he PTO guard is attached with two cap
screws.
Check the operation of the winch.
Attaching PTO-Driven Equipment
Your crawler may be equipped with a John Deere
Attach the PTO-driven equipment to the power Power Winch. This winch is driven from the rear of
take-off and start the crawler engine. Depress clutch the crawler and has a separate hydraulic control.
pedal and engage PTO control lever by moving the
lever forward . Then sl owly release clutch pedal. To operate the winch, start the engine and allow it
Operate the engine at 1900 rpm to obtain 1000 rpm to warm up properly. Adjust the engine speed from
PTO shaft speed. 1500 rpm to 2500 rpm. The winch may be operated
at any speed in this range.
A CAUTION : Always make sure the engine
. . is shut off and the PTO lever is disen- The winch control lever is located on the right-
gaged before attempting to clean out a PTO-driv- hand side of the operator's seat. The lever has three
en machine or adjust hitch or PTO linkage. positions: Hold, Wind, and Unwind.
Using PTO A CAUTION : Winch " HOLD" position WILL

The engine clutch can be disengaged and power . . NOT sustain a load on the cable. Do not
will still be transmitted to the powershaft. To do this, use winch as a derrick with an external pulley.
depress the clutch pedal only 3-1 /2 inches [88.9
mm] (or until resistance is felt). To disengage the
powershaft, press down fully on the engine clutch
pedal.
Litho in U.S.A.
10-14 Predelivery, Delivery, and After-Sale Services TM-1102 (Nov- 73)
When the control fever is in the center position, the

winch is in the "HOLD" position. In this position, the
winch brake prevents the cable drum from rotating.
------ ~
To release the cable, move the control fever rear-

ward to the " UNWIND" position. This allows the ca-
ble drum to "free-spoof" and unwind by the " fine- ~
~()
puff." The control fever wifl remain in the " UNWIND" '6 ~v
·) \:?
(J
position until released when it w ill return to the ,Q , J ()
"HOLD" position. ·~"
·~
"'-'
To wind the cable, push ·the fever forward to the :::::
;:::;
" WIND" position. The winch will continue to wind un-
til the lever is released. The engine speed can be
varied between 1500 rpm and 2500 rpm to regulate TZ 7 21 0
"-
the winch wind-in speed. When the control lever is
released , the lever will return to the "HOLD" position. Fig. 38-Attaching Cable To Winch
Winch control lever operational Yes No To conform to certain state laws, the winch cable
must be attached to the winch drum so that it can
31. Attaching Cable to Winch Drum come loose if the cable is unwound.
If the crawler is equipped with a winch, attach the Thread t he cable through the wi nch drum as
winch cable by one of the two foflowing proced ures. shown above and wind the cable onto the drum.
NOTE: When the cable is attached to the winch in

this manner, unwinding the cable below five turns on
the drum will allow the cable to disconnect from the
drum.
Winch cable attached correctly Yes No
32. Loader Bucket Level Indicator

Check the bucket level indicator operation and ad-
just, if necessary.
Th e bucket level indicator shows the operator

when the bucket is level or in "dig" position. The in-
dicator will work with the boom in any position.
Fig. 37-Attaching Cable To Winch
Thread cable through winch drum, fold end of ca-

ble back into drum, and pound it in.
Litho in U.S.A.
Crawler - J0450-C General 10
TM-11 02 (Nov-73) Predelivery, Delivery, and After-Sale Services 10-15
33. Electric Return-to-Dig Mechanism
1-End of Tube 2-Cut-Out Portion of Tube Fig. 41-Eiectric Return-To-Dig
Fig. 39-Bucket Level Indicator

Check the electric return-to-dig adjustment.
When the indicator is even with the end of the If the crawler loader is equipped with an electric
tube, the bucket will be level in the lowered position. bucket positioner and it is adjusted properly, the
bucket will be positioned in level or dig position when
When the indicator is flush with the bottom of the the boom is lowered to the ground.
cut-out portion of the tube, the bucket will be at the
proper digging angle when the boom is lowered. To adjust the bucket positioner, loosen the two
nuts holding the indicator rod. Level the bucket and
position the indicator rod until it depresses the lever
on the switch at the upper end of the indicator rod.
Tighten the two nuts after adjustment.
To adjust the switch on the control valve, loosen

the two screws holding the switch . Pos ition the
switch so that the actuator pin will depress the lever
on the bottom of the switch with the control handle in
the bucket roll back position.
Electric return-to-dig adjusted Yes No
34. Track Adjustment

Fig. 40-Adjusting Indicator
Check the track tension of each track. Proper track
To adjust the indicator. loosen the two nuts holding tension should be 718 to 1-1 /8-inch [22.23 to 25.58
the indicator rod. Level the bucket and position the mm) sag between rear sprocket and carrier roller.
indicator rod so the end is flush with the end of the
tube. Tighten the two nuts. NOTE: When measuring track sag, a pin and
bushing must be lined up over center of track carrier
Bucket level indicator adjusted Yes No roller.
Litho in U.S.A.
Adjust track sag as follows: When operating track in conditions where extreme
soil packing occurs in track system , check track ten-
sion often as tension may increase when soi l is
picked up. Also check coils of recoil springs. Mud
packing in the recoil spring can cause restriction of
the idler travel and recoil action. This restriction can
result in overstressing the track link assemblies, re-
coil mechanism , and final drive components.
IMPORTANT: When forward edge of track front

bracket is approximately 1-lnch [25.4 mm] from
the end of the track frame, track bushings and
pins should be inspected for excessive wear. Re-
place excessively worn bushing and pins as
needed. When the forward edge of the front idler
and forward end of the track frame are in line,
1-Track Sag 3-Decrease Tension track assemblies are in need of reconditioning.
2- Pin Centered 4-lncrease Tension
After adjusting for proper tension, check alignment
Fig. 42-Track Tension Adjustment
and adjust if necessary.
When measuring track sag, a pin and bushing Track adjusted Yes No
must be lined up over center of track carrier roller.
Adjust track sag so there is 718 to 1-1/8 inch [22.23 35. Track Alignment
to 25.58 mm] sag in center of track between rear Check track alignment after adjusting the track
sprocket and carrier roller (Fig. 42) . sag.
Track tension is adjusted by attaching flexible hose The importance of proper track alignment cannot
with special adapter f urnished with crawler on a be too greatly emphasized. If the sides of the drive
grease gun that has a maximum capacity of 8000 psi sprockets and front idler flanges show heavy wear,
[5.62 kg-mm 2). the track is probably out of alignment.
To tighten track, apply grease with gun until the Check track alignment by driving forward on level
proper tension is achieved (Fig. 42). ground for about 25 feet [7.6 m]. Stop crawler with-
out touching steering levers and examine location of
IMPORTANT: Never, under any circumstances, the track link in relation to the front idler flanges (Fig.
use a grease gun to adjust track having a capaci- 43). (In the illustration one shoe has been removed
ty higher than 8000 psi [5.62 kg-mm2]. Tee a pres- for better visibility.)
sure gauge (0 to 10,000 psi [703 kg-mm2] capaci-
ty) in grease gun tube to check pressure . If
piston cannot be moved with this type grease
gun, disassemble track adjuster and free seized
parts.
To loosen track, first loosen jam nut on set screw

of track adjusting cylinder. Then turn set screw coun-
terclockwise a slight amount to relieve track tension.
As pressure is relieved, grease will run out of hole in
bottom of cylinder. Turn set screw in to original posi-
tion and tighten jam nut.
IMPORTANT: Warn operator never to lubricate

fitting on hydraulic track adjusting cylinder ex-
cept when track is in need of adjustment.
Litho in U.S.A.
TM- 1102 (Nov-73) Predelivery, Delivery, and After-Sale Services 10-17
Shims are provided on each side at the rear of

track idler bracket to properly adjust position of track
on front idler. Remove one shim at a time from the
rear of idler bracket (Fig. 44) on the side of idler
flange and track link having the least clearance. Re-
move one shim. then test by running the tractor in
straight line. Proceed to remove shims until idler is
centered between track links.
Track aligned Yes No
LUBRICATION
All grease fittings were properly lubricated and
checked before the crawler left the factory. However,
to insure proper customer satisfaction, check each
fitting shown in the following pages and lubricate it, if
necessary, with John Deere Multi-Purpose Lubricant
1- Track Shoe 2- Trac k Idler or an equivalent.
Fig. 43-Checking Track Alignment 36. Winch Fairlead
If clearance between idler flange and track link is

not equal on both sides of the idler, tracks are not
properly aligned.
Fig. 45-Winch Fairlead Grease Fittings
Check the winch fairlead grease fittings for proper

lubrication . If fittings appear dry, lubricate each fitting
with two shots of John Deere Multi-Purpose Lubri-
cant or an equivalent.
Grease liNings lubricated Yes No
1-Adj ustlng Shims 2-Track Adjusting Cylinder
Fig. 44-Aiigning Track Front Idler
Litho in U.S. A.
37. Loader Cylinders and Pivot Points
Fig. 46-Loader Cylinders and Pivot Points
Check the above grease fittings for proper lubrication. If fittings appear dry, lubricate each fi tting shown above
with two shots of John Deere Multi-Purpose Lubricant or an equivalent. Wipe fittings clean before applying
grease gun. (On multi-purpose bucket, also lubricate clam pivot grease fittings. Scrape off any dirt packed be-
tween lower clam cylinder pivots and sides of multi-purpose bucket.) NOTE: Block up loader boom while greas-
ing.
38. Bulldozer Grease Fittings
Fig. 47-6410 Bulldozer Grease Fittings

Litho in U S.A.
TM- 7102 (Nov-73) Predelivery, Delivery, and After-Sale Services 10-19
Check the bulldozer grease fittings for proper lubrication. If fittings appear dry, lubricate each grease fitting
with two shots of John Deere Multi-Purpose Lubricant or an equivalent.
Bulldozer grease fittings lubricated No
Litho in U.S.A.
39. Backhoe Grease Fittings
-TJ20JOH
Fig. 50-9300 Backhoe Grease Fittings
TJ2011
Litho in U.S.A.
TM-1102 (Nov- 73) Predelivery, Delivery, and After-Sale Services 10-21
41. Control Lever Lubrication
Fig. 54-Control Lever (Loader Shown)
Lubricate the loader, dozer, and ripper control le-

Fig. 52-9250 Backhoe Swing Frame Grease Fittings
vers at their linkage points with same type oil as
used in the engine crankcase.
Check the backhoe grease fittings shown above
and on page 10- 10-20 for proper lubrication. If fit- Control levers lubricated Yes No
tings appear dry, lubricate each grease fitting with
two shots of John Deere Multi-Purpose Lubricant or
an equivalent.
Backhoe grease fittings lubricated Yes No
40. Ripper Grease Fittings
Fig. 53-Ripper Grease Fittings
Check the ripper fittings for proper lubrication. If fit-

an equivalent.
Ripper liNings lubricated Yes No
Litho in U.S.A.
10-22 Predelivery, Delivery, and After-Sale Services TM- 11 02 (Nov-73)
42. Accessible Hardware Torque 43. Backhoe Tapered Pins

Values
Check all accessible bolts and nuts for proper
tightness. If hardware seems loose, tighten it to the
proper torque. The table below gives correct torque
values for various bolts and cap screws. Most hard-
ware used is high-strength (note dashes on hex.
heads).
RECOMMENDED TORQUE IN LB -FT JKg· ml

COARSE AND FI NE THREADS
B D F
G @ /
Fig. 56-Backhoe Tapered Pins
Bolt
0 ED
Plain Three
@
Six
Check the torque on the backhoe tapered pins us-
ing the torque chart illustrated at left.
Diam ete r Head Dashes Dashes Backhoe tapered pins tightened to specifications.
1/ 4 Not used 10 11.41 14 [1.9 1 44. Final Check

5/ 16 Not used 20 12 .8 1 3014 .1 1
The final predelivery procedure is the overall
3/ 8 Not used 35 [4 .81 5016.9 1
80 [11. 1 1 cleanup of the crawler. Make the crawler LOOK like
7/1 6 3514.8 1 55 [7 .6 1
120 11 6.6 1 a new machine with the proper touch-up of chipped
1/2 5517.6 1 85 111.8 1
175124.2 1 paint and a good wash job. Deliver to the customer a
9/1 6 75 [10.4 1 130118.0 1
170 \ 23.5 1 240 l33.2 l machine he will be proud to own.
5/8 105 114.5 1
3/4 185125 .6 1 300 141.5 1 425 158.8 1
7/ 8 160 122. 1 1 445 \61 .5 1 685 194.71
1 250 [34.6 1 67019 2.5 1 1 030 [142.4 J
1-1 / 8 330 [45 .61 91 Ol125.8 j 1460[201.9 1
1-1/4 480 [66.4 [ 1250 1172.81 2060 \284 .8]
T30882
Fig. 55-Torque Chart
The types of bolts and cap screws are identified by

head markings as follows:
Plain Head : regu lar machine bolts an d cap

screws.
3-Dash Head: tempered steel high-strength bolts

and cap screws.
6-Dash Head: tempered steel extra high-strength

bolts and cap screws.
Machine bolts and cap screws 7/ 8-inch [22.23

mmJ and larger are sometimes formed hot rather
than cold, which accounts for the lower torque.
All accessible hardware

torqued
Litho in U.S.A.
TM-11 02 (Nov-73) ?redelivery, Delivery, and After-Sale Services 10-23
DELIVERY SERVICE AFTER-SALE INSPECTION

A thorough discussion of the operation and service The purchaser of a new John Deere machine is
of a new machine at the time of delivery helps to as- entitled to a free inspection at some mutually agree-
sure complete customer satisfaction. Proper delivery able time within the warranty period after the equip-
should be an important phase of a dealer's program. ment has been "run in," usually after 50 to 100 hours
A portion of the John Deere Delivery Receipt em- of machine operation. The terms of this after-sale in-
phasizes the importance of proper delivery service. spection are outlined on the customer's John Deere
Delivery Receipt.
It is a well-known fact that many complaints have
arisen simply because the owner was not shown how The purpose of this inspection is to make sure that
to operate and service his new machine properly. the customer is receiving satisfactory performance
Enough time should be devoted, at the customer's from his machine. At the same time, the inspection
convenience, to introducing the owner to his new should reveal whether or not the machine is being
machine and explaining to him how to operate and operated, lubricated, and serviced properly.
service it.
If the recommended after-sale service inspection is
The following procedure is recommended before followed, the dealer can eliminate a needless volume
the serviceman and owner complete the delivery ac- of service work by preventing minor irregularities
knowledgments portion of the Delivery Receipt. from developing into serious problems later on. This
will promote strong dealer-customer relations and
Using the operator's manual as a guide be sure present the dealer an opportunity to answer ques-
that the owner understands these points thoroughly: tions that may have arisen during the first few days
of operation.
1. The importance of safety.
2. The importance of lubrication and periodic ser- During the inspection service, the dealer has the
vices. further opportunity of promoting the possible sale of
3. The importance of the break-in period. other new equipment.
4. Controls and instruments.
5. How to start and stop the engine. Check operation of all controls and instruments for
6. All functions of the hydraulic system. freedom of movement and correct operation.
After explaining and demonstrating the above fea-

tures, have the owner sign the Delivery Receipt and
give him the operator's manual.
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CHECK AND CLEAN 3. Fuel Tank Sump

Check and clean the following crawler compo-
nents.
1. Ai r Cleaner
Fig. 59-Fuel Tank Sump
Drain fuel tank sump in the morning or after the

machine has been idle for a long period of time.
Open drain cock under seat and allow approximately
one cup of fluid to drain out. This will insure that all
1-Restriction Indicator 3-Filter Element moisture has been removed from the sump.
2-Safety Filter Element ~Baffle
Fig. 57-Air Cleaner Fuel tank sump drained Yes No
Check air filter restriction indicator, if equipped. If 4. Fuel Filter

red signal locks in full view. remove air filter and
clean. Replace air filter if necessary.
Air filter element ok Yes No
2. Pre-Cleaner
Fig. 60-Fue/ Filter
Check fuel filter for sediment and drain, if neces-

Fig. 58-Pre-Cleaner Attachment sary.
Check the pre-cleaner and empty it if the accumu- Sediment present in filler Yes No
lation of foreign material is up to the mark on the
plastic bowl.
NOTE: Under extremely dusty conditions, it will be

necessary to remove and clean the unit more often.
Never allow the precleaner to become clogged with
foreign material.
Pre-cleaner cleaned out Yes No

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5. Check Air Intake Hoses CHECK ELECTRICAL SYSTEM

Check clamps on hoses which connect air cleaner
and engine. Tighten hose clamps where necessary
1. Batteries
to prevent dirt from entering engine. Inspect hoses
for cracks.
Air intake hoses checked

Loose connections Yes No
6. Engine Crankcase Vent Tube

Remove vent tube and clean out with diesel fuel.
When installing the tube, be sure packing is secure
in groove of engine tappet cover bore.
Vent tube removed and cleaned
7. Transmission Filter Screen

Clean the transmission oil filter screen. Remove
Fig. 62-Batteries
cover from right front wall of transmission case
and pull out filter assembly. Wash filter element in Check battery electrolyte level. If distilled water is
not available, use clean soft water. Avoid use of hard
water. Remove foreign material from top of battery
and coat terminals with petroleum jelly. Clean vent
holes in battery caps.
IMPORT ANT: Never add water to battery in

freezing weather unless engine is to be run long
enough (2 or 3 hours) to assure mixing of water
and electrolyte.
Water added Yes No

Batteries checked and serviced
Fig. 61-Transmission Filter Screen

2. Charging System
diesel fuel, using a bristle brush (not a wire brush). When the crawler is running and the ammeter is
Rinse in clean diesel fuel , flush with water under charging, the charging system can be considered to
pressure, and dry with compressed air. Check seal be in proper working condition .
on end of filter for wear or damage. If seal is leaking
or if element is damaged, replace filter. Reinstall ele-
ment, seal inward. Hold spring in cup of filter and in-
stall cover with new gasket and seal. Secure with
three cap screws.
Transmission filler screen cleaned
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10-26 ?redelivery, Delivery, and After-Sale Services TM- 1102 (Nov- 73)
3. Lights The shift lever has four shift stations. These shift
stations correspond to the four ranges provided.
Within each of these ranges are high, low, and re-
verse gears which are selected by the H-L-R lever
located on the battery box. By using the H-L-R lever,
the operator can " down-shift" from high to low in or-
der to gain additional power, or can shift from low to
high to increase travel speed. Shifting is also conve-
nient between forward and reverse when "shuttling"
the crawler.
The H-L- R lever is used to shift into high, low, or

reverse gear within the range set by the shift lever.
Note the shift pattern. This lever is used for fast
"down-shift" or "shuttling" of the crawler as during
loading and dozer work.
The H-L- R lever may be locked in neutral by en-

Fig. 63-Light Switch
gaging the H-L-R neutral lock lever.
Check operation of crawler lights. Transmission operational
All lights are controlled by the "push-pull" light 2. Gauge Operation

switch. To turn on lights, pull out switch knob. To
turn off lights, push in switch knob. When operating the crawler, check the engine oil
pressure gauge, transmission oil temperature gauge,
All lights operational Yes No engine coolant temperature gauge and the ammeter.
CHECK OPERATION RED LI GHT

ORANG E GREE N
1. Check Transmission Operation
Fig. 65-Ammeter Fig. 66-Engine Coolant

Temperature Gauge
If the indicator hand of the engine coolant temper-

ature gauge goes into the red-orange zone, check
the cooling system.
If the ammeter needle is in the red-orange zone

while the engine is running, the alternator is dis-
charging . Shut off the engine immediately and trou-
ble shoot the electrical system.
1-H-L-R Neutral Lock 3-Shift Lever

2- H-L-R Lever
Fig. 64-Transmission Shifting
Check the transmission operation.
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The transmission temperature gauge indicates the

temperature of the lubricating oil in the transmission.
If hand enters the red-orange zone, operate in a low-
er gear. If hand remains in the red-orange zone,
check transmission oil level. Do not continue crawler
operations with hand in the red-orange zone.
All gauges operational Yes No
3. Hydraulic Brakes
Fig. 6-Engine Oil Pressure Gauge
The engine oil pressure gauge indicates the pres-

sure of the engine lubricating oil. Oil pressure will
vary slightly with wear, but with recommended oil,
the gauge indicator hand should be in the operating
range (indicated by green zone on the dial). If oil
pressure drops into the orange zone on the dial, stop
crawler immediately and check the crankcase oil lev-
el. If oil level is not low, check for restrictions in oil
lines or incorrect viscosity oil. 1-Brake Pedal 2-Parking Brake Lock
Fig. 69-Brakes
After starting the engine do not accelerate or apply
a load until the engine oil pressure gauge indicates
pressure. In cold weather, or after the engine has Check the brake pedal for adjustment and proper
been idle for several weeks, idle the engine for sev- operation. Apply parking brake lock. Parking brake
eral minutes at speeds below 1000 rpm before accel- lock should hold crawler from moving.
erating or operating engine under load.
Brakes operational Yes No
Fig. 68-Transmission Temperature Gauge
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10-28 Predelivery, Delivery, and After-Sale Services TM- 1102 (Nov-73)
4. Steering
Check steering levers and linkage for proper oper-
ation and adjustment.
1-Steering Valve Rods 3-Jam Nuts

2-Steering Valve Spool 4-Steerlng Valve
Eyebolts

T31992N.
1-Steerlng Brake Rods 2- Steerlng Valve Rods
Fig. 70-Steering Levers and Rods Adjustment rods (1) will just slip through the eyebolts. Tighten
one additional turn and tighten jam nuts (3).
Refer to Fig. 70 and adjust the steering brake rod
yokes. Adjust so that the top of the steering levers Adjust brake pedal with pedal back against the
move 10 :t 0.25 inches [254.00 :t 6.350 mm] when stop. Pull brake rods forward to take up pin clear-
the brake lever (4, Fig. 7, page 40-15-7) contacts the ance. Adjust brake rods to align holes and install
brake lever adjusting screw (1 ). Tighten steering pins. Tighten jam nuts.
brake rod yoke jam nuts (Fig. 70) .
Reach through the access hole in the side of
nuts until 60 pounds [27.2 kg) pull at the base of the
steering lever hand grip will just move the lever to
the stop.
Litho in U.S.A.
TM-1102 (Nov-73) Predelivery, Delivery, and After-Sale Services 10·29
5. Loader Control Lever For most accurate control and maximum power,
move the control lever only partially to the right.
When retracting, maximum power is obtained by

moving the lever all the way left.
Loader control lever operational Yes No
6. 6410 and 6415 Bulldozer Control Lever
1- Lower Boom 3-Raise Boom

2-Bucket Dump 4-Bucket Retract
Fig. 72-Loader Control Lever
Check loader control lever for proper operation.
Boom Control
1-Raise 3-Lower
The boom is operated by moving the control lever 2- Neutral 4- Fioat
either forward or rearward. Pushing the lever forward
lowers the boom and pulling it rearward raises the Fig. 73-6410 and 6415 Bulldozer Control Lever
boom.
Check bulldozer control lever operation.
If the operator releases the control lever at any
time during normal operation, it will automatically re-
Raise the blade by pulling the lever all the way
turn to neutra l, holding the boom in the position
back.
Lower the blade by pushing the lever forward, but
Bucket Control
not to the extreme forward position.
Moving the control lever rig.ht or left operates either
the bucket or fork. Pushing the lever to the right When the control lever is pushed to the extreme
dumps and pulling it to the left retracts the bucket or forward position (detent), the blade is in float posi-
fork. tion. In this position, the blade will follow the contour
of the ground.
When released, the control lever will always return
to neutral, holding the bucket or fork in the position
The speed of dumping or retracting can be con-

trolled by the distance the control lever is moved .
Moving the lever all the way right dumps the bucket
or fork in the shortest possible time.
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The control lever will return to neutral position au- The 6405 bulldozer blade may be angled 25 de-
tomatically when the lever is released from all posi- grees to the left or right.
tions except float position. Return lever to neutral
manually from the float position.
Bulldozer control lever operational Ye~ No
7. 6405 Bulldozer Control Lever
1-Angle leN 2-Angle Right

1-Raise Blade 3-lower Blade
2-Neutral 4-Fioat Blade Fig. 75·Biade Angling
Fig. 74-6405 Bulldozer Control Lever Angle the blade to the right by twisting the control
lever to the right.
Check bulldozer control lever operation. Angle the blade to the left by twisting the control
lever to the left.
The control lever is set to return to neutral auto-
matically when the lever is released from all positions The 6405 bulldozer blade may be tilted 14 inches
except float position. Return lever to neutral manually down.
from float position.
Raise the blade by pulling the control lever to the

full rear position.
Lower the blade by pushing the control lever for-

ward, but not to the extreme forward position.
Push the lever to the extreme forward position

this is the blade float position. The lever must be
manually returned to neutral position from float.
I
1-TIIt leN 2-Tilt Right
Fig. 76·8/ade Tilting
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Tilt the left side of the blade up by pushing the 9. Check Backhoe Stabilizer Control Le-
control lever to the far right position. vers
Tilt the left side of the blade down by pulling the

control lever to the far left position.
8. Attachment Control Lever

Check the attachment control lever for correct op-
eration .
Fig. 78-Stabi/izer Control Levers
Check the operation of stabilizer control levers.
To lower the stabilizers for backhoe operation,

move the control levers forward. To raise them, pull
the levers rearward.
1- Forward 2- Rearward
Backhoe stabilizer control levers operational Yes No
Fig. 77-ANachment Control Lever
10. Backhoe Boom and Swing Control

The attachment control lever (outside) controls op- Lever
eration of all hydraulic attachments other than loader
and bulldozer operations. This control is operated by
moving it either forward or rearward.
Attachment control lever operational Yes No
1-Down 3-Up
2-Right 4-Left
Fig. 79-Boom and Swing Control Lever
Litho in U.S.A.
10-32 ?redelivery, Delivery, and After-Sale Services TM-1102 (Nov-73)
Check the boom and swing control lever operation. Extend dipperstick (move bucket out) by moving
the control . lever forward and retract it (move bucket
Lower the boom by moving the control lever for- in) by moving the lever rearward.
ward. Raise the boom by moving the lever rearward.
Swing left by moving the lever to the left and swing Dump the bucket by moving the control lever to
right by moving lever to the right. the right and load it by moving the lever to the left.
By moving the lever to one of the intermediate po- By moving the lever to one of the intermediate po-
sitions, the boom can be swung to the left or right at sitions, the dipperstick can be extended or retracted
the same time it is being raised or lowered, perform- at the same time the bucket is being loaded or
ing two operations simultaneously. dumped.
Swing left and lower the boom by moving the con- Extend and dump the bucket by moving the lever
trol lever rearward and to the left. forward and to the right.
Swing left and raise the boom by moving the con- Retract and dump the bucket by moving the lever
trol lever rearward and to the left. rearward and to the right.
Swing right and lower the boom by moving the Extend and load the bucket by moving the lever
control lever forward and to the right. forward and to the left.
Swing right and raise the boom by moving the Retract and load the bucket by moving the lever
control lever rearward and to the right. rearward and to the left.
A swing brake, built into the swing cylinder, auto- Bucket and dipperstick control
matically slows the boom before it strikes the stops lever operational Yes No
on the main frame.
12. PTO Operation
Boom and swing control
Check the PTO operation, if equipped.
lever operational Yes No
Your crawler may be equipped with a 1000 rpm
11. Bucket and Dipperstick Control Lever
power take-off which allows for the operation of rear-
Check the bucket and dipperstick control lever op- driven tools.
eration.
1-Bucket Out 3-Bucket In

2- Dump 4-load
Fig. 80-Bucket and Dipperstick Control Lever Fig. 81-PTO Control Lever
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The power take-off shaft is engaged by a control Using PTO

lever located on the platform under the air cleaner.
The engine clutch can be disengaged and power
To engage the powershaft, depress engine clutch
will still be transmitted to the powershaft. To do this,
pedal, shift PTO control lever rearward, and slowly
depress the clutch pedal only 3-1/2 inches [88.9
release clutch pedal.
mm] (or until resistance is felt) . To disengage the
powershaft, press down fully on the engine clutch
pedal.
A CAUTION: Never dismount from the

. . crawler without first disengaging the PTO
shaft and stopping the engine. Never engage the
PTO when the engine is stopped.
PTO operational Yes No
13. Winch Control and Operation
1- PTO Master Shield 2- PTO Shaft Guard
Fig. 82-PTO
When attaching short-coupled equipment, it may

be necessary to remove the PTO master shield at
the rear of the crawler. To do so, remove the four
shield retaining cap screws and lift off the shield.
A CAUTION: Remove the master shield only

. . when necessary. Be sure that the shield
is In place any time the PTO guard is removed.
The PTO guard should always be installed on the

PTO shaft except when operating PTO-driven equip- 1- Wind 3-Unwind
ment. The PTO guard is attached with two cap 2-Hold
screws.
Fig. 83-Winch Control Lever
Attaching PTO-Driven Equipment
Attach the PTO-driven equipment to the power Check the operation of the winch.
take-off and start the crawler engine. Depress clutch
pedal and engage PTO control lever by moving the Your crawler may be equipped with a John Deere
lever for ward . Then slow ly re lease clutch pedal. Power Winch . This winch is driven from the rear of
Operate the engine at 1900 rpm to obtain 1000 rpm the crawler and has a separate hydraulic control.
PTO shaft speed.
To operate the winch, start the engine and allow it
A CAUTION: Always make sure the engine to warm up properly. Adjust the engine speed from
. . is shut off and the PTO lever is disen- 1500 rpm to 2500 rpm. The winch may be operated
gaged before attempting to clean out a PTO-driv- at any speed in this range.
en machine or adjust hitch or PTO linkage.
Litho in U.S.A.
10-34 ?redelivery, Delivery, and After-Sale Services TM-1102 (Nov-73)
The winch control lever is located on the right-

hand side of the operator's seat. The lever has three
positions: Hold, Wind, and Unwind.
A CAUTION: Winch "HOLD" position WILL

. . NOT sustain a load on the cable. Do not
use winch as a derrick with an external pulley.
When the control lever is in the center position, the

winch is in the "HOLD" position. In this position, the
winch brake prevents the cable drum from rotating.
To release the cable, move the control lever rear-

ward to the " UNWIND" position. This allows the ca-
ble drum to "free-spool" and unwind by the "line- 1-End of Tube 2-Cut-Out Portion of Tube
pull." The control lever will remain in the "UNWIN D"
position until released when it will return to the Fig. 84-Bucket Level Indicator
"HOLD" position .
When the indicator is flush with the bottom of the
To wind the cable, push the lever forward to the
cut-out portion of the tube, the bucket will be at the
"WIND" position. The winch will continue to wind un-
proper digging angle when the boom is lowered .
til the lever is released. The engine speed can be
varied between 1500 rpm and 2500 rpm to regulate
the winch wind-in speed . When the control lever is
released, the lever will return to the " HOLD" position.
Winch lever action checked
MAKE ALL NECESSARY

ADJUSTMENTS
1. Loader Bucket Level Indicator
Check the bucket level indicator operation and ad-
just, if necessary.
The bucket level indicator shows the operator Rg. 85-Adjusting Indicator
when the bucket is level or in "dig" position. The in-
dicator will work with the boom in any position. To adjust the indicator, loosen the two nuts holding
the indicator rod . Level the bucket and position the
When the indicator is even with the end of the indicator rod so the end is flush with the end of the
tube, the bucket will be level in the lowered position. tube. Tighten the two nuts.
Bucket level indicator adjusted Yes No
Litho in U.S.A.
TM- 11 02 (Nov- 73) Predelivery, Delivery, and After-Sale Services 10-35
2. Electric Return-to-Dig Mechanism Ad just track sag as follow:
Fig. 86-E/ectric Return- To-Dig

1-Track Sag 3-Decrease Tension
Check the electric return-to-dig adjustment. 2-Pin Centered 4-lncrease Tension
If the crawler loader is equipped with an electric Fig. 87·Track Tension Adjustment
bucket positioner and it is adjusted properly, the
bucket will be positioned in level or dig position when
When measuring track sag, a pin and bushing
the boom is lowered to the ground.
must be lined up over center of track carrier roller.
Adjust track sag so there is 7/8 to 1-1 /8 inch [22.23
To adjust the bucket positioner, loosen the two
to 25.58 mm] sag in center of track between rear
nuts holding the indicator rod. Level the bucket and
sprocket and carrier roller (Fig. 87).
position the indicator rod until it depresses the lever
on the switch at the upper end of the indicator rod.
Track tension is adjusted by attaching flexible hose
Tighten the two nuts after adjustment.
with special adapter f urnished with crawler on a
grease gun that has a maximum capacity of 8000 psi
To adjust the switch on the control valve, loosen
[5.62 kg-mm 2).
the two screws holding the swit ch . Position the
switch so that the actuator pin will depress the lever
To tighten track, apply grease with gun until the
on the bottom of the switch with the control handle in
proper tension is achieved (Fig. 87).
the bucket roll back position.
IMPORTANT: Never, under any circumstances,
Electric return-to-dig adjusted Yes No
use a grease gun to adjust track having a capaci-
ty higher than 8000 psi [5.62 kg-cm 2] . Tee a pres-
3. Track Adjustment sure gauge (0 to 10,000 psi [0 to 7.03 kg-mm 2]
Check the track tension of each track. Proper track capacity) in grease gun tube to check pressure. If
tension should be 7/8 to 1-1/8-inch [22.23 to 25.58 piston cannot be moved with this type grease
mm] sag between rear sprocket and carrier roller. gun, disassemble track adjuster and free seized
parts.
NOTE: When measuring track sag, a pin and
bushing must be lined up over center of track carrier To loosen track, first loosen jam nut on set screw
roller. of track adjusting cylinder. Then turn set screw coun-

Litho in U.S.A.
10-36 Predelivery, Delivery, and After-Sale Services TM- 11 02 (Nov-73)
When operating track in conditions where extreme

soil packing occurs in track system, check track ten-
sion often as tens ion may increase whe n soil is
coil mechanism, and final drive components.

bracket is approximately 1-inch [25.4 mm] from
place excessively worn bushing and pins as
needed. When the forward edge of the front idler
track assemblies are in need of reconditioning.
After adjusting for proper tension, check alignment 1- Track Shoe 2-Track Idler
and adjust if necessary.
Fig. 88-Checking Track Alignment
Track sag adiusted

4. Track Alignment
Check track alignment after adjusting the track properly aligned .
sag.
The importance of proper track alignment cannot

be too greatly emphasized. If the sides of the drive
sprockets and front idler flanges show heavy wear,
the track is probably out of alignment.
Check track alignment by driving forward on level

ground for about 25 feet [7.6 m). Stop crawler with-
out touching steering levers and examine location of
the track link in relation to the front idler flanges (Fig.
88). (In the illustration one shoe has been removed
for better visibility.)
1- Adj ustlng Shims 2-Track AdjuS11ng Cy linder
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Shims are provided on each side at the rear of 6. Bleeding The Fuel System
When it becomes necessary to bleed the fuel sys-
tem, use the following procedure.
rear of idler bracket (Fig. 89) on the side of idler
1. Fill tank with proper fuel.
move one shim, then test by running the tractor in
2. Open shut-off valve at tank outlet under seat.
Track aligned Yes No
5. Alternator Belt Tension
Fig. 91 -Filter Bleed Plug Fig. 92-lnlet Line
3. Loosen bleed plug on top of the filter. Pump pri-

mer lever until a solid stream of fuel (free of air bub-
bles) flows from the opening. Tighten plug.
4. Loosen pump inlet line. Pump primer lever until

a solid stream of fuel (free of air bubbles) flows from
line. Retighten line.
Fig. 90-Adjusting Alternator Belt Tension
5. Be sure to leave primer lever at lowest point of
Check alternator belt tension . Loosen the alterna- stroke.
tor bracket and adjusting cap screws and apply out-
ward force to the FRONT alternator frame until a firm Fuel systern bled
pull (20 pound [9.07 kg] force) on the belt midway
between the pulleys will deflect the belt 3/4 inch
[ 19.05 mm]. If belt gauge is used, tighten fan belt to
100-110 lb. [45.36-49.89 kg] strand tension. After 3
minutes of machine operation, tension should be 80
lb. [36.29 kg) minimum.
IMPORTANT: Do not pry on the rear half of the

alternator housing as this may misalign the com-
plete alternator assembly.
Belt tension lbs. [kg] tension

inch {mm] flex
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7. Check Engine Speed Controls
T20940N
1-Hand Throttle Lever 5-Adjustable Yoke 8-Adjustable Yoke

2-Lever·to·Bell Crank Link 6-Speed Control Cable 9-Pump Slow-Idle Stop Screw
3-Frlction Adjusting Nut 7- Bracket 10- Pump Fast-Idle Stop Screw
4-Bell Crank
Fig. 93-Speed Control Linkage
Check the engine speeds. If any adjustment is 3. Lightly rotate pump throttle arm to slow-idle po-
needed. follow the exact order listed below. Refer to sition. Engine speed should be at slow idle of 800
Fig. 93 as a guide to adjusting points. rpm. If not. adjust slow-idle stop screw (9) on top of
injection pump.
IMPORTANT: Be sure engine Is at operating
temperature before making speed adjustments. 4. With speed control cable disconnected, move
Use a master tachometer. All speeds given are hand lever forward to the high idle position. Adjust
for engine at no load. cable yoke (8) to provide for 1/8-inch [3.175 mm]
overtravel of the pump arm. (For more travel, adjust
cable at yoke (5) under dash.) Check slow idle.
pump arm. Loosen cable clamp (7).
2. Run engine and rotate pump throttle arm until 5. Move hand throttle fully rearward and turn off
fast-idle stop screw (10) contacts its stop. Engine ignition .
speed should be at fast idle of 2650 rpm. If not, ad-
6. Move hand throttle back and forth to check fric-
just pump stop screw (10) to correct. Lock screw with
tion on lever. Check for 5 to 11 lbs. [2.3 to 5.0 kg)
sealing wire .
drag with a spring scale. Adjust, if necessary, at nut
(3).
Litho in U.S.A.
Trvi-11 02 (Nov-73) Predelivery, Delivery, and After-Sale Services 10-39
CHECK ALL FLUID LEVELS 2. Crankcase Oil Level

1. Radiator KEEP OI L LEVEL
BETWEE N i'lARKS
----=
------ -··-"'--1.,...,.--
~~ =- J
Fig. 94-Radiator Filler Cap
1- Dipstick 2-011 Filler Cap

CAUTION : Do not remove radiator filler
A cap until the coolant temperature is below
its boiling point. Then loosen cap slowly to the
Fig. 95-Crankcase Oil Level
Check cran kcase oil level with unit on level

stop to relieve any excess pressure before re- ground. If oil level is at or below bottom mark on dip-
moving cap completely. stick, add sufficient oil of the proper viscosity and
type specified on page 10-15-3 to bring oil level to
Check the level of coolant in the radiator. Coolant between marks on dipstick. Do not operate engine
should be maintained at a level midway between the with oil level below the bottom mark.
radiator core and filler neck. Add permanent type an-
tifreeze if cold weather is anticipated. Crankcase oil level checked Yes No
Oil added Yes No
Radiator coolant level checked Yes No
Coolant or antifreeze added Yes No
Litho in U.S.A.
3. Hydraulic Reservoir Oil Level 4. Transmission Oil Level

Check oil level in loader hydraulic system. Oil level
should be halfway up in oil level window with the
bucket rolled back on the ground .
Fig. 97-Transmission Oil Dipstick
Fig. 96-Hydraulic System Oil Level Window and Latch The transmission dipstick is located under the
seat. The oil level should be between the marks on
To add oil, turn latch and lift reservoir cover. Turn the dipstick with threads resting on filler tube and the
pressure cap slowly and remove it. Add John Deere engine off. Add sufficient John Deere Type 303 Spe-
Type 303 Special-Purpose Oil or an equivalent until cial-Purpose Oil or an equivalent to bring oil to this
oil level reaches half circle on window. level.
NOTE: The hydraulic pump on crawlers not Oil level checked

equipped with auxiliary equipment must be disen- Oil added Yes No
gaged at all times. In order to protect the hydraulic
pump in case it is accidently engaged, the reservoir 5. Winch Housing Oil Level
should be kept full. When operating hydraulic auxilia-
ry equipment, refer to the appropriate equipment op-
erator's manual for hydraulic system oil capacity.
IMPORTANT: Do not operate crawler without

oil in reservoir. Doing so will damage the hydrau-
lic pump if engaged.
Hydraulic oil level at proper level Yes No

Oil added Yes No
1- Filler Plug 2-011 Level Plug
Fig. 98-Winch Oil Level
Litho in U.S.A
TM-1102 (Nov-73) ?redelivery, Delivery, and After-Sale Services 1 0-41
Check the oil level of the winch housing by remov- 7. Steering Reservoir Oil Level
ing the oil level plug on the lower right side . If oil is
not up to the hole, remove the filler plug and add oil
as specified on page 10-15-3.
Oil level checked

Oil add, if any qts [I]
6. Final Drives
1- FIII Plug 2-Level Plug
Fig. tOO-Steering Reservoir Fill and Level Plugs
Check the steering reservoir oil level. Remove oil

level plug. Oil should be to the level of the oil level
plug . If necessary to add oil, replace oil level plug,
remove fill plug and add sufficient John Deere Type
303 Special-Purpose Oil or an equivalent to bring oil
1- 0il Level Plug 2- Drain Plug
level to bottom of oil level plug.
Fig. 99-Final Drive
Oil level checked
The oil supply in the final drives should be main- Oil added, if any qts. (I)
tained at the level of the oil level hole. Check oil level
and, if necessary, add the amount of lubricant re-
quired to bring oil to this level. Use John Deere Type
303 Special-Purpose Oil or an equivalent.
Oil level checked

Oil added, if any qts (I}
Litho in U.S.A.
8. Check The Level of Track Front NOTE: Coat threads of fill plug (2) and check plug
Idler, Track Carrier Roller and {1) with Loctite or an equivalent sealant before re-
Track Roller Oil Level placing them.
Check the oil level of the track front idlers, track
3. After the oil has stopped flowing from the oil lev-
carrier rollers and track rollers as shown below.
el check hole, replace the check plug (1 ). Remove
grease fitting from the fill plug hole and IMMEDIATE-
LY replace fill plug (2).
Checking and Filling Track Carrier Roller
1- 0il Level Check Plug 2- Fill Plug
Fig. 101-0il Level Check and Fill

Plugs (Front Idler Shown)
Remove the oil level plug (1 , Fig. 101 ). Oil level 1- Track Carrier Roller 3-Track Roller Oil
should be at check plug hole level. or not more than 011 Level Check Plug Level Check Plug
1/8 inch below the bottom of the check hole. Use a 2- Track Carrier Roller 4-Track Roller Oil
wire or similar instrument with a 1/8-inch right angle Oil Fill Plug Fill Plug
bend in it to check oil level.
Fig. 102-0il Level Check and Fill
Plugs
If oil level is more than 1/8 inch below the oil level
check plug hole, add oil using the following proce-
dure: Check the track carrier roller oil level. Oil level
check plug (1 , Fig. 102) must be in the three o'clock
1. Replace the oil level check plug ( 1) and remove or nine o'clock position to obtain an accurate oil level
the fill plug (2) . IMMEDIATELY replace the fill plug reading.
with a 1/8-inch suitable (zerk or button head) grease
fitting. Oil level should be even with the check hole when
the plug ( 1) is removed.
2. Remove oil level plug (1 ). Attach a grease gun
filled with John Deere Torq-Gard Supreme SAE 30 If oil level is not correct, add John Deere Torq-
Oil or an equivalent to the grease fitting. Fill roller or Gard Supreme SAE 30 Oil or an equivalent.
idler until oil begins to flow from the oil level check
hole. Follow the preceding steps 1 through 3 when filling
the track carrier roller.
IMPORTANT: After filling roller or idler to de-
sired level, allow oil to stop draining from the oil Oil level checked
level check hole before replacing check plug (1 ). Oil added, if any Yes No
Failure to do so could result In roller idler seal
damage due to excessive oil pressure.
Litho in U.S.A.
CHECK ALL GREASE FITTINGS 2. Ripper Grease Fittings

Check all grease fittings for proper lubrication.
Grease, if necessary, and impress upon the owner
the importance of periodic greasing as outlined in the
operator's manual.
1. Winch Fairlead
Fig. 104-Ripper Grease Fittings
Check the ripper fittings for proper lubrication. If fit-

Fig. 103-Winch Fairlead Grease Fittings two shots of John Deere Multi-Purpose Lubricant or
an equivalent.
Check the winch fairlead grease fittings for proper
lubrication. If fittings appear dry, lubricate each fitting
Ripper fittings lubricated Yes No
with two shots of John Deere Multi-Purpose Lubri-
cant or an equivalent.
Grease fittings lubricated Yes No
Litho in U.S.A.
10-44 Predelivery, Delivery, and After-Sale Services TM-11 02 (Nov- 73)
3. Loader Cylinders and Pivot Points
Fig. 105-Loader Cylinders and Pivot Points
Check the above grease fittings for proper lubrication. If fittings appear dry, lubricate each fitting shown above
with two shots of John Deere Multi-Purpose Lubricant or an equivalent. Wipe fittings clean before applying
grease fun. (On multi-purpose bucket, also lubricate clam pivot grease fittings. Scrape off any dirt packed be-
tween lower clam cylinder pivots and sides of multi-purpose bucket.) NOTE: Block up loader boom while greas-
ing.
4. Bulldozer Grease Fittings
Fig. 106-64 10 Bulldozer Grease Fittings

Litho in U.S.A.
TM-11 02 (Nov-73) ?redelivery, Delivery, and After-Safe Services 10-45
Check the bulldozer grease fittings for proper lubrication. If fittings appear dry, lubricate each grease fitting
with two shots of John Deere Multi-Purpose Lubricant or an equivalent.
Bulldozer grease fittings lubricated Yes No
Litho in U.S.A.
10- 46 Predelivery, Delivery, and After-Sale Services TM-1102 (Nov-73)
5. Backhoe Grease Fittings
T3 20l0N
T32011
Fig. 110-9250 Backhoe Grease Fitting
Litho in U.S.A.
6. Control Lever Lubrication
Fig. 1 12-Control Lever (Loader Shown)
··r;sgoJaNi'
Lubricate the loader, dozer, and ripper control le-
Fig. 111-9250 Backhoe Swing Frame Grease Fittings
vers at their linkage points with same type oil as
used in the engine crankcase.
Check the backhoe grease fittings shown above
and on page 10-10-46 for proper lubrication. If fit- Control levers lubricated Yes No
an equivalent.
Backhoe grease fittings lubricated Yes No
Litho in U.S.A.
CHANGE FILTERS Remove winch filter element and discard it. Install
new element. making sure new sealing ring is insert-
1. Engine Crankcase Filter ed in end of element. Apply a thin film of oil to the
sealing ring. Spin on element by hand until sealing
ring just touches mounting pad and then turn an ad-
ditional 1-1 /2 turns. Do not overtighten. Check for
leaks and retighten if necessary, but do not overtigh-
ten.
IMPORTANT: The filter element has a special

bypass valve. Replace only with a genuine John
Deere filter element supplied by your John Deere
dealer.
3. Transmission Oil Filter
Fig. 113-Crankcase Oil Filter
Replace the crankcase oil filter. To remove filter el-

ement, turn it counterclockwise. Clean filter mounting
surface and install a new element, making sure new
sealing ring is inserted in end of element. Apply a
thin film of oil to the sealing ring. Turn element clock-
wise by hand until sealing ring just touches mounting
pad and then turn down an additional 1-1 /2 turns.
Do not overtighten.
With oil in crankcase, start engine and check for

leaks around filter element. Retighten if necessary,
but do not overtighten.
Fig. 115-Transmission Oil Filter
Deere filter element. To replace filter, remove grille. Turn filter element
counterclockwise. Discard old filter and install a new
2. Winch Oil Filter spin-on filter making sure new sealing ring is inserted
in end of element. Apply a thin film of oil to the seal-
ing ring. Turn element clockwise by hand until seal-
ing ring just touches mounting pad and then turn
down an additional 1-1/2 turns. Do not overtighten.
Start engine and check for leaks around filter ele-

ment. Retighten if necessary, but do not overtighten.

Deere filter element supplied by your John Deere
dealer.
Fig. 114-Winch Oil Filter NOTE: It is not necessary to drain oil from trans-
mission when replacing the filter. If the new element
is installed quickly_, little oil will be lost.
Litho in U.S.A.
4. Hydraulic Reservoir Return Line FLUID LEAKAGE

Filter (12. 75 Inch Reservoir)
Check the following systems for leakage due to
poor or faulty connections and broken hoses or lines.
A. Cooling system checked

B. Hydraulic system checked
C. Transmission system checked
D. Fuel system checked
E. Lubrication system checked
F. Air intake system checked
Fig. 116-Return Line Filter
Replace the return line filter.
Remove six cap screws holding the return line filter

and indicator to the reservoir. Lift the filter assembly
from the reservoir. Remove the filter from the filter
cap by unscrewing the bolt inside the filter.
Reassemble the filter unit using a new return line

filter. Replace the 0-rings at the return oil and suc-
tion oil ports.
Litho in U.S.A.
1. ACCESSIBLE HARDWARE 2. Backhoe Tapered Pins

TORQUE VALUES
Check all accessible bolts and nuts for proper
tightness. If hardware seems loose, tighten it to the
proper torque. The table below givBs correct torque
values for various bolts and cap screws. Most hard-
ware used is high-strength (note dashes on hex.
heads).
RECOMMENDED TORQUE IN LB·FT IKg -m I

COARSE AND FINE THREA DS
B D F
<3 ® /
Fig. 118-Backhoe Tapered Pins
Bolt
0
Plain
@\
Three
@ \
Six
Check the torque on the backhoe tapered pins us-
ing the torque chart illustrated at left.
Diameter H ead Dashes Dash es Backhoe tapered pins tightened to specifications.
1/4 Not used 1011.4] 1411.9]

5/16 Not used 20 12.8 ] 30 ]4.1 1
3/8 Not used 35 ]4.8] 50 ]6.9 ]
7/16 35]4.8 ] 55] 7.6 ] 80 111.1 ]
1/2 55 ] 7.6 ] 85 ] 11.8] 120116.6]
9/ 16 75 110.4 ] 130] 18.0 ] 175] 24.21
518 105 114.5 ] 170]23.5] 240 ]33 .2]
3/4 185]25 .6 ] 300141.5 ] 425 ]58.8 ]
718 160[22.11 445] 61.5 ] 685 ]94 .7 ]
1 250 ]34.6] 670]92 .5 ] 1030] 142.4 ]
1-1/8 330145.6] 910 ] 125 .8 ] 1460] 201 .9 ]
1-1/4 480[ 66.4 ] 1250 1172.8 ] 2060] 284 .8 J
T 30882
Fig. 117· Torque Chart
The types of bolts and cap screws are identified by

head markings as follows:
Plain Head: regular machine bolts and cap screws.
3-Dash Head: tempered steel high-strength bolts

and cap screws.
6-Dash Head: tempered steel extra high-strength

bolts and cap screws.
Machine bolts and cap screws 7/8-inch [22.23

mm) and larger are sometimes formed hot rather
than cold, which accounts for the lower torque.
All accessible hardware torqued
Litho in U.S.A.
TM-11 02 (Nov-73) Lubrication 15-1
Group 15
LUBRICATION
GENERAL INFORMATION
Illustrated below and on page 10-15-2 are replicas of the periodic service charts which are mounted inside
the crawler battery box. More detailed information on servicing the crawler can be found in the current JD450-C
Crawler Loader and Crawler Bulldozer operator's manual.
Use the operator's manual and the periodic service chart as references when servicing the crawler. Remind
your customer to thoroughly read his operator's manual before attempting to service or operate his crawler.
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T32 018N
Fig. 1-Periodic Service Chart (Loader)

Litho in U.S.A.
15-2 Lubrication TM-11 02 (Nov-73)
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T32 414
Fig. 2-Periodic Service Chart (Bulldozer)
Litho in U.S.A.
TA1- 1102 (fVov-73) Lubrication 15-3
LUBRICANTS
Carefully written and illustrated instructions are in Depending on the expected prevailing temperature
the JD450-C operator's manual. Remind the custom- for the fill period, use oil of viscosity as shown in the
er to follow the recommendations in his operator's following chart.
manual.
Other Oils
Effective use of lubricating oils and greases is per- Air John Deere Single VIs- Multi-VIsco-
haps the most important step towards low upkeep Temperature Torq-Gard Oil cosily Oil sity Oil
cost, long tractor life, and satisfactory service. Use Above SAE 30 SAE 30 Not recom-
only lubricants specified in this section; apply them at 32°F. [0.0°C.] mended.
intervals and according to the instructions in the lu-
brications and periodic service section. - 10°F. to SAE 10W-20 SAE 10W SAE 10W-30
30°F. [23.3°C. to 0.0° C.]*
ENGINE LUBRICATING OILS
Below SAE 5W-20 SAE 5W SAE SW-20
-10°F. (23.3°C.]
·*SAE SW-20 oil may also be used to insure opti-

mum ·lubrication at starting, particularly when engine
is subjected to - 10°F. [23.3°C.] or lower tempera-
tures for several hours.
Some increase in oil consumption may be expect-

We recommend John Deere Torq-Gard Supreme ed when SAE SW-20 or SAE SW oils are used.
engine oil for use in the engine crankcase. This oil is . Check oil level more frequently.
compounded specifically for use in John Deere en-
gines, and provides superior lubrication under all TRANSMISSION AND STEERING
conditions . NEVER PUT ADD ITIVES IN THE HYDRAULIC OILS
CRANKCASE. Torq-Gard Supreme oil is formulated Use only John Deere Type 303 Special-Purpose
to provide all the protection your engine needs. Addi- Oil or an equivalent in the transmission , steering and
tives could reduce this protection rather than help it. hydraulic system . Other types of oil will not give sat-
isfactory service, and may result in eventual damage.
If oil other than Torq-Gard Supreme is used, it This special oil, available from your John Deere deal-
must conform to the following specifications. er, may be used in all weather conditions.
SINGLE VISCOSITY OILS GREASES

AP I Service CD/SO Use John Deere Multi-Purpose Lubricant or an
MIL-L-2104C equivalent multi-purpose type grease for all grease
Series 3 fittings. Application of grease as instructed in the lu-
brication section will provide proper lubrication and
MULTI-VISCOSITY OILS will keep contamination out of bearings.
API Service CC/SD TRACK ROLLERS, FRONT IDLERS,

MIL-L-46152 AND CARRIER ROLLERS
Use John Deere Torq-Gard Supreme SAE 30 oil
or an equivalent.
STORING LUBRICANTS
Your tractor can operate at top efficiency only if
clean lubricants are used. Use clean containers to
handle all lubricants. Store them in an area protected
from dust, moisture, and other contamination.
Litho in U.S.A.
15-4 Lubrication TM-11 02 (Nov-73)
Litho in U.S.A.
Crawler - J0450-C Engine 20
TM-1102 (Nov-73) Engine Removal and Installation 5-1
Section 20
ENGINE
CONTENTS
Page Page
GROUP 5 - ENGINE REMOVAL AND GROUP 20 - ENGINE COOLING SYSTEM
INSTALLATION General Information ......................................... .20-1
Removai ............................................................... S-3 Radiator
Installation ............................................................ 5-4 Removal .........................................................20-1
Repair .............................................................20-1
GROUP 10 - BASIC ENGINE Installation ......................................................20-1
General Information .......................................... 10-1 Water Pump
Cylinder Head and Valves Removal ......................................................... 20-1
Valve Lift Check ............................................ 10-2 Repair ............................................................. 20-2
Removal ......................................................... 10-2 Installation ...................................................... 20-4
Repair ............................................................. 10-2 Thermostat and Housing
Assembly ........................................................ 10-4 Removal ......................................................... 20-4
Installation ...................................................... 10-5 Repair ............................................................. 20-4
Camshaft Installation ......................................................20-4
Removal ......................................................... 10-6
Repair ............................................................. 10-7 GROUP 25 - FUEL SYSTEM
Installation ...................................................... 10-7 General Information .......................................... 25-1
Cylinder Block, Liners, Pistons and Rods Fuel Tank
Removal ......................................................... 10-7 Removal .........................................................25-1
Repair ............................................................. 10-7 Repair .............................................................25-1
Installation .................................................... 10-1 0 Installation ......................................................25-2
Crankshaft, Main Bearings, and Flywheel Fuel Filter
Removal ....................................................... 10-12 Removal ......................................................... 25-2
Repair ........................................................... 10-12 Repair .............................................................25-2
Installation .................................................... 10-14 Installation ......................................................25-2
Balancer Shafts Fuel Transfer Pump
Removal ....................................................... 10-15 Removal ......................................................... 25-2
Repair ........................................................... 10-15 Repair ............................................................. 25-2
Installation .................................................... 10-15 Installation ......................................................25-3
Timing Gear Train Fuel Injection Pump
Removal ....................................................... 10-16 Removal ......................................................... 25-3
Repair ........................................................... 10-16 Repair .............................................................25-4
Installation .................................................... 10-17 (Refer to SM-2045 "Testing and Servicing
Fuel Injection Pumps and Nozzles")
GROUP 15 - ENGINE LUBRICATION SYSTEM Installation and Timing .................................. 25-4
General Information .......................................... 15-1 Bleeding ......................................................... 25-5
Oil Pump Fuel Injection Nozzles
Removal ......................................................... 15-1 Removal .........................................................25-6
Repair ............................................................. 15-1 Repair .............................................................25-6
Installation ...................................................... 15-2 (Refer to SM-2045 'Testing and Servicing
Oil Filter Fuel Injection Pumps and Nozzles")
Removal ......................................................... 15-3 Installation ......................................................25-6
Repair ............................................................. 15-3
Installation ...................................................... 15-3 GROUP 30 - SPEED CONTROL LINKAGE
Oil Cooler General Information .......................................... 30-1
Removal ......................................................... 15-3
Repair ............................................................. 15-3
Installation ...................................................... 15-3
Litho in U.S.A.
20 Engine Crawler - JD450-C
5-2 Engine Removal and Installation TM-11 02 (Nov-73)
CONTENTS-Continued
PAGE Page
GROUP 35 - AIR INTAKE SYSTEM GROUP 40- SPECIFICATIONS AND
General Information ..........................................35-1 SPECIAL TOOLS
Air Cleaner Engine Removal and Installation .................... .40-1
Removal ......................................................... 35-1 Basic Engine .................................................... .40-3
Repair .............................................................35-1 Engine Lubrication System ............................ A0-17
Installation ...................................................... 35-2 Engine Cooling System ................................. .40-19
Turbocharger Fuel System ................................................... .40-21
Removal ......................................................... 35-2 Speed Control Linkage .................................. .40-21
Testing ............................................................35-2 Air Intake System .......................................... .40-22
Repair .............................................................35-4
Installation ...................................................... 35-7
Litho in U.S.A.
Crawler - JD450-C Engine 20
TM-1102 (Nov-73) Engine Removal and Installation 5-3
Group 5
ENGINE REMOVAL AND INSTAlLATION
REMOVAL INSTALLATION
Most service procedures on the engine can be ac-
complished with the engine in the unit. If the crank-
shaft is to be removed or in event of a general
overhaul, remove the engine as follows:
Detach H-L-R oil filter base from inside of grille

housing. Remove hood and grille housing.
Disconnect all the necessary wiring, linkage and

lines from both sides of the engine.
Disconnect radiator hoses and remove radiator

(see Group 20 of this section) and hydraulic pump
(see Group 10, Section 50) with support as a unit.
Fig. 2-Transmission-Engine Indexing Point
To install engine correctly, line up cap screw holes

of engine with those of clutch housing. Bar engine
over, holding it in a horizontal position and exerting a
steady pressure on the engine toward the clutch
ho using antil the engine c lutch indexes with the
transmission input shaft.
Tighten upper flywheel housing to clutch housing

Fig. t - Engine Attaching Points cap screws with 250 lb-ft [34.56 kg-m] and lower cap
screws with 170 lb-ft [23.5 kg-m] .
Install two JD-244 engine lifting adapters in cylin-
der head.
Install radiator and hoses. Attach H-L-R oil filter to
inside of grille housing.
Attach JDG-1 sling to lifting adapters.
Connect all the necessary wiring, linkage and lines
Remove cap sc rews securi ng engine flywheel
to both sides of engine.
housing to clutch housing (Fig. 1).
Start engine and check for oil or water leaks.
Using hoist, pull engine forward off clutch housing
and remove engine from machine.
NOTE: Alternate method would be to remove the

engine. radiator and pump with support as one unit.
Litho in U.S.A.
20 Engine Crawler - J0450-C
5-4 Engine Removal and Installation TM-11 02 (Nov-73)
Litho in U.S.A.
TM-11 02 (Nov-73) Basic Engine 10-1
Group 10
BASIC ENGINE
GENERAL INFORMATION
The cylinder head holds the rocker arm assembly, Pistons are aluminum-alloy, cam-ground and
valve springs, and valves. weight controlled, with two compression rings and
one oil control ring.
Valve guides and seats are integral with the cylin-
der head. Connecting rods have a replaceable bronze bush-
ing for the piston pin and a replaceable, steelbacked,
Intake and exhaust valves have replaceable wear aluminum-lined bearing insert.
caps. Gasoline exhaust valves have valve rotators.
The crankshaft is a one-piece steel forging, and is
The camshaft is iron alloy with all cams integral. supported on main bearings. The bearings are re-
The engine camshaft has a lobe to actuate the fuel placeable, steel-backed, tin-plated, aluminum-lined
transfer pump. inserts. The rear main bearing has a thrust surface.
The camshaft is driven at one-half engine speed The crankshaft is drilled for pressure lubrication
by the top idler gear and is supported by three pres- from the main bearings to connecting rod bearings.
sure-lubricated bores integral with the cylinder block.
Camshaft thrust is taken by a thrust plate fastened to The ring gear for the starting motor is shrunk in
the front of the cylinder block. place on the front outer rim of the flywheel. On the
front outer rim of the flywheel is a "TDC" (top dead
Cylinder block and crankcase are cast in one center) bore that is used when timing injection pump,
piece. and adjusting valve tappets.
Cylinder liners are of the replaceable wet-sleeve Two balancer shafts are mounted in the lower half
type, made of hardened alloy cast iron and are a slip of the cylinder block and each rotates in three pres-
fit in the cylinder block. The flange of each liner rests sure-lubricated replaceable bushings.
on a shoulder within the block and is sealed by a
square rubber packing. The top edge of the liner is The balancer shafts rotate in opposite directions to
sealed flush with the cylinder block by the compres- reduce engine vibration. Thrust of the balancer shafts
sion of the cylinder head and gasket. Two 0-rings in is absorbed by thrust plates fastened to the front of
the block provide additional sealing. the cylinder block.
The crankshaft gear drives the gear train located

at the front of the engine. The upper idler gear trans-
mits power from the crankshaft gear to drive the
camshaft gear and the injection pump drive gear.
The lower idler gear drives the oil pump gear.
Litho in U.S.A.
20 Engine Crawler • JD450-C
10·2 Basic Engine TM- 1102 (Nov-73}
CYLINDER HEAD AND VALVES

REMOVAL
VALVE LIFT CHECK
The engine need not be removed to service
cylinder head, valves, and related parts.
Disconnect battery ground strap.
Drain coolant from engine before removing head.
Plug all open injection lines. Remove injection noz-

zles from head (see Group 25). (Nozzle tips extend
below face of cylinder head and may be accidentally
damaged .)
Note location of all parts during removal for reas-

sembly.
NOTE: Do not rotate crankshaft with cylinder head

Fig. 1-Checking Valve Lift remo ved unless all cylinder liners are secured with
cap screws and washers.
REPAIR
Measuring valve lift can give an indication of wear
on cam lobes, cam followers, and push rods. Cylinder Head
Set exhaust valve clearance of 0.018 inch [0.4572 Check to determine if cylinder head is flat and
mm] and intake va lve cleara nce of 0.014 inch smooth. If it is necessary to resurface the bottom
[0.3556 mm). deck of the head, remove no more than absolutely
necessary (not to exceed 0.0030 inch [0.762 mm]).
Place dial indicator on valve rotator or valve spring
cap. (Be sure that valve is fully closed and tne rocker Check distance from deck of the cylinder head to
arm moves freely.) Zero dial indicator. valves when seated. The distance for the intake
valves must be 0.023 to 0.047 inch [0.5842 to
Manually turn engine in running direction. When 1.1938 mm]. The distance for exhaust valves must
rocker arm contacts valve, check indicator travel as be 0.038 to 0.072 inch [0.9652 to 1.8288 mm].
the rocker arm moves valve to full open.
Exhaust valve lift should be 0.456 to 0.482 inch

[ 11.5824 to 12.2428 mm] and intake valve lift should
be 0.460 to 0.490 inch [ 11 .684 to 12.446 mm].
Litho in U.S.A.
TM-1102 (Nov-73) Basic Engine 10-3
Valve Guides
1- Telescope Gauge 2- Valve Guide

Fig. 3-Checking Valve Seat Concentricity for
Fig. 2-Checking Valve Guides
0.002 Inch [0.508 mm] Maximum Runout
Check valve guides for wear (Fig. 2). Use a #1002 Reface seals according to need and as directed by
Knurling Tool to knurl worn valve guides. (Use the refacing tool manufacturer. Valve seat specifications
knurling tool exactly as directed by the manufactur- are as follows:
er.)
Angle of valve seat ...................................... ......45°
The I.D. of a guide in a new cyli nder head is Width of valve seat ............... 0.0781 to 0.0937 in.
0.3745 to 0.3755 inch [9.512 to 9.538 mm]. Wear of [1 .984 to 2.380 mm]
an additional 0.0010 inch [0.025 mm] is acceptable.
Compare valve stem 0.0. and valve guide I. D. to de- Replace valve stem caps if worn or damaged.
termine clearance. Clearance between the two is
0.0020 to 0.0040 inch [0.051 to 0.102 mm]. Clear- Valves
ance up to 0.0060 inch [0.154 mm] is acceptable.
Check valve stem and face for wear or damage.
Oversize valves, available in 0.003, 0.015 and O.D. of a new valve stem is 0.3715 to 0.3725 inch
0.030 inch [0.076, 0.381 and 0.762 mm] sizes, can [9.436 to 9.462 mm]. Valve face angle is 43.5°.
be used to correct clearance problems.
Position valve stem caps over ends of valve
Valve Seats stems. Make certain the caps rotate freely on the
stems.
Check valve seats for cracks or pits.
For informat ion on valve refacing see
Check concentricity of valve seat with a dial indica-
tor (Fig. 3). Total run-out should not exceed 0.0020
inch [0.0508 mm].
E] a
"Basic Engines'' of FOS Manual 3D-EN-
GI NES.
Litho in U.S.A.
10-4 Basic Engine TM-1102 (Nov-73)
Inspecting Valve Springs Check rocker arm and rocker arm shaft for wear.
Rocker arm shaft 0. D. is 0. 7869 to 0. 7879 inch
Inspect valve springs for alignment, wear and
[19.987 to 20.013 mm]. Shaft may be 0.7849 inch
damage. Place springs on a flat surface to see that
[19.936 mm] and still be acceptable. I.D. of rocker
they are square and parallel. Do not use springs that
arm bore is 0.7900 to 0.7920 inch [20.066 to 2.012
are cocked, crooked or contain broken or rusty coils.
mm]. Bore can be worn an additional 0.0020 inch
[0.0508 mm].
Check valve spring length on a spring tester. Free
length of each spring may differ, but the compressed
If end of arms are worn, replace or resurface them.
length for each spring must be the same. Spring
specifications are as follows:
Thoroughly clean holes in rocker arm mounting
brackets. This is especially important for the rear
New Spring Measurement
bracket, because oil is fed to the rocker arm shaft
Free length (approx.) ................................... 2-1/8 in.
through this hole.
[50.93 mm]
Compressed at 54-62 lbs. [24.5 to 28.1 kg] -
If a failed valve has been replaced, also inspect
Valves closed ........................................ 1-13/16 in.
the rocker arm and push rod for that valve, and re-
[26.21 mm]
place if necessary.
Compressed at 133-153 lbs. [60.3 to 69.9 kg] -
Valves open .......................................... 1-23/64 in.
ASSEMBLY
[25.76 mm]
Rocker Arm Assembly
Inspecting Rocker Arm Assembly
Assemble parts on rocker arm shaft in locations
Make sure that rocker arm oil holes are not
from which they were removed (Fig. 1).
plugged.
~f---11
Oil hole in rocker arm shaft-to-shaft support must
9i'o-i ~ _..12 face downward when assembly is installed on cylin-
:-\d ~i-1_9>9 der head.
: 8~~r./3
1 I ~ Valve Assembly
: 7---e 13 1--1@
/ : ~ 7-;_...-8 Apply John Deere Valve Stem Lubricant
(¢ ~ 3 : 18-® ~13~L'I (AR44402) to valve stems and install valves in valve
~I 4 6--J 1s
14
- guides, working them back and forth to make sure
@~I 6~
i
. I .
16 they slip through the ports easily and seat properly .
T25061N
.... ' 5--11)117~ Note also the following:
1. Use new valve keepers.

1-Piug (2 used) 10--Adjusting Screw (8 used) 2. After assembly, "pop" each spring and valve
2-Rocker Arm Shaft 11-Cap Screw (4 used) assembly three or four times by tapping the end of
3-Washer (2 used) 12-Special Washer (4 used) each valve stem with a soft mallet.
4-Spring (3 used) 13-Retainer Lock (16 used)
5-lntake Valve (4 used) 14-Exhaust Valve Cap (4 used)
6-Valve Spring (8 used) 15-Push Rod (8 used)
7-Valve Stem Cap 16-Tappet (8 used)
(8 used) 17-Exhaust Valve (4 used)
8-Supports (4 used) 18-Valve Spring Cap (4 used)
9-Rocker Arm (8 used)
Fig. 4-Exploded View of Rocker Arm Assembly
Litho in U.S.A.
TM-1102 (Nov-73) Basic Engine 10-5
INSTALLATION
Install cylinder head gasket dry.
Fig. 5-Proper Sequence for Tightening

Cylinder Head Cap Screws Fig. 6-SeNing No. 1 Cylinder at Top Dead Center
Use specified flat washers under all cap screws. Adjust valve clearance on No. 1 and No. 3 exhaust
Do not dip cap screws in oil prior to installation. Start valves to 0.018 inch [0.4572 mm] and on No. 1 and
cylinder head to cylinder block cap screws by hand 2 intake valves to clearance of 0.014 inch [0.3556
and tighten evenly to 110 lb-ft [15.21 kg-m], follow- mm]. Using a feeler gauge to measure clearance,
ing sequence in Fig. 5. turn valve adjusting screw up or down until clearance
is correct (Fig. 7).
Install push rods in location from which they were
removed.
4 3 2 1
E E E I E
Position valve stem caps over ends of valve
stems. Make certain the caps rotate freely on the
• ••
stems.
Install rocker arm and shaft assembly on cylinder

head. Tighten cap screws to 35 lb-ft [ 4.84 kg-m]. 4 3 2
E E E E
Adjusting Valve Tappet Clearance
The engine may be either hot or cold during valve
adjustment. T 222 00N
Fig. 7-Adjusting Valve Tappet Clearance

Position No. 1 cylinder (located at fan end) on
TDC. Timing cover screw will enter its hole in fly- Remove timing screw from flywheel. Rotate engine
wheel (Fig. 6). flywheel 360 degrees and reinsert timing screw into
hole on flywheel rim.
Adjust valve clearance on No. 2 and 4 exhaust

and No. 3 and 4 intake valves to clearances specifi-
ed.
Remove timing screw from flywheel and reinstall

timing cover.
Retighten cylinder head cap screws and recheck

valve clearances after thirty minutes run-in with en-
gine at 1900 to 2200 rpm with 3/4 to full load. See
"Engine Break-In Procedure", page 20-40-11 .
Litho in U.S.A.
1 0-6 Basic Engine TM-1102 (Nov-73)
CAMSHAFT
Remove push rods. Use ND245 Magnetic Holding
REMOVAL
Tool Set (Fig. 9) to hold cam followers away from
To service camshaft and related parts , engine nor- camshaft if the cylinder head has not been removed,
mally need not be removed from unit. If engine has or remove followers if the head has been removed. If
to be removed, see Group 5 of this section. followers are removed, mark them for identification
on reassembly.
Disconnect battery ground cables.
Remove rocker arm and timing gear covers. Re-

move rocker arm assembly and push rods.
Remove fuel transfer pump.
Check camshaft end play. End play is governed by

the thrust plate thickness. End play is 0.0025 to
0.0085 inch [0.0635 to 0.2159 mm]. End play up to
0.0150 inch [0.38 1 mm) is acceptable.
1- Fo llower Holding 2- Cam Follower

Tool
Fig. 9-Magnetic Cam Follo wer Holding Tools
Remove top idler gear from engine front plate. This

will allow camshaft to rotate when lining up camshaft
attaching cap screws.
Fig. 8-Checking Camshaft End Play
Litho in U.S.A.
REPAIR INSTALLATION
Inspect camshaft journals and bores in block for Install the camshaft, noting the following:
wear or damage. Excessive wear may indicate ex-
cessive end play. 0.0. of journal is 2.1997 to 2.2007 1. Coat entire camshaft with a light film of oil.
inch [55.872 to 55.898 mm] . 1.0. of the bore is
2.2042 to 2.2052 inch [55.987 to 56.012 mm]. Maxi- 2. When installing camshaft, do not permit cam
mum allowable clearance is 0.0035 to 0.0055 inch lobes to drag on camshaft bores.
[0.0889 to 0.1397 mm].
3. Turn the camshaft gear until the cap screws
New thrust plate thickness is 0.1560 to 0. 1580 inch and locks which secure the thrust plate can be in-
[3.962 to 4.013 mm]. Maximum wear of 0.0050 inch stalled and tightened to 35 lb-ft [ 4.8 kg-m].
ro.127 mm] is allowable.
4. Recheck camshaft end play after all new or re-
Replace camshaft drive gear if necessary by paired parts have been assembled.
pressing shaft from gear. Press on gear until it is
tight against flange on camshaft. Timing mark must 5. Before installing idler gear, set flywheel at
face away from camshaft. "TDC" with No. 1 (front) piston on the compression
stroke and align the timing mark on the camshaft
Support camshaft under its first bearing whi le drive gear with the center of the crankshaft, using
pressing on gear. timing tool JD254.
Whenever a new camshaft is installed, replace the 6. With timing marks aligned , install top idler gear
tappets. and secure to front plate with flat washers and cap
screw. Tighten cap screw to 65 lb-ft [8.99 kg-m].
If replacing tachometer drive, support camshaft
and press in new drive with slot located 180° from Install all parts removed.
keyway in opposite end of camshaft.
CYLINDER BLOCK, LINERS, PISTONS, AND RODS
REMOVAL REPAIR
Remove the pistons and connecting rods, noting
Inspect all parts and compare with "Speci-
the following :
fications". Refer to "Basic Engine" in FOS
Manual- ENGINES-for additional repair
1. Engine normally need not be removed from unit
information.
to service pistons, connecting rods, and cylinder lin-
ers. If engine has to be removed, see Group 5 of this
Use a strong household detergent to remove all
section.
dirt and carbon from pistons. Clean carbon from pis-
ton ring grooves. Wash all parts thoroughly in clean-
2. Do not rotate crankshaft with cylinder head
ing solvent.
removed unless all cylinder liners are bolted down.
Bolt down cylinder liners before removing pistons.
3. Keep rod bearing inserts with their respective

rods and caps to assure correct reassembly.
4. Each connecting rod and piston must be rein-

stalled in the cylinder bore from which it was re-
moved. Observe the word "FRONT" stamped on the
head of all pistons and in the rib of the connecting
rods. These must face toward the fan end of the en-
gine at the time of reassembly.
Litho in U.S.A.
10-8 Basic Engine TM-11 02 (Nov-73)
Inspect and measure piston pin, pin bore in piston, Check clearance between piston and cylinder liner
and connecting rod bushing for wear or damage. Ex- bore to determine if replacement is necessary. Mea-
cessive wear can cause scored pistons or broken sure clearance with a feeler gauge at the bottom of
connecting rods. Specifications are as follows: piston skirt goo to pin bore. To establish taper and
out-of- round, check liner 1 inch [25.4 mm] from bot-
Wear
Item New Part Tolerance tom and 1 inch [25.4 mm) from top, lengthwise and
crosswise. Wear limits are as follows:
O.D. of
Pin 1.3748 to 1.3752 in. 0.0005 in. Specifications Measurement
[34.920 to 34.930 mm) [0.0127 mm] Liner Taper (max.) ..................................... 0.0020 in.
I.D. of [0.0508 mm]
Bore 1.3753 to 1.3757 in. 0.0010 in. Liner Out-of-Round (max.) ......................... 0.0020 in.
[34.9362 to 34.9428 mm] [0.0254 mm] [0.0508 mm]
I.D. of Clearance Between Liner and Piston ....... 0.0060 in.
Bushing 1.376 to 1.377 in. 0.0020 in. at Bottom of Skirt (max.) [0.1524 mmJ
[34.950 to 34.976 mm] [0.0508 mm]
Piston rings should never be reinstalled on a pis-
Use keystone ring groove wear gauge (JDE-62) as ton once they have been removed. Throw away old
shown in Fig. 10 to measure wear to the top piston rings and replace with new ones.
ring groove. If gauge shoulder touches ring land, the
top groove is excessively worn and the piston should Clean and inspect rods, caps, bearings, and piston
be replaced. pin bushings for wear or damage.
Check rod bearings for excessive wear. Use

" Piastigage" as directed by the manufacturer, if rods
are connected to the crankshaft.
NOTE: The use of "Piastigage" will determine

clearance between bearing and crankshaft journal,
but will not determine which surface is worn or the
condition of either bearing or journal surface.
If rod is out of engine, assemble and measure the

I.D. of the rod bearing, and the O.D. several places
6 on the crankshaft rod journal. Specifications are as
follows:
T2?S84
I.D. of bearing ........................ 2.7502 to 2.7522 inch
1-Piston 5-Gauge Shoulder
[69.8551 to 69.9059 mmJ
2- Keystone Ring Groove 6-Good Ring Groove
3-Wear Gauge 7-Worn Ring Groove
4-Ring Land O.D. of journal. ....................... 2.7480 to 2.7490 inch
[62.9412 to 62.9666 mm]
Fig. 10-Using Ring Groove Wear Gauge
Oil clearance should be 0.0012 to 0.0042 inch
Check the other two grooves for wear by inserting [0.0305 to 0.1067 mmJ between rod bearings and
a new ring in the proper groove at several points crankshaft journals. Replace bearings as necessary.
around the piston. Measure clearance with a feeler Undersize bearing inserts are available in 0.002,
gauge. If the clearance exceeds 0.008 inch [0.203 0.010, 0.020, and 0.030 inch [0.0508, 0.254, 0.508,
mm), replace the piston. and 0.762 mm] sizes.
Litho in U.S.A.
TA4-1102 (Nov-73) Basic Engine 10-9
A new piston pin bushing must be reamed after it When installing new cylinder liners in block, use a
is pressed into position to provide a "thumb press fit" depth gauge to check the height of the flange on the
for pin. liner in relation to the cylinder block (Fig. 11). The
top of the flange should be 0.0010 to 0.0040 inch
Clean block thoroughly with cleaning solvent or by [0.0254 to 0.106 mm] above the cylinder block with
pressure steam cleaning. Make sure all passages pack ings removed f rom the bottom o f t he liner.
and crevices are cleared of sludge, rust, and grease. Check this several places around the liner to make
Be sure all coolant passages are cleaned of lime de- sure the liner is seated squarely in the bore of the
posit and scale. cylinder block.
Check oil gallery steel ball plugs in cylinder block Be sure to pull cylinder liner and reinstall packing
for leaks. If gallery hole is leaking oil , steel ball plugs and 0 -rings before final assembly. Check 0 -ring
must be removed and holes in cylinder block tapped groove in block and remove any bu rrs or sharp
and plugged with pipe plugs. edges.
Inspect oil pressure regulating valve bushing in fan Deglazing Cylinder Liners
end of cylinder block. If valve seating area is worn or
The cylinder liners may be deglazed with a deglaz-
damaged, remove bushing from block and install a
ing tool or honing stone, but not rebored. When the
new bushing using the procedure shown on page
liner exceeds a 0.002 inch [0.0508 mm] maximum
20-15-3.
taper or exceeds 0.002 inch [0.0508 mm] out-of-
roundness, the liner must be replaced.
If dipstick nipple has been removed, coat threads
of nipple with joint sealing compound and install in
Use a 180-grit honing stone and light pressure to
cylinder block. Measure from block rail vertically to
produce the desired 15 to 35 micro-inch R.M.S. cyl-
center of nipple end. Measurement should be 8-1 I 4
inder wall finish (Fig. 12).
inches.
NOTE: If dipstick nipple has an integral 0 -ring, be

sure it is not twisted, sheared or damaged when in-
stalling nipple.
If filter base nipple is damaged. remove it and

press in a new nipple flush with face of bore in block.
Position nipple so that threaded boss is away from
side of block as far as possible.
Fig. 12-Deg/azing Cylinder Liner
Immediately after deglazing, clean liner bores with

hot water. soap and scrub brush. Rinse cylinder liner
Fig. 11-LocaUon of Liner in Cylinder Block bores with clean water until rinse water is clear. Wipe
liner dry with clean towels. Wipe bores with clean en-
gine oil.
IMPORTANT: Solvents will not remove honing

residue.
Litho in U.S.A.
10-10 Basic Engine TM- 11 02 (Nov-73)
ASSEMBLY 1. Install the expander in the oil ring groove. Install

the oil ring with dots (or "Top") facing up towards the
Assembling Connecting Rod and Piston top of the piston and position oil ring gap opposite
expander gap (Fig. 13).
Assemble pistons and connecting rods making
sure that identification marks on piston and rod are in
2. Install second compression ring (Fig. 13) with
same relative position as they were at time of disas-
dots (or "Top") facing up towards the top of the
sembly.
piston.
Each connecting rod and piston must be rein-
3. Install the first compression ring with dots (or
stalled in the cylinder liner from which it was re-
" Top") facing up towards the top of the piston.
moved. Observe the word "FRONT" stamped on the
head of all pistons and in the rib of the connecting
NOTE: If rings are not marked, install with either
rods. All identification marks must face toward the
side up.
fan end of engine.
4. Piston rings should move freely in their grooves.
Coat piston pin with a light film of oil and insert in-
to piston pin bore through connecting rod bushings
Installing Cylinder Liners
and on into opposite pin bore. A properly fitted piston
pin can be pressed into position with the thumb. In- Before installing liners it is important to make sure
stall new piston pin snap rings and check that rings the counterbore, under the liner flange at top is com-
are in grooves of piston pin bore. pletely free from dirt or nicks.
INSTALLATION Carefully install a new, dry packing over the bot-

tom end of the cylinder liner. Slide packing firmly
Installing Piston Rings on Piston against the shoulder of the liner, making sure that
the packing is not twisted or crimped.
Coat the outside of the pistons and rings with a
light film of oil. Use a JDE-45 Ring Expander to in-
Install cylinder bore 0-rings into the grooves in the
stall rings in their respective grooves.
cylinder block. Check that the 0-rings do not pro-
trude outside the grooves and are not twisted.
IMPORTANT: Use of incorrect size ring ex-
pander will damage rings.
Coat the liner packing, seating area of the liner,
and new cylinder bore 0-rings w ith John Deere
AR54 749 Soap Lubricant.
NOTE: If you suspect that a packing may have
o-·-'®
sheared or displaced during lowering into position,
the liner and packing assembly should be removed
and examined.
Work liners gently in place as far as possible by

hand. Finish seating liners by placing a wood block
over upper end and tapping block lightly with ham-
mer.
Cylinder liner will protrude over the top of the cylin-

der block more than normal due to the uncom-
pressed packing.
Clean cylinder liner bores with waterless hand

T 2 0925N
cleaner after installation in block. Wipe dry with clean
towels. Coat cylinder liner bores with engine oil just
1- 1st Comp. Ring 3-011 Ring
2-2nd Comp. Ring 4-011 Ring Expander before installing pistons.
Fig. 13-Ring Installation
Litho in U.S.A.
TM-11 02 (Nov- 73) Basic Engine 10-11
Installing Pistons
Use short cap screws and large flat washers to re-
tain liners in position while pistons are installed .
Place top piston ring gap over piston pin and stag-
ger ring gaps before installing pistons in cylinder lin-
ers.
' .
Fig. 15-/nstafling Pistons using JD-271 Compressor
·(.....·· .....
Use Compressor Tool JD271 to install pistons (Fig.

·.-.'' 15).
Apply light-weight oil to the bearing inserts and

crankshaft rod journals.
Dip connecting rod cap screws in oil and tighten

with 65 lb-ft [8.987 kg-m] .
rtAiile1li
Installing .Oil Pan
Fig. 14-/nstal/ing Connecting Rod
Apply Permatex No. 3 Sealing Compound to oil
Be sure the word "FRONT" stamped on the head pan gasket and cylinder block pan surface. Tighten
of the pistons faces toward the front of the engine oil pan-to-cylinder block and timing gear cover cap
before installing them in liners. On connecting rods, screws with 35 lb-ft [4.84 kg-m].
be sure the word "FRONT" faces toward the front
(Fig. 14). Engine Break-In
Refer to specifications and perform the break-in
steps to insure proper run-in of new parts. (See page
20-40-11.)
Litho in U.S.A.
10-12 Basic Engine TM-11 02 (Nov- 73)
CRANKSHAFT, MAIN BEARINGS, AND FLVWHEEL

Examine flywheel ring gear for wear or damage. If
REMOVAL new gear is needed, heat gear evenly (to not more
To service crankshaft, main bearings and flywheel than 360°F. [1 82.2°C.] ) and install hot, with cham-
it is necessary to remove engine from unit (Refer to fered edge of teeth toward front of flywheel.
Group 5 of this section) .
Check clutch pilot bearing for wear or tight spots.
Remove oil pan, timing gear cover, starting motor, To install new pilot bearing, pack with high tempera-
flywheel, and pistons. ture grease (AT30408) and drive in (shielded side
out) to bottom of bore. Reinstall snap ring if used.
Checking Crankshaft End Play
Check crankshaft gear for wear or damage. To re-
Measure crankshaft end play and determine if it is
place, remove gear with knife edge puller. To install,
within 0.0020 to 0.0080 inch [0.0508 to 0.2032 mm].
heat gear to approximately 360°F. [182.2C.] (do not
End play exceeding this specification indicates a
overheat), place Woodruff key in keyway and support
worn thrust bearing. However, a maximum end play
crankshaft under first throw while pressing on gear.
of 0.0150 inch [0.381 mm] is acceptable.
Inspect crankshaft journals. Dress journals with
fine emery cloth as needed.
Check thrust surfaces on thrust bearing journals to

make sure they will not damage the thrust bearing
flanges.
Check each journal with a micrometer at several

points to determine if journal is out-of-round by more
than 0.0030 inch [0.0762 mm] or if tapered more
than 0.0010 inch [0.0254 mm] per inch [25.4 mm] of
journal length.
Excessively eccentric or tapered journals will give

an uneven clearance between journal and bearing in-
sert. Regrind such journals and use the proper un-
dersize bearing inserts.
1-Pry Bar 2- Dial Indicator
Fig. 16-Checking Crankshaft End Play Note 0.0. of journals for later use to determine
clearance between journal and bearing insert.
REPAIR
Main Bearings
Crankshaft and Flywheel
Examine all main bearings for wear, scoring, or
Examine clutch friction surface on flywheel for heat damage.
checks or roughness.
Identify main bearing cap so they can be installed
A CAUTION: Oil fumes or oil can ignite on the main they were removed from .
. . above 380°F. [ 182.2°C.). Use a thermome-
ter and do not exceed 360°F. [182.2°C.). Do notal- Check thrust bearing thrust surfaces to confirm
low a flame or heating element to be in direct that thrust bearing wear was the cause for excessive
contact with the oil. Heat the oil in a well-ventilat- crankshaft end play.
ed area. Plan a safe handling procedure to avoid
burns. Remove piston cooling orifices from main bearing
webs and check for damage or clogging. Repair or
replace as necessary. Install orifices and tighten with
12 to 15 ft-lb [1 .66 to 2.07 kg-m].
Litho in U.S.A.
T~-1102 (Nov-73) Basic Engine 10-13
Main Bearing Clearance To remove old seal wear ring from crankshaft,
scribe lines across wear ring with the aid of a dull
If the crankshaft is out of the engine block, check
chisel until ring can be removed. IMPORTANT: Do
main bearing clearance by measuring the I.D. of the
not scribe lines too deep in wear ring, as crank-
bearing halves assembled in the block. Compare
shaft wear ring surface may be damaged.
with the crankshaft journal 0.0. measurements to
determine clearance. Specified new part diameters
and clearance are as follows:
O.D. of main bearing

journal .............. .. .. ...................3.1230 to 3.1240 in.
[79.3242 to 79.3496 mm]
1.0. of main bearing
(assembled) ............................ 3.1256 to 3.1276 in.
[79.3902 to 79.4410 mm]
Bearing to Journal Clearance... 0.0016 to 0.0046 in.
[0.0406 to 0.01 168 mm]
A maximum clearance of 0.0060 inch [0.1524 mm]
is acceptable.
Clearance can be determined with the use of
" Piastigage" while the main bearings are assembled
on the crankshaft. Follow the instructions supplied by
the manufacturer.
NOTE: If the engine is still in the tractor, use a
light jack to raise the crankshaft against the upper
1- JD·251 2- JD-251-3
half of the bearing. Keep all caps tight except the
bearing being checked. Do not turn crankshaft. Fig. 18-/nsta//ing Crankshaft Seal Wear Ring
The use of "Piastigage" will give bearing clear-
Install pilot ring (JD25 1-3), bevelled edge outward .
ance . but will not reveal whether wear is on the
over rear of crankshaft (Fig. 18). Slide new wear ring
crankshaft journal or on the bearing.
(rounded edge of ring outward) over pilot ring and
start wear ring onto crankshaft flange by hand (avoid
heavy pressure or cocking of wear ring). Place driver
(JD251) over pilot ring until it contacts wear ring. Tap
driver with a mallet until driver bottoms on pilot ring.
Rotate driver while tapping.
Do not nick or damage wear ring oil seal surface.

Check crankshaft and wear ring surfaces for nicks
and clean up if necessary.
Remove old oil seal from flywheel housing. Press

new seal in rear of flywheel housing (lip inward) us-
ing a suitable driver, until seal case is flush with ma-
chined face of seal bore in housing. (JDE-2A driver
can be used if available.) Be sure to support housing
around bore while pressing in a new seal.
Fig. 17-Determining Main Bearing Clearance
It bearing clearance exceeds wear tolerance, re-

place with new undersize bearings or regrind the
c rankshaft. Be sure to use t he proper undersize
bearings, 0 .002, 0 .01 0 , 0.020 and 0 .030 inch
[0.0508, 0.254, 0.508, and 0.762 mm] undersize
bearings are available.
Litho in U.S.A.
1 0· 14 Basic Engine TM-1102 (Nov-73)
INSTALLATION To facilitate installation of flywheel, screw two pilot

studs into flywheel mounting screw holes in crank-
Install inserts with thrust faces (Fig. 19) in rear
shaft. Tighten attaching cap screws to 85 lb-ft [11.75
main bearing bore. Install plain inserts in other main
kg-m].
bearing bores. Make sure that tangs on all inserts fit
the locking grooves in the bores and that the oil
Place crankshaft oil slinger over front end of crank-
holes in inserts line up with oil passages in the block.
shaft with inside of slinger against front gear on
crankshaft.
1-Crankshaft 3-JD-251·4
2-Wear Ring
Fig. 19-lnstalling Main Bearing Caps Fig. 20-lnsta//ing Flywheel Housing
Make sure bearing caps are installed on the mains Position JD-251-4 seal protector (Fig. 20) over
from which they were removed by referring to identi- rear of crankshaft and coat protector and wear ring
fication marks made at the time of removal. Loosely with engine oil. Install flywheel housing on rear of en-
install cap screws in main bearing caps- until finger gine. Be careful not to invert oil seal lip in flywheel
tight. housing.
Align upper and lower thrust flanges on rear ma:n Install all other parts removed.
bearing as follows: Tap the crankshaft to the rear to
line up the front flanges. Then tap the crankshaft to Install engine (Group 5 of this section).
the front to line up the rear flanges. Tighten main
bearing cap screws to 85 lb-ft l11.75 kg-m].
If crankshaft end play has not been checked with

all repair parts installed, check it by method given on
page 20-10-12. End play is 0.0020 to 0.0080 inch
(0.0508 to 0.2032 mm]. End play up to 0.0150 inch
[0.3810 mm] is acceptable.
Litho in U.S.A.
TM- 1102 (Nov- 73) Basic Engine 10-15
BALANCER SHAFTS
REMOVAL 2. Check thickness of thrust plate. These must be
within 0.1170 to 0.1190 inch [2.972 to 3.033 mm], as
To service balancer shafts and related parts, en-
the thrust plate determines balancer shaft end play.
gine normally need not be removed from unit. If en-
gine has to be removed, refer to Group 5 of this sec- 3. Inspect balancer shaft drive gears for worn,
tion . Then proceed as follows: cracked , and broken teeth.
1. Remove timing gear cover. Installing Drive Gear
2. Remove oil pump gear.
3. Remove lower idler gear.
4. Remove balancer shafts and identify shafts and

thrust plates as "right" and "left."
REPAIR
1. Determine if balancer shaft journals are within
1.4995 to 1.5005 inches [38.087 to 38. 113 mm] and
bushings are within 1.5020 to 1.5040 inches [38.151
to 38.202 mm] .
Fig. 21-Rep/acing Balancer Shaft Gear
Installing Bushings
The first two bushings can be replaced with the Position balancer shaft drive gear on front of bal-
engine in the unit using Tool JD249. To remove the ancer shaft so that slot in gear lines up with Wood-
third (rear) bushing, separate the engine from the ruff key, and timing mark on front of gear faces away
clutch housing. (Group 5). Press all bushings in from from balancer shaft. Press on gear to flush with end
front of engine until flush with bushing bore chamfer of shaft using JD247 Holding Tool to support shaft as
in block. (JD249 Tool can also be used to drive out shown in Figure 21. Be sure gear is flush with end of
old bushings.) shaft (within 0.0010 inch [0.0254 mm]) as this sets
balancer shaft end play.
Be sure that oil hole in each bushing lines up with
upper oil lead hole in cylinder block. INSTALLATION
1. Apply a light film of oil to balancer journals and
Staking Bushings bushings.
Position half-round part of JD255 Tool in bushing 2. Secure thrust plates to front plate with hardware
bore so that staking ball fits in round relief in bushing and tighten with 35 lb-ft [ 4.84 kg-m].
groove (opposite bushing oil lead hole) . Turn square
part of JD255 Tool so that proper size dowel fits in 3. Check balancer shaft for end play of no more
lower lead hole at bushing boss. Install socket head than 0.0080 inch [0.203 mm] or less than 0.0020
screws into tool halves, checking to see that staking inch [0.0508 mm].
ball is still in bushing relief area. If not, half-round 4. Install oil pump.
tool is in backwards and must be reversed. Then
tighten socket head screws evenly until half-round 5. Before installi ng lower idler gear. set flywheel at
surface of tool is pulled up flush with bushing. This "TDC" with No. 1 piston on compression stroke and
will indent bushing into lead hole and stake bushing align timing mark on balancer shaft drive gears with
in place. center of crankshaft using timing tool JD254.
6. Install all parts removed.
Litho in U.S.A.
10-16 Basic Engine TM- 11 02 (Nov-73)
TIMING GEAR TRAIN
REMOVAL 3. Remove upper and lower idler gears from en-

gine front plate. Attach a puller to oil pump gear and
To service gear train and related parts, with the
pull gear fro m shaft. N EVER PRY GEAR FROM
exception of the crankshaft, engine normally need
SHAFT.
not be removed. If engine must be removed, see
Group 5 of this section.
4. Remove oil pump (Group 15).
5 . Remove fue l in jection pump and d rive gear

(Group 25) .
6. Remove camshaft.
REPAIR
Checking Gear Train Backlash
If gear train noise is noted at the time of disassem-
bly, it usually indicates excessive gear lash or dam-
aged gear teeth.
Specified timing gear train backlash is as follows:
Gear Backlash
Camshaft to upper idler ......... 0.0028 to 0 .0135 inch
[0.0711 to 0.3429 mm]
Injection pump to upper
idler ......... .. .. ......... .. .............. 0.0028 to 0.0135 inch
[0.071 1 to 0.3429 mm]
1-Camshaft Gear 6-011 Pump Gear Crankshaft to upper idler .. ..... 0.0027 to 0.0116 inch
2-Upper Idler Gear 7- Lower Idler Gear
[0.0686 to 0 .2946 mm)
3-lnjection Pump Gear 8-Right Balancer
4-Crankshaft Gear Shaft Gear Crankshaft to lower idler ....... 0.0027 to 0.0137 inch
5-Left Balancer [0.0686 to 0.3480 mm)
Shaft Gear Oil pump to left balancer ...... 0.0020 to 0.0140 inch
[0 .0508 to 0.3556 mm]
Fig. 22-Timing Gear Train
Oil pump to lower idler.... ...... 0.0027 to 0.0137 inch
Whenever an engine is being completely recondi- [0.0686 to 0.3480 mm)
tioned or the crankshaft is being removed, the engine Lower idler to right
front plate with gear assemblies should be removed balancer ............................... 0.0018 to 0.0156 inch
from the engine using the following steps: [0.0457 to 0.3962 mm]
1. Remove timing gear cover.
2. Remove hex. nuts from the oil pump and injec-

tion pump drive gears and cap screws from upper
and lower idler gears.
Litho in U.S.A.
Idler Gears
Be sure that oil hole in upper idler gear is open.
Check both idler gears for excessive end play.

New part end play should be 0.0010 to 0.0070 inch
[0.0254 to 0. 1778 mm). A maximum 0.0150 inch
[0.381 mm) end play is acceptable.
Measure I.D. of bushing and O.D. of shaft to deter-

mine oil clearance of 0.0015 to 0.0035 inch [0.0381
to 0.0889 mm). A maximum 0.0061 inch [0.1524
mm] clearance is acceptable. New bushing I.D. is
1.7520 to 1.7530 inches [44.5008 to 44.5262 mm].
New shaft O.D. is 1.7495 to 1.7505 inches [44.4374
to 44.4627 mm].
If excessive wear or oil clearance is indicated, use

JD-252 Bushing Driver to install new bushing flush
with either side of gear.
Fig. 23-lnsta//ing Oil Seal in Timing Gear Cover
using JD-250 Driver
If idler gear shaft replacement is necessary, press
in new spring pins to 0.20 to 0.28 inch [0.508 to INSTALLATION
0.711 mm] above shaft.
Installing and Timing the Gear Train
Front Plate and Timing Gear Cover
The camshaft gear and injection pump gear must
Never pry or press against timing gear cover with be timed to the center of the crankshaft when they
excessive force. The cover is cast aluminum alloy are installed. Install and time gear assemblies using
and might be sprung or warped. the following steps:
If there is evidence of oil leakage on outside of 1. Turn crankshaft until No. 1 piston is at top dead
timing gear cover, replace crankshaft front oil seal. center (TDC) of its compression stroke. Remove tim-
ing hold cover and screw on flywheel housing. Re-
Coat outer surface of seal with joint sealing com- versing the screw, insert the smooth end into the
pound and inside surface with multi-purpose grease. flywheel housing bore. Rock the flywheel until the
Support the oil seal bore area of timing gear cover. screw slides into hole in flywheel.
Press in oil seal to bottom of bore with spring loaded
lip facing inward using special JD-250 driver (Fig. If engine is stripped, position crankshaft so that
23). No. 1 (fan end) connecting rod journal is at its high-
est point toward the deck of the eng ine at th is
time.The keyway in the crankshaft front gear (not
pulley keyway) should now point straight up toward
the top of the engine.
Do not rotate crankshaft after " TDC" setting has

been made.
Litho in U.S.A.
10-18 Basic Engine TM- 1102 (Nov-73)
2. Install camshaft. With engine at "TDC," use JD254 gear timing tool
to align the timing mark on the injection pump gear
between centers of crankshaft and injection pump
shaft (Fig. 25).
Use the timing mark on the injection pump

drive gear that indicates the number of cylinders
in the engine.
4. With camshaft and injection pump gears in-

stalled and timed, carefully install upper idler gear in-
to position using care not to rotate the timing gears.
Be sure inner thrust washer and idler gear shaft are
in place on rear of idler gear shaft. Over front of
gear, install outer thrust washer and cap screw. Us-
ing a screwdriver between gears to prevent rotation,
secure upper idler gear to front plate and tighten to
65 lb-ft [8.99 kg-m].
5. Install balancer shafts.
Fig. 24· Timing the Camshaft Gear with JD-254 Tool With engine at "TDC", use tool JD254 to align the
timing marks on the balancer shaft drive gears be-
With engine at " TDC," use JD254 gear timing tool tween center of the crankshaft and balancer shaft
to align the timing mark on the camshaft gear be- (Fig. 26) .
tween centers of the crankshaft and camshaft (Fig.
24). 6. Install oil pump and drive gear (Group 15).
3 . Install fuel injection pump and drive gear (Group Tighten oil pump gear hex. nut to 35 to 45 lb-ft
25) . [4.84 to 6.22 kg-m] after gears have been timed and
lower idler gear installed so that gears may be re-
strained with a screwdriver. Then stake threads on
shaft.
Fig. 25-Timing the Injection Pump Gear with JD-254 Tool
1-JD-254 Timing Tool 2- Timing Marks
Fig. 26· Timing the Balancer Shaft Gears
Litho in US.A.
. 7. With balancer shaft and oil pump gear installed, Final Installation
Install lower idler gear into position, using care not to
Apply a thin coat of high-temperature grease to the
rotate any gears. Be sure special bolt, washer, inner
inside lips of the front oil seal and install timing gear
thrust washer, and idler gear shaft are in place on
cover. Be careful not to invert lips of oil seal while in-
rear of idler gear shaft. Over front of gear, install out-
stalling cover.
er thrust washer and cap screw. Tighten cap screw
to 95 lb-ft [13.13 kg-m].
Before installing gear cover on engine be sure that
oil slinger is securely positioned over end of crank-
After all gears are locked in place, recheck all tim-
shaft with inside against gear. Also be sure oil pres-
ing marks with JD254 gear timing tool, making sure
sure regulating valve and spring are in place under
that marks still align between the centers of the re-
cover.
spective shafts and the center of the crankshaft with
the engine at "TDC." Then remove timing screw from
flywheel and install timing hole cover.
Litho in U.S.A.
10-20 Basic Engine TM-1102 (Nov-73)
Litho in U.S.A.
TM- 1102 (Nov-73) Engine Lubrication System 15-1
Group 15
ENGINE LUBRICATION SYSTEM
GENERAL INFORMATION OIL PUMP
The engine lubrication system consists of the oil
filter, oil pump, and oil cooler.
Removal
Check engine oil pressure before removing pump
The oil filter is mounted on the right side of the en-
(see Group 10, Section 70).
gine. It filters impurities out of the crankcase oil.
The engine oil pump is mounted in the oil pan. Oil Drain oil from engine and remove oil pan.
enters the pump from the rear through the pump in-
take tube and is discharged at the oil outlet hole into Remove cap screws holding pump to block.
an oil tube leading to the oil cooler, oil filter and then
to the gallery. Repair
A pressure regulating valve is located at the fan Remove idler gear (1 1, Fig. 1) from idler shaft (19);
end of cylinder block in the oil gallery. Under normal then support housing and press out shaft.
conditions it is not necessary to adjust pressure but it
can be done by adding or subtracting shims or add- Inspect pump housing surface which attaches to
ing a large aluminum washer behind the valve plug. cover for rough, burred or warped conditions. Re-
When oil pressure is greater than the spring pres- place if necessary.
sure, oil is bypassed to the crankcase and desired
pressure is maintained. Examine pump cover (4) mounting surface . A
damaged cover must be replaced. The seal between
An engine oil cooler is located on the right side of
cover and pump housing is dependent upon these
the engine. The cooler uses engine coolant to lower
two surfaces being perfectly flat and smooth.
the temperature of the crankcase oil.
r 8
I
(j
T3099 2
1-Cap Screw (2 used) 6-Drive Shaft with Gear and Pin 11~dler Gear
2-Cap Screw (2 used) 7-0rive Shaft 12-0-Ring
3-Lock Washer (4 used) ~Nut 13-0:..tlet Tube
4-Cover Assembly 9-ldler Shaft 14-Q-Ring
5-Groove Pin 10--Housing 15-011 Pump Intake
Fig. t-Oil Pump
Litho in U.S.A.
15-2 Engine Lubrication System TM-1102 (Nov-73)
Examine screen on cover to be sure it is clean and Remove oil pressure regulating plug shims (if
the wire mesh of the screen is not damaged. used) spring and valve. Save any shims used for
correct reassembly.
Inspect inlet and outlet tubes for clogging .
Inspect regulating valve seat in front of cylinder
Carefully inspect pump drive shaft assembly for block for damage (especially at raised rim of bush-
wear, especially at points of contact. Check diameter ing).
of drive shaft (0.6308 to 0.6312 inch [16.0223 to
16.0325 mm]) at point where it rides in bore of hous- Press new bushing into block using JD248 tool.
ing and replace if necessary. (The pump drive shaft Press in bushing until outer recessed edge of bush-
is not available separate from the pump, gear and ing is flush with bottom of counterbore in block. Do
groove pin.) not press on raised inner rim of bushing. This rim is
the regulating valv.e seat.
Measure width of gears (1 .6203 to 1.6223 inch
[41 .1556 to 41.2064 mm]). Check oil pressure regulating spring. Free length is
4.68 inches [118.872 mm] and test length is 1.68
Install gears in housing in running position and [42.672 mm] at 15 :±: 5 lbs . [6.804 :±: 2.268 kg]
measure radial clearance (0.0030 to 0.0060 inch pressure.
[0.0762 to 0.1524 mm]) between gears and straight-
edge. Check pressure regulating valve plug threads for
damage.
Place a straightedge across top of housing (to rep-
resent cover) and measure clearance (0.0012 inch to Assembly
0.0062 inch [0.0305 to 0.1575 mm] ) between gears
Press idler shaft (9, Fig. 1) into pump housing until
and straightedge.
flush with outer surface of housing.
Oil Pressure Regulating Valve
Place gear and shaft in housing. Install pump idler
gear on idler shaft in housing. Check to see that both
gears rotate freely in housing.
Install new 0-ring (12) in oil outlet opening in oil

pump cover.
Installation
Place pump housing with gears and drive shaft in
position in engine. Set engine at TDC and time left
balancer shaft to engine gear train (Group 10). Install
drive gear on shaft. Tighten hex. nut to 35 to 45 lb-ft
[ 4.8 to 6.22 kg-m) and then stake nut to shaft.
NOTE: If left hand balancer shaft has moved, re-

time balancer shaft to engine gear train (see Group
10).
Fig. 2-lnstalling Pressure Regulating Valve

Bushing with JD-248 Driver
Litho in U.S.A.
TM-11 02 (Nov-73) Engine Lubrication System 15-3
Position oil pump cover and screen up against Repair

pump housing. Install pump outlet oil tube in cover.
Fasten cover in place. Tighten to 35 lb-ft [4.8 kg-m].
Place valve and spring in valve hole in engine tim-

ing gear cover. With an aluminum washer on valve
plug and same number of shims (if used) in plug
counterbore as removed, install plug in timing gear
cover. This is a preliminary setting to be used until oil
pressure can be checked.
Fill lubrication system with proper oil. 15-~

After installing oil pump, check engine oil pressure
(see Group 10, Section 70).
12--~ ' 6
I I
13 14
ENGINE OIL FILTER
Removal
Unscrew filter element from engine and discard it.
Inspect oil passages at mounting point on cylinder
block for obstructions. If filter base nipple in block is
damaged, refer to Group 10 of this section for re-
placement details.
Repair
I
Replace oil filter element every 200 hours of oper- , e;
ation, or sooner if necessary.
T32284
8--(:::::;:J~,17
Advise the operator to replace filter element only
with a Joh n Deere f ilter elemen t suppl ied by his 1-Ciamp (8 used) 10-0il Cooler
dealer. 2-Hose 11- Nipple
3-Hose 12-Screw
The filter element has a special bypass valve to 4-Lower Tube 13-Lock Washer
5-Half Clamp 14-Half Clamp
protect the engine in case of filter clogging.
6- Cap Screw 15-Washer
7- Hose 16-Upper Tube
Installation 8-0·Aing 17-Special Plug
9-Relief Valve 18-Hose
Install new filter element. Turn element down until
sealing ring just contacts mounting pad ; then turn Fig. 3-0i/ Cooler
down an additional 1-1/2 turns.
Check water passages for lime deposits.
Check for leaks around filter element. Retighten if
necessary, but do not overtighten. Inspect internal passages for any evidence of wa-
ter or oil leakage.
OIL COOLER
Refer to Fig. 3 for relationship of parts.
Removal
Drain oil from engine crankcase and coolant from Installation
radiator. Follow removal procedure in reverse order.
Remove oil filter element. Be sure all connections are tight.
Disconnect coolant lines. Pull straight up on cooler

and remove from engine.
Litho in U.S.A.
15-4 Engine Lubrication System TM-11 02 (Nov-73)
Litho in U.S.A.
TM-11 02 (Nov- 73) Engine Cooling System 20-1
Group 20
ENGINE COOLING SYSTEM
GENERAL INFORMATION Installation
The engine cooling system consists of the radiator, To install the radiator, follow removal procedure in
water pump and thermostat and housing. reverse order.
Coolant temperature is controlled by a thermostat. Fill radiator with soft clean water and proper addi-
A bypass line from the thermostat housing to the wa- tive.
ter pump allows fast engine warm-up and a uniform
cooling temperature throughout the cylinder block. WATER PUMP
The pressure-type radiator cap is equipped with a
pressure valve which permits a pressure build-up in Removal
the cooling system.
Drain coolant from radiator and engine block.
The centrifugal-type water pump attaches directly
Remove radiator (see page 20-20-1 ).
to the cylinder block and is driven by the fan belt. A
bellows-type seal assembly is pressed into the pump
Remove fan belt. Remove cap screws attaching
housing between the pre-lubricated ball bearing and
water pump to engine and remove water pump.
the impeller. If the seal becomes worn or damaged,
water will escape through a drain hole near the bot-
tom of the pump housing.
Repair
Disassembly
RADIATOR
Remove the rear cover plate and gasket from the
pump housing (Fig. 2).
Removal
Remove engine side shields, hood, grille screen Select a drift which is slightly smaller than the
and housing. bearing shaft and supporting fan hub, press hub from
water pump.
Drain radiator and hydraulic oil cooler. Disconnect
all inlet and outlet lines into radiator and oil cooler. Support water pump housing and allow sufficient
clearance for impeller at center of support. Use a
Remove cap screws attaching radiator to frame JD262-A water pump bearing driver or any tubular
and remove radiator. type driver that contacts only the outer race of bear-
ing and press bearing assembly from housing.
Repair
Support impeller and press out bearing shaft using
Refer to "Cooling Systems" in FOS Manual
El a
- ENGINES for radiator inspection and re-
pair.
a drift which is slightly smaller than the bearing shaft.
Remove seal from bearing shaft. Note location of cup
and insert in impeller.
Litho in U.S. A.
20-2 Engine Cooling System TM-1102 (Nov-73)
T2209411 1 - - - - - - - - - - - - { 5 } - - -- - ------..j
1-lnsert 3-Seal 4-Bearing and Shaft

2- Cup 5-5-1/2 inches [139.7 mm]
Fig. t-Cutaway View of Water Pump Assembly
Inspection Assembly
Any leakage at the drain hole in bottom of housing Install a new seal in the pump housing. Coat out-
generally indicates a leaking seal. side of pump seal metal retainer with joint sealing
compound and wipe off any excess (spring-loaded
type seal only). Apply a thin coat of light oil to seal-
ing lip of seal before installing.
Install seal by hand as shown in Fig. 1. Rubber

sealing surface that contacts housing should be
clean and dry.
Litho in U.S.A.
TM- 1102 (Nov-73) Engine Cooling System 20-3
ltf'1
0
13
T3376 1N
1-Gasket 7-Bypass Elbow 13- Fan 18-Tube (2 used)

2-Cover 8- Housing 14-Cap Screw (4 used) 19-Stud
3-Gasket 9-Pipe Plug 15---Cap Screw (2 used) 20--Cap Screw
4-lmpeller 10--Fan Belt 16-Nut 21-Washer
5---Seal 11-Cap Screw (4 used) 17- Lock Washer (4 used) 22-Aiternator Adjusting Strap
6-Bearing 12-Fan Pulley 23-Cup and Insert
Fig. 2-Water Pump and Related Parts
Use a tubular type drive that contacts only the out-

er metal portion of the seal and press new seal
(metal side first) into pump housing. Press in until
metal flange bottoms on housing.
Using a JD262A water pump bearing driver or any

tubular type driver that contacts only the outer race
of bearing, press shaft and bearing assembly into
housing until outer metal case is flush with pump
housing.
Install impeller insert and cup in impeller. Place in-

sert in cup with " V" groove on insert toward cup. Be
sure parts are dry and clean. Dip cup and insert in oil
and install in impeller (cup to bottom of counterbore
in impeller). Insert should be flat and edge of cup un-
iform around insert when installed in impeller.
Fig. 3-/nsta//ing Impeller
Support pump assembly on end of bearing shaft
and press impeller (fins toward housing) into position.
Impeller should be pressed in until fins are flush Support impeller end of pump bearing shaft and
(within 0.0 10 inch [0.254 mm)) with metal rim of press fan hub into position on opposite end of shaft.
pump housing. Check with a straightedge and feeler
gauge as shown in Fig. 3. Fan hub should be pressed onto shaft according to
specifications. The distance from the fan surface on
pulley-to-rear surface of water pump housing (with-
out rear plate or gasket) should be 5-1 / 2 inches
[ 139.7 mm] .
Litho in U.S. A.
20-4 Engine Cooling System TM-11 02 (Nov-73)
Installation
Follow removal procedure in reverse order to in-
stall the water pump.
Install radiator on engine (see page 20-20-1) and

fill cooling system with clean soft water and proper
additive.
THERMOSTAT AND HOUSING

Removal
Remove cap screws holding thermostat housing to
water manifold and remove housing and thermostat.
Repair
If engine has been running too cold or hot, careful-
Fig. 4-lnsta//ing Fan Hub
ly inspect the thermostat for defects. Test in hot wa-
ter to check for proper opening and closing.
Using a new gasket, install pump rear cover on
pump assembly. Tighten attaching cap screws to 35 Thermostat should open at 180°F. [82.2°C].
lb-ft [4.8 kg-ml.
Installation
Follow removal procedure in reverse order.
Litho in U.S.A.
TM- 1102 (Nov- 73) Fuel System 25-1
Group 25
FUEL SYSTEM
GENERAL INFORMATION Remove operator's seat from unit.
The fuel system consists of a fuel tank, screen,
Drain fuel from tank.
transfer pump, fuel filter, injection pump and injection
nozzles.
NOTE: If fuel is to be reused, drain into a clean
container and keep covered.
The fuel tank is located behind the operators sta-
tion . A finger-shaped fuel tank screen located on the
Disconnect fuel outlet, return and drain lines from
bottom front of the fuel tank fuel strainer in the neck
tank.
of the tank removes most of the impurities.
Attach a chain to tank lifting hooks (Fig. 1). Re-
The transfer pump draws fuel from the tank and
move cap screws from lower tank flange and from
sends it to the fuel filter.
tank side brackets. Lift tank from unit.
The fuel filter, mounted on the right side of the en-
gine, further filters the fuel before it enters the injec-
Repair
tion pump. A CAUTION : Cleaning and repairing a fuel
. . tank is very dangerous . Live sparks,
The fuel injection pump gets fuel from the filters, smoking, or fire of any nature should never be
pressurizes it and sends it through high pressure permitted in the vicinity of the cleaning or repair-
lines to the injection nozzles. ing operation.
The injection nozzles (one for each cylinder) spray

fuel in to the combustion chambers.
FUEL TANK
Removal - -5
1- FIIIer Cap 11- Bushing

2-Gasket 12-Eibow
3-Fuel Strainer 13-Line Nipple
4-Snap Ring 14-Liner Coupler
5-Fuel Gauge 15-Drain Valve
6-Tank 16-Drain Line
7-Filter 17-Ciamp (2 used)
8-Eibow 18-Lock Washer (2 used)
9-Shut-Off Valve 19- Bushing
10--Cap Screw
Fig. 2-Fue/ Tank

Fig. 1-Fue/ Tank Lifting Hooks
Litho in U.S.A.
25-2 Fuel System TM -1102 (Nov-73)
Check fuel tank for leaks.
Remove and clean fuel neck strainer (3, Fig. 2)

and tank screen (7). Replace if either will not come
clean or if large holes appear.
EJ
Refer to FOS-30, ENGIN ES for detailed in-
formation on repair of fuel tanks.
0
Installation
Secure tank to lower bar and side flanges with cap
screws. Tighten tank lines and tube securely. Open
1-Bracket 1o-Eibow
fuel shut-off valve. Install seat. 2- Cap Screw (2 used) 11- Eiement
3--Eibow 12- Retaining Spring
Use a chain hoist to lower fuel tank into place on 4-Filter Body 13--Cap Screw (2 used)
unit. Attach fuel outlet line, fuel return line, and drain ~Fuel Line to Injection 14-Washer (2 used)
Pump 1 ~Pipe Plug
tube loosely to tank fittings.
~Packing (2 used) 1~Lock Washer (2 used)
7- Bieed Screw (2 used) 17- Nut (2 used)
Bleed the fuel system. 8-Connector 18-Eibow
9-Fuel Line to Transfer
FUEL FILTER Pump
Fig. 3-Fuel Filter

Removal
To remove filter element, pull off retaining spring Installation
and slip off cover and filter element. Follow removal procedure in reverse order.
To remove filter body, disconnect and cap inlet Bleed the fuel system.
and outlet fuel lines. Remove cap screws securing
body to mounting bracket. FUEL TRANSFER PUMP
Repair Removal
Refer to Fig. 3 during disassembly and assembly. Close fuel shut-off valve at tank.
Clean cover and replace element as needed. Disconnect fuel lines at pump. Remove cap screws
and remove pump.
Check openings in body for clogging.
Repair
Refer to Fig. 4 when disassembling and assem-
bling the pump.
To remove or install primer lever, compress rocker

arm lever.
Litho in U.S. A.
Crawler - J0450- C Engine 20
TM-1102 (Nov-73) Fuel System 25-3
A CAUTION : Escaping diesel fuel under

. . pressure can have sufficient force to pen-
etrate the skin causing serious personal injury.
Before disconnecting lines, be sure to relieve all
pressure.
Fuel escaping from a very small hole can be
almost invisible. Use a piece of cardboard or
wood, rather than hands to check for escaping
fuel.
If injured by escaping fuel , see a doctor at
once. Serious infection or reaction can develop if
proper medical treatment is not administered im-
T 23 20 6!1 mediately.
1- Gasket 4-Primer Lever
2- Packing 5--Fuel Pump To relieve pressure in the fuel system, slightly
3-0-Ring (diesel) crack high pressure injection line connections at ·
nozzles.
Fig. 4-Fuel Transfer Pump
Before removing fuel injection pump, thoroughly
Installation clean the pump, fittings, and all connections to be
Follow removal procedure in reverse order. disconnected.
IMPORTANT: Never spray cold water on or
Bleed fuel system. steam clean a warm injection pump.
FUEL INJECTION PUMP The fuel injection pump and engine should be stat-
ic timed before the injection pump is removed (see
Removal " Installation").
Removing Injection Pump From Drive Shaft

Disconnect fuel supply, fuel return, and the injec-
tion lines from the pump (Fig. 5). Plug all openings.
Disconnect the throttle linkage and wire throttle
lever in wide open position before removal of pump
to prevent loosening of internal parts.
Remove the pump mounting nuts and slide the
pump in a straight line away from the engine.
The pump drive gear and shaft will remain on the
engine front plate.
Removing Injection Pump, Drive Shaft, and Gear

NOTE: The injection pump drive shaft can be re-
moved without removing the timing gear cover. Loos-
en the nut on the end of the shaft and drive gear off
shaft from the rear using a brass drift. Install by plac-
ing the shaft in the gear and tightening the attaching
1- Attaching Points 5--Fuel Inlet nut drawing the shaft through the gear. Tighten nut
2-Throttle Linkage ~Tim ing Hole Cover
with 45 lb-ft [6.2 kg-m).
3-Fuel Return 7- Cam Advance Mechanism
4-lnjection Lines 8-lnjectlon Delivery Sequence
(VIew from end plate)
Fig. 5-Fue/ Injection Pump
Litho In U.S.A.
25-4 Fuel System TM-1102 (Nov-73)
If it is desired to remove the pump drive gear and Installation and Timing
shaft from the engine with the pump, the timing gear
If removed, install injection pump gear and shaft
cover must be removed (see Group 10).
on engine front plate. See Group 10 of this section
for timing injection pump gear.
Clean the injection pump and lines. Align the tim-
ing marks on the pump and insert the timing screw in
Install engine timing gear cover (if removed).
flywheel.
With timing gear cover removed, check to see that

the injection pump gear is properly timed to the
crankshaft (see Group 10).
Remove the upper idler gear.
Remove injection pump drive gear and shaft.
Remove pump mounting hex. nuts and lift pump

from engine.
Repair
For detailed information and specifications refer to
John Deere Service Manual SM-2045, " Testing and
Servicing Fuel Injection Pumps and Nozzles."
Drive Shaft and Gear

Remove thrust spring and pin from gear end of
shaft.
Loosen nut until flush with end of shaft.
1-Governor Weight Retainer 2-Timing Window
Remove nut and gear from shaft. Timing Line 3-Cam Timing Line
Inspect gear for wear or chipped teeth.
Inspect tang on drive shaft for a minimum width of Fig. 6-Timing Lines
0.305 inch [7.79 mm].
Inspect wear surfaces on drive shaft. With tim ing window (JD-259- 13366) in place,
check to be sure that timing line on governor weight
Check seals on drive shaft for hardness or cracked retainer hub registers with the line on the cam (Fig.
condition. Examine seal grooves on shaft for smooth 6).
finish. Any roughness at these points will cause seal
failure.
If engine has not been set on "top dead center"
Apply a generous coat of Lubriplate to the drive (No. 1 cylinder on compression stroke) rotate engine
shaft seals and slide seals into grooves using drive in direction of rotation (counterclockwise as viewed
shaft seal installation tool (13369). The seals must from flywheel end) until No. 1 cylinder is on com-
face in the opposite directions. Apply Lubriplate liber- pression stroke. Insert timing pin in flywheel as the
ally around the shaft between the seals. flywheel is rotated and comes in registry (inset, Fig.
6). Engine is now set at " top dead center."
Install gear on drive shaft using key and keyway to
locate gear on shaft. Tighten hex. nut with 35 lb-ft Install pump over shaft, making sure that reference
[4.8 kg-m]. mark on drive shaft tang aligns with mark on the slot
end of the distributor rotor in the pump.
Incorrect assembly of shaft into pump will result in

timing error of 180 degrees.
Litho in U.S.A.
TM-11 02 (Nov-73) Fuel System 25-5
Using dri ve shaft seal compress i ng t oo l Bleeding

(JD256- 13371 ), compress seal on shaft and slide
Any time the engine has been idle tor a long peri-
pump in place (Fig. 7). Install hex. nuts and tighten
od or the fuel system has been cleaned, bleed the
finger tight. Rotate pump first in the direction of rota-
fuel system before operation to remove trapped air.
tion and then in the opposite direction and again reg-
ister timing lines to take up all backlash. Tighten
1. Fill tank with proper fuel.
mounting nuts securely.
2. Open shut-off valve at tank outlet under seat.
Fig. B·Filter Bleed Plug (Left) and Inlet Line (Right)
3. Loosen bleed plug on top of the filter. Pump pri-

mer lever until a solid stream of fuel (free of air bub-
1- Mounting Studs 3-Seal Compressing Tool bles) flows from the opening. Tighten plug.
2-Seals
Fig. ?-Compressing Drive Shaft Seal 4. Loosen pump inlet line. Pump primer lever until
a solid stream of fuel (free of air bubbles) flows from
Do not turn drive shaft seal over while installing. If line. Retighten line.
resistance is felt, stop and check position of seal. If
seal has been forced back, replace seal. 5. Be sure to leave primer lever at lowest point of
stroke.
Recheck pump timing.
Connect injection lines using new washers. Tighten

connections 35 lb-ft [4.8 kg-m].
Connect fuel supply and return lines. Tighten only

enough to keep lines from leaking.
Connect throttle linkage.
Remove timing window and install timing window

cover.
Bleed fuel system.
Refer to Group 10, Section 70 for speed control

adjustment and injection pump cam advance adjust-
ment.
Litho in U.S.A.
25-6 Fuel System TM-1102 (Nov-73)
FUEL INJECTION NOZZLES Remove nozzle clamp cap screws and spacer.
Withdraw nozzle from cylinder head. If nozzles can-
Removal not be easily removed from cylinder head, use a
J DE38 Nozzle Puller to remove them. Use care
Remove the crawler hood.
when attaching the puller to the nozzle. Operate pull-
Clean the cylinder head area around the nozzles er so as to pull nozzles straight out of the bores.
and blow off with compressed air. Use hose clamp
IMPORTANT: Do not use a screwdriver or simi-
pliers (JDE49) to loosen clamp on leakoff boot and
lar tool to pry . Injector nozzles from cylinder
slip off boot. Remove the return leakoff line with the
head as distortion and permanent damage to
boots.
nozzles may occur. Injectors are easily removed
A CAUTION : Escaping diesel fuel under by hand unless lower carbon seal has failed, al-
. . pressure can have sufficient force to pen- lowing nozzle to become "set." In this case, the
etrate the skin causing serious personal injury. nozzle puller must be used.
Before disconnecting lines, be sure to relieve all
pressure. Repair
Fuel escaping from a very small hole can be IMPORTANT: Do not attempt to test or disas-
almost invisible. Use a piece of cardboard or semble nozzles unless the proper service tools
wood, rather than hands to check for escaping are available. Service Manual SM-2015 "Testing
fuel. and Servicing Fuel Injection Pumps and Nozzles"
contains specifications, special service tools, and
If injured by escaping fuel , see a doctor at
testing procedures necessary to service the
Roosa-Master injection nozzles.
proper medical treatment is not administered im-
mediately.
Installation
To relieve pressure in the fuel system, slightly
Install a new sealing washer onto the nozzle body.
crack high pressure injection line connections at
Use No. 16477 pilot tool to install a new carbon stop
nozzles.
seal (Fig. 10). Place the pilot on the spray tip of the
Use a wrench to hold nut on injector and unscrew nozzle and work the seal down over the pilot onto
the nut on fuel supply line. Cap openings as soon as the nozzle body, then into its groove.
lines are disconnected.
1- Carbon Seal 3-Pilot

2- Seal Washer
Fig. tO-Installing Sealing Washer and Carbon Stop Seal
Fig. 9-Using Nozzle Puller to Remove Nozzles
Litho in U.S.A.
TM- 1102 (Nov-73) Fuel System 25-7
Using a JDE39 Nozzle Bore Cleaning Tool, clean Tighten nozzle hold-down cap screws to 20 lb-ft
out the nozzle bores in the cylinder head. When us- [22.8 kg-m] and install leak-off boots and line.
ing the tool, gradually turn it into the bore.
NOTE: Always turn the tool clockwise as turning it

counterclockwise will duff the tool.
After the bores are clean , blow out with com-

pressed air. Be sure nozzle gasket mounting surface
on cylinder head is free from burrs or dirt. Foreign
material in this area could cause the nozzle body to
distort when clamped down, resulting in a sticking
valve.
Unplug holes in cylinder head and insert the noz-

zle into the cylinder head bore using a twisting mo-
tion. Fig. 11-Tightening Lines
NOTE: Be sure nozzle body is free from oil or Crank engine with starter until fuel flows around
grease when installing. loose injector lines. Using one hand and two wrench-
es, tighten injector lines as shown in Fig. 11 . Use on-
Turn injector locating clamp until forks fit down ly enough force to keep lines from leaking. Start
over inlet line . Install cap screw and leaf spring engine and check for leaks around nozzle connec-
around head of injector and position round spacer on tions. Retighten if necessary and install hood.
end of cap screw under leaf spring. Hand tighten cap
screw. Connect inlet line and hand tighten.
Litho in U.S.A.
25-8 Fuel System TM-11 02 (Nov-73)
Litho in U.S.A.
TM-11 02 (Nov-73) Speed Control Linkage 30-1
Group 30
SPEED CONTROL LINKAGE
GENERAL INFORMATION
Refer to Group 10, Section 70 for information on Speed Control Linkage.
Litho in U.S.A.
30-2 Speed Control Linkage TM-11 02 (Nov-73}
Litho in U.S.A.
TM- 11 02 (Nov- 73) Air Intake System 35-1
Group 35
AIR INTAKE SYSTEM
GENERAL INFORMATION Repair
The air intake system consists of the air cleaner Replace any air hoses that are cracked or dam-
and an optional turbocharger. aged.
The air cleaner assembly consists of an optional Replace the filter elements (1) if damaged, (2) af-
pre-cleaner, two filter elements and an air restriction ter one year of service, or (3) if element is not re-
indicator. sponding to cleaning, indicated by excessive smoke
or loss of power.
Dirty air entering the air cleaner flows first past the
filter fins which separate dirt from the air and deposit
the dirt in the dust cup. Air is filtered when it passes
through the filter element before flowing to the en-
gine.
A pre-cleaner (Fig. 2) may also be included in the

air intake system. Its purpose is to stop any large dirt
particles from entering the system.
A restriction indicator (Fig. 3) may be installed to

warn the operator whenever excessive restriction is
present in the air intake system.
The turbocharger is located on the top left of the

engine. It pressurizes the air coming from the air
cleaner and delivers it to the intake manifold. 1- Pre-Cieaner 15-Ciamp*
2-Pre-Cieaner Cover 16--Seal or Grommet
3-Pre-Cieaner Bowl 17-Cap Screw (2 used)*
AIR CLEANER 18-Nut (2 used)*
4-Pre-Cieaner Base
5-Cup 19--Washer (6 use<W
Removal 6--Baffle Skirt 2o-Cap Screw (2 used)*
7- Wing Nut (2 used) 21-Washer (approx.
To remove filter elements remove cup (5, Fig. 1) 8-Eiement 6 used)*
and baffle skirt (6) from cleaner cover under dash 9-Safety Element 22-Extension Bracket*
cowl. Remove wing nut (7) and pull out element. Re- 1o-Ciamp 23-Extension
move second wing nut and pull out safety element. 11- Bolt 24-Hose Clamp* *
12-Cieaner Assembly 25-Hose* *
13-Cap Screw (4 used) 26--Hose Clamp
To remove air cleaner assembly, remove intake 14-Lock Washer (8 used)* 27-Air Intake Hose
and outlet hoses and attaching hardware.
" Used only on crawlers without loader
*"'Used only on crawlers with loader
Fig. 1-Air Cleaner and Pre-Cleaner

(Withou1 Turbocharger)
Litho in U.S.A.
35-2 Air Restriction Indicator TM-11 02 (Nov-73)
Replace the filter element (1) if damaged, (2) after TURBOCHARGER

one year of service, or (3) if element is not respond-
ing to cleaning, indicated by excessive smoke or loss Removal
of power.
Disconnect exhaust adapter, exhaust elbow and air
r=l
L-!.1 Refer to FOS Manual - ENGINES - for in-
formation on cleaning air cleaner elements.
intake pipe. Disconnect and cap oil inlet and outlet
connections.
Remove cap screws securing turbocharger to en-

gine and remove turbocharger.
Refer to Fig. 1 during disassembly and assembly
of air cleaner.
Testing
NOTE: Never operate engine without filter element Radial Bearing Test
and dust cup in place.
Perform this test to determine whether it is neces-
sary to replace the thrust bearings, radial bearing,
The air restriction indicator (Fig. 2) can be tested
and/or rotating assembly of the center rotating as-
for proper operation. See Group 10, Section 70 for
sembly. The radial bearing test should be made with
testing instructions.
the turbocharger removed from the engine.
Using a mounting adapter and two-inch (50.8 mm]

indicator extension rod , fa sten a dial indicator
(plunger type with one-inch (25.4 mm] travel) to the
turbocharger Fig. 3.
Move the rotating shaft toward the compressor and

then away from the indicator using care to move the
shaft in the same direction as the dial indicator trav-
els.
Fig. 2-Air Restriction Indicator
Installation
Follow removal procedure in reverse order.
Check all air intake system fittings for possible air

leaks.
Fig. 3-Radial Bearing Test
Litho in U.S.A.
TM-1102 (Nov-73) Air Intake System 35-3
1- Compressor Housing 9-Thrust Collar 17-Wheel Shroud

2-Lock Nu1 1~Bearing 18---Piston Ring
3--lmpeller 11-Retaining Ring (4 used) 19-Turbine Wheel with Shaft
4---Backplate Assembly 12- Bearlng (2 used) 2~Special Bolt (6 used)
5-Ciamp (3 used) 13--0·Ring 21-Lock Plate (3 used)
6-lock Plate (3 used) 14---Center Assembly Housing 2.2-Ciamp (3 used)
7-Cap Screw (6 used) 15-Lock Plate (2 used) 23--Turbine Housing
8---Piston Ring 16-Cap Screw (4 used)
Fig. 4-Turbocharger
Apply side pressure at both ends of the shaft to-

ward the dial indicator and then away from the indi-
cator.
Equal pressure should be applied to both ends of

the shaft at the same time. Check total dial indicator
movement to see that the range of travel is limited to
0.003 - 0.006 inch [0.076 to 0. 152 mm]. If movement
is not within these specificiations, repair is neces-
sary.
Axial End Play Bearing Test

Perform this test to determine it the rotating as-
sembly must be repaired or replaced.
Refer to Fig. 4 and remove the compressor hous- Fig. 5-End Play Bearing Test
ing-to-back plate cap screws (7, Fig. 4) and pull off
compressor housing.
Litho in U.S.A.
35-4 Air Intake System TM-11 02 (Nov-73)
Fasten a dial indicator to the turbocharger so the

indicator tip rests on the end of the shaft (Fig. 5).
Move the shaft axially back and forth by hand. If

the total indicator readi ng is not within 0.001 - 0.004
inch [0.0254 to 0 .1016 mm], the rotating assembly
must be repaired or replaced.
Repair
Disassembly
Clean the exterior with a pressure spray of clean-
ing solvent before disassembly. As a part is re-
moved, place it in a clean protective container.
Remove the turbine housing-to-center housing cap

screws. lock plates, and clamps (Fig. 6). Tap with a 1- Holdlng Fixture 2- Compressor Wheel
soft hammer if force is needed to remove the turbine
Fig. 7-Removing Compressor
housing, being careful not to damage the turbine
wheel.
Remove the compressor wheel from the shaft.
Then remove the turbine wheel and shaft assembly
from the center housing, keeping it centered with the
bearings until it is clear of the housing. Fig. 8 shows
the turbine wheel assembly removed from the center
housing. The wheel shroud and piston pins may be
removed at this time.
1- Turbine Housing 4-Ciamp

2- Center Housing 5-Cap Screw
3--Lock Plates
Fig. 6-Turbine Housing Removal 1-Wheel Shroud 3--Shaft and Wheel

2- Piston Ring Assembly
Mount a suitable holding fixture (see "Special
Tools") in a vise (Fig. 7), and insert the turbine wheel Fig. 8-Shaft and Wheel Assembly
into the fixture. Remove the compressor wheel re-
taining nut using a double universal socket to avoid
possible bending of the shaft.
Litho in U.S.A.
TM-1102 (Nov-73) Air Intake System 35-5
Remove the back plate-to-center housing cap Cleaning

screws and lock plates (15 and 16, Fig. 4). Then re-
Before cleaning, inspect parts for signs of burning,
move the back plate, by tapping with a soft mallet.
rubbing, or other damage which might not be evident
after cleaning.
Soak all parts in clean carbon solvent for about 25

minutes. After soaking use a stiff bristle brush to re-
move all dirt particles. Dry parts thoroughly.
NOTE: Normally, a light accumulation of carbon

deposits will not affect turbine wheel operation.
Inspection
Burnish or polish out minor surface damage. Use
silicon carbide abrasive cloth for aluminum parts and
crocus abrasive cloth for the steel parts.
Replace any part which fails to meet the require-

ments given in the inspection procedures.
1-Rubber 0-Ring ~Piston Ring
2-Thrust Collar and Washer Replace the following parts: 0-ring (13, Fig. 4),
lock plates (6, 15 and 21 ), piston rings (8 and 18)
Fig. 9-Removing Thrust Collar and Thrust Washer
and retaining rings (11 ).
Remove the thrust collar and thrust washer as
shown in Fig. 9. Remove the rubber 0-ring from Replace all damaged bolts.
housing.
NOTE: If bearings and thrust washers show signs
Remove bearings and retainers from the center of nicks, scores, shellac deposits, or foreign material
housing (Fig. 10). imbedment, replace them.
General - Parts must not show signs of damage,

corrosion, or deterioration. T hreads must not be
nicked, crossed, or stripped.
Shaft and Turbine Wheel - Turbine wheel must

show no signs of rubbing, and vanes must not be
torn or worn to a feather edge. Shaft must show
no signs of scoring, scratches, or seizure wit~he
bearings. ~
Compressor Wheel - Must show no signs of rub-

bing or damage from foreign matter. Must be com-
pletely free of dirt or other foreig n material.
Impeller bore must not be galled.
Seal Parts - Must show no signs of rubbing or scor-

ing of the running faces.
Housings - Must show no signs of contact with ro-

1- Bearing 2- Retainlng Ring tating parts. Oil and air passages must be clean
and free of obstructions.
Rg. tO-Retaining Ring and Bearing Removal
Litho in U.S.A.
Assembly Install piston ring on thrust collar over shaft, and

flat against the center housing , engaging the pins in
Be sure each part is clean before assembling. As
the back of the thrust washer.
parts are assembled, cover openings to prevent entry
of dirt or other foreign material.
Install rubber 0-ring in groove in center housing.
NOTE: If any particle falls into the turbocharger
Be sure that thrust spring is installed in back plate
during assembly, remove the particle immediately,
(Fig. 12).
even if extensive disassembly is required.
Check piston ring clearance in turbine wheel ring

groove. Check for burrs or foreign matter.
Install inboard retaining rings (Fig. 11 ) using retain-

ing ring assembly tool (JD274). Lubricate bearings
with clean engine oil and insert in place. Install tur-
bine side and compressor side bearing retaining
rings.
Install piston ring on turbine wheel shaft. With tur-

bine wheel shaft upright, guide through the wheel
shroud and bearings. Do not use force to compress
piston ring into place. A gentle rocking and pushing
action will allow the piston ring to seat and the shaft
to bottom. A thin tool, such as a dental pick may be
used as an aid in compressing the ring if difficulty is
encountered.
1-Sprlng 2-Back Plate
Fig. 12-Back Plate Assembly
IMPORTANT: Back plate and spring are sold

only as an assembly. The installed depth of the
spring is a controlled dimension. Therefore, do
not remove or replace the spring by itself. Clean-
ing can be done without removing the spring
from the back plate.
Align mounting holes of center housing and back

plate and install back plate over shaft and thrust col-
lar. Use care not to break piston ring when engaging
seal in back plate bore. Back plate is easily installed
if open end of piston ring is engaged in back plate
bore first.
Install back plate-to-center housing cap screws

T27995N and lock plates. Tighten cap screws and bend ears
1-Sieeve Tool 4-lnner Ring Sleeve (JD274-1) of lock plates against head of cap screw.
2-Retaining Ring 5--Retalning Ring Installed
3-Ring Installer S-Bearing Installed
Install compressor wheel and tighten nut with 18 to
(JD274-3) 7-0uter Ring Sleeve (JD274-2)
20 lbs-in [0.21 to 0.23 kg-m] torque, then tighten
Fig, 11-lnstalling Retaining Rings through an angle of 90°.
Litho in U.S.A.
TM-11 02 (Nov-73) Air Intake System 35-7
Check axial end play and radial movements. If not Tighten the mounting stud nuts, then tighten the
within 0.003 to 0.006 inch [0.076 to 0.152 mm] back plate-to-compressor housing cap screws. Bend
(bearing clearance) or 0.001 to 0.004 inch [0.0254 to the ears of lock plate against head of cap screws.
0.1016 mm] (bearing end play), recheck parts to de-
termine the cause. When installing turbocharger exhaust adapter and
exhaust elbow be certain that the installation does
Check clearance between wheel shroud and tur- not apply a force on the turbine housing. The ex-
bine wheel. haust adapter must have 1I 16 inch [ 1.58 mm] mini-
mum end play and rotate freely.
Install compressor housing on center housing. On-
ly hand tighten cap screws until turbocharger has Inspect the air cleaner-to-turbocharger hoses to
been mounted. see that they are in good condition. If they are not,
replace with new ones. Install air intake pipe, and
Orient turbine housing to center housing. Coat bolt tighten hose clamps securely.
threads with a high temperature, anti-seizing com-
pound. Install bolts, clamps, and lock plates. Tighten IMPORTANT: Since the greatest amount of
bolts with 100 to 130 lbs-in [1.15 to 1.50 kg-m] suction occurs between the air cleaner and tur-
torque, and bend ears of lock plates against head of bocharger, it is essential that the hose connec-
cap screw. tions are tight to prevent entry of dirt into the
engine.
After assembly, push the rotating assembly as far
away as possible from the turbine end and check for Connect wiring to restriction indicator switch.
binding. Repeat check, pushing from the compressor
end. Connect the lubricating oil inlet manifold and return
pipe to the turbocharger, using new gaskets.
Installation
When starting engine with a new or repaired turbo-
Just prior to mounting the turbocharger, prime the
charger, hold the engine shut-off knob out and crank
turbocharger lubrication system. Fill the center hous-
the engine with the starter until the engine oil pres-
ing with engine oil through the oil drain hole. Turn
sure indicator light goes out. Start and run engine at
the rotating assembly by hand to lubricate the bear-
low idle while checking oil inlet and air passage con-
ings and thrust washer.
nections for leaks.
Install turbocharger on engine, and install new rub-
Install all parts removed.
ber 0-rings on coupler (turbocharger-to-intake mani-
fold). Use a new mounting gasket.
Check alignment of compressor housing to intake

manifold. If necessary, rotate compressor housing so
manifold coupling is radially centered in compressor
housing and intake manifold.
Litho in U.S.A.
Litho in U.S.A.
Crawler - JD450- C Engine 20
TM-1 102 (Nov- 73) Specifications and Special Tools 40-1
Group 40
SPECIFICATIONS AND SPECIAL TOOLS
ENGINE REMOVAL AND INSTALLATION
SPECIFICATIONS AND TORQUE VALUES
Engine to clutch housing

cap screw torque ....................................... 250 lb-ft
[34.56 kg-m)
Fig. 1-Engine to Clutch Housing Cap Screws
Litho in U.S.A.
40-2 Specifications and Special Tools TM-1102 (Nov-73)
ENGINE REMOVAL AND INSTALLATION

SPECIAL TOOLS
Convenience Tools
Tool Tool Number Use
JDG-1 * Engine Lifting Sling - To remove

engine.
Fig. 2-Engine Lifting Sling
JD244* Lifting Eyes - Used with JDG-1 for

removing engine.
Fig. 3-Lifting Eyes
*Order from: Service Tools, Inc.

1901 Indiana Ave.
Chicago, Illinois 60616
Litho in U.S.A.
Crawler - JD450-C . Engine 20
TM- 1102 (Nov- 73) Specifications and Special Tools 40-3
BASIC ENGINE
1 - Angle of valve seat ........... ............................. .45°

- 0.--
, - - -1 I - --
~---T""r1
- 1I 2 - Width of valve seat... ...........0.0781 to 0.937 in.
I I
[ 1.984 to 2.380 mm]
3 - Distance closed valve to head deck

(a) intake... ........... ................... 0.023 to 0.046 in.
[0.584 to 1.194 mm]
(b) exhaust... ........................... 0.038 to 0.072 in.
[0.965 to 1.854 mm]
4 - I.D. of valve guide ............. 0.3745 to 0.3755 in.

[9.512 to 9.538 mm]
Valve stem to guide
clearance ............................. 0.0020 to 0.0040 in.
[0.05 1 to 0.102 mm]
Wear tolerance .................................... 0.0020 in.
[0.051 mm]
Fig. 4-Cyfinder Head
- Angle of valve face

(a) intake .... ................................................... 43.5°
(b) exhaust. ...................... ................................ 44°
2 - 0.0. of valve head

(a) intake ...................... ....... 1.7670 to 1.7770 in.
[44.8818 to 45.1358 mm]
(b) exhaust... ....................... 1.5700 to 1.5800 in.
[39.878 to 40.132 mm]
3 - 0.0. of valve stem .............0.3715 to 0.3725 in.

[9.436 to 0.462 mm]
Oversize valves
available ............... .... 0.003, 0.015 and 0.030 in.
[0.076, 0.381 and 0.762 mm]
T2758211
Fig. 5-Valve
Litho in U.S.A.
BASIC ENGINE
SPECIFICATIONS AND TORQUE VALUEs-Continued
- O.D. of rocker arm shaft ... 0.7869 to 0.7879 in.

[ 19.987 to 20.013 mm]
Additional wear tolerance ................... 0.0020 in.
[0.0508 mm]
2 - Rocker arm shaft clamp to head

cap screw torque ............ .. ....................... 55 lb-ft
[7.60 kg-m]
T2758 4N
Fig. 6-Rocker Arm Shaft and Clamp
- Valve clearance
(a) exhaust... ........ .................................. 0.018 in.
[0.46 mm]
(b) intake ................................................ 0.014 in.
[0.35 mm]
5
l 2 - I.D. of rocker arm bore ..... 0.7900 to 0.7920 in.
[20.066 to 20.11 7 mm]
Additional wear tolerance ................... 0.0020 in.
[0.0508 mm]
3 - Valve spring length (valve open) at 131 ·to 152

lb. [60.32 to 68.94 kg] .............. .. ........... 1.36 in.
[34.54 mm]
TJ1J66N
Fig. 7- Valve Spring and Rocker Arm

n 4 - Valve spring length (valve closed) at 54 to 62 lb.
[24.50 to 28.12 kg] ................................. 1.81 in.
[45.97 mm]
Valve spring free length ................... ...... 2.12 in.

[53.8 mm]
5 - Valve lift
(a) exhaust.. ....................... ..... 0.456 to 0.482 in.
[11 .582 to 12.243 mm]
(b) intake ................................. 0.460 to 0.490 in.
[ 11.684 to 12.446 mm]
Litho in U.S.A.
TM- 11 02 (Nov-73) Specifications and Special Tools 40-5
BASIC ENGINE
SPECIFICATIONS AND TORQUE VALUES-Continued
- Rocker arm cover to cylinder head
cap screw torque .. .................................. 25 Ib-in
[0.288 kg-m]
2 - Cylinder head to block

cap screw torque ................................... 110 lb-ft
[1 5.2 kg-m]
Fig. B-Rocker Arm Cover and Cylinder Head After 30 minutes run at 3/4 to full load, loosen
one bolt 5 to 10 degrees and retighten to 11 0 lb-
ft [ 15.2 kg-m], repeat for each bolt.
3 - Maximum amount of material to be removed

from bottom of head ............ ............... .. 0.030 in.
[0.762 mm]
- O.D. of camshaft journal .. .2.1997 to 2.2207 in.

[55.773 to 55.899 mm]
Camshaft journal to bushing
clearance ......................... .... 0.0035 to 0.0055 in.
[0.0889 to 0.1397 mm]
Maximum allowable clearance ............ 0.0090 in.
[0.2286 mm]
2 - Camshaft end play ............. 0.0025 to 0.0085 in.

[0 .064 to 0.216 mm]
Maximum end play.............................. 0.0150 in.
[0.38 1 mm]
3 - Camshaft thrust plate to block

cap screw torque ..................................... 35 lb-ft
T31941N
[4.839 kg-m)
Fig. 9-Camshaft Bushing and Gear
4 - Camshaft gear to camshaft
cap screw torque .. ................................... 85 lb-ft
[11.75 kg-ml
5 - Thrust plate thickness ........ 0.1560 to 0.1580 in.

[3.988 to 4.013 mm)
Minimum thickness .............................. 0.1510 in.
[2.821 mm]
Litho in U.S.A.
40-6 Specifications and Special Tools TM-11 02 (Nov-73)
BASIC ENGINE
1 - 1.0. of piston pin bushing

in rod ................................... 1.3760 to 1.3770 in.
[34.950 to 34.976 mm]
Piston pin to connecting rod bushing
clearance ............................. 0.0008 to 0.0022 in.
.; 'y
[0.0176 to 0.0533 mm]
·~ ~ ' .. ··~
-. .....
2 - 1. 0 . connecting rod bearing
(assembled) ......................... 2. 7502 to 2.7522 in.
[68.865 to 69.906 mm]
Connecting rod bearing to
journal clearance ................ 0.0012 to 0.0042 in.
[0.0350 to 0 .1 067 mm]
Connecting rod undersize bearing inserts
available ............. 0.002, 0.01 0, 0.020 and 0.030
[0.05, 0.25, 0.51 and 0.76 mm]
3 - Connecting rod cap to rod

cap screw torque .................... [8.3 to 9 .7 kg-m]
Fig. tO-Connecting Rod
1 - Liner height above block ....... 0.001 to 0.004 in.

[0.025 to 0.102 mm]
2 - Piston to cylinder liner clearance at bottom

of skirt (max) ......................................... 0.006 in.
[0.15 mm]
Liner out-of-roundness
r - - - - - --,
I I
(max.) .......................... ......................... 0.0020 in.
I [0.05 mm]
I Liner taper (max.) ............................... 0.0020 in.
I [0.05 mm]
I I
I
L ___ __ __ JI
T31574N
Rg. 11-Pislon, Liner and Block
Litho in U.S.A.
BASIC ENGINE
Piston cooling orifices in main bearing web

torque ..............................................85 to 110 lb-in.
[0.98 to 1.27 kg-m]
Fig. 12-Piston Cooling Orifice
1 - Bushing inside diameter.. 1.5002 to 1.5040 inch

[38.151 to 38.202 mm]
2 - Shaft journals outside
diameter ........................... 1.4995 to 1.5005 inch
[38.087 to 38.113 mm]
3 - Thrust plate thickness ..... 0. 1170 to 0.1190 inch
[2.972 to 3.033 mm]
4 - Thrust plate to engine front plate cap
screw torque ........................................ ..... 35 lb-ft
[4.84 kg-m]
Idler gear flush with end of shaft
Fig. t3-Balancer Shafts within ............. ... .. ................................0.0010 inch
[0.0254 mm]
Litho in U.S.A.
40·8 Specifications and Special Toots TM- 1102 (Nov-73)
BASIC ENGINE
1 - Flywheel to crankshaft
[ 11.8 kg-m]
2 - Crankshaft rear oil seal to
housing runout... .................................. 0.0060 in.
[0.1 52 mm]
3 - O.D. main bearing
journal. ................................. 3.1230 to 3.1 240 in.
[79.32 to 79.35 mm]
Round within ........................................ 0.0030 in.
Fig. 14-Crankshaft Assembly [0.0762 mm]
4 - Crankshaft end play ........... 0.0020 to 0.0080 in.
[0.051 to 0.203 mm]
Maximum end play ..................... ........... 0.1 50 in.
[3.810 mm]
5 - Fan pulley to crankshaft
cap screw torque ...... ............................... 85 lb-ft
[11 .75 kg-m]
6 - I.D. of connecting rod
journal... ............................... 2.7480 to 2.7490 in.
[69.80 to 69.82 mm]
Round within .................... .................... 0.0030 in.
[0.0762 mm]
7 - Main bearing I.D.
(assembled) ......................... 3.1256 to 3.1276 in.
[79.391 to 79.441 mm]
Main bearing to journal
clearance ............................. 0.0016 to 0.0046 in.
[0.0406 to 0.11 68 mm]
Maximum clearance ............................ 0.0060 in.
[0. 1524 mm]
Journal taper per inch of
journal length .................................. ..... 0.0010 in.
[0.0254 mm]
Journal out-of-round ............................ 0.0030 in.
[0.0762 mm]
Main bearing undersize inserts
available .. ..... 0.002, 0.010, 0.020 and 0.030 in.
[0.05, 0.25, 0.51 and 0.76 mm]
8 - Main bearing caps to block
[ 11 .75 kg-m]
Litho in USA.
TM-11 02 (Nov-73) Specifications and Special Tools 40-9
BASIC ENGINE
SPECIFICATIONS AND TORQUE VALUE5-Continued
- Distance of front oil seal from front of

timing gear cover .................................... 0 .33 in.
[8.3 mm]
'l'2759UI
Fig. 15-Front Oil Seal Installed in
Timing Gear Cover
1 - O.D. of idler shaft .. .. .......... 1.7495 to 1.7505 in.

[44.437 to 44.463 mm]
2 - Idler shaft end play ............ 0.0010 to 0.0070 in.
[0.0254 to 0.118 mm ]
3- 1.0. idler bushing ................ 1.7520 to 1.7530 in.
(44.501 to 44.526 mm]
Oil clearance between shaft
and bushing ....................... . 0.0015 to 0.0035 in.
[0.0381 to 0.0891 mm]
Fig. t 6-Upper and Lower Idler Gears Maximum oil clearance ....................... 0.0060 in.
[0.1524 mm]
4 - Crankshaft upper idler gear
cap screw torque .......... ........................... 65 lb-ft
[8.99 kg-mJ
5 - Width of idler gears
at hub.................................. O.B650 to 0.8670 in.
[21.971 to 22.022 mm]
6 - Crankshaft lower idler gear
cap screw torque ......... ............................ 95 lb-ft
[13.134 kg-m]
7 - Width of idler gear
shaft... .................................. 0.8680 to 0.8720 in.
[22.047 to 22.149 mm]
Litho in U.S.A.
BASIC ENGINE
1 - Camshaft gear to upper
idler.. ..................... ........... . 0 .0028 to 0 .0135 inch
[0 .07 11 to 0.3429 mm]
2 - Injection pump gear to upper
idler. ...... .......... ......... ......... 0 .0028 tp 0.0135 inch
[0.0711 to 0 .3429 mm]
3 - Crankshaft gear to upper
idler. ............................ ...... 0 .0027 to 0.0 116 inch
[0.0686 to 0 .2946 mm)
4 - Crankshaft gear to lower
idler. ......... ......................... 0 .0027 to 0.0137 inch
[0.0686 to 0.3480 mm]
5 - Oil pump gear to left balancer
gear ........ .......................... 0.0020 to 0.0140 inch
[0.0508 to 0.3556 mm )
6 - Oil pump gear to lower
idler. ................. . .............. . 0.0027 to 0.0137 inch
[0.0686 to 0.3480 mm]
7 - Lower idler to right balancer
gear .................................. 0.0018 to 0.0 156 inch
[0.0457 to 0.3962 mm]
Fig. t 7-Gear Train Backlash
Litho in U.S.A.
BASIC ENGINE
ENGINE BREAK-IN
NOTE: Whenever possible, use a dynamometer to provide a more accurate break-in, assuring proper initial
seating of new piston rings.
Time Load* Engine Speed Remarks
10 Minutes No Load 800 rpm (Slow Idle) Check oil
10 Minutes No Load 1500 to 2000 rpm (1 /2 Throttle) pressure,
20 Minutes 1/4 Load 1900 to 2200 rpm coolant
30 Minutes 1/2 Load (3/4 Throttle) temperature,
30 Minutes 1/2 to 3/4 Load (use PTO stop and leakage.
30 Minutes** 3/4 to Full Load position if
100 Hours + All Loads so equipped) Field Only
*Loads can be simulated in the field by controlled machine operation.
**After this run, loosen cylinder head bolts 5 to 10 degrees; then retighten bolts one at a time, in sequence, to
110 lb-ft [15.2 kg-m]. Check and reset valve clearance.
+After break-in, drain crankcase oil, and remove filter. Install new filter and fill crankcase with oil of proper vis-
cosity and service classification.
Litho in U.S.A.
BASIC ENGINE
SPECIAL TOOLS
Essential Tools
('----~~:_ _ Jr.«-~{) 813 and 815* Mandrels - Used with bushing and
seal drivers.
( -~~~:-~
'---
[ -----;;~()- T 31578N
Fig. 18-Mandrels
1002** Knurling Tool - To knurl engine

valve guides.
.;._:. _., .;.·
"•J·~··-- , .· .'•
··<·-·". l&:,~t~92!r'
Fig. 19-Knurling Tool
JDE-62* Ring Groove Wear Gauge - To

measure keystone ring groove
wear.
Fig. 20-Keystone Ring Groove Wear Gauge

1901 Indiana Ave.
**Available from: United Tool Processes Corporation

Box 914
Litho in U.S.A.
New Cannon, Connecticut 06840
TM-1102 (Nov-73) Specifications and Special Toots 40-1 3
BASIC ENGINE
SPECIAL TOOLS- Continued
Essential Tools- Cont.
JDE45* Piston Ring Expander - To install

piston rings.
T2760J N
Fig. 21-Piston Ring Expander
JD271 * Piston Ring Compressor - To

compress piston rings when in-
stalling pistons.
F"tg. 22-Ring Compressor
JD-248* Oil Pressure Regulating Valve

Bushing Driver - To install oil
pressure regulating valve bushing.
1'3 1 580lV
Fig. 23-Driver
JD-250* Front Crankshaft Oil Seal Driver -

To install front crankshaft oil seal.
T31S81N
Fig. 24-Driver
* Order from: Service Tools, Inc.

1901 Indiana Ave.
Litho in U.S.A.
BASIC ENGINE
SPECIAL TOOLS-Continued
Essential Tools-Cont.
JD-251 * Rear Crankshaft Oil Seal Driver -

To install rear crankshaft oil seal.
Fig. 25-Driver
JD-251-5* Rear Crankshaft Oil Seal Installa-

tion Set - Includes JD-251-3 Pilot
Ring and JD-251-4 Seal Protec-
tor, used with JD-251 to install
rear crankshaft oil seal.
Fig. 26-Driver
JD-249* Balancer Shaft Bushing Driver -

To install balancer shaft bushings.
T3 11J44N
Fig. 27-Driver
JD-255* Balancer Shaft Bearing Staking

Tool - to install balancer shaft
bushing.
T$19 45/V
Fig. 28-Staking Tool

1901 Indiana Ave.
Litho in U.S.A.
TM- 11 02 (Nov-73) Specifications and Special Tools 40-15
BASIC ENGINE
Essential Tools- Cont.
JD-247* Balancer Shaft Holding Tool - To

hold balancer shaft when installing
drive gear.
TJ 1946N
Fig. 29-Ho/ding Tool
JD-252* Idler Gear Bushing Driver - To in-

stall idler gear bushing.
T31S84N
Fig. 30-Driver
JD-254* Gear Timing Tool - To time gear

train.
TJ1585N
Fig. 31-Gear Timing Tool

1901 Indiana Ave.
Chicago, Illinois
Litho in U.S. A.
40-16 Specifications and Special Tools TM-11 02 (Nov- 73)
BASIC ENGINE
SPECIAL TOOLs-Continued
Convenience Tools
ND-425** Magnetic Tool - To hold cam fol-

lowers.
T27597 fl
Fig. 32-Magnetic Holding Tool
974-A/ 974* Cylinder Liner Puller - To remove

cylinder liners.
Fig. 33-Cylinder Liner Pvller

1901 Indiana Ave.
**Available from : Nuday Tool Co.

14615 Wyoming Ave.
Detroit, Michigan 48238
Litho in U.S.A.

1 - Oil pump to block cap screw

torque ............................... ......................... 35 lb-ft
[4.8 kg-m)
2 - O.D. of drive gear shaft .... 0.6308 to 0.6312 in.

[ 16.022 to 16.032 mm)
3 - Oil pump gear to drive shaft

nut torque ............ ........... ... .......... .. 35 to 45 lb-ft
[4.8 to 6.2 kg-m]
Fig. 34-Engine Oil Pump Assembly
4 - Pump gears to cover
clearance .... ........... .............. 0.0012 to 0 .0062 in.
[0.0305 to 0.1575 mm]
5 - O.D. of idler shaft .............. 0.4850 to 0.4856 in.

[12.319 to 12.334 mm]
6 - Oil pump gear width .......... 1.6203 to 1.6223 in.

[41. 1556 to 41.2064 mm)
7 - Pump gears-to-housing
radial clearance ........... ..... .. 0.0030 to 0.0040 in.
[0.076 to 0.102 mm]
- Oil pressure regulating valve plug

torque .. .................................................... .. 80 lb-ft
[11.06 kg-m]
2 - Oil pressure regulating valve spring

free length (approximately) ..................... 4.68 in.
[118 .872 mm]
3 - Oil pressure regulating valve spring compressed

at 15 ± 1 lb. [6.8 ± 0 .45 kg) ......... ..... 1.68 in.
[42.66 mm]
Fig. 35-0il Pressure Regulating Valve
Litho in U.S.A.
40.-18 Specifications and Special Tools TM- 1102 (Nov-73)

SPECIFICATIONS AND TORQUE VALUES-Continued; SPECIAL TOOLS
1 - Oil pan to block cap screw torque

1/2 inch [12.7 mm] ................................. 85 lb-ft
[11 .8 kg-m]
2 - Oil pan to block cap screw torque
3/8 inch [9.5 mm] ................................... 35 lb-ft
[4.8 kg-m]
Fig. 36-0il Pan
SPECIAL TOOLS
Essential Tools
JD-248* Oil Pressure Regulating Valve

Bushing Driver - To install pres-
sure regulating valve bushing.
TJ1580N
Fig. 37-0river

1901 Indiana Ave.
Litho in U.S.A.
TM-1102 (Nov-73) Specifications and Special Tools 40-19

Radiator test pressure ...................................... 10 psi

[0. 70 kg/ cm2 ]
Radiator cap test pressure .............. 6.25 to 7.50 psi

[0.44 to 0.53 kg/ cm2 ]
Thermostat opening temperature .. ................... 180°F.

[82.2°C.]
- 0.0. of water pump shaft end

pressed into impeller .......... 0.6262 to 0.6267 in.
(15.905 to 15.918 mm]
Fig. 38-Water Pump Shaft and Impeller
2 - 1.0. of water pump impeller
bore ................................. .... 0.6242 to 0.6252 in.
( 15.854 to 15.880 mm]
- Water pump rear cover

cap screw torque ........................ .......... .... 35 lb-ft
[ 4.8 kg-m]
2 - Fan surface on pulley to

rear of water pump housing .. ............ ..... 5.71 in.
[145.03 mm)
3 - Water pump impeller flush to housing

within .. ....................................................... 0.10 in.
[0.25 mm]
Fig. 39-Water Pump
Litho in U.S.A.

SPECIAL TOOLS
Convenience Tool
JD-262-A* Water Pump Bearing Installation
( Tool - To install water pump bear-

ing.
T31591N
Fig. 40-Bearing Installation Tool
1901 Indiana Ave.
Chicago, 1/finois 606 16
FUEL SYSTEM
Fuel tank capacity .................................... 31 gal.
[1 17.3 I]
1 - Fuel injection pump drive shaft tang

thickness (Minimum) .............................. 0.305 in.
[7.747 mm]
T3 1592N
Fig. 41- lnjection Pump Drive Shaft
Tang Thickness
1 - Drive shaft hex. nut torque ................... .45 lb-ft.

[6.2 kg-m]
2 - Fuel inlet screw torque ......... ..................20 lb-ft.
[2.8 kg-m]
3 - Throttle control lock screw
torque ............................................35 to 40 Ib-in.
[0 .430 to 0.450 kg-m]
4 - Injection line connector screw
torque ....................................................... 35 ft-lb.
[4.8 kg-m]
Ag. 42-lnjection Pump and Nozzles 5 - Timing hole cover screw-torque .. 15 to 20 lb-in.
[0.1 73 to 0.23 kg-m]
6 - Injection nozzle hold down cap screw
torque ....................................................... 20 lb-ft.
[2.8 kg-m]
Litho in U. S.A.
FUEL SYSTEM
SPECIAL TOOLS
Essential Tools
13369* Installation Tool - To install injec-

(Not Illustrated) tion pump drive shaft seal.
Convenience Tool JD-256* Injection Pump Drive Shaft Seal

Installation Tool - To install drive
shaft seal.
T31599N
Fig. 43-0rive Shaft Seal Installation Tool
* Order from : Service Tools, Inc.

1901 Indiana Ave.
SPEED CONTROL LINKAGE

See Group 35, Section 70 for speed control linkage specifications and special tools.
Litho in U.S.A.
AIR INTAKE SYSTEM

- Exhaust adapter minimum

end play ................................ 1/32 in. [0.79 mm)
Fig. 44- Exhaust Adapter
1 - Radial bearing movement.. ................... 0.003 in.

[0.076 mm] to 0.006 in. [0.152 mmJ.
2 - Rotating assembly axial end
l
play .................................... 0.001 in. [0.025 mmJ
to 0.004 in. [0.1 02 mm].
3 - Impeller nut torque ....................... 18 to 20 lb-in.
[0.21 to 0.23 kg-m].
4 - Lock plate bolts torque ............... .40 to 60 lb-in.
[0.46 to 0.69 kg-m).
5 - Turbo housing to center housing nut
torque ............................................. 100-130 lb-in.
[ 1.15 to 1.50 kg- m).
T2?628N 4
Fig. 45-AiResearch Turbocharger
Litho in U.S.A.
AIR INTAKE SYSTEM

SPECIAL TOOLS
Essential Tools
JD-274* Turbocharger Snap Ring Assem-

bly Tools - To install the turbine
shaft bearing snap rings in the
body of the AiResearch turbo-
charger.
J D-274- 1 JD-274-2 J 0 -274 - 3
T276 29 N
Fig. 46-Snap Ring Assembly Tools
*Order from: Service Tools, Inc.,

1901 Indiana Avenue,
Chicago, Illinois 60616.
Litho in U.S.A.
AIR INTAKE SYSTEM

SPECIAL TOOLs-Continued
Convenience Tools
;:: I I ,, II I I II I ,.
I 1 11 1 *---- Turbine Wheel Holding Fixture ·
hi II "III I II ' I I
I
I II I
I
I l r:: To hold turbocharger during disas
_jJI II
" I
I I
sembly
I I
I
I
I I
I
I
l I
I~
I· ·-- 6
T276Jlll
1-3/4" [19.0 mm] 7-2-1/2" [63.50 mm]

2- 3/4" [19.0 mmJ 8--2-3/4" [69.9 mm]
3-3/4'' 119.0 mml 9-3/8" [9.5 mml
4-Bore to Clear Diameter, 11 Places
Wheel Hub Equally Spaced
5---6-1/2" [165.1 mm'l 10--1" (25.4 mmJ
6-6-1/2" [165.1 mml
Material: Hardwood or Aluminum

Fig. 47-Turbine Wheel Holding Fixture
*Make in dealers shop.

Litho in U.S.A.
Crawler - JD450-C Electrical System 30
TM-11 02 (Nov-73) Batteries 5-1
Section 30
ELECTRICAL SYSTEM
Page Page
GROUP 5 - BATTERIES GROUP 20 - GAUGES AND SWITCHES
General Information ............................................ 5-2 General Information .......................................... 20-1
Precautions ..........................................................5-2 Instrument Panel Removal ............................... 20-3
Removal ...............................................................5-3 Gauge and Switch Removal ............................ 20-3
Inspection .............................................................5-3 Instrument Panel Installation ............................ 20-3
Testing .................................................................5-3 Gauge and Switch Installation ......................... 20-3
Charging the Batteries ........................................ 5-5
Installation ............................................................5-6 GROUP 25 - SPECIFICATIONS AND
SPECIAL TOOLS
GROUP 10 - CHARGING SYSTEM Batteries .............................................................25-1
General Information .......................................... 10-1 Charging System ............................................... 25-2
Removal ............................................................. 10-2 Starting System .................................................25-6
Disassembly ....................................................... 10-2 Gauges and Switches ......................................25-9
Alternator Component Tests ............................ 10-6
Assembly ........................................................... 10-8
Test After Assembly ....................................... 10-1 0
Installation ........................................................ 10-1 0
GROUP 15 - STARTING SYSTEM

General Information .......................................... 15-1
Removal ............................................................. 15-2
Testing and Diagnosis ...................................... 15-2
Repair ................................................................ 15-3
Assembly ........................................................... 15-7
Installation .......................................................... 15-9
Litho in U.S.A.
30 Electrical System Crawler - JD450-C
5-2 Batteries TM-1102 (Nov-73)
Group 5
BATTERIES
GENERAL INFORMATION Second , be sure the battery is kept nearly charged
at all times. The state of charge should be checked
at frequent intervals by making specific gravity read-
ings with a battery hydrometer. See "Specific Gravity
Cell Comparison Test" in this group.
For additional information on batteries, refer
El a
to " Storage Batteries" in FOS Manual-
ELECTRICAL SYSTEM.
Precautions
h CAUTION: All exposed metal surfaces on
. . batteries are "alive." Never lay a metal
object on top of a battery as a short circuit may
result. Sparks or an open flame must be kept
away from batteries due to the presence of ex-
plosive gas in and around the batteries while
1- Ground Cable 3-Connectlng Cable they are being charged or in use.
2-Positive Cable 4-Ground Cable
BATTERY ACID IS HARMFUL ON CONTACT with
Fig. 1-Battery Connections
the skin or materials. If acid spills, here are some
Batteries are located under the left-hand arm rest. first aid tips to minimize the damage:
To gain access to the batteries, lift up the battery box
door and remove tool box and tool box tray. 1. Remove immediately any clothing on which acid
spills.
When replacing a battery, use the John Deere bat-
tery or its equivalent shown in the following chart: 2. If acid contacts the skin, rinse the affected area
with running water for 10 to 15 minutes.
Volts .... .......... ..................... ........... ............................ 12
John Deere Part Number ............................ AT29160 3. If acid ever splashes into the eyes, force the
BCI Group .......................................................... ... 30H lids open and flood the eyes with running water for
Cold Cranking Amps (0°F.) [ 17.8°C.] .. ................ 570 10 to 15 minutes. Then see a doctor at once. Don't
(-20°F.) [ -28.9°C.) .. ... ... ...... .. 450 use any medication or eye drops unless prescribed
Reserve Capacity (minutes at 25 amps) ...... ...... 180 by the doctor.
There are two important things that must be done 4. To neutralize acid spilled on the floor, use one
periodically in order to obtain long life from a battery. of the following mixtures:
First, the elect rolyte must at all times be kept a. One pound of baking soda in a gallon of water.
above the plates and separators. The electrolyte lev-
el should be checked o nce a week, or after fifty b. One pint of household ammonia in a gallon of
hours of operation. See "Checking Electrolyte Level" water.
in this group.
5. Acid from the batteries can also damage the
paint and metal surfaces of the machine. Avoid over-
filling the battery cells and protect the battery when
necessary.
Litho in U.S.A.
TM- 11 02 (Nov-73) Batteries 5 -3
REMOVAL Always wait until after checking specific gravity be-

fore you add water to the battery. This will assure a
Remove batteries as follows:
true reading. If level is too low to check specific grav-
ity, add water, operate engine for a few minutes to
1. Lift up battery box door and remove tool box
let water and electrolyte mix, then check.
and tool box tray.
In freezing weather, never add water to the battery
2. Note carefully the location of the positive ( + )
unless it will be operated immediately to allow proper
terminals so that the batteries are installed in the
mixing of water with electrolyte.
same way.
TESTING
3. Disconnect the ground cables (1 and 4) first.
Use only a box end wrench to loosen clamps on ter- Testing the battery will tell you whether the battery
minals. Remove clamps, using a screw-type puller. is usable , requires recharging , or should be replaced.
DO NOT hammer on the battery posts. Regular periodic testing provides a means of antici-
pating battery failure.
4. Remove the connecting cable (3) and positive
cable (2). Specific Gravity Cell Comparison Test
5. Remove the battery clamps and the batteries.
6. Check cables for worn or frayed insulation. Re-

place cable clamps or bolts if corroded.
INSPECTION ____ HOLD HYDROMETER

VERTICALLY STRAIGHT
Cleaning Batteries
Wipe batteries with a damp cloth. If terminals are - - 'TAKE READING
AT EYE LEVEL
corroded, use a stiff brush and wash with an ammo-
L ! ! o - - -FLOAT MUST
nia solution or a solution of baking soda (1/ 4 pound BE FREE
added to a quart of water). Keep vent plugs tight
while washing. After washing, flush battery and com-
partment with clear water. Then coat terminals with
petroleum jelly to protect against corrosion. Be sure
vent holes in vent plugs are open.
Checking Electrolyte Level T31402N
Check electrolyte level in each cell. Proper level is Fig. 2-Checking Specific Gravity
to bottom of filler neck. Always add distilled water if
available. If not, use clean soft water. Avoid hard Check the specific gravity of each cell with an ac-
water. curate hydrometer equipped with a thermometer.
Hold the hydrometer vertically and take the reading
NEVER A DD ACID TO THE BATTERY unless at eye level.
electrolyte is lost by spilling.
Litho in U.S.A.
5-4 Batteries TM-1102 (Nov-73)
Specific Gravity
Reading (Adjusted) State of Charge
160 GRAVITY POINTS
TEMPERATURE IN
° F Of ELECTROLYTE 1SO TO ADD OR
140 t--==:t--1 SUBTRACT 1.260 100%
130 t--==:t--1 FROM READING 1.230 75%
120 r.i=~-1 1.200 50%
110 ~~_,
1.170 25%
100 +8
+4
1.140 Very Little Useful Capacity
90
0 1.110 Discharged
-4
-8 The table above shows the state of charge of a
- 12
typical battery at various specific gravity readings.
- 24 High-Rate Discharge Test

-28
-32
To be sure of a battery's ability to deliver current
under load, give it a high-rate discharge test. This
test shows the internal conditions that might not oth-
erwise be detected.
T3140ZN
Fig. 3-Correcting Specific GravUy The following conditions must exist before this test
Readings to Allow for Temperatures
is made:
True readings are taken at 80°F. [26.7°C:) only. To
1. Battery specific gravity must not be less than
correct a reading, add four gravity points (0.004) for
1.215 at 80°F. [26.rC.]. Otherwise, erratic or unreli-
every 10°F. [ - 12.2°C.] that the electrolyte tempera-
able readings will result.
ture is above 80°F. [26.rC.]. Subtract four gravity
points (0.004) for every 10°F. [ -12.2°C.] that the
2. Battery electrolyte temperature must be be-
electrolyte is below 80°F. [26.7°C.]. A hydrometer
tween 70°F. [21 YC.] and 90°F. [32.2°C.].
reading of 1.260 at 0°F. [ - 17.8°C.] is corrected to
1.228.
Specific gravity should read from 1.215 to 1.270

(corrected for 80°F. [26.7°C.J electrolyte tempera-
ture).
The variation in readings between cells should be

no more than 50 specific gravity points (0.050).
If specific gravity readings show a difference be-

tween the highest and lowest cell of more than 50
specific gravity points (0.050) or more, the battery is
defective and must be replaced.
If the maximum difference between all readings is T 33000N
less than 50 specific gravity points (0.050) and the

Fig. 4-High-Rate Discharge Battery
lowest cell reading is 1.200 or above, the battery is Tester Connected to Battery
in good condition and may be returned to service.
Connect the high-rate discharge tester to the bat-
If the maximum difference between all readings is tery and be sure to follow the manufacturer's instruc-
less than 50 specific gravity points (0.050) but the tions (Fig. 4).
lowest cell reading is below 1.200, the battery is
good but needs to be charged by the slow method.
Litho in U.S.A.
TM-1102 (Nov-73) Batteries 5-5
The terminal voltage reading should remain above A battery that becomes sulfated, however, will not
9.0 volts. accept a high rate of charging current without possi-
ble damage. Its sulfated condition provides increased
If the terminal voltage falls below 9.0 volts, the bat- resistance to current flow within the battery. Flow of
tery is defective or it is not as fully charged as the a high rate of charging creates heat, which can result
specific gravity reading indicates in the specific gravi- in warping of the plates, boiling of electrolyte, and
ty test. eventual damage to the separators. Cell caps and
covers and the battery case may be damaged or
To be sure of the battery condition, carefully distorted.
charge it and repeat the test.
A battery in this condition must be charged over a
Remember these key facts when testing batteries. long period at a low rate. In this manner, sulfate for-
mation on the plates will be gradually broken down
1. In general, if all cells of a battery test the same, and the battery returned to its normal charged state.
the battery is good. If all are low, the battery usually
only needs recharging. NOTE: When charging batteries be sure to follow
the manufacturer's instructions for using the charger.
2. If there is a real difference between cells, the
battery generally must be replaced. For additional information on charging bat-
teries, refer to "Storage Batteries" in FOS
For additional information on "Battery Test- Manual - ELECTRICAL SYSTEM.
E] D
ing" refer to "Storage Batteries" in FOS
Manual ELECTRICAL SYSTEMS.
D
John Deere battery chargers can be used as a

booster to start the engine.
CHARGING THE BATTERY
IMPORTANT: A battery charger should not be
Batteries can be recharged in two ways:
used as a booster if a battery has a very low
charge (1.150 specific gravity reading or lower). A
1. Fast charging.
low charged battery greatly increases the possi-
2. Slow charging.
bility of mistakenly connecting the charger to the
battery in reverse, and it is possible to reverse
A battery that is in satisfactory condition but re-
the charge on a battery. If this is done the alter-
quires recharging will accept a large amount of
charging current without undesirable effect. This type nator diodes or the wire harness may be dam-
of battery may be charged quickly at a high rate with aged.
a battery fast charger.
If the battery has a specific gravity reading of
1.150 or lower, disconnect battery cables and charge
it until the specific gravity reading is 1.150 or above
before using a battery charger as a booster.
Litho in U.S.A.
5-6 Batteries TM-11 02 (Nov-73)
INSTALLATION 5. Check for correct polarity of the battery. Con-

nect the positive cable first. Before connecting the
Install batteries as follows:
ground cable, momentarily touch it against the bat-
tery post. With all switches and accessories off, no
1. Be sure the batteries are fully charged.
spark should occur. If spark does occur, do not con-
nect the ground cable. Check for reversed battery
2. Set batteries in tray making sure batteries are
polarity, improper alternator connection, defective
resting level.
electrical wire connection, or defective electrical
equipment.
3. Tighten the battery clamp nuts evenly until bat-
teries are secure. Do not overtighten as this will dis-
6. Tighten the clamps on the battery terminals.
tort or crack the battery case.
Use a box-end wrench carefully to avoid twisting the
battery terminal posts.
4. Clean the battery terminals and cable clamps
with a wire brush before attaching the clamps. This
will assure a good contact. Coat the terminals with
petroleum jelly to prevent corrosion. Never paint the
terminal posts.
Litho in U.S.A.
TM-11 02 (Nov-73) Charging System 10-1
Group 10
CHARGING SYSTEM
GENERAL INFORMATION The rotor assembly consists of a wire coil wrapped
around an iron core and mounted on a rotating shaft.
The coil is enclosed between two interlocking soft
iron sections. The ends of the coil are connected to
two slip rings mounted on one end of the shaft.
Small brushes ride on the slip rings.
The rotor turns on sealed ball bearings that contain

lubrication for the life of the bearing.
The stator assembly is a laminated soft iron ring

with three groups of coils or windings in the slots.
Each group is made up of from eight to sixteen coils,
depending on the design.
One end of each stator winding is connected to a

positive and negative diode. The other ends of the
stator windings are wye connected.
To convert the a.c . to d.c . cu rrent, diodes are

used. Six diodes are mounted at the slip ring end of
the alternator housing. Three negative diodes are
mounted in the rear housing. Three positive diodes
are mounted in the heat sink which is insulated from
the rear housing .
To understand the diodes, first remember these

two points.
1- Field Terminals 4-0utput Terminal 1. Alternating current flow is produced by the ro-
2-Ground Terminal 5-Stator Terminal
tor-stator combination. That is, during half the rotor
3- Capacitor 6-Wire Lead
revolution, current flow in the stator phases is in one
Fig. 1-A/Iernator direction. In the other half, flow is in opposite direc-
tion.
This alternator is a totally enclosed-type, designed
for dusty or hazardous environments. The alternator 2. Current flow from the alternator output terminal
is not waterproof and should not be submerged. is always the same direction.
Alternator can be divided into three main assem- This means that during each phase of a revolution,
blies: two diodes are used to convert a.c. to d.c. current -
one positive and one negative diode.
1. Rotor Assembly - magnetic field which rotates.
EJ
For additional information on alternators, re-
2. Stator Assembly - conductors which are station- fer to "Charging Circuits" in FOS Manual -
ary. ELECTRICAL SYSTEMS.
Cl
3. Rectifier Assembly - diodes which change a.c.
to d.c. current.
Litho in U.S.A.
10-2 Charging System TM-1102 (Nov-73)
REMOVAL Never hammer or jar the alternator as this may

ruin the diodes.
Disassemble alternator only as far as necessary to

correct the difficulty.
Brushes and Slip Rings

NOTE: It is not necessary to remove the alternator
from the unit to check the brushes.
Remove the brush cover with the black leads at-

tached to it from the brushes.
.
,·
-.
1-0utp ut Terminal 4-Ground Terminal
2-Stator Terminal &-Adjusting Strap
3-Field Terminal &-Mounting Bracket
Fig. 2-AIIemator Wiring and Mounting Bracket

'!'87e30
A CAUTION : Disconnec t battery ground
Fig. 3-Removlng Brush Assembly
. . straps f irst to prevent damage if leads re-
moved from alternator s hould be accidentally Remove the two screws holding brush assembly
grounded. and carefully remove assembly and insulator (Fig. 3).
Remove wires from output {1 ), stator (2), field (3) Replace brush assembly if brushes extend less
and ground (4) terminals. than 1/ 4-inch [6.35 mm] beyond the holder.
l oosen screw from adjusting strap (5) and remove IMPORTANT: If in the process of brush remov-
belt. Remove alternator attaching screw from mount- al the brush cover gasket (3, Fig. 4) should be-
ing bracket (6) and remove alternator. come damaged or torn, it must be replaced and
positioned properly.
DISASSEMBLY
Refer to Fig. 4 during disassembly and assembly. If the insulator which prevents the brush leads
from shorting on the rear housing and grounding the
Never immerse the alternator in cleaning solution. field, should become damaged or torn, it must be
Scrape off dirt and grease, then use a stiff brush and replaced.
solvent Dry with compressed air.
If the brushes are clogged with dust or dirt, clean
them with compressed air. Avoid using any type of
liquid as this increases the possibility of dust or dirt
hardening in the brush cavity and hindering the
movement of the brush.
Litho in U.S.A.
Crawler - J0450-C Electrical System 30
TM- 11 02 (Nov-73) Charging System 10-3
1- Drive Screw (2 used) 16-Lock Washer 31-Negative Rectifying Diode (3 used)

2-Brush Cover 17- Pulley 32-lnsulator (3 used)
3-Brush Cover Gasket 18-Key 33-Bearing Retainer
4---Brush Insulator 19-Spacer 34-Rear Housing
5-Brush and Holder 20---Screw (3 used) 35-Sieeve
~umper Cable 21-Lock Washer (3 used) 36-Washer (2 used)
7-Rectlfying Positive Diode (3 used) 22-Front Housing 37-Washer
8-lnsulator (5 used) 23-Special Washer 38-Nut
9-Bolt (2 used) 24---Gasket 39-Lock Washer
10---Stator 25-Ball Bearing 40---Washer
11-Bolt 26-Bearing Retainer 41-Bolt (4 used)
12- Washer (3 used) 27- Rotor 42-lns ulator
13-Nut (10 used) 28-Ball Bearing 43-Lock Washer
14---Lock Washer (9 used) 29-Positive Diode Plate 44---Capacltor
15-Nut 30---Speclal Bolt (3 used) 45-Lead Wire
Rg. 4-Aiternator
If slip rings are contaminated, clean with a nonpe-

troleum base cleaning solvent. If solvent does not
clean the slip rings, use crocus cloth.
Rear Housing Removal

Remove the four through bolts retaining the front
and rear housings. Using two screwdrivers (Fig. 5),
apply equal pressure to release the rear housing
from the front. Care should be taken that the stator
stays with the rear housing.
IMPORTANT: If housing gasket is damaged, re-

place it at time of assembly.
T676S7
\\\\
Fig. 5-Separating Front and Rear Housings
Litho in U.S.A.
1 0-4 Charging System TM- 11 02 (Nov-73)
Stator Remove the three black leads from the heat sink
screws and push heat sinks out of housing.
NOTE: Three mica insulators are set against the

inside of the rear housing and insulate the positive
heat sink from the housing. DO NOT lose them.
Fig. 6-Removing Stator from Rear Housing

Fig. 8-Removing Defective Positive Diodes
Grasping the stator, apply pressure and separate Using a small punch and A-206 tool (Fig. 8), press
stator from housing (Fig. 6). defective positive diodes out of heat sink.
Remove the stator wires from the terminals in the

rear housing . Note wire connections for assembly.
Diodes
Fig. 9-Removing Defective Negative Diode
Using A-213 tool (Fig . 9) press defective negative

diodes out of the rear housing.
o· IMPORTANT: The rectifying diodes used in this
® application have welded rather than soldered
leads. Do not attempt to use replacement diodes
Pf?.1 t5 0li with soldered leads.
Fig. ?-Removing Positive Diode Heat Sink
Litho in U.S.A
TM- 11 02 (Nov- 73) Charging System 10-5
Fig. 10-tnstalling Positive Diodes
Fig. 12-Pu/ley Removal
Rotor
Remove the three screws and lock washers from
the front housing (Fig. 13). If not already removed ,
remove Woodruff key from rotor shaft.
Fig. 11-lnstalling Negative Diodes
Place a new diode in diode hole. Rotate diode so

serrations on new diode do not line up with the ser-
rations made by original diode; this provides a more
efficient transfer of heat from the diode. Press diode
fully into hole using A-214 tool (Figs. 8 and 9).
Pulley Removal
The pulley is a slip fit on shaft with a Woodruff
key. To remove the nut and lock washer, clamp pul-
Fig. 13-Removing Rotor Retaining Hardware
ley in a vise, using an old oversized belt to protect
the pulley from damage by the vise jaws (Fig. 12).
Alternator should slide out of pulley. If not, a slight
rocking of the alternator body will loosen a tight pul-
ley.
Litho in U.S.A.
1 0-6 Charging System TM -1102 (Nov-73)
Fig. 16-Brush Assembly Test Points

Fig. 14-Pressing Rotor Out of Housing
Resistance should be high (infinite) or test lamp
Usi ng a press Fig. 14, press rotor out of front should not light. If resistance is low, or test lamp
housing. lights, brush assembly is shorted and must be re-
placed.
2. Continuity Test: Connect an ohmmeter or a test

lamp to field terminal and brush (test points A to B
and C to D). Use an alligator clip to assure good
contact to brush. IMPORTANT: Do not chip brush.
Resistance read ing should be zero or test light
shou ld light. Move brush and brush lead wire to
make certain that the brush lead wire connections
are not intermittent. Resistance reading should not
vary when brush and lead wire are being moved
around.
Fig. 15-Removing Rotor Bearings Rectifier Diode Test

Bearings are sealed and cannot be lubricated. Re- If a commercial alternator rectifier diode tester is
move the bearings using A-216 Puller and Adapter available, follow manufacturers instructions to test all
(Fig. 15). diodes. Do not use 120-volt AC test lamp.
ALTERNATOR COMPONENT TESTS A 12-volt battery-operated test lamp may be used

if a commercial tester is not available. Connect one
Make the following tests to locate faulty compo- test lead to diode heat sink (2, Fig. 17), and the oth-
nents prior to assembly. er to each diode wire terminal (1). Then repeat test
w ith test leads reversed. Lamp should light with
Brush Assembly Insulation Test leads in one position, but should not light with test
1. Insulation Test: Connect ohmmeter or a test leads reversed. All diodes in heat sink or rear hous-
lamp (12 volts) to field terminals and bracket (test ing should show the same results.
points E to A and E to C, Fig. 16).
Litho in U.S.A.
TM-11 02 (Nov-73) Charging System 10-7
Resistance reading should be infinite or test lamp

should not light. If resistance reading is not infinite or
test lamp lights, there is an open in the stator wind-
ings. Replace stator.
2. To test tor shorts, connect one ohmmeter or

test lamp probe to the stator windings and the other
test probe to the stator case. Resistance reading
should be infinite or test lamp should not light. If test
lamp lights or there is a resistance reading, a short
exists in the stator. Replace stator.
Rotor Test
. T27639
1- Terminal Screws 2- Heat Sink
Fig. 17-Rectifier Diode Test Points
If lamp lights, regardless of how test leads are

switched , the diode is shorted. If lamp fails to light in
either test, the diode is open. Replace defective
diodes. Observe correct polarity by color of lead wire.
Negative diode has a black lead wire and positive
diode has a red lead wire.
Stator Tests
T 2764l
1- Voltmeter 4-Variable Resistor

2-Aotor Assembly 5-Battery
3-Ammeter
Fig. 19-Rotor Current Draw Test Hook-Up
Test A: Continuity and Current Draw

T his test checks the rotor tor shorted or ope n
windings. Connect voltmeter to the slip rings. Then
connect an ammeter in series with a variable resistor
to the slip ring and 12-volt battery. Set the variable
resistor to maximum resistance. Connect the other
slip ring to the battery and adjust the resistor to ob-
tain full battery voltage.
Fig. 18-Stator Test Points
IMPORTANT: Do not remove the wire from the
An ohmmeter or test lamp may be used to test for slip ring at this time as it will cause an arc, dam-
opens. aging the slip ring surface and requiring cleanup.
1. Connect ohmmeter or test lamp probe to one of

the stator leads (A, B, or C) and connect the other
test probe to each remaining lead.
Litho in U.S.A.
30 Electrical System Crawler - J0450-C
10-8 Charging System TM-1 102 (Nov-73)
Rotor field current draw should equal .55 to 1.5

ampe re at 10.0 volts (70°F . to 80°F. ) [ 158.0° to
176.0°C ].
Shorted windings are indicated by excessive cur-

rent draw; open windings by no current draw at all.
Test B - Checking Field Coil for Leakage or "

Shorts
This test checks the field coil for leakage or shorts
to rotor poles. An ohmmeter or test lamp (12-volt)
may be used .
Fig. 21-lnsta//ing Bearing in Front Housing
Installing Rotor
T27 642
Fig. 20-Test 8 Test Points
Connect ohmmeter or test lamp probes to one of

the slip rings, and to rotor shaft. Ohmmeter resis-
tance should be infinite and test lamp should not
light. If resistance is not infinite or test lamp lights,
leakage or a short exists between the field coil and
rotor.
ASSEMBLY
Installing Front Bearing
Check that bearing cavity in front housing is clean
and that felt dust seal is installed in recess. Press
bearing into housing using A-203 tool (Fig. 21 ). Ap- Fig 22-lnstalling Rotor
ply even pressure only to the outside race of the
bearing. Install bearing retainer and secure with
screws and lock washers. Press assembled front housing onto rotor assem-
bly using A-209 tool (Fig. 22). Support end of rotor
shaft with A-205 tool inside of A-208 tool as illustrat-
ed (Fig. 22).
Litho in U.S.A.
TM-11 02 (Nov- 73) Charging System 10-9
Installing Rear Bearing Assembling Stator To Rear Housing

Check that rear bearing retainer is properly seated
in rear housing. Place stator in rear housing, with
leads extended toward heat sink. Assemble leads to
diode terminal screws. Each screw should hold a
black negative diode lead, a red positive diode lead,
and a lead from the stator. The terminal screw
nearest the stator terminal will also hold the stator
top lead wire. See Fig. 6.
Arrange all leads to prevent accidental contact with

surfaces, through bolts, or the rotor. Align stator slots
with through bolt holes.
Assembling Front and Rear Housing

Place front housing with rotor assembly in a vise,
with the drive end down . Place sealing gasket over
top edge of front housing. Place rear housing and
heat sink assembly over top end of rotor, align bear-
ing cavity, and press housings together.
Fig. 23-/nsta//ing Rear Bearing
Position gasket to align with through bolts and
Support front housing in press using A-208 tooL tighten bolts to 50 to 60 lb-in (0.576 to 0.691 kg-m].
Using A-206 Bearing Driver, press bearing on rotor Spin rotor by hand to check that diode wires are not
shaft up to shoulder. rubbing against rotor.
Install new rear bearing retainer in rear housing . Installing Brush Assembly
Place insulator over brush assembly. Slide assem-
Installing Diode Heat Sink bly into brush cavity and position with alignment pins.
Coat the three mica insulators with a thin coat of Secure insulator and brush assembly to rear housing
silicon grease or petrolatum . Make certain that all in- and tighten screws to 16 to 20 lb-in (0.184 to 0.230
sulating washers are properly positioned. Secure kg-m].
heat sink to housing with terminal bolts.
Position brush cover gasket on alternator and in-
Attach diode leads and stator leads to heat sink. stall the brush cover and connect the two black
leads.
Installing Pulley
Place pulley spacer over rotor shaft and install
Woodruff Key in slot. Place pulley on shaft and tight-
en nut to 35 to 50 lb-ft [ 15.9 to 22.7 kg-m] torque.
Litho in U.S.A.
10-10 Charging System TM-1102 (Nov-73)
TEST AFTER ASSEMBLY INSTALLATION
1- Aiternator 3-12-Volt Battery

2- Carbon Pile 4-Ammeter
Resist or 5---Voltmeter
6-Jumper Wire
Fig. 24-Aiternaror Test Connections
Mount alternator on electrical services. If services

instructions are not available, connect alternator as
shown in Fig. 24. Run alternator at 3000 to 4000
rpm. Momentarily connect jumper wire between alter-
nator output terminal and stator terminal to excite al-
ternator field. Adjust resistor to obtain maximum
output (15 volts). The ammeter reading should be 18 1- 0 utput Terminal 4-Ground Term inal
amps or more. 2-St at or Terminal 5---Adjusting Strap
3-Aeld Terminals 6-Mounting Bracket
Fig. 25-Aiternator Wire Connections
Install alternator. Connect alternator wires (Fig. 25)

making sure all connections are clean and tight.
Connect battery ground straps. (See Section 70,
Group 10 for adjusting belt tension.)
Litho in U.S.A.
TM-1102 (Nov-73) Starting System 15-1
Group 15
STARTING SYSTEM
GENERAL INFORMATION Overrunning Clutch Drive
The starting motor consists of a drive housing,
overrunning clutch and pinion, shift lever, field frame,
solenoid. armature. field coil assembly, brushes and
commutator end frame.
The shift lever mechanism and the solenoid plung-

er are enclosed in the drive housing to protect them
from exposure to dirt, icing conditions and splash .
1-Collar 4-Spring
Armature 2-Spring 5-Rollers
3-Shell 6-Pinion
The armature is supported on three bushings in
the drive housing, center bearing and commutator Fig. 1-0verrunning Clutch
end frame. The armature assembly consists of a
stack of iron lamination located over a steel shaft, a
commutator assembly and the armature windings. The overrunning clutch drive has a shell and
The windings are heavy copper ribbon that are as- sleeve assembly which is splined internally to match
sembled into slots in the iron laminations. The wind- splines on the armature shaft. The pinion is located
ings ends are soldered or welded to the commutator inside the shell along with the spring-loaded rollers
bars which are electrically insulated from each other that are wedged against the pinion and taper cut in-
and from the iron shaft. side the shell. The springs may be either the helical
or accordian type, and four rolls are used. A collar
Field Windings and spring located over the sleeve are the other ma-
The frame and field assembly consists of field jor components.
windings assembled over iron pole pieces which are
attached to the inside of a heavy iron frame. The iron The overrunning clutch drive is designed to be
frame and pole shoes not only provide a place onto serviced as a complete unit, therefore, do not disas-
which the field coils can be assembled. but also pro- semble. Replace if necessary.
vide a low reluctance, or low resistance path for the
magnetic flux produced by the field coil windings. An important service check on roll clutches in-
volves the clearance in the crank position between
Solenoid Switch the pinion and pinion stop with the pinion pushed
back toward the shift lever . Proper clearance is
The solenoid switch consists basically of two wind- needed to prevent rubbing of the collar against the
ings mounted around a hollow cylinder containing a shift lever during motor operation and to insure prop-
moveable core or plunger. A shift lever is connected er engagement before cranking begins.
to the plunger, and a push rod and contact disk are
assembled in line with the plunger. Never run the starting motor more than twenty
seconds at a time or overheating will result. Allow
The two windings in the solenoid are called the motor to cool at least two minutes before running it
hold-in winding and the pull-in winding. The hold-in again.
winding contains many turns of fine wire, and the
pull-in winding the same number of turns of larger For additional information on starting mo-
wire.
Q 0
tors, refer to " Starting Circuits" in FOS
Manual- ELECTRICAL SYSTEMS.
Litho in U.S.A.
15-2 Starting System TM-1102 (Nov-73)
REMOVAL
T2096JN
1- Voltmeter 3-Battery
2-Carbon Pile 4-Ammeter
Fig. 3-Solenoid Test Points
Testing Hold-In Windings

1-"BAT" Terminal 3- Battery Positive Cable
2-"S" Terminal Disconnect solenoid. Connect ammeter in series
with a switch to terminal "S" and to battery. Connect
Fig. 2-Starting Motor Wiring voltmeter to terminal "S" and to solenoid ground.
Connect carbon pile resistor across the battery. Con-
Disconnect battery ground straps from batteries. nect other battery post to solenoid ground. Close the
switch and adjust carbon pile to obtain 10 volts. The
Disconnect positive battery cable from starting mo- ammeter reading should be 14.5 to 16.5 amps.
tor.
High Ammeter Reading
Remove the mounting cap screw and stud nut. Re-
move starting motor from engine. Windings are grounded or shortcircuited
TESTING AND DIAGNOSIS Low Ammeter Reading

Excessive resistance is present (usually
Solenoid Tests (Starting Motor Removed) in a connection)
Testing Pull-In Windings
No Ammeter Reading
Disconnect field connector from solenoid motor ter-
minal. Connect ammeter in series with a carbon pile Windings are open circuited
resistor to terminal "S" and to battery. Connect volt-
meter to terminal " S" and to solenoid motor terminal To prevent overheating, do not energize the pull-in
(Fig. 3). With carbon pile in the off position, connect winding longer than 15 seconds. Current draw will
other battery post to solenoid motor terminal. Quickly decrease as the winding temperature increases .
adjust the carbon pile to obtain 5 volts. The ammeter
reading should be 13 to 15.5 amps. If the fault cannot be repaired and the solenoid
performance is questionable, replace the windings.
Litho in U.S.A
TM-1102 (Nov-73) Starting System 15-3
Starting Motor No-Load Test 3. Failure to operate with high current draw indi-
cates :
a. A direct ground in the terminal or fields.
b. Frozen bearings (this should have been de-

termined by turning the armature by hand) .
4. Failure to operate with no current draw indi-

cates:
a. Open field circuit. This can be checked after

disassembly by inspecting internal conditions
and tracing circuit with a test lamp.
b. Open armature coils. Inspect the commutator

for badly burned bars after disassembly.
c. Broken brush springs, worn brushes, high in-

sulation between the commutator bars, or
TZ12159N
other causes which would prevent good con-
1- Carbon Pile 4-Voltmeter tact between the brushes and commutator.
2-Battery ~Jumper Lead
3-Ammeter 6-Tachometer 5. Low no-load speed and low current draw indi-
Fig. 4-No-Load Test Hook-Up cates:
Make connections shown in Fig. 4 (some amme- a. High internal resistance due to poor connec-
ters do not require a shunt). Close switch to operate tions, defective leads, dirty commutator and
starter and adjust carbon pile to obtain specified volt- causes listed under no. 4.
age. Current draw and rpm should be as follows:
6. High free speed and high current draw indicates
Motor Test Min. Max. Min. Max. shorted fields. If shorted fields are suspected, re-
No. Volts Amps Amps RPM RPM place the field coil assembly and check for improved
performance.
1109251 9.0 20 120 9000 14000
REPAIR
*Includes solenoid. Disassemble starting motor only as far as neces-
sary to make repairs (Fig. 5).
Interpret the test resul ts as follows:
Mark position of commutator end frame with regard
1. Rated current draw and no load speed indicates to main frame to aid in alignment during reassembly.
normal condition of the starting motor.
Disconnect field connector (Fig. 5) . Remove com-
2. Low free speed and high current draw indicates: mutator end frame and field frame.
a. Too much friction - tight, dirty, or worn bear- Remove solenoid and solenoid return spring.
ings, bent armatu re shaft or loose pole
shoes allowing armature to drag. Remove center bearing, shift lever pivot screw, ar-
mature, and thrust collar from drive end housing.
b. Shorted armature. This can be further check
on a growler after disassembly.
c. Grounded armature or fields. Check further

after disassembly.
Litho in U.S.A.
15-4 Starting System TM- 11 02 (Nov- 73)
T32150N
1- Bushing 11- Solenoid Assembly 21-Thrust Collar 30-Brush Pivot Pin (2 used)
2- Lubricating Wick 12- Field Coil Connector 22-Field Frame 31- Bushlng
3-Piug (2 used) 13-Armature 23-lnsulating Bushing 32-Commutator End Frame
4-Shift Lever Pivot Screw 14-Thrust Washer 24-Field Coli Assembly 33-Lubricating Wick
5--Drive End Housing 15--Bushing 25--Brush Support 34-Through Bolts (2 used)
~Spring Pin 1~Center Bearing 2~Brush Spring 35--Brush Ground Lead
7- Shlft Lever 17--Brake Washer 27-lnsulated Brush (2 used)
8--Solenold Plunger 18--0verrunnlng Clutch Holder 3~Grounded Brush Holder
9-Solenoid Return Spring 19-Pinion Stop 28-Brushes 37-Field Pole Shoe (4 used)
10-Gasket 20-Retaining Ring 29-Brush Mounting Screws 38-Pole Shoe Screw (8 used)
(2 used)
Fig. 5-Starting Motor
Litho in U.S.A.
TM- 1 702 (Nov- 73) Starting System 15-5
To remove brush holders, slide pivot pins out.

When installing brushes, tighten brush screws after
assembling starting motor.
Armature
If the commutator is excessively worn, dirty, out of
round, or if it has high insulation, it should be turned
down on a lathe. Do not under cut the insulation.
The comm utator may be cleaned with No. 00

sandpaper. Do not use emery cloth.
The armature should be checked for short circuits,

opens and grounds.
1. Short circuits are located by rotating the arma-

ture in a growler with a steel strip such as a
hacksaw blade held on the armature. The steel
1-Pipe Coupling 2-Pinion Stop
strip will vibrate on the area of the short circuit.
Fig. 6-Removing Retainer Shorts between bars are sometimes produced
by brush dust or copper between bars.
Slide a standard half-inch pipe coupling onto the
shaft so it butts against the pinion stop. Tap cou- 2. Opens may be located by inspecting the points
pling, driving stop toward the armature end, off the where the conductors are joined to the commu-
retaining ring (Fig. 6). tator for loose connections. Poor connections
cause arcing and burning of the commutator. If
Remove retaining ri ng. If it is badly distorted, use a the bars are not badly burned, leads originally
new retaining ring when reassembling the clutch. soldered to the riser bars can be resoldered.
Remove pinion stop, clutch assembly, brake wash- 3. Grounds in the armature can be detected by the
er and center bearing from armature. use of a test lamp. If the lamp lights when one
test prod is placed on the commutator and the
Do not clean any parts in grease dissolving sol- other test prod on the armature core or shaft,
vents. Wipe the drive with a clean cloth. the armature is grounded. If the commutator is
worn, dirty, out of round, or ·has high insulation,
Checking Brushes the commutator should be turned down.
Inspect brushes. If they are oil soaked or are worn
to approximately 5/16 inch [7.94 mm], replace them.
Make sure the brush holders are clean and the

brushes are not binding in the holders. The full brush
surface should ride on the commutator to give proper
performance. Check by hand to insure that the brush
springs are giving firm contact between the brushes
and commutator. If the springs are distorted or dis-
colored , they should be replaced.
Litho in U.S.A.
15-6 Starting System TM-11 02 (Nov-73)
Field Coils Bushings

Pre-Lubricated Bushings
When installing pre-lubricated bushings, use an ar-
bor (see " Special Tools") to prevent bearing col-
lapse. After installation , check bushing size. Burnish
bushing to size if necessary.
Wick-Lubricated Bushings
T32155N Remove plug and wick. Drive out old bushing.
1- Brush 3-0pen Circuit Test Press new bushing to same depth as old bushing.
2-Field Connector 4-Grounded Winding Use a drill the same size as oil wick hole and drill the
Terminal Test bushing. Carefully ream bushing to size so that it is
straight and centered. Saturate new wick with SAE
Fig. 7-Fie/d Winding Test
10 engine oil. Install wick and plug.
Bushing, Overrunning Clutch

The field coils should be checked for grounds and I. D ................................................ 0.5620 - 0.5630 in.
opens using a test lamp. [14.274 - 14.300 mm]
Wear tolerance ........................................... 0.5740 in.
1. Grounds - Disconnect field coil ground connec- [ 14.579 mm)
tions. Connect one test prod to the field frame
and the other to the field connector. If the lamp Bushing, Drive Housing
lights, the field coils are grounded and must be I. D.................... ............................ 0.4990 - 0.5010 in.
repaired or replaced. [12.674 - 12.725 mm)
Wear tolerance ........................................... 0.5110 in.
2. Opens - Connect test lamp prods to ends of
[ 12.979 mm]
field coils. If lamp does not light, field coils are Oil clearance ............................... 0.0020 - 0.0050 in.
open. [0.050 - 0.127 mm)
Wear tolerance ............. .. ............................ 0.0170 in.
If the field coils need to be removed for repair or [0.431 mm]
replacement, a pole shoe spreader and pole shoe
screwdriver should be used. Care should be taken in Bushing, Commutator End Frame
replacing the field coils to prevent grounding or I. D ............................................... . 0.5625 - 0.5635 in.
shorting them as they are tightened into place . [ 14.288 - 14.312 mm)
Where the pole shoe has a long lip on the side, it Wear tolerance ............................ ............... 0.5730 in.
should be assembled in the direction of armature ro- [14.554 mm]
tation.
Oil clearance ............................... 0.0020 - 0.0050 in.
[0.050 - 0.127 mm]
Overrunning Clutch Assembly Wear tolerance ........................................... 0.0160 in.
The pinion should turn smoothly with a slight drag [0.406 mm]
in the overrunning direction and lock up in the oppo-
site direction. If not, the entire clutch and pinion as- Bushing, Center Bearing
sembly must be replaced as the assembly cannot be J.D ................................................ 0.7570 - 0.7620 in.
repaired except for the spring and collar. [18.228 - 19.354 mm]
Wear tolerance .................................. ......... 0.7220 in.
[ 19.608 mm]
Oil clearance .. .. ........................... 0.0070 - 0.0150 in.
[0.178 - 0.381 mm]
Wear tolerance ................... ........................ 0.0250 in.
[0.635 mm]
Litho in U.S.A.
TM- 1102 (Nov-73) Starting System 15-7
Solenoid Switch 1. With the pinion stop placed over the shaft
(cupped surface facing the end of the shaft) , force
Remove nuts and sealing washers from solenoid
the retaining ring over the shaft with a light hammer
motor and " S" terminals when removing switch cov-
blow and slide ring into the groove (Fig. 8).
er.
Replacement "S" terminal clips and motor terminal

studs are soldered to winding leads. Use new sealing
washers when assembling the solenoid.
ASSEMBLY
To assemble starter, reverse the disassembly pro-
cedures.
Lubricate splines and drive end of armature shaft

with SAE 10 engine oil. Heavier oil may cause failure
to mesh at low temperature. Lubricate the bearing
surfaces of the center bearing, drive end frame, and
commutator end frame with Delco-Remy lubricant
No. 1960954.
With overrunning clutch in place. install pinion stop

with cupped side out and retaining ring.
Proceed as follows when assembling retaining ring 1- Pinion Stop 2-Retaining Ring
and pinion stop on shaft
Fig. 9-Forcing Pinion Stop Over Retaining Ring
2. To force the pinion stop over the ring, place a

suitable washer over the shaft and squeeze with
pliers (Fig. 9) . Remove the washer.
Use Permatex No . 2 sealing compound between

solenoid flange and starting motor field frame.
Carefully install field frame so that brush holders

are not broken. Align brushes with commutator and
tighten brushes.
If it is necessary to seat brushes , use No . 00

sandpaper. Clean all dust from starting motor.
1-Retaining Ring 2-Groove
Fig. 8-Forcing Retaining Ring Over Shaft
Utho in U.S.A.
15-8 Starting System TM-1102 (Nov-73)
1- Piece of Paper 2-Brush Attaching Screw
Fig. 10-Testing Brush Spring Tension
Place a piece of paper under the brush (Fig. 10).

Hook a spring tension scale on the head of the brush
attaching screw. Pull the scale on a line parallel to
the brush and note the reading when the paper is re- 1-Battery 3-Starting Motor
leased. Minimum brush spring tension is 80 ounces 2-Solenoid 4-Jumper Wire
[2268.0 g]. Bend springs, if it is necessary, to adjust
Fig. It-Circuit tor Checking Pinion Clearance
the tension .
Pinion Clearance
The pinion clearance cannot be adjusted but
should be checked after reassembly of the starting
motor to insure proper clearance. Improper clearance
is an indication of worn parts.
To check pinion clearance use the following steps:
1. Disconnect the motor field coil connector from

the solenoid motor terminal and insulate it care-
fully.
2. Connect a battery. of the same voltage as the 1-Pinion 3-Feeler Gauge

solenoid (12 volt), from the solenoid switch ter- 2-Pinion Stop
minal to the solenoid frame (Fig. 11).
Fig. 12-Checking Pinion Clearance
3. Momentarily flash a jumper lead from the sole- 4. Push the pinion back toward the commutator
noid motor terminal to solenoid frame. This will end as indicated by the arrow in Fig. 12 to elim-
shift the pinion into cranking position and it will inate slack movement.
remain so until the battery is disconnected.
5. Measure the distance between pinion and pin-
ion stop. T he clearance should be between
O.Q1 0 inch 0.25 to 0.140 inch [3.56 mm].
Litho in U.S.A.
TM-1 102 (Nov-73) Starting System 15-9
INSTALLATION
Install starting motor.
Connect battery positive cable (3, Fig. 13) and red

and black wires to "BAT' terminal (1). Connect natu-
ral wire to "S" terminal (2).
Connect battery ground cables to batteries.
1-"BAT" Terminal 3-Battery Positive Cable

2-"S" Terminal
Fig. 13-Starting Motor Connections
Litho in U.S.A.
15-1 0 Starting System TM-1102 (Nov-73)
Litho in U.S.A.
TM-1102 (Nov-73) Gauges and Switches 20- 1
Group 20
GAUGES AND SWITCHES
GENERAL INFORMATION The transmission oil temperature gauge measures
the temperature of the oil circulating in the transmis-
Refer to Section 70, Group 15 for testing and wir-
sion . The transmission oil temperature should remain
ing schematic for the gauges and switches.
within the light green zone under normal operating
temperatures. If the temperature exceeds 200°F.
Engine Oil Pressure Gauge
[93.3°C.), the cause should be determined and cor-
rective action taken.
The temperature sender is located on the filter

cover on the right-hand side of the transmission.
Engine Water Temperature Gauge
Fig. t-Engine Oil Pressure Gauge
The engine oil pressure gauge indicates the pres- Fig. 3-Engine Water Temperature Gauge
sure at which the engine lubricating oil is circulated
The engine water temperature gauge measures
through the engine. See Section 20, Group 15 for
the engine coolant temperature.
engine oil pressure specification.
The normal operating range is 160°F. to 224°F.
The gauge sending wire is connected to a sending
[71 .1 to 106.7°C.]. If the engine runs at a higher or
unit located at the rear of the engine on the right
lower temperature, the cause should be corrected
hand side.
immediately.
Transmission Oil Temperature Gauge
The temperature sender is located on the top of
the cylinder head at the rear of the engine.
Ammeter
RE O LIGHT
ORANGE EN
Fig. 4-Ammeter
Fig. 2-Transmission Oil Temperature Gauge
When the engine is started, the ammeter should

show a high charging rate, then gradually fall back to
the middle of the ammeter as the batteries become .
charged.
Litho in U.S.A.
20-2 Gauges and Switches TM-1102 (Nov-73)
If the ammeter shows consistently high charging Cigar Lighter

rates or is discharging while the engine runs, it indi-
cates either a faulty battery, alternator, regulator or
improper wiring. If the machine has just been re-
paired, check the wiring with the wiring schematic in
Section 80, Group 20. To test the alternator and reg-
ulator, see Section 80, Group 20.
Hour Meter
The hour meter is an electrical energized clock
which records the number of hours the engine has
operated. Starting and stopping of the clock is con-
trolled by the key switch "IGN" terminal.
The negative terminal of the hour meter is con-

nected to the hour meter case and the case is
grounded to the machine. Therefore, a separate
Fig. 5-Resetting Cigar Lighter Circuit Breaker
ground wire is not necessary.
If the cigar lighter fails to operate, its circuit break-
Start Switch er may be open and must be reset. Remove instru-
The start switch completes the circuit between the ment panel. Insert a wire in the small hole at the rear
key switch and the start-safety switch. When the of the lighter (Fig. 5).
start switch is depressed with the key switch in the
"IGN" position and the transmission in neutral, cur- Light Switch
rent flows from the key switch, through the start The light switch is the push-pull type, with one po-
switch, start-safety switch and back to the starting sition. It is energized by the key switch " ACC" termi-
motor solenoid "S" terminal. nal.
Circuit Breaker Start-Safety Switch
The electrical system is protected by a 20 amp cir- The start-safety switch is located on the transmis-
cuit breaker located on the back side of the instru- sion cam shaft support on the left-hand side of the
ment panel. transmission. See Section 40, Group 20, for start-
safety switch adjustment.
A 40 amp current will trip the breaker within one
minute. With the key switch turned off, the circuit
breaker will reset itself automatically within 35 sec-
onds.
Key Switch
The key switch is a one piece sealed switch that
cannot be repaired. When the key switch is straight
up and down, it is in the "OFF" position. When the
key is turned counterclockwise the "ACC" terminal is
energized and when the key is turned clockwise the
" IGN" and "ACC," terminals are energized.
Litho in U.S.A.
TM-tf02 (Nov-73) Gauges and Switches 20-3
REMOVAL Gauges and Switches

Disconnect battery ground straps.
Instrument Panel
Disconnect the battery ground straps. Remove the four screws from the instrument panel
and pull instrument panel back away from cowl.
Remove side shields, pre-cleaner, exhaust pipe,
and hood. Disconnect necessary wires to remove defective
gauge or switch.
INSTALLATION
Instrument Panel
Connect tachometer cable and install instrument
panel. Screw ball on throttle lever.
Install instrument panel wire harness in grommet

and connect harness connectors and the three lead
wires. Refer to Section 70, Group 15, for wiring
schematic if needed.
Install all parts removed and connect battery

ground straps.
Gauges and Switches

Install new gauge or switch. Connect wires re-
moved. Refer to Section 70, Group 15, for wiring
1-lnstrument Panel Wire Harness Connector 2-Grommet schematic if needed.
Fig. 6-Wire Harness Connectors Fasten instrument panel to cowl and connect bat-
tery ground straps.
Disconnect the two wire harness connectors and
the three single lead wires from the instrument panel
wire harness connector (1 ).
Remove instrument panel wire harness connector

from grommet (2).
Remove the four screws from the instrument panel

ball from throttle lever and disconnect cable from
tachometer.
Remove instrument panel with wire harness.
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20-4 Gauges and Switches TM-11 02 (Nov-73)
Litho in U.S.A.
Group 25
BATTERIES
Battery ground ....................................................... ............................ _............. ............................................. Negative

Full charge specific gravity (corrected for 80°F [26.rC] electrode temperature) ................................. ....... 1.260
Maximum variation between cells during specific gravity test (specific gravity points) ............. .. ................ 0.050
High-rate discharge test (mi!1imum reading) .............................................................................................. 9.0 volts
When replacing the battery(s) use the John Deere battery or its equivalent shown in the following chart:
Cold
Cranking Reserve
AMPS Capacity
John Deere SCI o•F - 200F (Minutes at
Volts Part Number Group [17.8"C] [ - 28.9°C] 25 amps)
12 AT29160 30H 570 450 180
SPECIAL TOOLS
Convenience Tools
TY-1337 (10 amp)* Charge battery
TY -1338 (15 amp)*
TY-1339 (30 amp)*
TY-1340 (100 amp)*
Fig. 1-Battery Charger *Order from your John Deere Dealer
Litho in U.S.A.
BATTERIES
SPECIAL TOOL5-Continued
Convenience Tools
Check specific gravity
Fig. 2-Hydrometer
Check battery internal condition
©@ ©
AMPS VOlTS
CAAI~ ~l (
TS 3 000N
Fig. 3-High-Rate Discharge Battery Tester
CHARGING SYSTEM
Rating ................... ......................... 12 volts, 22 amps
Ground ............................................ .. .............Negative
Stator Winding ............... ................ ..... .. ........ ...... .. Wye
- Brush minimum length

beyond holder ...................... 1/4-inch [6.35 mm]
Fig. 4-Brush Length
Litho in U.S.A.
TM- 11 02 (Nov- 73) Specifications and Special Tools 25-3
CHARGING SYSTEM
SPECIFICATIONS AND TORQUE VALUES- Continued
1 - Brush screws ....... .. ..... ................ 16 to 20 lb. in.
[0.184 to 0.230 kg-m)
2 - Through bolts .............................. 50 to 60 lb. in.
[0.576 to 0 .691 kg-m)
Fig. 5-Brush Screws and Through Bolts
- Pulley nut ...... ....... .............. .. ........ 35 to 50 lb. ft.

[15.8 to 22.6 kg-m]
Fig. 6-Pu//ey Nut
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CHARGING SYSTEM
SPECIAL TOOLS
Essential Tools
<
···'·
~· '. ·~·-
,,_ .-,_,_.
··' ..-.·.-.
•;<- '-·
" . ) .. • ·!;
.,.
·'·
Rg. 7-A200JD* Alternator Service Tool Set
1 -
A-203** .... .....To install front bearing
2 -
A-208** ......... To install rotor and rear bearing
3 -
A-213* * ........ . To remove negative diodes
4 -
A-216** ......... Remove front and rear bearings
5 A-201 ** ......... To install front bearing
-
6 -
A-214** ......... To install diodes
7 -
A-209** .. .. ..... To install rotor
8 -
A-206** ....... .. To remove positive diodes and in-
stall rear bearing
9 - A-205** ...... .. .To install rotor
*Order From: Service Tools Inc.

1901 Indiana Ave.
**Tools are part of A200JD Alternator Service Tool
Set and cannot be purchased individually.
Litho in U.S.A.
CHARGING SYSTEM
Convenience Tools
To test diodes
T31?04NY
Fig. 8-Aiternator Diode Tester
To test brushes, rotor, stator -and

diodes.
Fig. 9-0ilmmeter
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STARTING SYSTEM
No Load Test
Motor Test Min. Max. Min. Max.
No. Volts Amps Amps RPM RPM
1109251 9.0 20 '~ 120* 9000 14000
*Includes solenoid.
Solenoid Test
Pull-In (current draw at 5 volts) ........................ ............................... .. .......................................... 13 to 15.5 amps

Hold-In (current draw at 10.0 volts) ................................................ .. ..... .. .................... ............. 14.5 to 16.5 amps
Starting Motor - Model No. 11 09251

1 - Brush minimum length beyond holder ... S/1 6 in.
(7.94 mm]
Fig. 10-Brush Length
- Brush spring minimum tension ................. 80 oz.

[2268.0 g)
Fig. 11-Brush Spring Tension
Litho in U.S.A.
TM- 11 02 (Nov- 73) Specifications and Special Tools 25-7
STARTING SYSTEM
- Drive housing bushing
1.0 ........................................ 0.4990 to 0.5010 in.
[1 2.674 to 12.725 mm]
Wear tolerance ............................................ 0.511
[ 12.979 mm]
Oil clearance.......................0.0020 to 0.0050 in.
[0.050 to 0.127 mm]
[0.431 mm]
2 - Overrunning clutch bushing

I. D........................................ 0.5620 to 0.5630 in.
[ 14.274 to 14.300 mm]
[ 14.579 mm]
3 - Center bearing bush ing

1.0 .................... .................... 0.7570 to 0.7620 in.
[18.228 to 19.354 mmJ
Fig. 12-Starting Motor Wear tolerance .................................... 0.7720 in.
[ 19.608 mm)
Oil clearance ....................... 0.0070 to 0.0150 in.
[0.1 78to0.381 mm]
[0.635 mm]
4 - Commutator end frame bushing

1.0 ........................................0.5625 to 0.5635 in.
[ 14.288 to 14.312 mm]
[1 4.554 mml
Oil clearance ....................... 0.0020 to 0.0050 in.
[0.050 to 0.127 mm]
Wear tolerance ................................... 0.0160 in.
[0.406 mm]
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25-8 Specifications and Special Toafs TM-1102 (Nov-73)
STARTING SYSTEM
SPECIFICATIONS AND TORQUE VALUEs-Continued
- Pinion clearance ..................... 0.01 0 to 0.140 in.
[0.25 to 3.56 mml
Fig. 13-Pinion Clearance
SPECIAL TOOLS
Convenience Tools
To test armature for shorts, opens

and grounds
.,
Fig. 14-Armature Tester
To install pre-lubricated bushings

f--3/4"-{
IR1S727N
Fig. 15-Pre-Lubricated Bushing Arbor
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TM- 1102 (Nov-73) Specifications and Special Tools 25-9
STARTING SYSTEM
SPECIAL TOOLS -Continued
Convenience Tools
To check brush spring tension
F~g. 16-Spring Tension Gauge
GAUGES AND SWITCHES

Bulbs
Gauge bulbs ..................... .......................G.E. 1816
Lights (sealed beam) .............................. G.E. 4406
Circuit breaker 20 amps

Amps to trip circuit breaker ............... 40 amps for
one minute
Reset time ............. ................................ 35 seconds
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25-1 0 Specifications and Special Toafs TM-1102 (Nov-73)
Litho in U.S.A.
Crawler - JD450-C Power Train 40
TM-1102 (Nov-73) Engine Clutch Assembly 5-1
Section 40
POWER TRAIN
Page Page
Group 5 - Engine Clutch Assembly Group 20 - Final Drive Assembly
General Information ............................................ 5-2 General Information ..........................................20-1
Removal ...............................................................5-3 Removal .............................................................20-2
Repair ..................................................................5-4 Repair ................................................................20-3
Adjustment ...........................................................5-5 Installation ..........................................................20-6
Clutch Housing and Controls .............................5-6
Repair ..................................................................5-6 Group 25 - Power Take-Off and
Installation ............................................................5-7 Winch Drive
Group 10 - H-L-R Transmission Removal .............................................................25-1
General Information .......................................... 10-1 Repair ................................................................25-2
Removal ............................................................. 10-2 Installation ..........................................................25-3
Repair ................................................................ 10-3
Range Change Unit ...................................... 10-4 Group 30 - Specifications and
Speed Change and Ring Gear Units ........ 10-16 Special Tools
Installation ........................................................ 10-26 Engine Clutch Assembly .................................. 30-1
Gear Shift and H-L-R Levers Quadrant.. ..... 10-27 H-L-R Transmission .......................................... 30-4
Gear Shift and H-L-R Levers and Linkage .. 10-28 Steering Clutch and Brake Assembly ............. 30-8
Lever Adjustment. ........................................ 10-29 Final Drive Assembly ...................................... 30-1 0
Group 15 - Steering Clutch and

Brake Assembly
Removal ............................................................. 15-2
Repair ................................................................ 15-3
Brake Anchor and Band ............................... 15-3
Steering Clutch Assembly ............................. 15-4
Steering Levers and Rods ........................... 15-5
Brake Pedal and Shaft.. ............................... 15-6
Adjustment ......................................................... 15-7
Installation .......................................................... 15-7
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40 Power Train Crawler - JD450-C
5-2 Engine Clutch Assembly TM-11 02 (Nov-73)
Group 5
ENGINE CLUTCH ASSEMBLV
GENERAL INFORMATION
The clutch mechanism is located on the rear of the
engine flywheel and is enclosed by the clutch hous- ~y- ..
ing (Fig. 1). A pedal mechanically controls the clutch
throw-out bearing which engages or disengages the
driven disk by means of a spring-loaded pressure
'
'
'
plate. An 11-inch driven disk is used.
Partially depressing the clutch pedal stops tractor

motion but does not stop powershaft rotation. Thus
"live power" is available at all times for PTO or winch
drive operations.
When the clutch pedal is depressed, clamping ac-

tion of the pressure plate is released , allowing the
clutch driven disk to stop rotating with the pressure
plate and flywheel. This is the disengaged position.
When the clutch pedal is released, coil springs

within the pressure plate mechanism act against the
pressure plate disk and clamp the friction surfaces of
the driven disk between the pressure plate and the
clutch surface of the flywheel. This causes the clutch
driven disk to rotate with the pressure plate assembly
and flywheel, thereby transmitting engine power to
the transmission. This is the engaged position.
Clutch and clutch control linkages have been so

designed that minor adjustment of the clutch is made T 20 9 6 2
externally, thereby eliminating disassembly of the
1- Fiywheel 6-Throw-Out Bearing
clutch except at time of major overhauls (Fig. 1). 2- Ciutch Driven Disk Carrier
3-Ci utch Housing 7-Ciutch Pressure Plate
Clutch controls and pedal shaft are mounted in 4-Carrler Return Spri ng 8-Ciutch Lever
center portion of the clutch housing. Movement of the 5-Ciutch Pedal Return 9--Ciutch Throw-Out
clutch pedal is transmitted through the clutch linkage Spring Bearing
to the throw-out bearing. Fig. t -Ciutch and Control Linkage
The front input shaft transmits engine power from The clutch also serves as the PTO or winch drive
the flywheel through the splined hub of the clutch clutch. The powershaft drive gear, splined to the in-
driven disk directly to the transmission. The front end put shaft under t he front cove r, drives the PTO
of the front input shaft is supported by the clutch pilot driven gear and shaft or the winch drive shaft. Power
bearing located in the flywheel. is transmitted only when the engine is running and
the clutch is engaged. The H-L-R transmission "live
power" operation is provided by partially depressing
the clutch, stopping tractor motion but not stopping
power to the powershaft.
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TM-11 02 (Nov-73) Engine Clutch Assembly 5-3
REMOVAL
NOTE: On crawler-loader units, leave loader and
cowl support intact. Remove engine, then loosen
special set screw which secures fork to clutch shaft.
Move clutch shaft to left. Roll back clutch and brake
pedals. Disconnect all wiring and control linkage from
clutch housing. Remove cap screws securing clutch
housing to cowl support, to side frames, and to
transmission. With the aid of a hoist, remove clutch
housing by sliding forward off transmission dowels
and out under loader and cowl support.
Remove engine from unit as instructed in Section

20, Group 5.
Disconnect all the necessary wmng, linkage and

lines from cowl. Remove cap screws securing cowl
to clutch housing and with the aid of a chain hoist, lift
cowl from unit.
1-Spacer Support 3-Spacer Support

2-Ciutch Housing Attaching Points Attaching Points
Fig. 3-Attaching Points
Disconnect clutch pedal return spring and yokes

from brake levers.
Remove cap screws securing clutch housing (Fig.

3) and with the aid of a hoist, remove clutch housing
from unit.
1- Return Spring 3-PTO Linkage

2-0perating Rod 4-Throw-Out Bearing
5--H-L-R Operating Arm
Fig. 2-Ciutch Control Linkage
Disconnect clutch control linkage (Fig . 2). Remove

oil cooler line and elbow from right side of clutch
housing-to-transmission front cover.
1-Pressure Plate Assembly 3-Fiywheel

2- 0ri ven Disk
Fig. 4-Removing Clutch Assembly on Engine Flywheel
Remove pressure plate attaching cap screws and

lift pressure plate and driven disk from flywheel.
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5-4 Engine Clutch Assembly TM-1102 (Nov-73)
REPAIR
~9
8~~
7---i
\
®
1-Pilot Bearing 8--Nut {2 used) 17- Pin 23--Link (3 used)

2- Driven Disk 9-Fork 18--Ciutch Adjusting 24-Spring Ring
3--Lock Washer (6 used) 10--Return Spring Lever 25-Adjusting Screw (3 used)
4-Special Cap Screw 11- Shaft 19-Pressure Plate 26-Return Clip (3 used)
(6 used) 12- Ciutch Pedal Assembly 27-Pivot Pin (3 used)
5-Throw-out Bearing 13--Ciutch Adjusting Bolt 20--Bracket 28--Jam Nut (3 used)
Carrier 14-Detent Seat 21-Pressure Spring 29-Special Washer (3 used)
F-Sprlng 15-Yoke (6 used) 30--Pressure Plate
7- Special Set Screw 16-Cotter Pin 22- Release Levers
(2 used) (3 used)
Fig. 5-Ciutch Assembly
Remove all grease and dirt from the clutch operat- With an open end wrench, loosen jam nuts (28).
ing parts. Back out the three adjusting screws from pressure
plate (30) and remove return clips.
IMPORTANT: Do not immerse clutch drive fac-
ings in any type of cleaning solution as it will Release assembly by gradually releasing load on
tend to glaze them. press. The clutch may then be disassembled for in-
spection. To separate release levers from bracket,
Refer to Fig. 5 for identification of parts during dis- first grind off peened ends of pivot pins (27).
assembly and assembly of clutch.
Check pressure plate for cracks, warped condition,
Place the pressure plate assembly on a flywheel, and excessive wear. Check pressure springs in the
pressure plate down, and centrally located. Depress assembly for damaged, weak, or rusty coils. Each
the inner ends of the release levers (22) as far as part should be carefully inspected for wear and re-
possible without forcing against bracket (20). This placed if there is any question of its serviceability.
can be accomplished by placing the flywheel on a
hydraulic press and applying the load through a steel
plate representing the clutch release bearing.
Litho in U.S. A.
Pressu re sp rings (21, Fig. 5) should check as

follows:
Free length ......................... 3.075 in. [77.978 mm I
Test length ......................... 1.685 in. [42.672 mml
Compressed at 124 lbs. f56.245 kg.l
The clutch driven disk (2) and the pressure plate

(30) friction surface must be flat within 0.006 in.
10.1524 mm l.
Examine clutch facings. If there is evidence of ex-

cessive wear, greasy condition, or glazing, replace
the facing. Normally clutch facings should be re-
placed at the time of every major engine overhaul.
Check pilot bearing for excessive wear or tight

spots by rotating inner bearing race with finger.
1- Pressure Plate Assembly 3-Fi ywheel
Replace bearing if defective. Pack new bearing 2- Driven Dis k
with AT30408 high-temperature grease or an equiva-
Fig. 6-/nstalling Clutch Assembly on Engine Flywheel
lent. Drive in new bearing (shielded side out) to bot-
tom of counterbore with a driver which will contact
only the outer bearing race. Using either a clutch disk centering shaft (JDE-52)
or a clutch shaft, position clutch pressure plate as-
Assemble clutch levers and bracket with new pivot sembly and driven disk over end of shaft and into
pins. Peen over ends of pins to secure assembly. place on rear of flywheel. Bolt the pressure plate to
flywheel. Refer to Fig. 6.
Assemble clutch levers and bracket with new pivot
pins. Secure pins in position and install pressure ADJUSTMENT
springs into their recesses.
Adjust the setting of the clutch levers using gauge
Assemble bracket. spring. and clutch lever subas- (JD-227) as follows.
sembly over pressure plate making certain slots in
bracket align with pressure plate drive lugs. Lubri-
plate sides of drive lugs to assure free operation of
clutch assembly.
Place this assembly on hydraulic press and apply

pressure on the lever directly above the pressure
spring while forcing the spring into position in brack-
et.
Assemble return clips under adjusting screws in

pressure plate. Make certain return clips are in prop-
er position, and then tighten lock nuts.
1-Ciutch Release Levers 2- lever Adjustment
Fig. ?-Adjusting Clutch Levers
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40 Power Train Crawler - J0450-C
5-6 Engine Clutch Assembly TM- 11 02 (Nov-73)
Place the gauge over the pressure plate with the 3. Remove jam nut and set screw fastening throw-
gauge legs resting on the flywheel and notched area out bearing fork to clutch pedal shaft
over a clutch lever. Move the adjusting screw in or
out to place clutch levers at the proper level. Repeat 4. Unhook return spring from throw-out bearing
the above procedure on remaining clutch levers. Re- carrier and slide bearing on carrier from tube on
fer to Fig. 6. transmission front cover.
After the release levers are adjusted and lock nuts 5. Disconnect fork from clutch ad justing lever.
tightened, exercise the clutch levers several times.
Recheck adjustment and change if necessary. If the 6. Loosen jam nut and set screw and remove
levers dropped excessively, this process should be clutch adjusting lever.
repeated until the setting is permanent.
7. Slide off clutch pedal.
IMPORTANT: To insure proper clutch function-
ing, the variation in adjusted height of release le- NOTE: If clutch housing, clutch pedal shaft, clutch
vers should not exceed 0.010 inch [0.2540 mm l. pedal return spring or throw-out bearing fork are
damaged and must be replaced, clutch housing must
CLUTCH HOUSING AND CONTROLS be removed from crawler. Inspect parts and replace
as necessary.
Repair
Inspect housing for cracks or other damage. Re-
Refer to Fig. 8 and perform the following steps:
place if necessary. Examine bushings in pedal shaft
bores. Install left bushing until flush · with outside
edge of housing. Drive in other bushing until flush
with inside edge of bore in housing.
T32027/ll
1-Sprlng 8-Ciutch Pedal

2- Throw -Out Bearing Carrier 9- Adjusting Bolt
3-Set Screw (2 used) 1~Detent Seat
Fig. 8-Ciutch Control Linkage 4-Nut (2 used) 11- Yoke
5-Fork 12-Cotter Pin
1. Remove cotter pin and pin attaching PTO con- 6-Return Spring 13--Headed Pin
7-Shaft 14-Adjusting Lever
trol lever to shifter shaft.
Fig. 9-Ciutcfl Control Linkage
2. Remove the stop nut fastening valve operating

arm to link. Rotate arm upward to free from threaded
bolt. Be careful not to lose spacer and spring.
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Check throw-out bearing (2, Fig. 8) for evidence of of clutch, and reaching inside of housing, position
overheating (blue discoloration of surface). If bearing fork and spring. Push shaft on into right wall of hous-
appears to have been over-heated or is rough, re- ing. Install pedal and adjusting lever. Join clutch
place bearing. housing to transmission case. Refer to Fig. 3.
NOTE: Throw-out bearing should not be soaked in 2. Fasten adjusting lever with set screw and jam
solvent as it is pre-packed with grease. Wipe clean nut. Tighten set screw and jam nut to 35 lb-ft l4.839
with cloth dampened in solvent. No attempt should kg-m i.
be made to oil bearing.
3. Install adjusting bolt and detent seat in pedal.
Inspect shaft (7) for evidence of wear, especially at Attach yoke to bolt and ad justing lever.
points of contact. Inspect clutch pedal and adjusting
lever (14) for cracks or other damage. Examine ad- 4. Slide throw-out bearing and carrier onto tube
justing bolt and detent seat for damage. Replace as and connect carrier return spring.
necessary.
5. Make sure pedal return spring is hooked behind
Inspect clutch throw-out bearing fork for cracks or tab on left side of clutch housing. Pushing yoke to
worn portions (especially at point where fork contacts rear against force of spring, index holes in yoke and
throw-out bearing carrier). Examine large pedal re- shaft. Install set screw and jam nut. Tighten jam nut
turn spring and carrier return spring for damaged or to 35 lb-ft [4.839 kg-m 1.
set coils.
6. Insert threaded link with spring in operating
arm . Install spacer, washer and lock nut.
7. Connect PTO control lever to shifter shaft using

pin and cotter pin.
INSTALLATION
Connect parts removed under "REMOVAL" on
page 40-5-3.
Refer to Section 20, Group 5 and install engine.
Fig. tO-Clutch Control Linkage
Refer to Fig. 9 and perform the following steps :
1. If clutch pedal shaft, throw-out bearing fork

and pedal return spring were removed they must be
installed before clutch housing is joined to trans-
mission. Insert clutch pedal shaft through left wall
Litho in U.S.A.
5-8 Engine Clutch Assembly TM-1102 (Nov-73)
Litho in U.S.A.
TM-11 02 (Nov- 73) H-L-R Transmission 10-1
Group 10
H-L-R TRANSMISSION
GENERAL INFORMATION
·~
I ,C, •
®
~- -;;
- ~
'
3~- . - .
~·':f;¥io29if1?; ·~.~· :>. ,>.
1- Ring Gear and Hub Compartment 6--Front Drive Shaft 11-Ciutch Control Unit
2-Speed Change Compartment 7-High Clutch 12- Rear Orive Shaft
3-Range Change Compartment 8-Reservoir Filter Screen Cover 13- Pinion Shaft Assembly
4-Transmission Front Cover 9-Reverse Clutch 14-Ring Gear Assembly
~H-L-R Oil Pump 10-Low Clutch
Fig. 1-Transmission Case and Components
The H-L-R transmission is basically a collar shift The transmission case (Fig. 1) contains three sep-
transmission plus a hydraulic reverser and under- arate compartments. From front to rear they are:
drive unit. The two features work as follows:
Range Change Compartment (3). A control valve
Manual Shifting of Gears. Shift lever beside opera- unit operates the three hydraulic clutches- high, low,
tor's seat is used to select one of four shift stations and reverse- mounted on the clutch shaft. The
by manual shifting of collars on gears in the speed transmission front drive shaft and two countershafts
change compartment. transmit rotation to the clutch shaft.
Shifting "On the Go." Reverser lever on the battery Speed Change Compartment (2). The rear drive
box is used to reverse the gear train or to shift from shaft carries four gears which mesh with gears on
high to low gear under load without clutching by the pinion shaft. The pinion shaft carries the shifters,
means of hydraulic clutches in the range change shifter collars, and driven gears which transmit a
compartment. specific speed through the pinion to the ring gear.
The reverser lever can select a high , low or re- Ring Gear and Hub Compartment (1). This com-
verse gear for any of the four shift stations, making partment houses the ring gear and hub which receive
available eight forward gears and four reverse gears. rotation from the pinion and transmit it to the final
drives.
Litho in U.S.A.
10-2 H-L-R Transmission TM-11 02 (Nov-73)
REMOVAL Replacing Transmission Case

NOTE: Removal of transmission is required only
Servicing Transmission Range and
when the transmission case is damaged and must be
Speed Change Compartments Only
replaced.
To gain access to the gears and shafts in the
range change and speed change compartments If transmission case must be replaced, perform all
(except for the pinion shaft assembly) the following of the preceding steps and continue as follows:
tractor components must be removed:
6. Remove final drive housing from steering clutch
1. Remove engine from clutch housing as instruct- housing as instructed on page 40-20-2.
ed in Section 20, Group 5.
7. Using a chain hoist, support transmission case.
2. Remove engine clutch housing from transmis-
sion as instructed in Section 40, Group 5. 8. Remove steering clutch housing from transmis-
sion case as instructed on page 40-20-2.
Proceed with service of range change and speed
change assemblies in front two compartments of 9. Remove transmission case using chain hoist.
transmission case. Refer to page 40-10-3.
Servicing Transmission Ring Gear

and Pinion
With engine and clutch housing removed, the
transmission ring gear and pinion shaft assembly is
accessible only when the following tractor compo-
nents are removed:
1. Disconnect track assembly as instructed in Sec-

tion 60, Group 5.
2. Remove track drive sprocket, back off final drive

pinion set screw, and remove bearing quill and final
drive pinion shaft.
3. Remove steering clutch and brake assembly

from steering clutch housing as instructed in Section
40, Group 15.
NOTE: On crawler-loader tractors, loader does not

have to be removed.
4. Remove throw-out bearing and throw-out bear-

ing carrier.
5. Carefully remove both ring gear bearing quills

and shims and remove ring gears from transmission
case.
Litho in U.S.A.
Crawler - J0450-C Power Train 40
TM-11 02 (Nov-73) H-L -R Transmission 10-3
REPAIR
Range Change Unit

Disconnect rods from shifter arm and from steering
levers. Remove cap screws and lift top cover from
transmission case.
Fig. 3-Removing Operating Linkage and

Countershaft Quills
5. Remove retainer ring and free link from shift

valve arm.
6. Remove accumulator housing and shift valve by

lifting straight up.
7. Drive out roll pin and pull clutch valve operating

shaft.
Fig. 2-Removing Transmission Front Cover
8. Remove countershaft quills and shim packs.
To remove the transmission front cover, refer to
Fig. 2 and proceed with the following steps: NOTE: Be sure to mark quills "LEF T" and
"RIGHT'' before removing them. This will assure that
1. Drive out roll pin and tap arm from shaft. correct shim packs are installed for each counter-
shaft.
2. Remove cap screws and hex. nuts and carefully
pull front cover from case. 9. Remove cap screws from front input shaft quill
but do not remove quill at this time.
3. Detach oil lines from tee and clamp. Remove
lines and tee from case.
4. Remove two cap screws f rom accum ulator

housing.
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10-4 H-L-R Transmission TM- 11 02 (Nov- 73)
Fig. 4-Attaching Lifting Device to H-L-R

Clutches and Control Unit
10. Attach jaws of a gear puller or similar device 1- Shim Pack 2- Siot Facing Up
under rims of dual clutch drum as shown. Hook a Fig. 5-Ufting H-L-R Clutches and Control
chain hoist to the puller. Unit from Case
11. Remove cap screws holding control valve

housing to rear wall of case. Remove lock plate and
washers.
12. Reach through slot in valve housing and move

retainer ring to rear out of rear input shaft groove.
13. Tap out pin in clutch shaft. Let it drop into

case. Turn rear input shaft so that slot faces up. This
will give clearance for removing clutch unit.
Take up slack in lifting chain until puller jaws sup-

port clutch unit. Remove front input shaft and quill.
Work clutches, control unit, and countershafts slowly
forward.
When rear of clutch shaft clears slot in rear input,

tilt up rear of clutch unit as shown (Fig . 6) and care- 1- Underdrive Countershaft 2- Reverse Countershaft
fully lift unit from case.
Fig. 6-Removing Countershafts
NOTE: Be careful with shim pack on rear of clutch Remove countershafts from case.
valve unit. Remove and save all shims for correct
reassembly. Remove clutch shaft pin and any other loose parts
from bottom of case.
Litho in U.S. A.
TM-11 02 (Nov-73) H-L-R Transmission 10-5
1- Disengage Tangs
Fig. 7-Removing Sealing Rings From Clutch Shaft
Remove five sealing rings from clutch shaft (Fig.

1- Shaft Protector 2- Front Clutch
7). Do this by pressing in side of ring opposite joint,
disengaging tangs, and releasing. Fig. 9-Pu//ing Front Clutch From Shaft
Pull front clutch assembly using a gear puller (Fig.

9). This pack is keyed to the clutch shaft. Be sure to
use a protector over end of clutch shaft.
1- Thrust Washer 2- Key
Fig. tO-Removing Key and Thrust Washer
Remove key from clutch shaft (Fig. 10). Then lift

1-Snap Ring 2- Hub off thrust washer.
Fig. 8-Removing Snap Ring From Front Clutch
Pull out front clutch hub (Fig . 8). Jiggle hub while
pulling to free disks from splines.
Remove snap ring holding front clutch drum.
Litho in U.S.A.
Support dual clutch pack in a press and press out

clutch shaft as shown (Fig . 12). The pack is keyed to
the shaft. Be sure to use a protector over end of
shaft.
1- Hub 3- Snap Ring

2- Thrust Washer
Fig. It-Removing Clutch Hub, Thrust Washer

and Snap Ring
Pull out clutch hub (Fig. 11 ). Ji gg le hub while

removing to free disks from splines. Then lift off
thrust washer and remove snap ring from groove on
clutch shaft. 1- Thrust Washer 4-Snap Ring
2-Hub 5-Key
3-Thick Thrust Washer
Fig. 13-Removing Parts from Clutch Shaft
Remove snap ring and remove parts from clutch

shaft (Fig. 13).
1- Protector Over Shaft
Fig. 12-Pressing Off Dual Clutch Pack
Litho in U.S.A.
Snap ring must be removed to free large release

spring or spring pack from clutch drum (Fig. 15}. This
demands a special pressing tool. Shown in Fig. 15 is
an AM236T engine oil filter cap with one side cut out.
This tool allows the spring to be pressed down until
snap ring can be removed from groove. Then release
pressure slowly.
h CAUTION : Clutch release springs are

. . under high pressure when loaded. Make
sure tool is centered while pressing and keep fin-
gers away.
Remove clutch release spring parts from hub. Four

spring washers are used as a clutch release mecha-
nism .
Fig. 14-Removing Snap Ring from Clutch Pack
Remove piston from clutch drum. Do this by turn-
Remove large snap ring from clutch pack (Fig. 14). ing drum over and pounding against a wooden block
Lift whole pack from drum. or, blow out with air pressure in hole in inner surface
of drum. Piston should then slide out.
Remove sealing ring from rim of piston. Also re-

move sealing ring from drum.
NOTE: Other two clutch packs can be disassem-

bled in same manner as above. Keep packs together
for correct reassembly.
1- Release Spring 3-0il Filter Cap

2-Cut Out Area 4-Snap Ring
Fig. 15-Presstng Down Clutch Release Spring To

Remove Snap Ring
Litho in U.S.A.
Crawler _ JO
T:._::M~-.:_1~10~2_!!_1Jc450-C
40
10-8 p ower Train
- - H-L-R
.. r,ransmission __ Nov-73)
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41-C:~~~ ~.ner
40-P'
2-Snap ~~r Clutch Gear
1-High R 14-Pin 28-Snap
2 R"mg
Seal
16-Woodruff ~ Clutch Drum 30-Ciutch p~~ched Plate
15--High Ran 9---Ciutch N 4 - S . ISton
3--Snap R'mg 2
43--Spnng (4 used)
4-0uter 17-Woodruff Key 31- Ciutch Of e (4 used) nap Ring
Plate Cl utch l ocking 8-Seal R" ey (2 used) 32-0uter PI sk (4 used)
1 ate 44-Ciutc h Plate (2 used)
45--CI
19---Drill mg (5 used)
5-Ciutch Notched ed Brass p· 33--Backin
Ring g Plate Snap utch Disk
(4 used) Plate 46-Ciutch Notched(4 used)
PI
2
2c;=TBearing Race m
34-Drum (3 used) ate
6- Ciutch Disk
7-Ciutch PIate (4 used)
ransmiss·•on Clutch Shaft
22- Pin Ring Retammg
.. Snap
47-CIutch Backl
48-Snap Rl ng Plate
8-Snap Ring 23- Ciutch Dr 35--Thrust
36--R w
asher 49--- ng
9---Sp . 24-Piston 0 um everser Ra Snap Ring
10-CI nng (4 used) 25--Piston I uter Seal 37- Thrust w nge Pinion 50-Thrust w
11 p ·utch Piston 26-Ciutch Pn_ner Seal 38-S asher 51 L asher
- •ston Inner Se 2 1ston nap Ring - ow Rang p·
12- Piston 0 al 7-Spring (4 used) 39---Piston Outer Seal 52-Thrust W asher
e mion
13--Th . uter Seal
rust Washer
Fig. 16- H -L-R Ctutches
Litho in U.S.A.
TM-1102 (Nov- 73) H-L -R Transmission 1 0-9
Install pistons in both clutch drums. Make sure

sealing rings are installed on rim of piston and on
hub of drum. Check to see that two small bleed
holes in piston are open and clean. Line up dowel
and tap in piston to bottom.
Stack four spring washers over center of clutch

drum. Stack them alternately with the outer rim of the
first washer bent up away from piston. Refer to Fig.
18.
T21101 1- Release Spring 2-Snap Ring
1- Snap Ring 2-Spring Washers Fig. 18-/nstalling Snap Ring
Fig. 17-Correct Position of Spring Washers and Snap Rings

IMPORTANT: Make sure ring seats in groove
Install snap ring to hold clutch release spring pack all around (Fig. 17). Then release pressure s lowly
(Fig. 18). and recheck it.
1- Notched Plates 2-High Clutch 3-Low Clutch 4-Reverse Clutch
Fig. 19-Correct Arrangement of Disks and Plates in Clutch Packs
Litho in U.S.A.
10-10 H-L-R Transmission TM- 11 02 (Nov- 73)
IMPORTANT : Fig . 19 shows the correct se-

quence of disks and plates in each clutch pack.
Observe that some steel plates have a notch on
one tang. These plates are slightly wavy in de-
sign and must be installed in the exact sequence
shown for p roper H-l -R clutch operation.
Assemble high clutch pack into single drum, over

piston, as shown in Fig. 19.
1- Thrust Washer 4-Snap Ring

2-Hub 5---Key
3-Thick Thrust Washer
Rg. 20-lnsta//ing Snap Ring to Hold Clutch Pack
Fig. 21-lnstalfing Parts on Clutch Shaft
Install snap ring in groove of thick outer plate to
hold pack in drum (Fig. 20).
Install clutch pack in reverse clutch drum . (See

Fig. 19 for correct order of parts.)
Stand clutch shaft on end (Fig . 21) and install thick

thrust washer with bronze surface next to gear. Seat
on slotted shoulder. Then install low clutch hub. Se-
cure hub on shaft with thrust washer and snap ring.
Key center of clutch shaft.
Litho in U.S.A.
TM-1102 (Nov-73) H-L-R Transmission 10-11
NOTE: Low clutch hub can be identified by two ra-

dial oil grooves on its gear face .
1- Press 5-Fiat Plates 1- Hub 3-Snap Ring

2-Shaft Protector 6-Reverse Clutch 2-Thrust Washer
3-Ciutch Disks 7-Low Clutch
4-Key 8--Snap Ring Fig. 23-lnstalling Snap Ring, Thrust Washer and Hub
Fig. 22-Pressmg Clutch Shaft into Dual Clutch Drum
Place low and reverse clutch drum on platform of a

press (Fig . 22). Place two flat plates (without notch-
es) in low clutch drum.
Alternate four disks and three plates in a pack.

(Plates should have notch on one tang.) Place thick
plate on top of pack. Position pack on splines of
clutch shaft hub as shown (Fig. 22).
.,.," ..·
Insert clutch shaft in drum as shown and line up

keyway. Press in clutch shaft, being careful to keep
disks up on splines. Also match tangs with slots in 1- Thrust Washer 2-Key
drum as you press shaft into bottom . Secure pack in
drum with snap ring. Fig. 24 -lnstatling Thrust Washer and Key
Install thrust washer over clutch hub pinion (Fig.

Turn over clutch assembly and install snap ring
24). If hub is all the way down , washer should just fit
(Fig. 23). Then install thrust washer. Spline hub to
down around shoulder of shaft as shown. Key shaft.
clutch disks by jiggling until it bottoms.
Press front clutch pack on shaft, aligning key.
Litho in U.S.A.
10-12 H-L -R Transmission TM-11 02 (Nov-73)
Fig. 26-lnsta//ing Sealing Rings on Clutch Shaft
Install five sealing rings on clutch shaft (Fig . 26).

Do this by placing ring in groove, pressing in on side
opposite joint, engaging tangs, and releasing.
1- Snap Ring 2- Hub
Fig. 25-lnsta//ing Snap Ring to Hold Front Clutch
Install snap ring in shaft groove to secure front

clutch (Fig. 25). Then install hub inside disks by jig-
gling until it bottoms.
Litho in U.S. A.
3
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14
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T2110 4
1-Special Cap Screw (9 used) 7- Bearing Cup (3 used) 12-Ball Bearing

2- Bearing Quill 8-Roller Bearing Cone (3 used) 13-Snap Ring
3-Shim (as required) 9-Needle Bearing 14-Bearing Quill
4-Bearing Cup 1o-Front Drive Shaft 15-Bearlng Quill
5-Roller Bearing Cone 11-Snap Ring 16-Underdrlve Countershaft
6-Reverse Counters haft
Fig. 27-Front Drive Shaft and Countershafts
Clean all parts thoroughly in solvent before in- Inspect shims on countershaft bearing quills for
specting . damage and replace as necessary.
Inspect front drive shaft bearing for possible dam- Inspect bearing cups and cones for excessive
age. Check to see that inner and outer race of bear- wear or damage. Replace if necessary.
ing is perfectly smooth . If either race is rough ,
replace bearing. Inspect roller bearing cones for damaged or worn
rollers.
Inspect splines on front of front drive shaft for wear
or possible damage. Inspect countershaft gears for excessive tooth
wear or broken teeth .
Check all snap rings for wear or "sprung" condi-
tion. Inspect quill attaching cap screws for excessive
wear or damage and replace as necessary. If nylock
Inspect front quill for cracks or other damage. Re- screws are not tight in threaded holes they must be
place if necessary. replaced.
Inspect pinions and collar gears for excessive To service the clutch control valve refer to Section
tooth wear or broken teeth. 50, Group 20.
To service the transmission pump refer to Section

50, Group 5.
Litho in U.S.A.
10-14 H-L-R Transmission TM- 1102 (Nov-73)
1- Link 4-Siot
2-Underdrlve Counter shaft 5-Reta inlng Ri ng
3- Reverse Countershaft
Fig. 28-Range Change Compartment

1-Shim Pack 2-51ot Facing Up
Lay countershafts loosely on case as shown (Fig.
28). Pull shafts forward through front bearing bores Fig. 29-lnstal/ing H· L· R Clutch and Control
to give extra clearance. As an aid in lining up gears Unit into Case
when installing clutch packs, loop a wire under rear
of each countershaft. Install vertical lubricating line in transmission case
before clutch pack is installed.
Proper end play of 0.003 to 0.005-inch [0.0762 to
0.1270 mm) in the underdrive countershaft and the Be sure correct shim pack is secure on rear shoul-
reverse countershaft is established by shims under der of clutch valve. (This shim pack sets the end play
their bearing quills. for the rear input. See page 40- 10-24.)
Install a dial indicator and measure end play in Using a gear puller clamped over rims of dual
each countershaft. Remove quill and add or deduct clutch drum as shown, lower clutch unit into case.
shims as necessary to obtain proper end play. Tilt down front of unit so that it slides past wall of
case. Then engage rear of unit in rear input slot and
When correct thickness of shim pack has been es- lower assembly into case. Be careful with shim pack.
tablished, secure quill with cap screws.
Install clutch pressure line in transmission case.
Turn range change shifter arm down so that link Position lubricating line and clutch pressure line in
lies against side of case as shown. manifold and tighten securely.
Slip retainer ring over rear input shaft and position

to rear of groove. Turn rear input so that slot on end
faces up for extra clearance (Fig. 28).
Litho in U.S.A.
Crawler - JD450-C Power 40
1- Lock Plate and 3-Retalner Ring

Cap Screws 4-Pin
2-Front Input Shaft
Fig. 31-lnstalling Countershaft Quills and
Operating Linkage
Fig. 3(}-H-L-R Clutches and Control Unit Installed
in Case
1. Secure front input shaft quill to case.
Loosely insert front input shaft and quill into case
to guide front of clutch unit. Carefully work assem- 2. Install countershaft quills and shim packs.
blies to rear while supporting parts with puller and
loops of wires. Make sure countershaft rear bearings NOTE: Be sure to match quills with their proper
guide into their cups and all gears are engaged. countershafts. Check identifying marks made during
removal.
Line up splines on rear of clutch shaft with splines
in rear input shaft. Pin holes must line up (see inset Check for free turning of all gears, rotating front
in Fig. 30). input shaft by hand. If gears are binding , loosen
quills and recheck alignment of shafts and gears.
Insert pin through clutch shaft and rear input, then
slide retainer ring forward into groove on rear input to 3. Lift up clutch valve and insert point of valve
hold pin in place. operating lever into valve slot, under roll pin. Offset
in lever must face to rear of case.
Install lock plate and cap screws on rear of case
wall. Draw up screws slowly and watch for any bind- 4. Insert valve operating shaft into case. Align hole
ing. in rear of shaft with hole in clutch valve lever and tap
shaft on through until holes line up. To avoid possi-
ble breakage, support lever while tapping shaft. Drive
spring pin through lever and shaft.
5. Install accumulator housing. Insert shift valve in

bore while lowering assembly onto mounting dowel.
6. Attach shifter link to shift valve arm and secure

with retainer ring.
Litho in U.S.A.
40 Power Train Crawler • J0450-C
10·16 H-L-R Transmission TA1- 1102 (Nov-73)
Speed Change and Ring Gear Units Slide shifter forks shaft forward into range change
compartment and lift shifter forks from speed change
Refer to page 40-10-2 for instructions on removing
compartment.
tractor components to gain access to the speed
change and ring gear compartments.
Remove speed shifter arm and Woodruff key from
shifter shaft on outside of transmission case and re-
move shifter cam and shaft.
NOTE: Shifter cam and shaft may also be re-

moved by removing the self-locking nut fastening
cam to shaft and lifting cam out of case. Camshaft
and shifter arm can then be removed from outside of
case.
1-Pinion Shaft Assembly 3-Shifter Cam

2- Rear Drive Shaft 4-Front Bearing Cup
Fig. 32-Removing Rear Drive Shaft
Carefully drive rear drive shaft front bearing cup

from its bore. Continue to drive front bearing cone off
shaft. Lift shaft subassembly from compartment. Re-
fer to Fig. 32.
1-4th Speed Gear 5-Rear Shifter Gear
Remove output shaft oil line. 2- Thrust Plate 6-Locklng Thrust Washers
3-3rd Speed Gear 7- Front Shifter Gear
Remove cotter pin, nut, snap ring and bearing, and 4-1st SpeGd Gear 8-Front of Tractor
shim pack from front of pinion shaft. Fig. 33-Untocking Thrust Washers on Pinion Shaft
Remove the ring gear quill attaching screws. Insert With cotter pin, hex. nut, bearing , shim pack, and
two of the cap screws in the quill threaded holes and spacer removed from front of pinion shaft, locate the
tighten evenly, forcing quill from case. Carefully re- three locking thrust washers on the pinion shaft (Fig.
move both ring gear quills and shims. Lift ring gear 33). From front of tractor to rear they are positioned
and housing from compartment. as follows: The first thrust washer is between the
front shifter gear and the 4th speed gear; the second
Remove shifter spring retainer, washer, shifter washer is located between the thrust plate and the
spring, detent ball retainer, and detent ball from port 3rd speed gear; the third washer is positioned be-
in transmission case. tween the rear shifter gear and the 1st speed gear.
Litho in U.S.A.
TM- 11 02 (Nov-73) H-L-R Transmission 10-17
To unlock the thrust washers, use a screw driver Carefully pull pinion shaft to the rear until it can be
to rotate the washers in their grooves until the lifted from the differential compartment (Fig. 34). As
splines on the shaft and washers index (Fig. 33). shaft is withdrawn, the gears and shifter collars will
Slide the washers to the front (see arrows, 34). Now slide off front of shaft. Place one hand under the
the pinion shaft can be removed. parts during shaft removal and lift them from speed
change compartment, keeping them in order to aid in
reassembly. If a thrust washer should become locked
when removing the shaft, repeat unlocking procedure
described above.
Clean all parts thoroughly in solvent before in-

specting.
Inspect front drive shaft bearing (9, Fig. 35) for

possible damage. Check to see that inner and outer
race of bearing is perfectly smooth. If either race is
rough, replace bearing.
Inspect splines on front of front drive shaft for wear

or possible damage.
Check all snap rings for wear or "sprung" condi-

1-Gears and Collars 2- Pinion Shaft tion.
Fig. 34 -Removing Pinion Shaft, Gears, and Collars
3
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T21104
1-Special Cap Screw S-Roller Bearing Cone 9-Needle Bearing 13-Snap Ring
(9 used) 6-Reverse Countershaft 10-Front Drive Shaft 14-Bearing Quill
2- Bearing Quill 7-Bearing Cup (3 used) 11-Snap Ring 1S-Bearlng Quill
3-Shim (as required) 8-Roller Bearing Cone 12-Ball Bearing 16-Underdrive Countershaft
4-Bearing Cup (3 used)
Fig. 35-Front Drive Shaft and Countershafts

Litho in U.S.A.
10-18 H-L-R Transmission TM-1102 (Nov- 73)
Inspect front quill (14) for cracks or other damage. Inspect shims for damaged condition. If replace-
Replace if necessary. ment is necessary, be sure to install new shims of
same thickness as those removed or readjust bear-
Inspect pinions and co llar gears for excess ive ings.
tooth wear or broken teeth.
Inspect roller and taper bearing cones for dam-
Inspect shims (3) on countershaft bearing quills for aged or worn rollers.
damage and replace as necessary.
Inspect bearing cups and cones for excessive
Inspect bearing cups and cones for excessive wear or damage . Replace if necessary.
wear or damage. Replace if necessary.
Inspect shaft retainer, lock plate, cap screws, and
Inspect roller bearing cones for damaged or worn snap rings for excessive wear or damage and re-
rollers. place as necessary.
Inspect countershaft gears for excessive tooth Inspect teeth on the four speed gears for exces-
wear or broken teeth. sive tooth wear or broken teeth.
Inspect quill attaching cap screws for excessive Inspect sh ifter gear collars (especia ll y splined
wear or damage and replace as necessary. If nylock hubs) for damaged condition.
screws are not tight in th readed holes they must be
replaced . Inspect teeth and splined hubs of both shifter
gears for excessively worn or damaged condition.
Inspect internal driving teeth of rear drive shaft (23,
Fig. 36) for excessive tooth wear or broken teeth.
1-Cotter Pin 9-Shifter Collar (2 used) 15---First Speed Gear 21-Bearing Cup
2-0utput Shaft Nut 1 ~Shifter Gear (2 used) (43 teeth) 22-Bearing Cone
3-Roller Bearing Cone 11-Thrust Washer (3 used) 16-Shim (as required) 23-Aear Drive Shaft
4-Bearing Cup 12-Fourth Speed Gear 17-Bearing Cup 24-Roller Needle
5---Snap Ring (26 teeth) 18--Bearing Cone 25---Bearing Cone
6-Shim (as required) 13-Thrust Plate 19-Pin 26-Bearing Cup
7- Spacer 14-Third Speed Gear 2~Pinion Shaft with 27-Shim (as required)
8--Second Speed Gear (32 teeth) Ring Gear 28-Retaining Ring
(38 teeth)
Fig. 36-Speed Change Gears and Shafts
Litho in U.S.A.
Inspect roller bearing cones for damaged or worn Inspect ring gear and hub (13, Fig. 37) for cracks
rollers. or excessive wear.
Inspect locating pin in threaded end of pinion shaft Inspect bearing cups (7) in the two quills for ex-
for damage. If pin is bent or sheared off, replace with cessive wear and replace as necessary.
new pin.
Inspect bearing cones (6) for worn or damaged
IMPORTANT: If pinion shaft is no longer ser- rollers. When new bearings are installed, always
viceable and must be replaced, it will be neces- check bearing preload and ring gear backlash as de-
sary to replace the ring gear and hub also as scribed on page 40- 10-20.
these parts are furnished only as matched sets.
If oil seal (3) in quill is worn or damaged , install
Inspect thrust plate and washers for wear or dam- new seal with sealing lip to inside of quill. Coat lip of
age. Replace if necessary. seal with Lubriplate.
Inspect pinion shaft retaining hex. nut for stripped Inspect tubes (1) in quill for wear or damage. If re-
threads. Examine shims and spacer for damage. Re- placement is required, press in new tube until inner
place parts as necessary. end is flush with inside edge of bore.
Inspect pinion shaft front and rear bearing cups for Inspect ring gear and pinion teeth for excessive
excessive wear or damage. Install rear cup with large wear and tooth damage. If wear is excessive, it will
diameter facing to the rear and install front cup with be necessary to replace the ring gear and pinion
large diameter facing to the front. shaft as a matched set.
NOTE: If either a new transmission case, a new

ring gear hub quill, or a new ring gear and hub pinion
shaft set are to be installed, it will be necessary to
readjust pinion shaft preload and to readjust pinion
and ring gear backlash.
1-Tube (2 used) 4-Bearlng Cup 7-Bearing Cup 1G-Loc k Washer (12 used)
2- Quill 5-Bearing Cone 8-Quill 11-Shim (as required)
3-0il Seal (2 used) 6--Bearing Cone 9-Cap Screw (12 used) 12-0·Ring (2 used)
13-Pinion Shaft with Ring Gear
Fig. 37-Ring Gear and Hub
Litho in U.S.A.
Clean transmission case thoroughly and inspect for It is essential that the cone point of pinion be ex-
cracks or other damage. Remove all lose parts which actly on centerline of ring gear as shown in Fig. 38.
may have dropped in case.
This relationship is obtained by controlling the
When installing a new transmission case, ring gear number of shims between the output shaft rear bear-
and pinion set, rear input shaft, or the bearing quills, ing cups and transmission case.
cones, or cups which support these parts, it will be
necessary to make certain adjustments to be sure of To determine number of shims required proceed
proper tooth contact, quiet operation, and longer ser- as follows:
vice life . These adjustments are as follows:
A. Use the figure 1.4375 inches [36.576 mm] as a
1. Cone Point Adjustment nominal measurement of the height of the output
shaft beari ng cone and cup.
The pinion is actually a part of a cone; that is, if
B. Observe the actual dimension stamped on the
the pitch lines of the pinion teeth were extended they
top rear of the transmission case . This dimension is
would come together at a cone point (Fig. 38). The
the distance from the centerline of the ring gear
dimension which is etched on the end of each pinion
crossbores to the output shaft bearing cup backing
is the actual distance from the base of the pinion
shoulder in the transmission case.
gear to the cone point.
C. Observe the dimension etched on the ground
face of the bevel pinion. (Use 6.335 inches [ 161 .036
mm) for the bevel pinion shaft only if no dimension is
etched on the ground face).
D. To determine shim pack, subtract the measur-
ements found in Steps A and C from measurement
observed in Step B.
Example : 6.335 inches [161.036 mmJ, the number

etched on the pinion, plus 1.4375 inches [36.576
mm), the nominal bearing cone and cup measureme-
nt, equals 7.7725 inches [ 197.612 mm]. Subtracting
this from 7.7945 inches [ 197.866 mm], the number
etched on the transmission case, equals 0.022 inch
[0 254 mm]. the total thickness of shims that must be
added.
After correct shim pack has been installed behind

bearing cup, proceed with "Ring Gear Bearing Pre-
load Adjustment."
2. Ring Gear Bearing Preload Adjustment

Two adjustments of the ring gear and hub assem-
bly are necessary for quiet and proper operation.
They are:
a. Preload on bearings.
b. Backlash between ring gear and output shaft
pinion .
1- Ring Gear 5-Shims
2-Cup 6-0imension of Pinion These adjustments are made by use of shims lo-
3-Bearing Cone 7- Etched Dimension on
cated between the transmission case and ring gear
4-Differential Compart- Pinion
ment Front Wall S-Cone Point hub bearing quill {Fig. 39). The total thickness of
shims on both sides determines the preload. Back-
Fig. 38-Ring Gear and Pinion Cone Point Adjustment lash is established by shifting shims from one side to
the other. Preload must be adjusted before checking
backlash.
Litho in U.S. A.
3. Pinion Shaft Bearing Preload Adjustment

Pinion shaft must have a preload (0.003 to
0.005-in. [0.0762 to 0.1270 mm]). This preload is ob-
tained by varying the number of shims behind the
front bearing cone. Refer to Fig. 36, for parts identifi-
cation and sequence of assembly.
To establish preload on pinion shaft, proceed as

follows:
Install bearing cup (4) and snap ring (5) in front

wall of speed change compartment. Position shim
pack (16), bearing cup (1 7), and bearing cone (18).
Install pinion shaft and one gear (as a means of

holding shaft from turning). Position spacer (7) on
front of shaft with chamfered edge of hole against
shoulder of shaft with locating pin in pinion shaft in-
dexed in slot on spacer. A "pip" mark on threaded
1-Left Hand Quill 4-Ring Gear and Hub
2-Right Hand Quill &-Space end of pinion shaft indicates proper location of pin in
3-Shims shaft. Install a preliminary shim pack (6) on shaft and
install front bearing cone and nut. Tighten nut se-
Fig. 39-Ring Gear and Hub Bearing Preload Adjustment curely.
To determine thickness of shim packs required to Seat bearing cups by lightly tapping on shaft. In-
preload ring gear bearings to 0.002 to 0.005 inch stall a dial indicator and measure introduced end
[0.0508 to 0.1270 mm), proceed as follows : play on shaft (Fig. 40). Rotate the shaft while taking
the reading. If there is no end play, remove nut and
Place the ring gear and hub assembly in transmis- bearing cone and add enough shims so there is a
sion case (refer to Fig. 39 for identification of parts measurable amount of end play.
and sequence of installation).
As a starting point, use no shims between the

transmission case and the right-hand ring gear hub
bearing quill.
Install right-hand quill so that the right-hand bear-

ing cone fits into the right-hand bearing cup. Secure
with cap screws .
Install the left bearing quill with enough shims to

obtain a measurable amount of end play.
The measured end play plus 0.002-inch [0.0508

mm] subtracted from the left bearing quill shim pack
will give the specified preload.
Once ring gear bearing preload has been set, re-

move ring gear from transmission case being sure
that right-hand quill (and its shims) and left-hand quill
(and its shims) are tagged and kept together so that 1- Pinion Shaft 2-Dial Indicator
they may be correctly reinstalled.
Fig. 40-Measuring Preliminary End Play in Pinion Shaft
Litho in U.S.A.
10-22 H-L-R Transmission TM-11 02 (Nov- 73)
IMPORTANT: For a more acc urate bearing pre- final assembly of shaft. Position roller bearing cone
load setting, introduced end play should not ex- (3) and thread hex. nut on shaft
ceed 0.005-in. [0.1270 mm]. End play readings in
excess of this figure cannot be measured accu- IMPORTANT: Before tightening hex. nut, be
rately because the roller bearing easily becomes sure pin on output shaft is indexed with slot on
misaligned. Also, the longer indicator travel is spacer or pin may be damaged or broken off.
difficult to measure accurately.
Keep shaft from turning and tighten nut to 300 lb-ft
Record measured end play shown by dial indicator [41.476 kg-m] lining up a slot with one hole in end of
and take from shim pack the thickness of shims pinion shaft. (If cotter pin hole in shaft does not line
equal to end play reading to give the desired preload up with a slot, tighten until hole does line up-do not
(0.003-0.005 in. [0.0762-0.1270 mm] and 6 to 12 lb. loosen.)
in. [0.069-0.138 kg-m] rolling torque.)
Remove blocking from behind pinion shaft.
To check or ad just ring gear preload, it will be nec-
essary to remove pinion shaft at this time. Be careful Install speed change shifter cam shaft oil seal in
that pinion shaft preload shim pack is not damaged transmission case with sealing lips facing inward.
or lost. Coat lip of seal with John Deere multi-purpose
grease or an equivalent prior to installing shifter cam
Refer to Fig. 36 for identification of parts and se- shaft.
quence of installation.
Assemble shifter cam and shaft using self-locking
Insert pinion shaft with rear bearing cone into rear nut.
end of speed change compartment Slide shaft for-
ward about one-half the distance of the shaft and in- IMPORTANT: Remove burrs or other damage
stall parts in the following sequence : from shaft that may ruin oil seals during assem-
bly.
First install first speed gear (15) (small teeth to
front); then slide a locking thrust washer (with outside NOTE: Be sure to align "V" mark on shifter cam
tangs) on shaft; next install rear shifter gear and col- with "V" mark on cam shifter shaft. The shifter will
lar (9 and 10). not function unless the two marks are properly
aligned.
Inch pinion shaft forward and install third speed
gear (14) (small teeth to rear) on shaft, followed by a Install cam and shaft in speed change compart-
locking thrust washer and thrust plate. After moving ment with grooves facing center of compartment.
the shaft further into speed change compartment, in-
stall the fourth speed gear ( 12) (small teeth to front)
and another thrust washer.
Slide shifter gear and shift collar on pinion shaft.

Install second speed gear (8) (small teeth to rear) .
NOTE: Before completing pinion shaft assembly,

refer to "Speed Change Shifter Mechanism " on this
page.
Position spacer with large diameter of spacer fac-

ing to the rear. Install previously established shim
pack (6).
Slide pinion shaft all the way to the front, indexing

the small pin on the shaft with slot in spacer. (A
"pip" mark on end of shaft indicates proper position
of pin.) Place a wooden block against the rear of the
pinion shaft to hold it securely in place to facilitate
1- 1st and 3rd Speed Fork 3-2nd and 4th Speed Fork
2- Shlfter Forks Shaft
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Fig. 41-lnsta//ing Speed Change Shifters
Key shifter arm to cam shifter shaft and secure Proper end play (0.003 to 0.005-in. [0.0762-0.1270
cap screw. mm]) in the underdrive countershaft is established by
shims under the bearing quill.
Install detent ball, retainer, spring , washer and re-
tainer in rear port of speed change compartment. Install a dial indicator as shown in Fig. 42 and
measure end play in countershaft. Remove quill and
Install 2nd and 4th speed shifter fork on shifter fork add or deduct shims as necessary to obtain proper
shaft so that fork seats in groove of forward shifter end play.
collar and roller seats on rear groove of shifter cam
(Fig . 41). NOTE: Remove quill and shim pack so shaft can
be free for installation of H-L-R clutch packs. Keep
Install 1st and 3rd speed shifter fork on shifter fork shims together with quill.
shaft so that fork seats in groove of rearward shifter
collar and roller seats in front groove of shifter cam. After installation of H-L-R clutch packs, position
shim pack and secure quill with cap screws.
Install underdrive countershaft with long end to
rear. Install reverse countershaft with long end to rear.
Install underdrive countershaft bearing quill with Install reverse countershaft bearing quill with shim
shim pack. pack.
Prope r end play ( 0 .003 to 0 .005 - in.)

[0.0762-0. 1270 mm] countershaft is established by
shims under the bearing quill.
1- Dial Indicator 2- Bearing Quill
Fig. 42-Measuring End Play in Underdrive Countershaft
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10-24 H-L-R Transmission TM- 1102 (Nov-73)
Install a dial indicator as shown in Fig. 42, and

measure end play in countershaft. Remove quill and
add or deduct shims as necessary to obtain proper
end play.
NOTE: Remove quill and shim pack so shaft can

be free for installation of H-L-R clutch packs. Keep
shims together with quill.
After installation of H-L-R clutch packs, position

shim pack, and secure quill with cap screws.
Install rear input shaft into speed change compart-

ment and out through bore of compartment front wall,
and then slide shaft rearward until rear taper bearing
cone is seated in its cup. Install front bearing cone
and cup.
Install clutch oil manifold (Fig: 43). Use a shim

pack on rear shoulder. Install lock plate and three
cap screws on rear of wall to secure unit. Draw up
valve slowly and watch for any binding. Make sure
that shaft does not begin to bind, and rotate shaft to 1-H-L-R Clutch Oil Manifold 3-Dial Indicator
be sure bearings are seating properly. Tighten cap 2-Shim Position
screws securely.
Fig. 43-Measuring End Play on Rear Input Shaft
Proper end play in the rear input shaft is set by
shims on the rear shoulder of the H-L-R clutch oil When proper end play has been obtained, remove
manifold (0.003-0.005-in.) (0.0762-0.1270 mm]. clutch oil manifold . Keeping proper shim pack togeth-
er.
Install a dial indicator against the 4th speed gear
as shown in Fig. 43 and measure end play in shaft To determine amount of shims required to provide
while moving rear input with a small bar as shown. specified backlash (0.006-0.008-in.) [0. 1524-0.2032
Remove clutch oil manifold and add or deduct shims mm) between ring gear and pinion, proceed as fol-
as necessary to obtain proper end play. lows:
IMPORTANT: Avoid heavy pressure on pry bar Reinstall the ring gear and h ub assembly and
when checking end play. quills with their proper number of shims as deter-
mined in "Ring Gear Bearing Preload Adjustment"
(page 40-1 0-20). Be sure to install new 0-rings on
quills.
Tighten all quill attaching cap screws securely.
Set up a dial indicator as shown in Fig. 44, and

measure backlash at several different points around
the entire circumference of ring gear. If backlash
reading is 0.006-0.008 in. [0.1524-0.2032 mm].
backlash is set.
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Refer to page 40-1 0-14 and install countershafts in

range change compartment. Position clutch unit in
case as described.
Install countershaft quills. See page 40-10-15.
Install transmission front cover.
Fig. 44-Measuring Pinion and Ring Gear Backlash
To decrease backlash, transfer shims from left quill

to right quill. To increase backlash, transfer shims
from right side to the left side.
IMPORTANT: If shims are removed from one Fig. 45-lnstalling Transmission Front Cover
bearing quill, same thickness of shims must be and Oil Pump
added to the other bearing quill to maintain prop·
er preload adjustment on ring gear bearings. 1. Oil line must not touch accumulator housing or
lube line fitting.
NOTE: Backlash is reduced or increased an
amount less than the shim thickness. 2. Install accumulator housing cap screws and
tighten securely.
Backlash movement compared to shim thickness is
as follows: 3. Install transmission front cover, using a new
gasket. Be sure that cooler bypass valve and spring
Approximate are in bore in rear of cover. Secure front cover with
Shim Backlash cap screws, hex. nuts, and lock washers shown .
Thickness Movement
4. Tap arm onto shaft and secure with spring pin .
0.0 10-inch [0.254 mm] 0.008-inch [0.203 mm]
0.005-inch (0.127 mm] 0.004-inch [0.102 mm]
IMPORTANT: To avoid possible breakage of
0.002-inch [0.051 mm] 0.0016-inch [0.0255 mm]
clutch valve arm, support rear end of shaft while
driving on front arm.
5. Apply Lubrip late to lips of oil seal in pump

cover.
6. Place outer and inner rotors in pump cover and

install new sealing ring in cover groove. Slide cover
onto front input shaft with a slow rotary motion. Align
cover on dowels and secure with cap screws and
lock washers.
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10-26 H-L-R Transmission TM-1102 (Nov-73)
Install transmission top cover. Use Loctite plastic INSTALLATION

gasket (AT26341 or an equivalent) to seal transmis-
Refer to page 40-1 0-2 and reverse removal proce-
sion top covers.
dure used.
Be sure clutch lubricating bypass valve spring and
plug are in bore in top front of case. Tighten screws
down evenly to avoid stress on cover and then tight-
en them to 50 lb-ft [6.913 kg-m] front and 35 lb-ft
[ 4.839 kg-m] rear.
Connect rods to steering levers.
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TM-1102 (Nov- 73) H-L-R Transmission 10-27
GEAR SHIFT AND H-L-R LEVERS QUADRANT
T32042N
1- Cover 5--Bolt (2 used) 9-Spring 13-Lock Lever

2- Cap Screw (3 used) ~Washer 10-Cap Screw (2 used) 14-Set Screw
3-Lock Washer (5 used) 7- Neutral Lock 11- Quadrant
4-Nut (3 used) 8--Steel Ball 12- Spring Pin
Fig. 46-Gear Shift and H-L-R Levers Quadrant
Refer to Fig. 46 for identification and location of Refer to Fig. 47 for location of parts during disas-
parts. sembly and assembly.
Remove seat cushion and take out cap screws Remove cotter keys and pins from H-L-R lever rod
and hex. nuts fastening cover (1) to side of battery (17) and gear shift speed change link (19) .
box.
Remove bolt (1 ), spacer, lock washer and nut.
Remove knobs (1 0, Fig. 47) from gear shift and H-
L-R levers. Examine pivot (7) for cracks or wear and replace if
necessary.
Lift quadrant assembly from mounting and place
on bench for further disassembly if needed . Inspect pivot bushing (6) for damage or excessive
wear. If necessary, press in new bushing flush to
When disassembling the quadrant (11, Fig. 46), be edge of pivot.
careful not to lose steel ball (8).
Inspect H-L-R lever rod (17) and gear shift speed
Inspect parts and replace as needed. change link (19) for bent condition.
Assemble quadrant before installing to battery box.
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GEAR SHIFT AND H-L-R LEVERS AND LINKAGE
Q-10
Q-10
11
17
5 18
I
T2~760 ~ 1
1-Bolt 6---Bushing 11-H-L-R Lever 17- H-L-R Lever Rod
2-Spacer 7-Pivot 12- Nut 18--Pin
3--Spacer 8--Pin (3 used) 13--Lock Washer 19-Link
4-Spring 9-Gear Shift Lever 14-Spring Pin (2 used) 20--Voke
5--Cotter Pin (4 used) 10--Knob (2 used) 15--Voke 21- Washer
16---Nut (2 used) 22-H- L-R Lever Pivot
Fig. 47-Gear Shift and H-L-R Levers and Linkage
Assemble levers to pivots using spring pins. Be Adjust adjustable yoke (20, Fig. 47) to position
sure spring pins are installed properly between pivots gear shift lever (9) an equal distance from gear shift
and levers. lever position pin in second and third detent posi-
tions.
Position pivot and lever assemblies in battery box.
Check to be sure spring (4) is properly positioned in Install pin and cotter pin. Tighten the yoke jam nut.
recess.
Connect linkage previously removed.
Position shift and H-L-R levers quadrant (1 1, Fig.

46).
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H-L-R Lever Adjustment

Shift H-L-R lever (11, Fig. 47) in neutral detent
(between high and reverse).
Hold H-L-R lever against back edge of slot in neu-

tral lock (7, Fig. 46). Apply pressure to take play out
of neutral lock.
Starting with the H-L-R rod yoke (15, Fig. 47) ad-
just long. Shorten the H-L-R rod yoke until pin (8)
slips through the yoke and pivot arm (22). Turn yoke
1/2 additional turn but not so short that the pin will
not slide freely into yoke and pivot arm.
Install pin and cotter pin. Tighten the yoke jam nut.
Litho in U.S.A.
Litho in U.S.A.
TM-1102 (Nov-73) Steering Clutch and Brake Assembly 15-1
Group 15
STEERING CLUTCH AND BRAKE ASSEMBL V
GENERAL INFORMATION
1--Brake Band Yoke 6--Brake Lever 11--Brake Anchor

2--Link 7--Adjustlng Nut 12--Brake Band
3--Adjusting Link 8--Sprlng 13--Pin
4--Brake Lever Adjusting Screw 9--Stud 14--Brake Lever Shaft
5--Jam Nut 1G-Brake Strut 15--Brake Drum Set Screw
Fig. 1-Steering-Brake Assembly
The combination clutch and brake mechanism on In addition , a brake pedal is used to stop tractor
each rear axle engages or disengages the flow of motion on both axles by means of a contracting
power to each rear axle by means of individual steer- brake band device. The relationship of steering
ing fevers. clutch and brake linkage is shown in Fig. 1.
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15-2 Steering Clutch and Brake Assembly TM- 11 02 (Nov-73)
REMOVAL Disconnect spring (3, Fig. 2) from pin (4). Remove

pin and lift brake anchor (5) from case.
NOTE: Alternate method of removing steering
clutch assembly without removing final drive housing
Back off brake drum set screw (15, Fig. 1) and re-
is to disconnect track assembly and remove track
move bearing quill.
drive sprocket. Refer to Section 60, Groups 5 and
10.
Remove pressure line (2, Fig. 2) and leak off line
from steering clutch.
Disconnect all the necessary w1nng, linkage and
lines from rear tank unit (hydraulic reservoir, battery
Support steering clutch assembly. This can be
box and fuel tank). Remove cap screws securing
done by drawing both ends of the brake band togeth-
rear tank unit support to steering clutch housing and
er with a heavy wire. Position hoist to lift between
lift rear tank unit from machine.
brake band ends.
Remove steering clutch housing cover.
Remove pinion shaft bearing quill (2, Fig. 5, page
40-20-3). Install suitable puller in threaded center
hole of pinion shaft (1 0) and carefully remove shaft.
Remove steering clutch drive shaft (pull through fi-

nal drive housing).
Lift steering clutch assembly from case.
To serve steering clutch housing, remove final

drive assembly. Refer to Section 40, Group 20.
1-Steering Clutch 4-Pin

2- Pressure Line 5-Brake Anchor
3-Spring
Fig. 2-Brake Anchor Location
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TM-1102 (Nov-73) Steering Clutch and Brake Assembly 15-3
REPAIR
T31245
1-Brake Lever Shaft 1Q-Pin (2 used) 19-Link

2-Special Washer 11- Retainlng Ring (4 used) 2Q-Pin
3-Snap Ring 12- Brake Strut (2 used) 21-Pin
4-Adjusting Nut 13-Brake Yoke 22-ou Seal
5-Spring 14-Stud 23-Spring
6--Brake Band Yoke 15-Brake Band 24-Brake Lever
7-Snap Ring 16--Snap Ring (5 used) 25-Groove Pin
8-Pin 17- Special Washer
9-Brake Anchor 18-Adjusting Link
Rg. 3-Brake Anchor and Band
Check brake band (15, Fig. 3) for worn condition. When installing pin (8) the snap ring groove must
Replace if cross hatch pattern of lining has worn thin. be to the left as seen from the operator's seat.
Check pins ( 10) for bent or worn condition. Re- Check springs (23) and (5) for broken coils.
place as needed.
IMPORTANT: When assembling brake anchor
Replace any parts which may show damage or ex- assembly in steering housing, make certain brake
cessive wear. struts (12) are engaged properly with the brake
band.
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15-4 Steering Clutch and Brake Assembly TM-11 02 (Nov-73)
T31235
1-Snap Ring 9-Ciutch Hub 17-Sealing Ring (2 used)

2- Steerlng Brake Drum 10-Sealing Ring 18-011 Seal
3-Jam Nut 11-Sealing Ring 19--Ciutch Pressure Manifold Ring
4-Set Screw 12-Ball (2 used) 20-Special Washer
5-Driving Plate (8 used) 13-Ciutch Piston Housing 21-Snap Ring
6-Steering Clutch Facing (8 used) 14-Washer (6 used) 22-PIIot Ball Bearing
7-Snap Ring 15-Cap Screw (6 used) 23-Drive Shaft
8-Steering Clutch Hub 16-011 Seal
Fig. 4-Steering Clutch Assembly
Remove pressure plate and inspect steel plates 1. Install one composition facing against the brake
and composition facings for burrs, warpage, or ex- drum.
cessive wear. Excessive wear can be detected by
comparing the thickness of contact areas with that of 2. With snap ring in place on hub, alternately in-
noncontact areas. stall eight steel plates and seven composition facings
on hub.
All plates and facings should be flat and free from
defects of any kind. Examine brake drum for galls or 3. Install pressure plate and tighten cap screws to
scores. Remove any defects which may cause the specifications.
brake to drag or operate improperly.
Examine splines on shaft for damage or abnormal
wear. Clutch hub is not intended to be a tight fit on
clutch drive shaft. Do not be concerned if it is slightly
Install steel driving plates and composition facings loose.
in hub as follows:
Litho in U.S.A.
TM-11 02 (Nov-73) Steering Clutch and Brake Assembly 15-5
1-Bearing (4 used) 7-Pin (4 used) 13--Washer (2 used)

2-Steerlng Lever, R.H. 8-Brake Rod (2 used) 14-Pickup Lever, L.H.
3--Pickup Lever, R.H. 9-Jam Nut (2 used) 15-Steering Lever, L.H.
4-Washer (2 used) 10-Adjustable Yoke (2 used) 16-Steering Lever Shaft
5-Snap Ring (2 used) 11-Ciutch Rod (2 used) 17-Set Screw
6-Cotter Pin (4 used) 12-Cotter Pin (4 used)
Fig. 5-Steering Levers and Rods
Examine bearing (1, Fig. 5) for worn condition. Re- Inspect brake rods (8) and clutch rods (11) for bent
place as needed. condition. Replace as needed.
Check steering lever shaft (16) for bent or worn

condition.
Litho in U.S.A.
15-6 Steering Clutch and Brake Assembly TM-1102 (Nov- 73)
1-Brake Pedal 7-Brake Lever (2 used) 12- Brake Lever

2-Brake Lock 8-Brake Rod (2 used) 13-Set Screw
3-Yoke (2 used) 9- Sprlng 14-Nut
4-Cotter Pin (4 used) 10--Sprlng Pin (3 used) 15--Washer
5--Pin (4 used) 11- Brake Shaft 16-Washer
6-Nut (2 used)
Fig. 6-Brake Pedal and Shaft
Check brake rods (8, Fig. 6) for bent condition. Install brake rods (8) and brake lock (2) prior to in-
stallation of platform.
Inspect brake levers (7) and (12) for excessive
wear. Replace as needed. Adjust brake lock (2) with washers (1 5) as required
(not to exceed a total of four) to provide 0.125 inch
Examine brake shaft ( 11) and replace if excessive- [3.200 mm] contact between the platform and brake
ly worn or damaged . lock.
Tighten special set screw (13) to 170 lb-ft [23.503

kg-m]. Next tighten nut (14) to 105 lb-ft [14.517 kg-
m].
Litho in U.S.A.
TM-1102 (Nov-73} Steering Clutch and Brake Assembly 15-7
ADJUSTMENT INSTALLATION
Refer to "Removal" on page 40-15-2 and reverse
procedure.
1-Brake Lever 4-Brake Lever

Adjusting Screw 5-Dimension 3.06-in.
2-Jam Nut [n .724 mm)
3-Steering Clutch 6-Pin
Housing
Fig. 7-Nomina/ Brake Lever Adjustment
Adjust brake lever adjusting screw (1, Fig. 7) to

position brake lever (4) so that dimension from top of
pin (6) to top of steering clutch housing is 3.06 inch
[77.724 mm]. Tighten jam nut (2).
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15-8 Steering Clutch and Brake Assembly TM-11 02 (Nov-73)
Litho in U.S.A.
TM- 1102 (Nov- 73) Final Drive Assembly 20-1
Group 20
FINAL DRIVE ASSEMBLY
GENERAL INFORMATION
1-Pinlon Shaft 4-Final Drive Housing 7-0il Pan

2-Shlms for Preload Adjustment ~il Seal with Belleville Washers 8-Bull Gears
3-Track Drive Sprocket &-Flanged Axle Shaft 9-Nut for End Play Adjustment
Fig. 1-Final Drive Assembly
The final drive assembly transmits power from the Each final drive unit contains one rear axle mount-
steering clutches to the rear track drive of the ma- ed on two tapered roller bearings and driven off the
chine. final drive pinion by a large bull gear.
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40 Power Train Crawler - J0450-C
20-2 Final Drive Assembly TM-11 02 (Nov- 73)
REMOVAL
Raise one side of tractor by placing floor jack se-

curely under front cross member. Start engine and
shift transm ission into first gear. Pull back on steer-
ing lever that controls track not raised off floor (this
disengages steering clutch and applies brake to that
side). Engage engine clutch, permitting raised track
to rotate until master pin has moved around drive
sprocket and is approximately 6 inches from floor.
CAUTION : Be sure that track to be rotat-

A ed is clear of floor and opposite track is
locked in position so that crawler does not move.
Remove sprocket shield or sprocket weight from

machine.
A special tool used in the removal and installation

of crawler sprocket weights may be produced locally.
See Fig. 2.
1- Set Screw 3-Shlms

2- Piug 4-Bearing Quill
Fig. 3-Removing Final Drive Pinion Shaft
Remove final drive bearing quill and plug. Rotate

steering clutch until set screw is visible in hole and
loosen set screw.
Install suitable puller in threaded center hole of fi-

nal drive pinion shaft and remove shaft.
Fig. 2-Removing Sprocket Weight
Position special tool as shown in Fig. 2 to remove

or install sprocket weights .
Release track tension, remove track master pin

and move track assembly clear of drive sprocket.
Drain oil from final drive housing and remove track

drive sprocket from unit.
Fig. 4-Removing Final Drive
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TM-1102 (Nov-73) Final Drive Assembly 20-3
Under tractor, remove two inner cap screws at- Using a hoist. lift final drive assembly away from
taching steering clutch housing to final drive. steering clutch housing. The special yoke shown in
Fig. 4 can be constructed from 1/ 2-inch round stock
Remove cap screws which hold final drive housing and will facilitate removal of the final drive assembly.
to steering clutch housing.
REPAIR
1-Cap Screw (2 used) 11- Ball Bearing 22-Bearing Cone 33-Cap Screw (9 used)
2- Quill 12-Bearing Cone 23-Bearing Cup 34-Washer (9 used)
3-Shim (as required) 13-Bearing Cup 24-Piug (4 used) 35-Stud
4-Bearlng Cup 14-011 Seal 25-Spacer 36-Nut
~Bearing Cone 1~ap Screw (4 used) 2&-Washer (4 used) 37-Lock Washer (3 used)
&-Cap Screw (2 used) 1&-Lock Washer (4 used) 27- Spacer 38-Gear
7-Cap Screw (2 used) 17-Cover 28-Bearlng Cup 39-Gasket
8-Housing 18-Gasket 29-Bearlng Cone 40-0il Pan
9-0owel (3 used) 19-Cotter Pin 30-0il Seal Kit 41-Piug
1O-Pinion Shalt 20-Siotted Nut 31-0il Seal 42-Lock Washer (12 used)
21-Special Washer 32-Fianged Axle 43-Cap Screw (12 used)
Fig. 5-Fina/ Drive Assembly
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20-4 Final Drive Assembly TM-1102 (Nov-73)
Remove oil pan and inner bearing cones. Examine splines on axle shaft for galling or exces-
sive spline wear. Remove all metal deposits from
Remove slotted nut and the two pipe plugs from splines caused by galling. Inspect final drive gear for
the final drive housing. wear or damage to gear teeth or splines.
Carefully inspect bearings for wear which may

have been caused by foreign material entering the
housing through a damaged seal. Inspect the final
drive housing for any damage which would make it
unserviceable.
IMPORTANT: Belleville washers on the flanged

axle oil seal must be replaced every time axle
shaft is removed frorn final drive housing.
Exam ine sealing faces for wear to determi ne

whether seal rings can be reused or must be re-
placed. If highly polished sealing band is in the mid-
dle or toward the outside of the seal face, sealing
rings can be reused . If highly polished sealing band
is not uniform or is toward the inside of the seal face,
Fig. 6-Removing Flanged Axle sealing rings must be replaced.
Use push-puller to remove flanged axle shaft (Fig.

6). Then slide flanged axle and related parts free
from housing.
Examine the final drive pinion shaft (1 0, Fig. 5) for

excessive spline wear and damage to the oil seal
and bearing contact areas. The oil seal and bearing
contact areas must be free of nicks, bu rrs, and
roughness. Check pinion for damaged or excessively
worn gear teeth. Replace pinion shaft if necessary.
Inspect bearing (11) inside final drive pinion shaft

If replacement is necessary, install new bearing in
pinion shaft with open side toward the shaft.
Inspect bearing quill (2) and housing (8) for dam-

age or excessive wear and replace if necessary. Ex-
amine oil seal ( 14) in housing and replace if it has
permitted oil to leak into clutch housing . Install new
seal wit h lip pointing toward inside of final drive 1-Fianged Axle 4-Metal Sealing Rings
housing. Seal should be pressed in flush with bottom 2-Axle Bearing Spacer 5-Rubber Sealing Rings
of bearing cone . 3-0il Seal Bearing Area 6-Piastic Retainer Band
Fig. ?-Replacing Flanged Axle Oil Seal

Remove bearing and seal housing from flanged
axle by attaching a knife-edge puller under housing. 1. Clean the bores and shoulders where oil seal
fits with a cleaning solvent and wipe dry. Surfaces
that contact rubber sealing rings must be free of
grease, oil, dirt, and scale.
Litho in U.S.A.
TM-11 02 (Nov-73) Final Drive Assembly 20-5
2. Remove and discard retainer band from seal.

Check rubber sealing rings to be sure they are flush
against the inside shoulder of the metal sealing rings.
3. All seal parts must be free of grease. oil . dirt,

and scale.
4. Sealing rings must be handled with care. The

lapped sealing faces of the metal sealing rings must
not be damaged, scratched, or contaminated with dirt
or grease.
5. Install one seal half (metal ring and rubber ring)

into the final drive housing. Install second seal half
(metal ring and rubber ring) into the flanged axle.
Check each sea l half to be sure that seal is not
cocked and that rubber rings are seated evenly at
the bottom of the bore.
6. Wipe both metal sealing faces clean with a lint Fig. B·Measuring Axle Shaft Introduced End Play
free wiper and apply a thin film of clean SAE 30 oil.
Install inner bearing cover with a new gasket and
IMPORTANT: Oil must not wet areas other than tighten cap screws securely.
the lapped surface of the metal sealing rings.
Install final drive oil pan with a new gasket and
Press the outer bearing cone against shoulder on tighten all cap screws securely.
the flanged axle.
Before installing final drive housing on machine, in-
Slip outer spacer onto axle. stall final drive pinion shaft in housing. Install a pre-
liminary shim pack to record a measurable amount of
Roll final drive gear into housing. end play. Install bearing quill and torque retaining
cap screws.
IMPORTANT: Make certain gear is inserted
with long hub end toward sprocket side of hous- Using a dial indicator, record the end play and take
ing. from the shim pack the thickness of shims equal to
end play reading plus an additional 0.002 [0 .0508
When installing flanged axle shaft, avoid getting mm] inch to give the desired preload setting .
any dirt, oil, or other foreign material on oil seal.
Retain the proper shim pack and remove pinion
Place inner spacer in end of shaft with shoulder shaft from final drive housing for final assembly of
facing away from gear. Start inner bearing cone on steering clutches in machine.
shaft. Place washer on end of shaft and start slotted
hex. nut on shaft. Before final installation of bearing quill and shims,
apply a light coat of sealer to the quill and the final
With all parts assembled on flanged axle shaft, drive housing.
tighten slotted hex. nut to give 0.002 to 0.005-inch
[0.0508 to 0.1270 mm] end play as shown in Fig. 8.
Advance nut if necessary, to line up slot in nut with
cotter pin hole in shaft. Then tighten nut ONE addi-
tional slot and lock with cotter pin.
Litho in U.S.A.
20-6 Final Drive Assembly TM-1102 (Nov-73)
INSTALLATION
Before installing final drive housing on tractor, in-
stall final drive pinion shaft in housing and determine
the number of shims necessary behind quill to obtain
0.0000 to 0.0030 inch [0.0000 to 0.0762 mm] pre-
load. (See page 40-20-5 for details). Then remove fi-
nal drive pinion shaft and proceed with installation by
reversing removal procedure.
Fill bearing bore in end of final drive pinion shaft

half full of AT30408 high temperature grease or an
equivalent and coat pinion and bearing surfaces with
oil. Carefully insert pinion shaft through final drive
housing and pinion shaft oil seal, and on into steer-
ing clutch splines. DO NOT FORCE THE PINION
SHAFT into position as forcing the shaft will misalign
the bearings and damage the oil seal and inner
splines on the steering clutch.
Refer to page 40-20-2 and reverse removal proce-

dure.
Litho in U.S.A.
TM-11 02 (Nov-73) Power Take-Off and Winch Drive 25-1
Group 25
POWER TAKE-OFF AND WINCH DRIVE
GENERAL INFORMATION Pulling the PTO control lever to the rear moves the
powershaft drive gear rearward into mesh wit h
splines on the front shaft. Power is picked up from
the powershaft drive gear by the powershaft driven
gear which turns the powershaft. The engine clutch
must be fully disengaged before powershaft can be
engaged or disengaged by the lever. The powershaft
drive gears and bearings are lubricated by oil in the
transmission reservoir.
REMOVAL
Remove drain plug from transmission case and
drain the entire case.
Remove engine from clutch housing as instructed,

Section 20, Group 5.
Separate engine clutch housing from transmission,

To remove transmission front cover, drive out roll

Fig. 1-Powershaft and Winch Drive
pin fastening valve operating arm to shaft. Lift trans-
JD450-C Crawlers can be equipped with a 1000 mission front cover with gears and shifter away from
rpm power take-off or winch drive unit. The powers- transmission case.
haft is the same in both applications and drives
equipment from the rear of the crawler (Fig. 1). To remove the powershaft, take out the three cap
screws fastening the rear powershaft housing to
The powers haft gives a standard speed of 1000 transmission case. Withdraw powershaft with bearing
rpm when operated with the engine at the recom- from transmission case.
mended PTO speed of 1900 rpm.
The powershaft is continuous running, that is, it is
possible to stop tractor movement without stopping
powershaft rotation. By depressing the clutch pedal
3-112 inches (or until resistance is felt), crawler
movement is stopped, but the power shaft will still ro-
tate if the control lever is in the engaged position.
The front drive shaft carries the powershaft drive
gear which is in constant mesh with the powershaft
driven gear. A shifter fork controlled by the PTO con-
trol lever moves the drive gear internal splines in and
out of mesh with splines on the front drive shaft. The
shifter and PTO gears are housed in the transmis-
sion front cover.
The powershaft driven gear is splined to the pow-
ershaft wh ich extends from the front wa ll of the 1- Ball Bearing 3- 0 il Seal
2-Powershaft 4-Houslng
transmission case out to rear of the transmission .
The shaft is supported on the front by a roller bear- Fig. 2-Removing Powershaft Rear Housing
ing and on the rear by a ball bearing in the rear pow-
ershaft housing.
Litho in U.S.A.
40 Power Train Cra wler - JD450-C
25-2 Power Take-Off and Winch Drive TM-1102 (Nov-73)
REPAIR
1- Spring Pin* 9-PTO Shifter Yoke* 17-Powershaft* 2s-Powershaft Shield*

2- Crank* 10-0il Seal* 18-Snap Ring* 26-Washer (2 used)
3-PTO Shifter• 11- Drive Gear 19-Ball Bearing* 27-Lock Washer (4 used)*
4-Pin* 12- Snap Ring 2o-Gasket* 28-Cap Screw (4 used)*
s-Cotter Pin* 13-Snap Ring (2 used) 21 - 0il Seal• 29- Cap Screw (2 used)
6-Steel Ball* 14-Ball Bearing 22-Rear Housing* 30-Powershaft Guard*
7- Spring"' 1s-Oriven Gear 23-Lock Washer (5 used)"' 31 - Retaining Ring (2 used)*
8- Ball* 16-Roller Bearing 24-Cap Screw (3 used) 32- Snap Ring**
*Used with PTO only

**Used without PTO only
Fig. 3-Powershah and Winch Drive Assembly
Pull PTO shifter yoke (9, Fig. 3) and drive gear

(11) from the front cover. Be careful not to lose ball
(8) and spring (7). Check gear for chipped or worn
teeth . Examine PTO shifter yoke for bent condition.
Check grooves or shaft portion of yoke for wear. Ex-
..
~ amine ball for flat spots. Replace damaged parts as
needed .
Remove snap ring holding driven gear and bearing
in front cover. Remove gear. Inspect ball bearing on
hub of driven gear to see that it rotates freely. If
bearing is worn or damaged, remove snap ring and
slip bearing from hub of gear. Inspect teeth on driven
gear for wear or breakage. Replace worn or dam-
aged parts as needed.
Check oil seal in shifter bore of cover and examine
roller bearing in transmission case front wall. Re-
place as needed.
Inspect powershaft for damaged splines or bent
1-Drive Gear 3-Drlven Gear
2- Shifter Yoke condition. Check ball bearing on shaft.
Check oil seal in rear housing. If replacement is
Fig. 4-Transmission Front Cover
necessary, install new seal with sealing lips facing
drive .
Litho in U.S.A.
TM-11 02 (Nov-73) Power Take-Off and Winch Drive 25-3
Refer to Fig. 3, for location and identification of Install ball bearing (16) on powershaft ( 17) by as-
parts. sembling from long end of shaft (driving only on inner
race of bearing). Position snap ring.
Install a large snap ring (13) in forward groove of
the transmission front cover. Loosely slip the other Slide powershaft into transmission case. Be sure
large snap ring on hub of driven gear (15). Install splines on front end of powershaft fit into splines of
bearing on hub of gear and secure with snap ring powershaft drive gear.
(12). Slip bearing and gear hub into bore of front
cover and lock in place by seating the large snap NOTE: Coat lip of oil seal (21) with number 107
ring in its groove. Lubriplate prior to installing powershaft rear housing
on the powershaft. Tape powershaft splines to pro-
Coat sealing lips of PTO shifter yoke bore oil seal tect oil seal in housing.
(1 0) with Lubriplate. Place spring (7) and ball (8) into
shifter detent bore in cover. Position PTO shifter Install powershaft rear housing using a new gas-
yoke (9) on drive gear and slide slotted end of shifter ket. Remove tape from splines.
into bore from inside of cover. Mesh gear teeth with
driven gear. INSTALLATION
Install clutch housing (Section 40, Group 5).
Install transmission front cover using a new gasket.
Attach linkage removed during disassembly.
Install engine (Section 20, Group 5).
Fill transmission case with quantity and viscosity of

oil recommended in Section 10, Group 15.
Litho in U.S.A.
25-4 Power Take-Off and Winch Drive TM-11 02 (Nov-73)
Litho in U.S.A.
TM-11 02 (Nov- 73) Specification and Special Tools 30·1
Group 30
ENGINE CLUTCH ASSEMBLY
1. Free length ......................... 3.075-in. [77.978 mm]

2. Test length ......................... 1.685-in. [42.672 mm)
Compressed at 124 lbs. (56.245 kg]
T32048N
Fig. 1-C/utch Pressure Spring
1. Flywheel friction driving surface

flat within ................................ 0.006-in. [0.15 mmJ
T32047N
Fig. 2-F/ywheel Drive Surface
Litho in U.S.A.
30-2 Specification and Special Toots TM-1102 (Nov-73)

1. Pressure plate driving surface
flat within ................................ 0.006-in. [0.1 5 mm]
T32048N
Fig. 3-Pressure Plate Drive Surface
1. Variation in adjusted height of release levers

not to exceed ....................... 0.010-in. [0.254 mm]
Fig. 4-Ciutch Lever Variation
Litho in U.S.A.
TM-11 02 (No v- 73) Specifications and Special Tools 30-3

t . Adjusting lever set screw and
jam nut ............................. ... 35 lb-ft. [4.839 kg-m]
Fig. 5-C/utch Control Linkage
SPECIAL TOOLS
Essential
JDE-52* Properly line up clutch disk
TJ205 1fl
Fig. 6-C/utch Disk Centering Shaft
J D-227* Adjust engine clutch fingers
T32052N
Fig. 7-Ciutch Finger Adjusting Gauge
1901 Indiana Avenue
Litho in U.S.A.
30-4 Specifications and Special Tools TM-1102 (Nov- 73)
H-L-R TRANSMISSION
1. Reverse countershaft end play .. ............. 0.003 to

0.005 in. [0.0762 to 0.1270 mm]
Fig. 8-Reverse Countershaft
1. Underdrive countershaft end play ........... 0.003 to

0.005-in. [0.0762 to 0.1270 mm]
Fig. 9-Underdrive Countershaft
Litho in U.S.A.
H-L-R TRANSMISSION
1. Nominal measurement of the height
of the output shaft bearing cone
and cup ............................ 1.4375-in. [36.576 mml
T32055N
Fig. 10-0utput Shaft
1. Ring gear bearing preload ....... 0.002 to 0.005 in.

[0.0508 to 0.1270 mm)
T32056N
Fig. 11-Ring Gear and Hub Bearing
Litho in U.S.A.
40 . Power Train Crawler - JD450-C
H-L-R TRANSMISSION
- Pinion shaft preload 0.003 to 0.005 in. [0.0762
to 0.1270 mm] with 6 to 12 lb- in. [0 .069 to
0.138 kg-m] rolling torque .
Fig. 12-Pinion Shaft
- Pinion shaft nut-to-pinion shaft ............. 300 lb-ft.

[41.476 kg-m] (If cotter pin hole in shaft does
not line up with a slot. tighten until hole does line
up-do not loosen).
2 - Ring gear-to-pinion shaft backlash ....... 0.006 to

0.008-in . [0.1524 to 0.2032 mm]
T320 58N
Fig. 13-Pinion Shaft and Nut
Litho in U.S.A.
H-L-R TRANSMISSION
1. Rear input shaft end play ....... 0.003 to 0.005-in.
(0.0762 to 0.1270 mm]
Fig. 14-Rear Input Shaft
Transmission top cover

1. Front cover cap screws ...... 50 lb-ft. [6.9 13 kg-m)
2. Rear cover cap screws ....... 35 lb-ft. [4.839 kg-m]
Fig. 15- Transmission Top Cover
Litho in U.S.A.
STEERING CLUTCH AND BRAKE ASSEMBLY

1. Tighten cap screw to 10 lb-ft . [1 .383 kg - m)

and backout 1/4 turn. Tighten jam nut.
T3208 3N
Fig. 16-Steering Brake Drum
1. Special set screw-to-brake

shaft .. .................. ........ ...... 170 lb-ft. [23.503 kg-m]
2. Jam nut.. ....... ................... 105 lb-ft. [ 14.517 kg-m]
T32064N
Fig. 17-Brake Pedal Shaft Set Screw
Litho in U.S.A.

- Brake lever linkage pin-to-top of steering

clutch housing nominal setting ................ 3.06-in.
[77.724 mm]
NOTE: During initial setting, turn in adjusting

screw far enough to prevent linkage from going over
center.
Fig. 18-Brake Lever Nominal Setting
Litho in U.S. A.
30-10 Specifications and Special Toots TM-1102 (Nov-73)
FINAL DRIVE ASSEMBL V

1. Flange axle shaft introduced end

play ......................................... 0.002 to 0.005 inch
(0.0508 to 0.1270 mm]
Advance nut if necessary, to line up slot in nut
with cotter pin hole in shaft. Then tighten nut one
additional slot and install cotter pin.
Fig. 19-Axle Shaft Introduced End Play
Litho in U. S. A.
Crawler - JD450-C Hydraulic System 50
TM-11 02 (Nov-73) Transmission Pump 5-1
Group 50
HYDRAULIC SYSTEM
Page Page
GROUP 5 - TRANSMISSION PUMP GROUP 25 - STEERING VALVE
General Information ............................................ 5-3 General Information .......................................... 25-1
Removal ...............................................................5-3 Removal .............................................................25-2
Repair ..................................................................5-3 Repair ................................................................25-2
Installation ............................................................5-3 Installation ..........................................................25-2
GROUP 10 - MAIN HYDRAULIC PUMP GROUP 30 - LOADER CONTROL VALVE

General Information .......................................... 10-1 General Information .......................................... 30-1
Removal ............................................................. 10-1 Removal .............................................................30-4
Repair ................................................................ 10-2 Repair ................................................................30-4
Installation .......................................................... 10-3 Installation ..........................................................30-6
GROUP 15 - WINCH HYDRAULIC PUMP GROUP 35 - BULLDOZER CONTROL VALVE

General Information .......................................... 15-1 General Information .......................................... 35-1
Removal ............................................................. 15-1 Removal .............................................................35-3
Repair ................................................................ 15-1 Repair ................................................................35-3
Installation .......................................................... 15-2 Installation ..........................................................35-5
GROUP 20 - CLUTCH CONTROL VALVE GROUP 40 - BACKHOE CONTROL VALVE

General Information ..........................................20-1 General Information ......................................... .40-1
Removal .............................................................20-7 Removal ............................................................ .40-3
Repair ................................................................20-7 Repair ................................................................ 40-3
Installation .......................................................... 20-9 Installation ......................................................... .40-5
GROUP 45 - WINCH CONTROL VALVE

General Information ......................................... .45-1
CAUTION: Escaping fluid under pressure Removal ............................................................ .45-2
A can have sufficient force to penetrate the
skin causing serious personal injury. Before dis-
Repair ............................................................... .45-3
Installation ......................................................... .45-3
connecting lines, be sure to relieve all pressure.
Before applying pressure to the system, be sure GROUP 50 - CYLINDERS
all connections are tight and that lines and hoses General Information .......................................... 50-1.
are not damaged. Fluid escaping from a very Loader Boom Cylinders .................................... 50-1
small hole can be almost invisible. Use a piece of Loader Bucket Cylinders .................................. 50-2
cardboard or wood, rather than the hands to Log and Lumber Clamp Cylinders .................. 50-2
search for suspected leaks. Bulldozer Boom Cylinders ................................ 50-3
Bulldozer Angling Cylinder ............................... 50-4
If injured by escaping fluid, see a doctor at Bulldozer Blade Tilt Cylinder ........................... 50-5
once. Serious infection or reaction can develop if Ripper Cylinders ................................................ 50-6
proper medical treatment is not administered im- Backhoe Bucket Cylinder ................................. 50-7
mediately. Backhoe Dipperstick Cylinder .......................... 50-9
Backhoe Boom Cylinder ................................... 50-8
Backhoe Swing Cylinder ................................ 50-10
Backhoe Stabilizer Cylinders ........................ 50-11
Multipurpose Bucket Cylinders ....................... 50-18
Litho in U.S.A.
50 Hydraulic System Crawler - JD450-C
5-2 Transmission TM-11 02 (Nov-73)
CONTENTS OF THIS SECTION-Continued
Page Page
GROUP 55 - MISCELLANEOUS HYDRAULIC GROUP 60 - SPECIFICATIONS AND
COMPONENTS SPECIAL TOOLS
Reservoir and Filters ........................................ 55-1 Transmission Pump .......................................... 60-1
Transmission Oil Cooler and Filter ................. 55-2 Main Hydraulic Pump ....................................... 60-2
Selector Valve ................................................... 55-4 Winch Hydraulic Pump .....................................60-3
Flow Divider Valve ............................................ 55-5 Clutch Control Valve ......................................... 60-4
Multi-Purpose Bucket Clam Relief Valve ........ 55-6 Steering Valve ................................................... 60-5
Breakaway Couplers ......................................... 55-8 Loader Control Valve ........................................ 60-6
Bulldozer Control Valve .................................... 60-7
Backhoe Control Valve ..................................... 60-8
Winch Control Valve ......................................... 60-9
Cylinders ............................................................60-9
Miscellaneous Hydraulic Components ........... 60-15
Litho in U.S.A.
TM-11 02 (Nov-73) Transmission Pump 5-3
Group 5
TRANSMISSION PUMP
GENERAL INFORMATION REPAIR
Remove pump rotors (8, Fig . 2) from the pump
housing (5).
Clean all parts in solvent and dry with compressed

air.
Examine pump gears for broken splines or lobes.

Re move any nicks, burrs, or sharp edges usi ng
emery cloth. Check gear faces and mating surfaces
for excessive wear or scoring. Replace any damaged
parts. (Rotors are replace9 as matched sets.)
Inspect parts in pump cover for damage. If tube is

damaged, remove it and press in a new tube 7 .28 in.
[184.9 mm] above rear gasket surface of pump cov-
er.
1- Transmission Pump
2-Transmission Front Cover If oil seal in cover is damaged, remove retaining
ring and roller bearing to gain access to oil seal.
Fig. 1-Transmission Pump Location Press in new seal from rear. Front of seal to ma-
chined face of cover must be 2.72 in. (69. 1 mm).
The transmission pump (1, Fig. 1) is attached to Lips of seal should face driver.
the transmission front cover (2) .
Examine roller bearing for wear or scoring . If dam-
The transmission pump sucks oil from the trans- aged , install a new bearing in its bore. Position re-
mission case reservoir and delivers the oil to a pres- taining ring. Assemble the inner and outer gears and
sure regulating valve to supply oil to engage the H-L- sealing ring into pump cover.
R clutches, oil for transmission lubrication, oil for
steering, and oil through the oil cooler and fil ter. INSTALLATION
REMOVAL Install transmission pump on transmission front
cover. Replace sealing ring (9, Fig. 2) if damaged or
Separate clutch housing from transmission case as deteriorated.
outlined in Section 40, Group 5.
Remove cap screws from clutch oil pump cover.

Pull cover from front input. Remove pump rotors.
Litho in U.S.A.
5·4 Transmission Pump TM-11 02 (Nov-73)
1-Tube 6-Cap Screw (3 used)

2- 0il Seal 7-Lock Washer (3 used)
3-Roller Bearing 8-Pump Rotors
4-Retaining Ring 9-Sealing Ring
5--Cover 10-Dowel Pin (2 used)
Fig. 2-Transmission Pump Assembly
TRANSMISSION FRONT COVER Separate clutch housing from transmission case as

outlined in Section 40, Group 5.
Removal
Remove cap screws from transmission front cover.
Remove cover.
Repair
Remove large plug from top of front cover and pull
pressure regulating valve assembly from bore. Save
all shims under plug.
Pull oil cooler bypass valve and spring from rear

bore of front cover.
Pull clutch lubrication bypass valve and spring

from bore in top front of transmission case.
Wash all valve parts in solvent and dry with com-

pressed air.
Flush out valve bores in front cover and case. Ex-

amine valve bores for scoring or burrs using a pin-
.. /- (' ..... point flashlight.
1'21119
Try valves in bores; lightly hone any rough spots

1-0il Cooler Bypass Valve 5--Spring
2-0il Pressure Regulating 6-Spring using emery cloth. Lap valves to seats if pitted. After
Valve 7- Spring lapping, flush out bores thoroughly. Replace any
3-Shim(s) 8-Ciutch Lubricating badly damaged parts.
4-Piug Bypass Valve
Fig. 3-Transmission Front Cover and Oil Supply

Regulating Valves
Litho in U.S.A.
Crawler - JD450-C Hydraulic System SO
TM-11 02 (Nov-73) Transmission Pump S-5
. Examine springs for worn or broken coils. Replace Installation

1f there IS any doubt of their strength.
Be sure clutch lubricating bypass valve spring and
plug are in bore in top front of case (Fig. 3). Tighten
Insert oil pressure regulating valve in vertical bore
screws down evenly to avoid stress on cover and
of tra~smission front cover. Place spring over valve,
then tighten them to 50 lb-ft [6.9 kg-m] front and 35
then mstall plug, using same number of shims as
lb-ft [4.8 kg-m] rear.
removed.
Connect rods to steering levers.
IMPORTANT: Be sure regulating valve is in-
stalled in bore with double spool end outward.
Insert oil cooler bypass valve and spring in top

rear bore of front cover.
Slide clutch lubricating bypass valve and spring in-

to right front bore in top of transmission case (refer
to Fig. 3).
Litho in U.S.A.
5-6 Transmission Pump TM-11 02 (Nov-73)
Litho in U.S.A.
TM- 11 02 (Nov-73) Main Hydraulic Pump 10-1
Group 15
MAIN HYDRAULIC PUMP
GENERAL INFORMATION
1-Thrust Plate 5-Front Plate 9---Backup Gasket

2- Back Plate 6--Shaft Seal 1G-Protective Gasket
3-ldler Gear Assembly 7-Drlve Gear Assembly 11- Diaphragm
4-Pump Body 8- Diaphragm
Fig. 1-Hydraulic Pump {23 gpm Pump Illustrated)
The hydraulic pump is a positive-displacement, REMOVAL

gear-type pump mounted at the front of the engine
Clean area around pump. Disconnect and cap
block.
lines and remove pump from unit
The pump is driven by the crankshaft and operates
whenever the engine is running.
Refer to "Gear-Type Pumps" in FOS Man-
EJ a
ual-HYDRAULICS for additional description
and theory of operation.
Litho in U.S.A.
1 0-2 Hydraulic Pump TM- 11 02 (Nov-73)
REPAIR
Main Hydraulic Pump
1- Back Plate 6-0rive Gear 11-8prlng (2 used) 16-Cap Screw (4 used)

2- Thrust Plate 7-Diaphragm 12-Ball (2 used) 17-Loc k Washer (2 used)
3-0-Ring (2 used) 8-Backup Gasket 13-Front Plate 18-Cap Screw (2 used)
4-Pump Body 9-Protector Gasket 14-Cap Screw (4 used) 19-ldler Gear
5--Dowel (2 used) 10-Diaphragm Seal 15--ShaH Seal
Fig. 2-Hydrau/ic Pump (23 gpm Pump Illustrated)
Scribe a mark across pump front plate, body, and Assemble pump as follows using Fig. 2 as a guide.
back plate for proper reassembly.
( 1) Position diaphragm on gasket with bronze face
Disassemble pump using Fig. 2 as a guide. of diaphragm up. Entire diaphragm must fit inside the
raised rim of the rubber seal.
(1) Check pump gear and shaft dimensions.
(2) Assemble pump with 0-rings between pump
(2) Measure inside diameter of shaft bushings. Oil bodies. Be sure 0 -rings are fitted into grooves in
grooves in bushings should be in line with dowel pin pump sections before assembly.
holes in plates, and at the outer sides of their re-
spective bores. Bushings in front plate should be (3) Assemble pump making sure that scribe marks
flush with islands in groove pattern. Bushings are not made during disassembly match on plates and body.
available as separate service parts.
(4) Tighten cap screws to 40 lb-ft. [5.53 kg-m) (27
(3) Using a straightedge and feeler gauge, mea- to 30 lb-ft. [3.73 to 4.15 kg-m) on 15 gpm [56.8 I)
sure wear on gear areas of back plate surface. pumps).
(4) Measure inside gear pockets of pump body. (5) Coat new drive shaft with Lubriplate and install
seal. Relationship of oil seal to front plate surface is
0.1560 in. [3 .962 mm) (flush on 15 gpm [56.8 I]
pumps) below surface.
(6) Rotate the drive shaft. A smooth heavy drag in-

dicates proper assembly. A jerky drag or frozen shaft
indicates an improperly assembled pump.
Litho in U.S.A.
TM- 1102 (Nov- 73) Main Hydraulic Pump 10-3
Pump Disconnect
1- Ada pter 6-Sprlng 11- Lever 16-Drive Shaft

2-Bushlng 7- Fork 12-Groove Pin 17-Spring
3-Cap Screw (4 used) ~pri ng 13-Ball 18-Washer (Dozer only)
4-Pump Drive 9-Disconnect Shaft 14-Groove Pin 19-Coup ler
5--Coupllng 1(}-.-Sprlng Pin 15--Snap Ring 2G-Sprlng Pin
Fig. 3-Pump Disconnect
The crawler may be equipped with a field installed INSTALLATION

hydraulic pump disconnect. Be sure pump mounting area and oil lines are free
of dirt before mounting the pump to prevent dirt from
To service the hydraulic pump disconnect, remove entering the hydraulic system.
the grille housi ng, rad iator , hydrauli c pump and
mounting bracket from the machine.
Disassemble and inspect all parts for wear or dam-

age using Fig . 3 as a guide.
Asse mble pump disconnect using Fig . 3 as a

guide.
Litho In U.S.A.
10-4 Main Hydraulic Pump TM-1102 (Nov-73)
Litho in U.S.A.
TM- 11 02 (Nov-73) Winch Hydraulic Pump 15-1
Group 15
WINCH HYDRAULIC PUMP
GENERAL INFORMATION REMOVAL
The winch system consists of a control valve, hy- Check relief valve pressure before removing winch
draulic pump, and housing with gear train . to seJvice pump.
The winch pump is of the positive-displacement Drain winch housing.

gear type and is located in the winch housing under
the output shaft. The pump is driven by the pinion Remove cover on bottom of winch housing and
shaft drive gear and supplies pressure oil for clutch- disconnect hydraulic pump oil pressure line at elbow
ing and releasing the winch brake. (Fig. 1).
Refer to "Gear-Type Pumps" in FOS Man- Remove cap screws securing pump bracket to
EJ a
ual-HYDRAULICS for additional description
and theory of operation.
winch housing and remove pump.
REPAIR
Disassemble pump using Figure 2 and the follow-
ing steps:
Scribe pump body and cover for reassembly pur-

poses.
To separate pump cover from body, tap protruding

end of drive shaft lightly with a plastic hammer. Be
very careful to avoid damaging finely machined sur-
faces.
Remove wear plate assembly (3) and steel plate

from pump body.
NOTE: Whenever pump is disassembled for in-

spection and repair, replace wear plate assembly. In-
Fig. 1-Pump Attaching Cap Screws
stallation of old parts could result in possible
leakage.
Clean all parts in solvent. Inspect pump parts for

wear or damage.
Inspect needle bearings (4) for wear or damage.
Litho in U.S.A.
15-2 Winch Hydraulic Pump TM-11 02 (Nov-73)
13
T2 15 59
1-Special Screw 6-Drlve Shaft 11-Dowel Pin

2-Seal Plate 7-0·Ring 12-Biock
3-Wear Plate 8-Cover 13-Body
4-Needle Bearing 9-Cap Screw 14-Needle Bearing
5--Key 1~dler Gear
Fig. 2-Winch Hydraulic Pump
Press needle bearings into pump body . and cover

until they bottom out (Fig. 3). Body needle bearings
should be 0.0150 to 0.0200 in. [0.381 to 0.508 mm]
below pump machined surface and cover bearings
should be 0.0050 to 0.0150 in. [0. 127 to 0.381 mm]
below pump machined surface. Be sure bearings are
bottomed out to avoid the possibility of interference
with the pump gears and to assure proper mating of
the body and cover.
Inspect bearing at drive shaft end of pump body.

To replace, press in new bearing until it bottoms.
Inspect pump mounting bracket for damage and

replace if necessary. If dowels securing bracket to
winch housing are damaged, remove old dowels and
press new dowels into winch housing to 0.25 in.
[6.35 mm].
T215 61
1-See Specifications 3-Pump Body Assemble pump, using Figure 2 as a guide. Be
2- Bearlngs 4-Pump Cover sure to use new wear plate assembly and o-·rings.
Fig. 3-lnstalling Pump Bearings
INSTALLATION
Secure pump with mounting bracket to winch
housing. Connect pressure line and install bottom
plate .
Litho in U.S.A.
TM-11 02 (Nov-73) Clutch Control Valve 20-1
Group 20
CLUTCH CONTROL VALVE
GENERAL INFORMATION
1- Pressure Oil 5--Ciutch Valve 9-Needle Valve 13-High (To Clutches)

2- Trapped Oil 6-Supply Oil From Pump 10---Pilot Valve 14-Low (To Clutches)
3-Pressure-Free Oil 7- Accumulator 11-Check Valve
4-Shift Val ve 8-Bypass Valve 12- Reverse (To Clutches)
Fig. 1-Ciutch Control Unit Operating in High Gear
The clutch control unit receives pressure oil from opens to give full flow to the clutch pack after en-
the supply system and regulates it by means of a gagement and stays open during a rapid hi-low shift;
valve circuit to engage and disengage the clutch the needle valve, which is an adjustable orifice to
packs during various shift cycles. The control unit regulate the speed of clutch engagement; the check
mou nts over the cl utch shaft in the rear of the valve, which keeps pressure oil in the accumulator
range change box of the transmission. The valves circuit during neutral for use in the next shift; the ac-
located in the clutch cont rol unit are : the shift cumulator piston, which "surges" oil to fill the engag-
valve, linked to the reverser lever, which directs ing clutch for a smoother shift; and the clutch valve,
engaging oil to the selected clutch pack; the pilot linked to the clutch pedal, which finally engages or
valve, also linked to the reverser lever, wh ich neutralizes the whole valve circuit.
controls the bypass valve; the bypass valve, which
Litho in U.S. A.
20-2 Clutch Control Valve TM- 11 02 (Nov-73)
The action of the valves in the clutch control unit Cycle 1 (Fig. 2)
during each shift cycle is explained on this and the
Shifting the reverser lever from High to Low gear
following pages.
moves both the shift and pilot valves, because they
are linked together mechanically. The following inter-
Operating in High Gear
action occurs:
Pressure oil from the supply system flows around
The pilot valve rotates but no oil is dumped as ori-
accumulator, goes through clutch valve, and holds
fice has been bypassed between low and high.
the check valve open. Oil has full flow around bypass
valve, which is held open by oil pressure. Pressure The shift valve is lifted, dumping oil from the high
oil flows on around clutch valve and across to slot in clutch to disengage it, and engaging the low clutch.
shift valve. This slot engages the high clutch pas- Now pressure oil rushes into the low clutch, via the
sage and keeps pressure oil against the clutch to
hold it engaged.
Additional oil is fed into the unit only on "demand"

to make up for leakage and keep pressure oil against
the engaged clutch.
The accumulator has reloaded with oil for the next

shift.
1- Pressure Oil 9-Bypass Valve

2-Trapped Oil 10-Needle Valve
3-Pressure Free Oil 11-Check Ball
4-Shift Valve 12-Pilot Valve
5-Ciutch Valve 13-Check Valve
6-Supply Oil From Pump 14-Reverse (To Clutch)
C] l 7- Accumulator 15--High (To Clutch)
mz ~Pressure Check Point 'i6-Low (To Clutch)
6]3
Fig. 3-Cycfe 2-Unit Shifting High to Low Gear
1- Trapped Oil 9-Bypass Valve orifice bypass valve, completing engagement very
2-Low Pressure Oil 10--Needle Valve rapidly.
3-Return Oil 11- Pilot Valve
4-Shlft Valve 12-Check Valve Pressure at " Check Point" should drop rapidly
5-Ciutch Valve 13-To Reservoir from pressure oil to low pressure oil when accumula-
6-Supply Oil From Pump 14-Reverse (To Clutch)
7-Accumulator 15--High (To Clutch) tor discharges.
~Pressu re Check Point 16-Low (To Clutch)
Cycle 2 (Fig. 3)
Fig. 2-Cycfe 1-Unit Shifting High to Low Gear
The pressure oil also reloads the accumulator for
Shifting From High to Low Gear the next shift.
(a "Rapid Shift")
Pressure at "Check Point " fo r th is final cycle
This is a rapid shift and can be divided into two cy- should show at fast rise from low pressure oil to
cles. pressure oil after start of shift.
NOTE: Shifting from Low to High gear is accom-
plished in the same manner as described except that
the shift valve engaging slot moves from Low to
High.
Litho in U.S.A.
TM-1102 (Nov- 73) Clutch Control Valve 20-3
W1<1&.W412 1
Eit1@13
1- Pressure Oil 9-Bypass Valve 1- Pressure 011 10-Bypass Valve

2- Pressure Free Oil 10-Needle Valve 2-Low Pressure 011 11-Needle Valve
3-To Reservoir 11-Pilot Valve 3-Pressure Free Oil 12-Pilot Valve
4-Shift Valve 12- Neutral Passage 4-To Reservoir 13-Neutral Passage
5-Ciutch Valve 13- Check Valve 5-Shift Valve 14-Check Valve
6-Supply Oil From Pump 14-Reverse (To Clutch) 6-Ciutch Valve 15-Reverse (To Clutch)
7- Accumulator 15-High (To Clutch) 7-Supply Oil From Filter 16-High (To Clutch)
8-Pressure Check Point 16-Low (To Clutch) a- Accumulator 17-Low (To Clutch)
9-Pressure Check Point
Fig. 4-Unit Shifting High to Reverse Gear (Step 1)
Fig. 5-Unit Shifting High to Reverse Gear (Step 2)
Shifting From High to Reverse Gear
Step 2 (Fig. 5)
This is a "cushion" shift and can be divided into
five steps. T he pilot valve has now tu rned to seal off the
"neutral" passage.
Step 1 (Fig. 4)
At the same moment, the shift valve slot engages
The reverser lever is shifted from high toward re- the reverse clutch passage. Now pressure oil rushes
verse gear. into the reverse clutch , reducing pressure in the con-
trol unit.
The pilot valve has started to turn and engages a
"neutral" passage. Oil escapes, allowing bypass This pressure drop allows the spring-loaded accu-
valve to close. mulator to discharge and "surge" oil in to help till the
reverse clutch cavities. This "surge" does not en-
The shift valve starts to lower, dumping oil from gage the reverse clutch but it does take up slack vol-
the engaged high clutch. ume to assure a smooth engageme nt. As the
accumulator discharges, pressure in the control unit
Pressure oil in the control unit, however, remains beyond the orifice at the needle valve should drop
constant at this moment. rapidly to low pressure after start of shift.
Litho in U. S.A.
20-4 Clutch Control Valve TM-1102 (Nov-73)
1- Pressure Oil 9-Bypass Valve 1- Pressure Oil 9-Bypass Valve

2-Low Pressure Oil 10-Needle Valve 2- Low Pressure Oil 10- Needle Valve
3-Pressure Free Oil 11-PIIot Valve 3- Pressure Free Oil 11-Pilot Valve
4-Shift Valve 12-Check Valve 4-Shlft Valve 12-Check Valve
~Clutch Valve 13-Reverse (To Clutch) ~Clutch Valve 13-Reverse (To Clutch)
6-Supply Oil From Pump 14-High (To Clutch) 6-Supply Oil From Pump 14-High (To Clutch)
7- Accumulator 1 ~Low (To Clutch) 7-Accumulator 1~Low (To Clutch)
8-Pressure Check Point 8-Pressure Check Point
Fig. 6-Unit Shifting High to Reverse Gear (Step 3) Fig. 7-Unit Shifting High to Reverse Gear (Step 4)
Step 3 (Fig. 6) Step 4 (Fig. 7)

The accumulator stays in discharge position and Oil coming through the needle valve orifice re-
allows some oil entering unit to flow directly around charges the accumulator, slowly building up pressure
its shoulder to reverse clutch. in the clutch to give a cushioned engagement.
Other oil entering unit follows the usual route past Pressure oil from the accumulator also enters the
valves but must then flow through orifice at needle bypass valve through an orifice as the accumulator
valve, since bypass valve is closed . The accumu- recharges and moves back against the spring to the
lator, in the discharged position , feeds oil past the open position . The speed at which the accumulator
land on its piston until the engaged clutch is filled. recharges is adjusted by means of the needle valve.
When pressure in the clutch reaches the low pres-
sure setting, the accumulator starts to recharge, clos-
ing the land and forcing all oil to go through the
orifice. Pressure should remain at low pressure mo-
mentarily after start of shift.
Litho in U.S.A.
TM-1102 (Nov-73) Clutch Control Valve 20-5
1- Pressure Oil 8-Bypass Valve 1- Pressure 011 8- Bypass Valve

2-Pressure Free 011 9-Needle Valve 2-Trapped Oil 9- Needle Valve
3-Shlft Valve 10--Pilot Valve 3-Pressure Free Oil 10--PIIot Valve
4-Ciutch Valve 11-Check Valve 4-Shlft Valve 11- Check Valve
5-Supply Oil From Pump 12-Reverse (To Clutch) 5-Ciutch Valve 12- Reverse (To Clutch)
6--Accumulator 13-High (To Clutch) 6--To Reservoir 13-High (To Clutch)
7-Pressure Check Point 14-Low (To Clutch) 7-Accumulator 14-Low (To Clutch)
Fig. 8-Unit Shifting High to Reverse Gear (Step 5) Fig. 9 -Unit When Clutch Pedal is Depressed
Step 5 (Fig. 8)
As the pressure continues to rise, the bypass valve
Depressing Clutch Pedal (Fig. 9)
opens suddenly and admits a full flow of oil to com- When the clutch pedal is depressed, the clutch
pletely engage and hold the reverse clutch. This valve lifts, dumping oil from the engaged clutch. The
should cause an instant rise to pressure oil. Pressure same motion in the clutch valve seals off passages
on engaged clutch should remain constant until a in the valve housing, retaining oil supply in valves
new shift is made. and in front of accumulator. The check valve ball al-
so closes and holds pressure at other end of the
Neutral circuit.
The neutral cycle is the same as "Step 1" on page
When the clutch pedal is released again, the clutch
50-20-3. Oil flow is shown in Fig . 4. The pilot valve
valve drops and oil retained in the valving goes to
dumps oil, allowing the bypass valve to close. This
work again with only a slight delay.
seals off the full flow passage to the clutches. At the
same time, the shift valve dumps oil from the en-
gaged clutch and the pressure slot in the shift valve
is closed off.
Litho in U. S.A.
1- Pressure Oil 5-High Clutch ~lutch Hub 13-Piston

2- Low Pressure 011 6-Reverse Clutch 10-Disk 14-Release Spring Pack
3-Return Oil 7- Low Clutch 11-Piate
4-Needle Bearing 8-Ciutch Shaft 12-Ciutch Drum
Fig. 10-Ctutch Engagement (Shifting High to Low Gear)
Function of H-L-R Clutches shaft. The plates mesh with the clutch drum, which is
keyed to the clutch shaft. However, until a clutch is
Each of the three hydraulic clutches- high, low,
engaged, the clutch shaft is idle. When the low clutch
and reverse - is operated by a pack of alternating
is engag ed, the power f rom the countershaft is
disks and plates (Fig. 10). When these parts are
passed through the clamped disks and plates to the
clamped together by a hydraulic piston , the clutch is
clutch shaft. This shaft sends the proper rotation and
engaged . When they are released by spring action,
speed to the rear input.
the clutch is disengaged. Any time one clutch is en-
gaged, the other two clutches are disengaged.
At the same time pressure oil is fed into the low
clutch, oil is escaping from the high clutch. This al-
Clutch Engagement (Fig. 10)
lows a spring to release the disks and plates, disen-
When the reverser lever is shifted from high to low gaging the clutch . The reverse clutch is already
gear, the shift valve directs pressure oil to the rear oil disengaged. Engagement of high or reverse clutches
ring on the clutch shaft. This oil flows down a drilled is similar.
passage inside the clutch shaft and out to a compart-
ment in front of the low clutch piston . Oil pressure lubrication of Clutches
expands this compartment and moves the piston
Lubricating oil (low pressure oil) flows constantly
against the clutch pack. Now the disks and plates
out the engaged clutch hub to flush and cool the
are clamped together, rotating as a unit.
disks and plates. This oil flows down a fourth drilled
passage in the clutch shaft. The needle bearing on
Power is transmitted by this engagement as
the front of the clutch shaft and the clutch hub bush-
follows: The disks constantly rotate with the
ings are also lubricated by this oil.
clutch hub , driven by the underd rive counter
Litho in U.S.A.
TM-1102 (Nov-73) Clutch Control Valve 20-7
REMOVAL Inspect filter screen. Wash carefully in solvent. Do

not crush. Replace if damaged.
Remove the transmission front cover. Remove ac-
cumulator housing (8, Fig. 11) and attached linkage
Replace all 0-rings and gaskets.
from clutch oil manifold (32). If it is necessary to re-
move the manifold, refer to the Range Change Com-
Wash all parts in solvent and dry. Clean any dirt
partment Servicing in Section 40, Group 10. The shift
from valve grooves or slots. Inspect ground surfaces
valve housing (50) can be removed, if necessary, by
of valves for any nicks or burrs. Hone lightly if neces-
loosening the cap screws (28 and 52).
sary. Try valves in their bores; they should slide free-
ly. The clutch valve (42), with light oil on its lands,
REPAIR
must fall freely to bottom of bore in valve housing by
NOTE: These are precision hydraulic parts. Use its own weight. Examine valve balls for pitting. Try in
care to keep them clean and free from damage. The seats. If rough, lap them to seats; then wash parts.
smallest nick, burr or particle of dirt can cause a Check springs for worn or broken coils.
failure.
Examine needle valve (55). If point is worn or
Drive out spring pin (14) securing pilot valve arm deeply grooved, replace needle valve.
to shaft. Pull pilot valve arm (15), being careful to
catch detent ball and spring. Pull pin and remove Press accumulator housing dowel pin (accumulator
shift valve from link. housing oil lead hole) flush with face of housing.
Remove detent plate (11) and pull pilot valve (1 0). Press bypass valve pressure orifice (20) in accu-
Tip housing until small ball rolls out of bore. Carefully mulator housing to bottom of 0.248 in. [6.30 mm] di-
pull filter screen (19) from bore using piece of wire. ameter with chamfered end in.
Remove bypass valve cover with stop. Pull accu- Install needle valve in bore. Screw down until fin-
mulator piston and bypass valve assemblies. ger tight, and back off three turns. This is a prelimi-
nary setting. Tighten jam nut.
Remove three cap screws and separate shift valve
housing (50) from manifold. Catch check valve ball IMPORTANT: If the needle valve is turned in
as parts are separated. Remove spring and stop too tightly, the needle valve, or its seat, may be
from bore. Screw out needle valve. Lift clutch valve damaged.
from bore.
Install 0-rings in bores of control valve housing.
Inspect control housings for damage or cracks. Check to see that dowel is in place. Place new gas-
Remove plugs and flush out all passages with clean- ket on shift valve housing.
ing solvent; then dry with compressed air only. See
that all passages are open and clean. Inspect valve Install stop and spring in bore. Hold check valve
bores and accumulator cylinder for scoring. ball on its seat and carefully place shift valve housing
on its mounting. Install three cap screws and locks.
Press shift valve housing oil lead hole dowel pin Recheck gasket position and tighten screws.
(51) flush with face of housing.
Insert modulating spring and headed pin into top of
Inspect restrictors in pilot valve dumping orifices. clutch valve. Drive spring pin through valve. Slide
Pin holes must be clean and perfectly round. Also clutch valve into its bore.
check orifices for clogging. Use a pinpoint flashlight
to make these checks. Insert bypass valve in bore (Fig. 12). End with
double ramp should be out next to spring and stop
pin. Insert pin in spring and push both into bore.
Litho in U.S.A.
20-8 Clutch Control Valve TAA-1102 (Nov-73)
T 2 8 401
1- Speclal Cap Screw 13-Detent Spring 28-Cap Screw 42-Ciutch Control Valve
(2 used) 14-Spring Pin 29-Lock Washer (3 used) 43-Spring
2- Bypass Valve Cover 15-Pilot Valve Arm 3~0-Ring (7 used) 44-Pin
3-Special Spring Spacer 16-Pin 31 - 0 -Ring 45-Retalning Ring
4-lnner Accumulator 17- Special cap Screw (4 used) 32- Ciutch Oil Manifold (2 used)
Piston Spring 18-0 -Ring 33-Dowel Pin 46-Pin
5-0uter Accumulator 19-Cap with Screen 34-Washer (6 used) 47-Pin
Piston Spring 2~rifice 35-Lock Plate 48- Link
6-Cap Screw (2 used) 21-Steel Ball 36-Cap Screw (3 used) 49-Shlft Valve
7- Lock Plate 22- Pipe Plug 37-Check Valve Stop 5~Shift Valve Housing
8-Accumulator Housing 23-Dowel 38-Accumulator Check 51-Dowel Pin
9-0-Ring 24-Accumulator Piston Valve Spring 52-Cap Screw
1~Pilot Valve 25-Bypass Valve 39-Steel Ball 53-Cap Screw
11-Detent Plate 26-Bypass Spring 4~Gasket 54-0-Ring
12-Steel Ball 27-Valve Stop Pin 41 - Spring Pin 55-Needle Valve
56-Jam Nut
Fig. 11-Ciutch Control Unit
Litho in U.S.A.
TM- 1102 (Nov-73) Clutch Control Valve 20-9
.1. .L" J·.·

. .
.
.
::
.
,,' ." <;-
1- Bypass Valve 4-Stop Cover 7-0uter Accumulator Piston Spring

2-Bypass Spring 5-Spacer a-Accu mulator Pis ton
3- Stop Pin 6-lnner Accumulator Piston Spring 9- Accumulator Housing
Fig. 12-Accumulator and Bypass Valve Assemblies.
Install accumulator piston in bore (Fig. 12). Slide

ro und spacer over rod on stop cover. Assemble
springs over rod and insert in accumulator bore.
Press down cover and secure with cap screws.
Place small ball in hole in pilot valve bore (Fig.

13). Then insert p ilot va lve in bore. Install filter
screen in bore with new 0-ring. Install detent plate,
making sure large 0 -ring is secure in groove.
Place shift valve link in arm yoke and insert pin.

Insert spring in arm bore. Hold ball on spring, and
slide arm on pilot valve shaft. Seat ball in a detent
hole in plate . Drive in spring pin to secure arm to
shaft.
1- 0-Ring 4-Detent Plate INSTALLATION

2- Filter Screen 5-Pilot Valve
3-0-Ring 6-Ball Install unit in transmission case . Tighten cap
screws. Connect oil lines.
Fig. 13-lnsta//ing Pilot Valve and Parts
Litho in U.S.A.
Litho in U.S.A.
TM- 1102 (Nov-73) Steering Valve 25-1
Group 25
STEERING VALVE
GENERAL INFORMATION
T 32069N
TJ 2068 N
1- Pressure Oil 3-Valve Spool 1-Pressure Oil 4-Valve Spool

2-Steerlng Valve 2-Return Oil 5-To Transmission
3-Steerlng Valve
Fig. 1-Steering Lever Released
Fig. 2-Steering Lever Moved Rearward
The steering valve is cast into the transmission
rear cover (Figs. 1 and 2). The valve contains two sage and releases a small amount of oil from the
spools, one for the right steering clutch and one for clutch pack and spring pressure pushes against the
the left steering clutch. piston, releasing the clutch pack.
When a steering lever is released, the valve spool The small amount of oil released from the clutch
allows pressure oil to push against a piston in the pack is returned to the transmission by a return pas-
clutch pack, engaging the steering clutch. sage in the bottom of the transmission rear cover.
The amoun t of oil returned is only the amount
When a steering lever is moved rearward , it enough to release the pressure from the clutch pack.
moves a valve spool to block the pressure oil pas-
Litho in U.S.A.
50 Hydraulic System Crawler - J0450-C
25-2 Steering Valve TM-1102 (Nov-73)
REMOVAL NOTE: Install valve spools in valve before install-

ing the new spool seals. Be sure seal/ips are toward
Remove linkage from valve spools. Remove oil
outside of valve.
lines from valve and remove valve.
REPAIR INSTALLATION
Install steering valve on transmission. Connect oil
Remove valve spools from valve. They simply slide
lines. Adjust linkage, see Section 70, Group 20.
out. Remove spool seals.
Inspect valve bores and spools for scoring and pit-

ting and replace as necessary.
When assembling, install new spool seals.
Litho in U.S.A.
Crawler - J0450-C Hydraulic System 50
TM-1102 (Nov-73) Loader Control Valve 30-1
Group 30
LOADER CONTROL VALVE
GENERAL INFORMATION
T21 4 98
1- Pressure Oil 3-System Relief 5--lnlet

2-Return 0 11 4-0utlet
Fig. 1-Pressure and Return Ports in Boom Section
Valve Construction Control Valve Flows

The loader control valve is an open-center, three- For a thorough understanding of control valve op-
spool, stack-type valve. The boom, bucket and auxil- eration, review the following oil flow illustrations.
iary sections are separate bodies with the valve
pressure and return ports located in the boom sec- When the control valve is in neutral position, the oil
tion. A power beyond port is located in the auxiliary flow is the same through the boom , bucket and auxil-
section. iary sections.
All three valve sections have lift checks, which A relief valve is incorporated on the boom-raise
serve as one-way valves to keep oil on the applied side of the valve. An anti-cavitation check is used on
side of the cylinders from flowing back through the the boom-lower side of the valve. Oil from the pump
valve. enters the inlet port, and divides into two columns.
One column becomes functional inlet oil and the oth-
The boom valve spool uses a detent in the spool er inlet oil. Oil in the functional inlet travels through
end cap to retain the spool in the float position. Both the valve stacks and is blocked at the end plate.
the boom and bucket sections have circuit relief
valves and anti-cavitation checks to protect their par- With the valve spools in neutral, inlet oil is free to
ticular circuits. pass to the end plate. At the end plate, oil is chan-
neled back through the valve sections and out the
The bucket section may be equipped with an elec- return port to the reservoir. Oil in the cylinders and
trical return-to-dig option. lines is trapped between spools in the central valve
section.
The auxiliary valve section is served by the system
relief valve; no circuit relief valves are used in the
section.
Litho in U.S.A.
30-2 Loader Control Valve TM-1102 (Nov-73)
CD
5f.Jj ®
T21 49 9 ~b~1t~' 0
1-011 Under Slight Pressure 4-0utlet 7-Anti-Cavitation Check
2-Return Oil ~Inlet 8-To Boom Cylinders
3-Trapped Oil 6--Check Poppet 9-Functional Inlet
Fig. 2-Boom Section in Neutral Position
B CD
ll~ ®
T2 1 500
1-Pressure Oil 3-Anti-Cavltation Check ~To Bucket Cylinders

2- Return Oil 4-Circuit Relief &-Regenerative Channel
Fig. 3-Bucket Section in Fast Dump Position (Regenerative Cycle)
Inlet oil travels past the boom spool (which is in With the bucket spool in full dump position, the re-
neutral), but is blocked by the bucket spool which is generative channel is opened to the cylinder port un-
in a power position. Functional inlet oil is blocked at der power. As the cylinder rods begin to move, oil
the end plate and must flow past the bucket spool to displaced from the cylinders is now directed to the
the bucket cylinders. other end of the cylinder instead of the reservoir as
in a normal dump position. This "closed" circuit be-
tween the two ends of cylinders creates an increased
volume of oil going to the cylinders and a fast bucket
dump.
Litho in U.S.A.
1-Detent Position 5-Acc. Terminal 9-lndicator Rod 13-Ball Guide

2- Release Position 6-To Light Switch 10-Spool Switch 14-Detent Balls
(Solenoid Energized) 7-White Lead 11-Activator Pin 15-Detent Seat
3-Detent Ramp 8-Bucket Switch 12-Bucket Spool 16-Solenoid
4-Key Switch
Fig. 4-Eiectrical Return-To-Dig Mechanism
Refer to " Electrical System", Section 30 to service As the bucket rolls back, the indicator rod hits the
the electrical components of the return-to-dig mecha- bucket switch. This closes the circuit and energizes
nism. the solenoid which turns the ball ramp releasing the
When the bucket spool is moved rearward, the ball detent balls. The spool centering spring now returns
guide that carries the balls up the detent ramp is also the spool to the neutral position stopping the bucket
forced rearward allowing the balls to roll between the at return-to-dig position. With the ball guide in the
detent ramp and the detent seat lip. After the balls neutral position, the activator pin moves down and
have passed the detent seat lip, the detent ramp opens the spool switch de-energizing the solenoid.
moves forward, locking the balls behind the detent The spool may be mechanically released from the
seat. detent position by manually moving the spool lever
During the rearward movement of the ball guide, forward. As the ball guide moves forward the detent
the activator pin moves up and closes the spool seat is forced forward against spring tension allowing
switch (detent position). The bucket switch is normal- the balls to roll down the detent ramp to a released
ly open until closed by the indicator rod. position.
Litho in U.S.A.
30-4 Loader Control Valve TM- 1102 (Nov-73)
REMOVAL
Operate control valve lever until all hydraulic pres-
sure is relieved.
Release pressure in reservoir by slowly removing

filler cap at top of tank.
Remove valve from unit.
REPAIR
Service individual valves separately. Be sure valve
T21502
bodies and their spools are kept together as these
1-Upper Section 4-Spring parts are matched.
2-$crew Plug s-Lower Section
3-Pilol Poppet 6-Poppet Remove tie bolts and separate valve sections.
Fig. 5-System Relief Valve
Remove valve bonnets and remove spools from
A non-adjustable, pilot-operated relief valve within valve housing. Before removing boom spool, be sure
the control valve provides system relief. The valve spool is in float position.
consists of an upper and lower section. The upper
section contains the pilot poppet and the lower sec- Clean and dry all parts thoroughly and inspect for
tion houses the main relief poppet. The system relief wear or damage as follows:
valve operates on the differential oil pressure princi-
ple. Inspect valve housings for cracks or damaged
threads. If a housing is damaged, replace the hous-
ing and valve spool as a matched assembly.
Use new 0-rings when assembling valve housings.
Remove burrs from spool assembly parts using

fine emery cloth. If a spool is worn or damaged, re-
place the spool and valve housing as a matched
assembly.
If a spool spring is worn or broken, replace it. Use

new 0-rings and backup washers when reassem-
bling the spools.
Inspect the lift check cage, spring, and poppet, and

replace damaged or worn parts.
1-5hims 4-Body
2-5eal 5-Cap Use new 0 -rings and backup washers when reas-
3-Poppet sembling the lift check cage.
Fig. 6-Circuit Relief Valve
Inspect anti-cavitation valve and replace if worn or
The relief valves used in the boom and bucket damaged .
valve sections are of the direct poppet type. Pressure
oil enters through the radial holes in the valve body. Use new 0-ring and aluminum check ball when
As oil pressure on the face of the poppet overcomes reassembling the anti-cavitation check valve.
spring tension, the poppet is opened allowing oil to
flow to the reservoir.
Refer to "Hydraulic Valves" in FOS Manual
EJ 0
- HYDRAULICS for basic information on the
operation of pilot operated relief valves.
Litho in U.S.A.
~
- · 2
~i 55 21
T28398
1- Relief Valve 11)- Check Ball 31-Jam Nut 4~0-Ri ng

2-0-Ring 17-Retainer 32-Relief Valve 47-Ball Retainer
3--0-Ring 18--Anti-Cavltation Check 33-Stop Collar 48--Ball
4-Check Poppet 19-Seal 34-Spri ng 49-Auxiliary Section
5-Spring 20-Seal 35-Spool Collar SO-Bucket Section
~0-Ring 21-Vee Seal 3~Detent Ball 51-Boom Section
7-Piug 22-Stop Collar 37-Cap Screw 52-System Relief Valve
8--0-Ring 23-Sprlng 38--Bonnet 53-Auxiliary Spool
9-Backup Washer 24-0etent Collar 39-Diaphragm 54-Bucket Spool
10-Spring 25-0etent Adapter 40-Piug 55-Boom Spool
11- Lower System Relief 2S-Oetent Ball 41-0-Ring 5~Relief Pin
12- Sectlon Ring 27- Retaining Ring 42- Piug 57- Lock Washer
13-Seal 28--Ball Retainer 43-0-Ring 58-Lock Washer
14-Backup Washer 29-Bonnet 44-Stud 59- Lock Nut
15-Upper System Relief 30---Machine Screw 45-Anti-Cavltation Check 60-0-Ring
61- Piug
Fig. ?-Exploded View of Control Valve
System relief valves are not field adjustable and When installing the system relief valve, tighten to
any attempt to adjust the valves will damage them. 40 lb-ft. [5.53 kg-m].
Individual service parts are available for valve re- The circuit relief valve cartridges are factory set
pair. and should not be adjusted. The relief pressure on
each circuit relief valve is stamped on the head end
If a drop-off in pressure occurs, replace the valve
of the cartridge.
lower section.
When replacing circuit relief valves, install new 0-
If the system pressure is low, replace the valve up-
rings and tighten the cartridge to 20 lb-ft. [2.76 kg-
per section. m].
If there is no pressure, replace the complete relief
valve.
Litho in U. S.A.
30-6 Loader Control Valve TM-1102 (Nov-73)
INSTALLATION Install spools in proper valve section.

Thoroughly clean and dry all parts. Oil all parts
Stack valve sections in proper sequence and tight-
lightly prior to assembly.
en tie bolts evenly to 20 lb-ft. [2. 76 kg-m).
Replace all 0-rings and backup washers with new
parts. Install control valve in loader and connect linkage
and oil lines.
Use heavy grease to hold detent balls in place
when assembling the boom control valve spool.
RETURN-TO-DIG MECHANISM
TJJ702N
1-Lock Washer 9-Ball Guide 17-Spring 25--Solenoid Cover

2- Spool 10-Body Sleeve 18-Detent Seat 26-Cap Screw (4 used)
3-Vee- Type Seal (2 used) 11- Shoulder Screw 19-Ball Ramp 27-Lock Washer (2 used)
4-PIIot Ring 12-Ball (4 used) 2G-Spring 28-Lead Wire
5--Spring Guide 13-Needle Roller (2 used) 21-Retalnlng Ring 29-Switch
&-Centering Spring 14-Nut (2 used) 22-Shim 3G-Groove Pin
7-Spring Guide 15--Detent Body 23-Solenoid Body 31- Semiconductor
8-Snap Ring 16-Spring Retainer 24-Rotary Solenoid 32- Machine Screw
33-Swltch Enclosure
Fig. 8-Detent Assembly
REMOVAL Disconnect wiring and remove solenoid assembly.

The four steel balls (12) will usually fall from their
The return-to-dig mechanism can be removed from
seat in the ball guide (9) so be careful not to loose
the bucket section of the control valve without re-
them.
moving the control valve.
The detent body is held loosely in place by the
Completely loosen the cap screws (26, Fig. 8). Ro-
snap ring (8) pushed on to the ball guide. Do not pull
tate the mechanism so the cap screw is on the top to
the detent body off the ball guide.
clear the reservoir. Remove the cap screw. Do the
same for the remaining cap screws.
Litho in U.S.A.
Disconnect the bucket control valve linkage at the NOTE: When making the electrical connections be
spool to avoid bending the linkage when removing sure to connect the black end of the semi-conductor
the remainder of the mechanism. (31) to the terminal side of the switch (29).
Use a 1I 4 inch hex. wrench to remove the shoul- The shim (22) fits in the bore of the detent body.
der screw (11 ). It will be necessary to use a wrench Be sure it is properly installed or the assembly will
at the front of the valve spool (2) to keep it from not go together correctly. It is helpful to use grease
turning. to hold it in place against the detent seat a bit on the
high side of dead center. Snug up the cap screws
There is a needle roller (13) in the detent body un- and push the shim down so it will fit in the detent cap
derneath the switch (29). Be careful not to lose the when the cap screws are tightened.
roller.
Adjustment
Remove remainder of mechanism. The pilot ring
The return-to-dig mechanism may be adjusted to
(4) need not be removed. If it is removed reinstall
return the bucket to a slight dig or slight roll-back
with chamfered edge toward the solenoid.
position.
REPAIR
Adjusting the bucket indicator rod forward provides
Refer to Section 70, Group 15 to service the elec- a bucket dig position.
trical components of the return-to-dig mechanism.
Adjusting the bucket indicator rod rearward pro-
Clean and dry all parts thoroughly and inspect for vides a bucket roll-back position.
wear or damage. Check springs for fatigue.
To adjust the boom switch, raise the boom slightly
Refer to Fig. 8 during installation of the mecha- and dump the bucket to retract the indicator rod into
nism. the tube.
Be sure snap ring (8) is on the ball guide (9). In- h CAUTION: Shut engine off and support
sert the ball guide through the back end of the detent . . the bucket to prevent personal injury.
body (15). Set the body sleeve (1 0) on the detent
body. Insert the spring guide (7), spring (6), and Loosen the two screws on top of the return-to-dig
spring guide (5) into the body sleeve. Attach this por- support and adjust roller on the boom switch lever so
tion of the mechanism to the valve spool (2) with the it is at least to the center of the tube when looking
shoulder screw (11 ). Tighten securely. down the tube bore. Tighten the two screws.
Grease the four balls ( 12) with heavy grease so To adjust the spool switch, loosen the two screws
they will remain in place when installed. It is helpful holding the switch. Position the switch so that the ac-
to insert the balls in the ball guide by turning the tivator pin will depress the lever on the bottom of the
valve spool so the holes in the ball guide are on the spool switch when the control valve handle is in the
bottom when inserting the balls. bucket roll-back position.
When installing the remainder of the mechanism

be sure the flat surface of the detent seat (18) rests
against the spring (17). Be careful not to unseat the
balls from the ball guide during installation. To get
the retaining cap screws in place rotate the mecha-
nism the same as for removal.
Litho in U.S.A.
30-8 Loader Control Valve TM- 11 02 (Nov-73)
CONTROL VALVE LINKAGE
1-Cap Screw (2 used) 7-Nut 13-Lever 1~Cotter Pin (2 used)

2- Lock Washer (6 used) 8-Auxiliary Lever 14-Snap Ring 20-Nut (2 used)
3-Shaft ~Spring Clip (3 used) 15-Pin (2 used) 21-Pivot
4-Snap Ring (4 used) 10-Llnk (3 used) 16-Lever 22-Bolt (2 used)
5-Boom Bell Cran k 11-Bushing (3 used) 17-Spring Pin 23-Lever Ball
&-Bucket Bell Crank 12-Ball Joint 18-Plvot 24-Link
Fig. 9-Control Valve Unkage
Inspect control valve linkage for worn or damaged Coat bearing surfaces of all bell cranks with
parts and replace as necessary. grease before assembling to shaft.
Litho in U.S.A.
TM-11 02 (Nov-73) Bulldozer Control Valve 35-1
Group 35
BULLDOZER CONTROL VALVES
GENERAL INFORMATION
Mechanical Bulldozer Valve dozer raising, lowering, tilting and angling cycles are
easily controlled by this type of linkage. Poppet type
Mechanical bulldozers are equipped with a two-
check valves and an adjustable relief valve are built
spool hydraulic control valve. The valve body is a
into the valve assembly. The valve body is a sturdy
one-piece casting. One of the two double-action
one-piece casting.
valve spools controls bulldozer boom raising and
lowering. The other spool is reserved for an auxiliary
Control Valve Power Beyond Sleeve
function . A float position is provided on the bulldozer
control valve spool for use as required. Poppet type In cases when it is necessary to add an additional
check valves and an ad justable system relief valve hydraulic function an auxiliary valve may be installed .
are incorporated into each control valve assembly.
Hydraulic pressure oil for auxiliary valve is taken
from the bulldozer valve by means of a power be-
All-Hydraulic Bulldozer Valve
yond sleeve. The power beyond sleeve closes off the
All - hydraulic bulldozers are equipped with a neutral circuit to the bulldozer control valve return
three-spool control valve. A single 'T-Sar" control port. Return oil from both auxiliary and bulldozer con-
lever is used to actuate the three valve spools. Bull- trol valves is returned directly to the reservoir.
CONTROL VALVE OIL FLOWS
1-0il Under Slight Pressure

2- Return Oil
3-Trapped Oil
4-Piug
5-0utlet
6-Auxlllary Port
7-Boom Port
8- Poppet Check Valves
9-lnlet
T21505
Fig. 1-Contro/ Valve in Neutral Position (2-spool valve shown)
Control Valve in Neutral Position oil unseats the two check poppet valves and moves
down the control valve power channels. Since the
When the control valve spools are in neutra l
valve spools are blocking the valve power ports, oil
position (Fig. 1), oil from the pump enters the con-
cannot reach the bulldozer cylinders. The oil in the
trol valve and follows a direct channel past the
valve power ports is trapped by the valve spools.
spools and back to the reservoir. At the same time,
Litho in U.S.A.
35-2 Bulldozer Control Valve TM- 11 02 (Nov-73)
1-0il Under Slight Pressure

2-Return Oil
3-Trapped Oil
4-Piug
~Outlet
6-Auxlllary Port
7-Boom Port
8-Detent Engaged
9-lnlet
::;: : : : : : ;:;: : 0
~0
T21506
.,·;0
Rg. 2-Control Valve in Float Position (2-spool valve shown)
Control Valve in Float Position With the spool in the detent position, both boom
cylinder ports are interconnected and open to the
Oil under slight pressure enters the control valve
reservoir allowing the cylinder pistons to move back
inlet port and travels through the neutral circuit past
and forth as the blade floats over the ground. Dis-
the spools and back to the reservoir. Oil also lifts the
placed oil is free to return to the reservoir. Oil in the
two check poppet valves and travels down the valve
auxiliary valve spool ports remains trapped .
power channels but cannot reach the cylinder ports
as the valve spools are blocking the channels.
1- Pressure Oil
2-Return Oil
3-Trapped Oil
4-Bulldozer Valve (Neutral
Position)
~Auxiliary Val ve (Lowering
Cy cle)
6-0utlet
7- lnlet
8-Power Beyond Sleeve
Fig. 3-Three-Spool Control Valve with Auxiliary Valve
Three-Spool Control Valve with beyond sleeve and connected to reservoir through an
Auxiliary Valve additional reservoir oil line. With the auxiliary valve
spool in a power posit ion, oil enters the inlet port as
Oil enters the bulldozer control valve inlet port,
pressure oil. Return oil from the auxiliary valve is re-
and with the valve spools in neutral, travels through
turned directly to the reservoir. H'gh oil pressure re-
the neutral circuit and out the power beyond port.
sulting from auxiliary valve functions is relieved by
The return oil c hannel is blocked by the power
the bulldozer relief valve .
Litho in U.S.A.
TM-1102 (Nov-73) Bulldozer Control Valve 35-3
REMOVAL
Operate control valve lever until all hydraulic pres- If bulldozer control valve or auxiliary valve is to be
sure is relieved . Release pressure in reservoir by removed for servicing and it is believed that frag-
slowly removing filler cap. ments of failed parts may have entered the bulldozer
hydraulic system, completely drain the system and
If the unit is equipped with an auxiliary function , replace or clean the hydraulic filters.
operate the auxiliary control valve lever until all hy-
draulic pressure is released.
REPAIR
I 2rop{/f({jj
33--@ 23
34-\!;!
2
21
£ f ~~ 1 14 1 13
9 15
18_.;.--~
20 19
T 17870
17 ~
1-Bonnet (3 used) 9--Spool Seal (6 used) 18-Spring Washer (3 used) 27- Detent Segment
2-Snap Ring (2 used) 10-Houslng 19--Spring 28-Spring
3-Stop Disk (2 used) 11- Seal 20-Spacer 29--Collar
4-Machine Screw (2 used) 12-Piug 21-Ball 30-Detent Plunger
~Lock Washer (2 used) 13-Spool (2 used) 22-Seat 31- Lock Washer
6-Stop Collar (2 used) 14-Fioat Spool 23-0-Ring 32--cap Screw
7-Spring 15-Relief Valve Body 24-Poppet Check (2 used) 33-Washer
8- Washer (3 used) 16-Gasket 25-0-Ring 34-Nut
17-Shim 26-Piug (2 used) 35-Cap Screw
Fig. 4-Three-Spool Bulldozer Control Valve
Service the valve body and spools as a matched Refer to Figs. 4 and 5 for sequence of disassem-
set. Be sure to keep spools matched with their prop- bly and assembly of the bulldozer control valve and
er bore. the auxiliary valve.
Disconnect hydraulic lines and remove the bulldoz- Remove snap rings and stop disks from control
er control valve from unit. Remove auxiliary control valve . Remove float detent cap. Tap all spools lightly
valve if unit is equipped with an auxiliary function. and remove from control valve housing.
Disassemble control linkage from valve . Clean and dry all parts thoroughly and inspect
parts for wear or damage.
Litho in U.S.A.
35-4 Bulldozer Control Valve TM-1102 (Nov-73)
~12
1-Bonnet Cap 8-Stop Washer 15-Gasket

2-Snap Ring 9-Spool Seal (2 used) 1~Seat
3-Stop Disk 1G-Valve Housing 17- 0-Ring
4-Screw 11-Gasket 18-Check (2 used)
5-Lock Washer 12- Piug 19- 0 -Ring
~Stop Collar 13-Spool 2G-Check Plug
7-Spring 14-Piug 21-Cap Screw (2 used)
22-Cap Screw
Fig. 5-Aux/liary Valve
Check valve housings for cracks or damaged If valve diagnosis indicated that control valve
threads. If housings are damaged, replace the hous- check poppets were leaking , examine each poppet
ings and valve spools as matched assemblies. check for wear or damage. Also check poppet seats
integral with control valve housing for wear or pres-
If valves show signs of external oil leakage, in- ence of foreign matter.
spect spool seals in control valve housings for wear
or damage. Replace spool seals any time valve is Thoroughly clean and dry all parts . Oil all parts
disassembled or leakage is observed . prior to assembly.
Remove burrs from spool assembly parts using Install spools in proper valve bore.
fine emery cloth. If spools are worn or damaged, re-
place spools and valve housing as a matched as- Inspect control valve linkage for worn or damaged
sembly. parts.
Inspect spool springs for fatigue.
Check relief valve ball (21, Fig. 4) and seat (22) for
wear or imperfections which could cause leakage.
Test relief valve springs for a test length of 2.3 in.
[58.4 rnrn] with 243 to 297 lbs. [ 11 0.2 to 134.7 kg].
Litho in U.S.A.
TM-1102 (Nov-73) Bulldozer Control Valve 35-5
T2 1 508
~20
1-Sprlng Clip 8---Stud 15--Spring Pin (2 used) 22-Jam Nut (2 used)
2- Connector Link (2 used) 9-Cap Screw (4 used) 16-Pivot Base 23-Push Rod
3-Lever Assembly 11>-Attachlng Standard 17-~asher (2 used) 24-Ball Joint
4-Rear Lever 11-Spring Pin 18---Bushlng 25--Tooth Washer (2 used)
5--Stud 12- Spring Pin (2 used) 19-~asher 26-Nut (2 used)
6-Spring Pin 13-Pivot Block 20-Cap Screw 27-Lock ~ashers (2 used)
7- Attaching Standard 14-Rotary Pivot 21-Ball Joint
Fig. 6-Three-Spool Valve Linkage
s!:J?'
7 -- ~
6- ~!
u 3151
1- Cap Screw 5--Sprlng Pin
2- Sprlng Clip 6-Cap Screw
3-Coupler Link 7- Cap Screw
4-Lever 8---Mounting Bracket
Fig. 7-Auxiliary Valve Linkage
INSTALLATION
Be sure area is clean before installing valve to pre-
vent dirt from entering hydraulic system.
Install valve.
1-Knob (2 used) 6-Sprlng Clip
2-Lever (2 used) 7-Roller Link
3-Jam Nut (2 used) 8---Spring Clip
4-Pivot (2 used) 9-Spring Pin
5--Roller Link 11>-Base
11-Cap Screw
Fig. 8-Two-Spool Valve Linkage
Litho in U.S.A.
35-6 Bulldozer Control Valve TM-1102 (Nov-73)
Litho in U.S.A.
TM- 11 02 (Nov-73) Backhoe Control Valve 40-1
Group 40
BACKHOE CONTROL VALVE
GENERAL INFORMATION
T2S051
1- Circuit Relief 6-Boom Gyi. (Rod End) 11-Stab. Cyl. (Left Piston) 15-Boom (Piston End)
2- Stab. Cyl. (Right Rod) 7- Stab. Cy1. (Left Rod) 12- Crowd Gyl. (Rod End) 16-Stab. Cyi. (Right Piston)
3-Growd Cyl. (Piston End) 8-Pressure Port 13-Bucket Cyl. (Rod End) 17-Piug
4-Bucket Cyl. (Piston End) 9-Return Port 14-Swing Cyi. (Right) 18-0rlfice (later units)
!>-Swing Cyi. (Left) 10-0rifice Plate
Fig. 1-Backhoe Control Valve
The backhoe control valve is an open-center, six-

spool, stack-type valve.
All six va lve sections are separate bodies contain-

ing sing le spoo ls. All valve sections conta in lift
checks which serve as one-way valves to prevent
pressure oil from entering the port passages and
causing cylinder movement.
The crowd, boom and swing sections contain di-

rect acting circuit relief valves to protect their circuits
from excessive pressures.
Refer to " Hydraulic Valves" in FOS Man- 1-Pressure Oil 2- Return Oil
ual- HYDRAULICS for basic information on
Fig. 2-Direct Acting Relief Valves
[ ] the operation of direct-acting relief valves.
Anti-cavitation check valves are contained in the
boom and swing valve sections.
Field adjustment is possible on all relief valves. The pressure port is located in the port plate and
Litho in U.S.A. the return port is in the end plate.
40-2 Backhoe Control Valve TM- 1102 (Nov-73)
Control Valve Oil Flows
Ill CD
~11 ®
T21 5Jl
1- Pressure Oil 3-To Cylinder 5-Circuit Relief Valve 7-Anti-cavitation Valve

2- Return 011 4-From Cylinder 6-Lift Check 8-Circult Relief Valve
Fig. 3·0il Flow Through Valve Section (Boom Section Illustrated)
Neutral Oil Flow Boom Power Circuit (Fig. 3)

With all spools in neutral position, oil from the When the boom spool is extended or retracted to
pump enters the port plate and is split into two lower or raise the boom, functional oil is directed
columns: past the valve spool to the boom cylinders.
1. One column flows through the valve stacks and Displaced oil from the cylinders is forced back to
is stopped at the end plate. This is called functional the control valve through the valve outlet and back to
oil-oil that can be diverted to one or more cylinders the reservoir. Oil in the remaining cylinders remains
by moving one of the control valve spools to an trapped by the valve spools.
operating position.
To prevent cavitation, a portion of the return oil
2. The other column of inlet oil flows freely through may unseat the anti-cavitation check valve in the
the valve stack into the end plate and back to the valve housing and supplement the flow to the boom
reservoir. cylinders.
Litho in U.S.A.
TM- 1102 (Nov-73) Backhoe Control Valve 40-3
REMOVAL
Operate backhoe control valve levers until all hy- If control valve stack is to be removed for servicing
draulic pressure is relieved. and it is believed that fragments of failed valve parts
may have entered the hydraulic system, completely
Label control valve ports and lines for proper as- drain the system and replace the hydraulic filters.
sembly.
REPAIR
~
~~
T 20304
1- Serew (2 used) 6-0 -Ring 11- Spring 16-Machine Screw (2 used)

2-cap Assembly 7-Spool 12-0-Ring 17-Dust Seal Retainer
3-Spool Screw 8-0-Ring 13-Lift Cheek 18-centering Spring
4-Washers (2 used) 9-Valve Housing 14-Breather Washer
5-Retainer 10-Piunger 15-Spool Seal
Fig. 4-Contro/ Valve Section (Stabilizer Valve Illustrated)
Control Valve Remove check valves from valve sections and in-
spect for damage. Check the springs for a length of
Service individual valves separately. Be sure valve
0.62 in. [ 15.7 mm] with 75 lbs. [34.0 kg] .
bodies and their spools are kept together because
these parts are matched assemblies.
Remove any burrs or rough spots f rom spool
bodies with fine emery" cloth. If spools are worn or
Remove tie bolts and separate valve sections.
damaged, rep lace spool and valve housing as a
matched assembly.
Remove end caps and remove spools from valve
housings.
Inspect hole in orifice plates for plugged condition.
Install all plates with the smooth side toward the
Clean and dry all parts thoroughly and inspect for
valve housing.
wear and damage.
Inspect lift checks for damage. Check springs for a
Check valve housing for damage or evidence of length of 0. 75 in. [ 19.05 mm] with 0. 12 lbs. [0.05 kg].
leakage. Replace housing and spool as a matched
assembly.
Litho in U.S. A.
40-4 Backhoe Control Valve TM-1102 (Nov-73)
Thoroughly clean and dry all parts. Oil all parts Stack port plate, valve sections, and end plate in
lightly prior to assembly. proper sequence.
Replace all 0-ring and backup washers with new Install tie bolts and tighten evenly with 25 to 40 lb-
parts. ft [3.46 to 5.53 kg-m].
Install spools in proper valve section.
Relief Valve
T2 5052
1- Relief Valve Cage* 5-Seat* 9-Back-up Washer

2- 0-Ring 6--Back-up Washer 1o-O-Ring
3-Shims (as requi red) 7-0-Ring 11-Poppet*
4-Sprlng* 8-Cartrldge 12-Snap Ring
·•Not available for service
Rg. 5-Direct Acting Circuit Relief Valve
Remove relief valve from valve housing. Thoroughly clean and dry all parts. Inspect parts
and replace as necessary.
Disassemble relief valve using Fig. 5 as a guide.
When assembling the relief valve, be sure to use
Position the hex. head of the relief valve cartridges all the shims removed .
in a vise and remove snap ring and retainer.
Assemble parts in cage and install retainer and
Remove parts from valve cage. snap ring.
Litho in U.S.A.
TM-1102 (Nov- 73} Backhoe Control Valve 40-5
Control Valve Linkage
~-o 1---o
2----.1
32
T2 1 51JN
1- Hand Grip (4 used) 9- Nut (2 used) 17- Link (2 used) 25-Washer (4 used)
2- Lever (2 used) 10-Handle Mount (2 used) 18-Spring Pin (4 used) 26-Spacer (2 used)
3-Hex. Nut (2 used) 11-cotter Pin (2 used) 19-Pivot Block (2 used) 27- Pivot Shaft (2 used)
4-Cotter Pin (2 used) 12- Pin (4 used) 20-Lever Block (2 used) 28-Lock Washer (4 used)
5-Pivot Pin (2 used) 13-Cotter Pin (4 used) 21 - Lever Link (2 used) 29-Nut (4 used)
6-Spring Pin (4 used) 14-Link (2 used) 22- Cotter Pin (2 used) 30-Washer (6 used)
7- Stablllzer Lever (2 used) 15-Spring Pin (2 used) 23-Pin (2 used) 31- Pivot Shaft (2 used)
8-Handle Mount (2 used) 16-Lever Block (2 used) 24-Cap Screw (4 used) 32- Mounting Frame
Fig. 6-Backhoe Control Valve Levers and Linkage
Inspect control valve linkage for worn or damaged INSTALLATION

parts.
Install control valve and connect linkage and oil
lines.
Coat shafts and movable linkage parts with grease
before assembly.
Ru n machine and check backhoe circuit for proper
operation and leaks.
Litho in U.S. A.
40-6 Backhoe Control Valve TM-11 02 (Nov-73)
Litho in U.S.A.
TM- 1102 (Nov-73) Winch Control Valve 45-1
Group 45
WINCH CONTROL VALVE
GENERAL INFORMATION
T21179
(Hold Position)
T 2118 0
(Wind Position)
1-Pressure Oil 4-Ball Connector 7- Pump 1O-Spool Detent

2- Return Oil 5--Valve Spool 8-To Sump 11-Brake Piston
3-Filter 6- Relief Valve 9-From Reservoir 12- Pressure Plate
Fig. 1-Winch Control Valve Operation
Litho in U.S.A.
45-2 Winch Control Valve TM-1102 (Nov-73)
T 21181
(Free Spool Position)
1-Pressure Oil 4-Ball Connector 7-Pump 10-Spool Detent

2- Retum Oil 5-Valve Spool 8-To Sump 11- Brake Piston
3-Filter 6-Relief Valve 9-From Reservoir' 12- Pressure Plate
Fig. 2-Winch Control Valve Operation
The control valve spool is manually operated by a (3) In the "FREE-SPOOL" (rear) position (Fig. 2)
control lever mounted on the left side of the opera- the winch drum is released. The valve spool prevents
tor's seat. The lever has three positions: oil from passing through the valve. Pressure backs
up to the brake cylinder, disengaging the brake.
(1) In the "HOLD" (center) position (Fig. 1) the
winch drum is in neutral. Pressure oil from the pump REMOVAL
passes through the valve spool, through the filter,
Clean area around winch control valve before re-
and dumps back into the reservoir.
moving. Disconnect control cable and remove valve.
(2) In the " WIND" (forward) position (Fig. 1) the
winch drum is engaged. The valve spool closes off
the passage to the filter and regulates pressure oil
flow to engage the clutch. Back-up pressure from the
engaged clutch releases the brake and the gear train
turns the winch drum.
Litho in U.S.A.
TM-11 02 (Nov-73) Winch Control Valve 45-3
REPAIR
24-1
25--tjl
26- @
28- 1
27--E)
3~0
- -_ I
T 27252
1-Set Screw 13-Body and Seat 2~Piug

2-Handle Cap 14-Level Seal Plug (2 used) 26--0-Ring
3-Spring 1 ~Backup Ring (4 used) 27-Ball Guide
4-0-Ring 16--0-Ring (4 used) 28-Sprlng
~Valve Cap 17-Retainer (4 used) 29-Detent Plug (2 used)
6--Backup Ring 18-Compression Spring (4 used) 30-0-Ring (2 used)
7-0-Ring 19-0-Ring (5 used) 31-Thrust Bearing
8-Thrust Bearing Race 20--Valve Cap 32-Detent Spring (2 used)
9-Rotor and Shaft 21-Nut 33-0etent Ball (2 used)
10--0-Ring 22- Washer 34-Cap Screw (4 used)
11-Valve Seat (4 used) 23-Seal 3~Spring Washer (4 used)
12-Curved Washer (2 used) 24-Adjusting Screw 36--Steel Ball
Fig. 3-Winch Control Valve
Use Fig. 3 as a guide and disassemble control INSTALLATION

valve.
Install control valve on winch. Connect control le-
ver cable.
Clean o ld parts in solvent and dry with com-
pressed air. Inspect parts for wear or damage.
Control Lever Adjustment
Check relief valve and seat for wear or damage. Push control lever forward (with a force not to ex-
ceed 50 lbs. [22.7 kg]) until the internal stop inside
Replace all 0-rings and assemble control valve. the control valve is contacted.
Adjusting Relief Valve NOTE: If you cannot contact the internal stop in-
side the control valve adjust yoke accordingly.
Test relief for correct pressure setting of 850 to
1050 psi [59.8 to 73.8 kg/cm 2 ] at 1900 engine rpm .
When the internal stop inside the control valve has
been contacted, adjust lever stop cap screw to con-
If adjustment is necessary, remove cap, loosen
tact control lever. Then back out control lever stop
jam nut and turn set screw in or out until the correct
cap screw 1/2 turn and tighten nut.
pressure is obtained.
Litho in U.S.A.
45-4 Winch Control Valve TM-11 02 (Nov-73)
Litho in U.S.A.
TM-11 02 (Nov-73) Cylinders 50-1
Group 50
CYLINDERS
GENERAL INFORMATION
The hydraulic cylinders used on the crawlers are The backhoe crowd and boom cylinders are hy-
double acting and use " V"-packing type seals on draul ically cushioned. This prevents harsh stops
their pistons. Piston rods are heat treated, chrome when the cylinder reaches the end of its stroke.
plated, and polished. Replaceable non- metalic wear
rings are used on piston retainers to prevent scoring See "Hydraulic Cylinders" in FOS Manual -
of the cylinder barrels.
E] HYDRAU LICS for additional information on
cylinders and an explanation of the hydrau-
lic cushion design.
REMOVAL
1-Bushing (2 used) &-Retainer 11-V-Packing 1&--Wiper Seal

2-Barrel 7-V-Packing 12- Wear Ring 17- Piston Rod
3-Set Screw B-O-Ring 13-0-Ring 18-Bushing ...
4-Speclal Nut 9-Piston 14-Backup Washer 19-Grease Fitting
~Wear Ring 10-Snap Ring 1~Rod Guide
Fig. 1-Loader Boom Cylinder Assembly
Loader Boom Cylinders Loader Bucket Cylinders

Be sure boom is properly supported before remov- Lower boom to gro und and rest bucket flat on
ing cylinder to prevent boom from dropping and ground. Remove cylinders and cap lines.
causing injury.
Litho in U.S.A.
50 Hydra ulic System Crawler - JD450-C
50-2 Cylinders TM -1102 (No v-73)
8 9 10 11 12
~\
I sI (,\\'
4 t
7
1 \
@~~ ~ ·~ ®lI
I® <§5 ~ 13
T 19381
1- Bushing (2 used) ~Retainer 11-V-Packing 15--Backup Washer

2- Barrel 7-V-Pack ing 12- Wear Ring 1~Wiper Seal
3-Set Screw 8-Q-Ring 13-Rod Guide 17- Piston Rod
4-Stop Nut 9-Piston 14-0 -Ring 18-Bushing (2 used)
5--Wear Ring 1~nap Ring
Fig. 2-Loader Bucket Cylinder Assembly
8 9
I \
N 3-!
4 T
I~ ~~
\'or;\\\JJ
6 7
\\1
/ ~\ ~ ®\W}\JJ 1
co~~ 1s(i9~ \
~ 17 1\~·
~-10 13 14 15 1r 1)1\ ~~
I
0
11 12 , ~ ®))
I \ A\®
T 18t2Z
()tD\V
1-Bushlng (2 used) ~Piston 11-Snap Ring 1~Backup Washer
2- Barrel 7-0-Ring 12- V-Packing 17- Rod Guide
3-Set Screw 8-V-Packlng 13-Wear Ring 18-Piston Rod
4-Special Nut 9-Piston 14-Wiper Seal 19-Bushing
S-Wear Ring 10-Grease Fitting 15--0 -Ring
Fig. 3-Lumber Clamp Cylinder Assembly
Log and Lumber Clamp Cylinders Bulldozer Cylinders

Lower boom to ground and lower clamp to avoid Lower bulldozer blade to ground before removing
injury when removing cylinders. Remove cylinders. cylinders to avoid injury. Remove cylinders.
Litho in U.S.A.
TM-1102 (Nov-73) Cylinders 50-3
6 7 8
5 ~J~
\~~~~
15 1~
6
14 \
13 \
21 \ f'\ ~
1112 \ ~ \J
10 \ \ ~~
\'~~()
TJt 0 10P
1- Bushlng (2 used) 6-V-Packing 11 -0-Ring 16-Spanner Nut

2-Barrel 7- 0·Ring 12- Backup Washer 17-Bushlng (2 used)
3-Stop Nut &-Piston 13-Rod Guide 18-Rod
4-Weer Ring 9-Snap Rl ng 14-Snap Ring 19-Grease Fitting
s-Retainer 1G-V-Packing 15-Wiper Seal 20-Repair Kit
21-Wear Ring
Fig. 4-Log Grapple Cylinder Assembly
1- Barrel 6--0-Ring 11-0-Ring 16-Bushing (2 used)

2-Stop Nut 7-Piston 12-Backup Washer 17-Rod
3-Piston 8-Snap Ring 13-Snap Ring 18-Grease Fitting
4-Wear Ring 9-V-Packing 14-Wiper Seal 19-Repair Kit
5-V-Padtlng 10-Rod Guide 15-Spanner Nut 20-Wear Ring
21-Repair Kit
Fig. 5-Uft Cylinder Assembly
Litho in U.S.A.
50-4 Cylinders TM-1102 (Nov-73)
1-Barrel 6-0-Ring 11-0-Ring 16-Bushing (2 used)

2-Stop Nut 7-Piston 12-Backup Washer 17-Rod
3-Wear Ring 8-Snap Ring 13-Snap Ring 18-Grease Fitting
4-Piston 9-V-Packlng 14-Wlper Seal 19-Wear Ring
5---V-Packing 10-Rod Guide 15---Spanner Nut 20-Repair Kit
Fig. 6-Bulldozer Angling Cylinder Assembly
Litho in U S.A.
TM- 1102 (Nov-73) Cylinders 50-5
t 2 3 4 5 6 7 8 9 19 10
C]~@(@()J~~cba((@
0666
11 12 13 14 15 17~~
~ 1"""""1(((((.,.,_«((- - \ . __ _ __;B ./a

16-8 y
14 12 11 9 5 6 3 19
1'J20?JN
~6~~0~@ 00
1- Barrel ~-Ring 11-0-Ring 1~Bushing (2 used)
2- Stop Nut 7- Piston 12- Backup Washer 17-Rod
3-Wear Ring 8-Snap Ring 13-Snap Ring 18-Grease Fitting
4---Piston 9-V-Packing 14---Wlper Seal 19-Wear Ring
5-V-Packing 10-Rod Guide 15-Spanner Nut 20-Repair Kit
Fig. 7-Bulldozer Tilt Cylinder Assembly
Litho in U.S.A.
Ripper Cylinders
11 12 13
9 10 \ \ I
a \ \ A~
~@@Ua~
r---
~~
r 2978!
1-Grease Fitting 6-V-Packlng 11-V-Packlng 16-Snap Ring

2- Bushing (2 used) 7-Snap Ring 12-0-Ring 17- Wiper Seal
3-Barrel 8-Jam Nut 13-Piston 18-Spanner Nut
4-Rod Guide ~Wear Ring 14-0- Ring 1~Rod
5---Wear Ring 10-Retainer 15---Backup Washer 20-Bushing
21- Repalr Kit
Fig. 8-Ripper Uft Cylinder Assembly
Lower ripper to the ground. Clean area around oil

line connections. Remove and cap oil lines.
Remove cylinder from ripper.
Litho in U.S.A.
Backhoe Bucket Cylinder

15
11 12 1314b
10 \ \ II
~®~®~ '
T29371
1-Grease Fitting 7-Return Tube 14--0-Ring 21-Backup Washer

2-Bushing (2 used) 8-Adapter 1&--Piston 22-Snap Ring
3---Barrel 9-0-Ring 16--Snap Ring 23- Wiper Seal
4-Cap Screw 1G-Stop Nut 17- V-Packing 24--Spanner Nut
&-Lock Washer 11-Wear Ring 18-Wear Ring 2&--Bushing (2 used)
&-Washer 12-Retalner 19--Rod Guide 26--Piston Rod
13-V-Packlng 20-0-Ring 27- Grease Fitting
F19. 9-Bacl<hoe Bucket Cylinder Assembly
Extend the boom and dipperstick. With bucket on Remove the bucket cylinder.
the ground, support the dipperstick at the bucket end
pivot point to prevent the bucket from pivoting.
Litho in U.S.A.
50-8 Cylinders TM- 1102 (Nov-73)
Backhoe Boom Cylinder

11
18 13 1~ ~ft\
\ \ \ ,. ~ \!J
~8
6
(}0\§1 ®I \14 17
I12 15
co 24 2s
26
I
23 I
20 21 2\ \ \ ~~
ao~~®~ 7'3 1750N
1-Grease Fitting 7- Backup Washer 14-V-Packing 21-Backup Washer

2-Bushing (2 used) 8-Sieeve 15-0-Ring 22-Snap Ring
3-Barrel ~ut 16-Piston Rod 23-V-Packing
4-0-Ring (2 used) 1 ~Return Tube 17- Piston 24-Wear Ring
5-Connector 11-Set Screw 18-Brake Seal (2 used) 25-Rod Guide
6-0-Ring 12-Special Lock Nut 1~Wear Ring 26-Wiper Seal
13-Piston 2~-Ring 27-Grease Fitting
Fig. tO-Backhoe Boom Cylinder Assembly
Extend the boom and dipperstick. Rest the bucket Remove the boom cylinder.
on the ground.
Litho in U.S.A.
TM-1102 (Nov-73} Cylinders 50-9
Backhoe Crowd Cylinder
9 13 14 15
I 10 11 12 I I I
•
~~~oo~
25
I
~
(E
T24647
1-Grease Fitting 7-Q-Ring 13-V-Packlng 19-V-Packlng

2-Bushlng (2 used) 8-Adapter 14-0-Ring 2G-Wear Ring
3-Barrel 9-Set Screw 15--Piston 21-Rod Guide
4-Lock Washer 1G-Stop Nut 16-0-Ring 22-Wiper Seal
~ap Screw 11- Wear Ring 17- Backup Washer 23-Bushing
6-Return Tube 12-Retainer 18-Snap Ring 24-Piston Rod
25-Grease Fitting
Fig. 11-Backhoe Crowd Cylinder Assembly
Extend the boom and dipperstick (do not com- Place a support at the boom and dipperstick pivot
pletely extend the dipperstick). Rest the bucket on point.
the ground.
Remove the crowd cylinder.
Litho in U.S.A.
50-10 Cylinders TM- 11 02 (Nov-73)
Backhoe Swing Cylinder (9250)
T28912 N
1-Cylinder Head 6--Barrel 11-Piston 16-Wiper Seal

2- 0-Ring (2 used) 7- Special Lock Nut 12-Snap Ring 17-Bushlng
3-Backup Washer (2 used) 8-Piston 13-V-Packing 18--Piston Rod
4-Set Screw (2 used) 9-V-Packlng 14-Wear Ring 19-Grease Fitting
5-Bushing (2 used) 10-0-Ring 15-Rod Guide 20-Brake Seal (2 used)
21-Wear Ring
Fig. 12-Backhoe Swing Cylinder Assembly (9250)
Extend the boom and dipperstick. Rest the bucket Remove the swing cylinder.
on the ground to prevent the backhoe from swinging.
Litho in U.S.A.
TM-1 102 (No v-73) Cylinders 50-11
Backhoe Stabilizer Cylinders
12
100~'
6 7
8\~V"
' ww
~
4 \ \ \ ~~
M\ ~-~
\) 3
v® 17
16 \
15 \ ~
13 't ~~u 19
u 1033 ~C)\J
1-Bushlng (2 used) 6-V-Packing 11-Wear Ring 16-Wiper Seal
2-Barrel 7-0-Ring 12- Rod Guide 17-Spanner Nut
3--Stop Nut 8-Piston 13-0-Ring 18-Bushing (2 used)
4-Wear Ring 9-Snap Ring 14--Backup Washer 19-Piston Rod
5-Retainer 1~V-Packing 15-Snap Ring
Fig. 13-Backhoe Stabilizer Cylinder Assembly

Lower the stabilizer to the ground. Remove the Clamp the rod end in a vise taking care to prevent
stabilizer cylinder. damage to the piston rod. Remove nut from end of
rod. Slide parts from end of rod.
REPAIR
Wash all parts thoroughly with diesel fuel and in-
If cylinder packings have failed, some fragments of spect the following:
the deteriorated parts may have entered the system.
Completely drain the system and replace the filter. 1. Barrel, rod guide and rod for scoring , and 0-
rings for surface damage.
Clamp the cylinder in a vise to prevent it from turn-
ing. Remove set screw and rod guide. Use a span-
ner wrench to loosen rod guide.
Remove piston rod, rod guide and piston from bar-

rel.
Litho in U.S.A.
50 Hydraulic System Cra wler - JD450-C
50-12 Cylinders TM- 1102 (Nov-73)
2. V-packings and wear rings for breaks, cuts or Install V-packing in rod guide with the apex of the
embedded foreign material. V toward the wiper seal and secure with snap ring.
3. Piston rod seal and wiper for wear or damage. Slip rod guide assembly on piston rod being care-
Remove sharp edges from piston rod with emery ful not to damage packing.
cloth .
Piston V-Packing
Repair kits are available for overhauling all cylin-
V-packings are originally installed on the piston
ders . Discard used parts and use all new parts pro-
with the apex of the V pointing away from the barrel
vided in kits when assembling cylinders.
(Fig. 15). When replacing V-packings in the field this
procedure can be used if a suitable ring compressor
Lubricate all 0-rings, seals, and packings before
is available to compress packings when installed in
assembly.
cylinders.
Install new wiper seal in rod guide.
Install new wear ring in rod guide. Position backup

washer and 0-ring on rod guide.
1-Retainer 4-Nut
2- Wear Ring ~Cylinder Barrel
3-Piston
Fig. 15-0rigina/ Installation of

V-Packing
T 21514
1-0-Ring 4-Wear Ring
2- Snap Ring ~Wiper Seal
3-V-Packlng 6--Backup Washer
Fig. 14-Rod Guide Components
Litho in U.S.A.
TM- 11 02 (Nov-73) Cylinders 50-13
If a suitable compressor is not available, assemble

the packings with the apex of the V pointing toward
the barrel (Fig. 16). This eliminates scuffing that may
occur in assembly; however, the V-packing may be-
come torn if the cylinder has to be disassembled in
the future.
Position piston on piston rod. Install wear ring on

piston retainer. Position retainer on piston rod and
secure with stop nut.
4
Install piston rod assembly into barrel.
T31516N~ Secure piston rod assembly in barrel with rod

guide and tighten to specified torque . Install set
1- Retainer 4-Nut screw and tighten after rod guide is tightened to
2- Wear Ring 5-Cylinder Barrel proper torque.
3-Plston
Fig. 16-lnstallation of V-Packing INSTALLATION

Without Compressor
Be sure area is clean before installing cylinders to
prevent entry of dirt into the system. Install cylinders.
BACKHOE SWING CYLINDER (9300)

General Information As the shaft and vane assembly rotates, the shaft
vane gradually closes the larger brake hole. (The
A rotary, vane-type, double-acting swing cylinder
small brake hole is never closed.) This gradual clos-
with incorporated brake swings the boom. The cylin-
ing causes a reduction in the flow of return oil from
der is composed of a barrel and vane assembly, top
the swing cylinder to the reservoir. The reduction in
and bottom plates, splined shaft, and a vane assem-
the flow of return oil slows down the rotation of the
bly.
swing cylinder providing a hydraulic braking action.
During operation, the cylinder barrel is held in a
The braking action is the same in either direction.
stationary position by the swing cylinder link assem-
bly, while the splined shaft and vane assembly rotate
within the barrel. The top plate, which is stationary
with the barrel, has two brake holes drilled on each
side of the barrel vane.
Litho in U.S.A.
1-Pressure Oil 3-Barrel Vane 5--Splined Shaft 7-Top Plate

2-011 Under Slight Pressure 4-Shaft Vane 6-Barrel 8---Brake Holes
Rg. 17-Swing Cylinder Hydraulic Brake Operation
Removal Remove the tapered pin and tapered bushing.

Extend the boom and dipperstick along the ground
Remove cap screws holding the top and bottom
so they are resting on the bucket.
shaft couplings to the pivot casting.
Remove hoses from back of swing cylinder.
Break shaft coupling dowels loose by prying rear-
ward on swing cylinder barrel.
Replace cap screw with special swing cylinder re-
moval bar (Fig. 17).
Carefully slide the cylinder out and up.
Litho in U.S.A.
TM-1102 (Nov-73) Cylinders 50-15
the cylinder barrel. Turn jack screws alternately and

evenly so that top and bottom plates are always
square.
Slide top plate from splined shaft being careful not

to damage 0-ring and backup washer.
Vane Right Vane Left
Fig. 20-Removing Shaft Vane
The shaft vane must contact either the right or left

side of the barrel vane (Fig. 20) before it can be re-
moved. Rotate it either to the right or left position.
Remove the shaft vane being careful not to scratch

the barrel surface.
Support the barrel vane so it cannot drop inside

1- Removal Bar 4-Torque Link the barrel, and remove the barrel vane.
2- Two Hoses 5-Bottom Coupling
3-Tapered Pin 6-Top Coupling
Fig. 18-Removing Swing Cylinder
Repair
Fig. 21-Removing Shaft Vane
Place splined shaft in vise being careful not to

scratch the shaft. Mark the shaft and vane before
Fig. 19-Removing Top Plate disassembly so the vane can be installed in exactly
the original position.
Clamp swing cylinder in special fixture (Fig. 19).
Drawings of this fixture are shown in "Special Tools." To remove dowel pins, place a spacer and nut on
Use two 7/8-inch [22.2 mm) cap screws as jack a pin (Fig. 21) and tighten to end of threads . Remove
screws (Fig. 19) and force the top plate from the nut, add a second spacer, install the nut and
tighten until pin is removed.
Litho in U.S.A.
50·16 Cylinders TM-1102 (Nov-73)
0 -11
14
I 1s
~;
c::.-:.:.,;
1- Dowel (4 used) 7- 0 -Ring (2 used) 13-Seal Washer (6 used)

2- Washer (24 used) 8-Backup Seal (4 used) 14-Cap Screw (12 used)
3-Cap Screw (24 used) 9--Vane Seal (2 used) 15-Dowel (8 used)
4-Dust Seal 1G-Cyllnder Vane 16-Vane and Shaft Assembly
5-Top Plate 11-0-Ring (2 used) 17-Bottom Plate
6-Backup Washer (2 used) 12-Barrel
Fig. 22-Swing Cylinder
Wash all parts thoroughly with a solvent and in- If brass choke plates on the vane of the splined
spect for scoring of cylinder and surface damage to shaft (16) are damaged, replace the shaft and vane
0-rings, backup washers, and packings. assembly. Damaged choke plates will stop brake ac-
tion of the swing cylinder.
Litho in U.S.A.
Soak backup washers in oil and install them . At- Installation

tach rubber packing to the vanes.
Lightly grease the shaft splines to rnaRe future re-
moval easier .
. J
Insert the swing cylinder removal bar into swing
cylinder and raise the cylinder with a chain hoist.
Fig. 23-lnsta/ling Shaft and Vane
IMPORTANT: Always use new sealing washers

under heads of cap screws when installing vane.
Attach the vane to the barrel with cap screws.

Tighten with 370 to 380 lb-ft (51 .1 to 52.5 kg-m].
T2 1522
Place the vane on the shaft in the exact position
1-Timing Arrows 3-Coupling
from which it was removed (as indicated by markings 2-Splined Shaft 4-Swlng Cylinder
made before removal). Drive in dowels and secure
vane with cap screws. Fig. 24- Timing Coupling and Shaft
Install splined shaft in cylinder barrel with the large Place the ring spacer over the splined shaft at the
brass choke plates toward the top of the barrel. Posi- bottom. Align stamped arrows on each end of shaft
tion the shaft so that the vane contacts either the with mark on each coupling (Fig . 24), and place cou-
right or left side of the barrel vane (Fig . 19). plings on splined shaft.
Push cylinder in place until the dowels in the cou-
Rotate the splined shaft until the barrel vane and plings align with dowel holes in the pivot casting.
shaft vane are exactly opposite each other (Fig. 22).
Install cap screws holding shaft couplings to pivot
NOTE: Do not attempt to force the shaft and vane casting. Tighten to 300 lb-ft [ 41.8 kg- m].
assembly into position. When properly assembled, Align the torque link with the upper bracket on the
parts should rotate smoothly. cylinder barrel and insert tapered pin. Place the ta-
pered bushing in the upper bracket.
Insert backup washer and 0 -rings in bore of the
top and bottom plate. Install a lock nut on each end of the tapered pin.
Tighten bottom lock nut with 175 to 195 lb-tt [24.2 to
Replace 0-rings in top and bottom of cylinder bar- 26.9 kg-m] to draw tapered pin through lower brack-
rel. Attach top and bottom plates to the barrel. et. Then tighten top lock nut with 175 to 195 lb-ft
(24.2 to 26.9 kg-m]. It is important that the bottom
lock nut be tightened first.
Litho in U.S.A.
50-18 Cylinders TM-11 02 (Nov- 73)
MULTIPURPOSE BUCKET CLAM CYLINDER
r).a..'
~.;)
T29 430
1- Bushing (2 used) 7- Seal 13- Piston

2- Piston Rod 8-0uter Wiper 14-Special Washer
3-Grease Fitting 9-Plston 1~Special Bolt
4-Packing Gland 10-Packlng (2 used) 16-Cylinder Tube
~Ring 11-Ring 17- Speclal Screw
6-0·Ring 12- lnner Wiper
Fig. 25-Ciam Cylinder
Removal Pull piston rod assembly from cylinder. Inspect cyl-

inder tube for wear grooves, scratches, or pits which
If clam cylinders require servicing, remove them
could cause cylinder leaking . Replace cylinder if any
from bucket as follows:
of these conditions are present.
Lower loader boom to the ground. With crawler en-
Clamp piston rod-eye in a vise and remove special
gine stopped , actuate all loader control levers to re-
bolt (15) from other end of rod . Remove pistons and
lieve oil pressure.
packings. Check pistons for wear or damage. Re-
place if necessary. Replace packings (10) if dam-
A See caution note on page 50-5-1 .
aged.
Replace rings (5 and 11 ) if damaged . Replace seal

Break clam cylinder connections. Remove cylinder
(7) and wipers (8 and 12).
pins and lift cylinders from bucket.
Repair
Clamp cylinder securely in a vise. Remove special
screw (17), then turn packing gland out of cylinder
tube using a spanner wrench. Do not allow piston
rod to drop on threaded part of cylinder tube.
Litho in U.S.A.
TM- 1102 (Nov- 73) Cylinders 50-19
Assemble cylinder using reverse procedure from

that of disassembly. Coat all 0 -rings, backup wash- ---------,--~~~-2
ers, and cylinder bore with a light film of oil.
Torque special bolt (15) in piston rod to 1000-1 200

lb-ft [ 138.2 to 165.9 kg-m).
After piston has been started into the cylinder tube,

slide packing gland into position. Work piston rod fur-
ther into the tube, keeping rod in a straight line with
the tube.
Screw packing gland into the tube and tighten to

100-200 lb-ft [13.8 to 27.6 kg-m) using a spanner
wrench. Tighten until torque is reached and special
screw holes line up.
If a new packing gland or cylinder tube is used, T J0792N

drill a new hole for the special screw (2, Fig. 25), half
in the packing gland and half in the tube. Do not drill 1- Cyllnder Tube 3-Packlng Gland
in line with spanner wrench holes. Use a No. 26 drill 2-Special Screw 4-Piston Rod
and drill approximately 0.31 in. [7.94 mm] deep.
Fig. 26-Special Screw Location
Installation
Install clam cylinder.
Check hydraulic system oil level. Replace any oil

lost during cylinder removal. (See Section 10 of this
manual.)
Litho in U.S.A.
Litho in U.S.A.
TM- 1102 (Nov-73} Miscellaneous Hydraulic Components 55-1
Group 55
MISCELLANEOUS HYDRAULIC COMPONENTS
RESERVOIR AND FILTERS
General Information
The hydraulic reservoir is the sump area for the
hydraulic functions and is pressurized to keep out dirt
and to hold pressure for positive flow to the pump.
The hydraulic system filtering unit consists of a re-

turn line filter element that filters the oil as it returns
to the reservoir.
Should the return line filter become plugged, a

valve at the top of the reservoir allows oil to bypass
the filter and enter the reservoir.
Removal ©>---10
Remove the filter cap (4, Fig. 1) to remove the re-
turn line filter.
Repair
Replace the return line filter at the service periods
o-Il@>-12
outlined in the operator's manual. Also replace return
line filter when major service work is performed on
the crawler hydraulic components. 13
T 19206
When servicing the filter, replace the two 0 -rings
(5 and 10).
1-Cap Screw (6 used) 8-Sprlng
Installation 2- Pressure Cap 9-lndlcator Piston
3-Pipe Plug 10-0-Ring
Install the filter assembly being careful not to dam-
4-Filter Cap 11-Filter Cap
age the gasket (15). ~-Ring 12- Washer
6-Spring Pin 13-Machine Bolt
7-Washer 14-Micronlc Fllter
15--Gasket
Fig. 1-Return Line Filter
Litho in U.S.A.
55-2 Miscellaneous Hydraulic Components TM-1102 (Nov-73}
TRANSMISSION OIL COOLER

AND FILTER
General Information
Transmission oil is pumped through a pressure
regulating valve to engage the H-L-R clutches, lubri-
cate the transmission , and to the oil cooler and filter.
Oil from the filter then goes to lubricate the transmis-
sion.
As the H-L-R clutch engages and oil is no longer

demanded, a larger volume of oil is diverted through
the oil cooler and filter.
If the oil filter clogs, a relief valve opens allowing

oil to bypass the filter and return directly to the lub-
ricating circuit.
Oil Filter Assembly Removal

Remove grille from tractor.
1- Radiator Cooler 3-Hoses
Loosen hose clamps and free inlet and outlet 2-Cooler-To-Radiator 4-Bracket Cap Screws
Cap Screws
tubes.
Fig. 2-Removing Oil Cooler
Remove top cap screw from filter base bracket and
lift out filter assembly. Transmission Case Oil Filter
Assembly Removal
Removing Oil Cooler Unit
Remove hood from tractor. Remove side frame-to-
grille housing cap screws. Also remove bottom plate-
to-grille housing cap screws. Then tilt grille housing
forward on pivot pins as shown in Fig. 2.
Loosen radiator collar and remove rear cap screws

securing oil cooler to radiator (not shown) .
Remove two cap screws hold ing radiator bracket

to cooler.
1-Cover 5--Filter Element
2-Gasket 6-Filter Case
Loosen hose clamps and free hoses from cooler 3-Seal 7-Seal
inlet and outlet. 4-Spring
Fig. 3-Transmission Case Oil Filter Unit

Remove front cap screws securing oil cooler to ra-
diator and lift out oil cooler.
Remove cap screws securing cover to transmis-
sion case. Remove filter unit.
Litho in U.S.A.
TM-1102 (Nov-73) Miscellaneous Hydraulic Components 55-3
Repair - Oil Cooler

Straighten any bent fins and clean trash from
screen.
Flush out passages in oil cooler. Blow out with

compressed air. Check for any restrictions in lines
and passages. Inspect hoses for "mushy" condition.
Repair - Oil Filter

Install a new John Deere element, making sure
that sealing ring is secure in bottom groove of ele-
ment. Apply a thin film of oil to sealing ring.
Apply a thin film of oil to the bottom of the oil filter

gasket. Tighten oil filter 3/4 to 1- 1/4 turns after gas-
ket contacts the oil filter base.
Installation - Oil Cooler

Install oil cooler. securing front cap screws to radi-
ator.
1-Bracket Attaching Cap Screws 3-Hoses
2-FIIter Element
Attach cooler inlet and outlet hoses.
Fig. 4-fnsta/ling Oil Filter Assembly
Attach radiator bracket to cooler. Install rear cap
screws securing oil cooler to radiator. Installation - Transmission Case Oil
Filter Assembly
Installation - Oil Filter Install a new John Deere element. making sure
Set oil filter assembly into place inside grille hous- that sealing ring is secure in bottom groove of ele-
ing (Fig. 4). Insert hoses on tubes and attach filter ment. Apply a thin film of oil to sealing ring.
bracket using two cap screws and lock washers.
Apply a thin film of oil to the bottom of the oil filter
Tighten hose clamp securely.
gasket. Tighten oil filter 3/4 to 1-1 /4 turns after gas-
Spin off old filter element and discard it. Install a ket contacts the oil fil ter base.
new John Deere element, making sure that sealing
Refill transmission with oil of the proper quantity
ring is secure in bottom groove of element. Apply a
and viscosity (Section 10).
thin film of oil to sealing ring and turn element down
until the seal contacts the base. Tighten element an
additional 3/4 to 1-1/4 turns.
Install grille on tractor.
Litho in U.S.A.
55-4 Miscellaneous Hydraulic Components TM- 1102 (Nov-73)
SELECTOR VALVE
GENERAL INFORMATION
T28403
1- Press ure Oil 3-Aow To Rear 4-Pump Inlet &-Flow To Front

2- Trapped Oil Mounted Equipment s-Rellef Valve Mounted Equipment
Fig. 5-Selector Valve Operation
The selector valve directs oil fiow to either front Thoroughly clean and dry all parts. Inspect the
mounted or rear mounted equipment determined by spool for dents and scratches.
the position of the valve (Fig. 5).
Replace spool and housing as a matched set. Re-
A system relief valve is incorporated into the selec- place all 0-rings and backup washers.
tor valve to provide pump protection.
Thoroughly lubricate 0 -rings, when assembling, to
REMOVAL prevent damage to them.
Remove selector valve from unit.
Secure the selector valve to the unit and connect
hoses and fittings as previously removed.
REPAIR
Remove snap ring from bottom end of spool and The relief valve (1 1) can be adjusted by adding or
disassemble valve using Fig. 6 for a guide. removing washers (14} .
Litho in U.S.A.
TM- 11 02 (Nov-73) Miscellaneous Hydraulic Components 55-5
~=:./
/ -L~-==----:;~
I
I
-3,'
I
I
I
I
I
I
5-©>
:
I 4- 0 I
12-0
' , __ .... / ' '
T3 2074N
1-Handle 11- Relief Valve

2- Spring Pin 12-Snap Ring
3-Spool 13-Snap Ring
4-Backup Washer 14-Washer
(2 used) 15--Screen
5-0 -Ring (3 used) 1 ~-Ring
6-Valve Body 17- Screen
7-0·Ring 18-0rifice Plate
8-Spool Detent Plug 19-Sprlng
9-0·Ring 20-PIIot Assembly*
T21495
10-Backup Washer 21-Cage*
* Not available as individual service part. 1- Pump Oil Flow 4-From Pump
2- Function Oil Flow 5-To Reservoir
Fig. 6·Selector Valve 3-Return Oil Flow 6- To Control Valve
Fig. 7-Fiow Divider
FLOW DIVIDER REMOVAL

GENERAL INFORMATION Remove flow divider from unit and disassemble.
When the function control valve requires less GPM
capacity than the pump delivers, the flow divider pro-
REPAIR
vides the required GPM to the control valve and re- Thoroughly clean and dry all parts.
turns excess GPM to the reservoir (Fig. 7).
Inspect the spool and the housing for wear and
scoring. Rep lace the spoo l and housing as a
matched set.
Litho in U.S.A.
55·6 Miscellaneous Hydraulic Components TM-1102 (Nov- 73)
MULTIPURPOSE BUCKET
8--1 CLAM RELIEF VALVE
o - 2
<»-3 GENERAL INFORMATION
i--4
<::>- 3 A single-acting circuit relief valve, located at the
t--5 top rear of the bucket, provides pressure relief when

the attachment control lever is in neutral. The relief
fl-6
o--2
valve allows a fully or partially opened clam to close,
preventing damage to the clam when tractor forces
the clam against an obstacle.
REMOVAL
TH/14 ~7
1- Piug 4-Spring
2-0-Ring (2 used) 5-Spool
3-Disk (2 used) f-.Housing
7-Piug
Fig. 8-Fiow Divider
Replace worn or damaged parts. Make sure the

hole in the orifice disk is open.
INSTALLATION
Secure flow divider to the unit. Connect hoses and
fittings. 1- Relief Valve
Fig. 9-Multipurpose Bucket Relief Valve
Litho in U.S.A.
TM- 1102 (Nov-73) Miscellaneous Hydraulic Components 55-7
REPAIR
u ""
1- Pipe 4-0-Ring 7-Spring

2-Piug 5-Seat 8-Shims (as req uired)
3-Body 6--Piunger 9--Cap
Fig. 10-Muftipurpose Bucket Clam Relief Valve
Whenever clam cylinder operation is abnormal INSTALLATION

(bucket does not remain open in bulldozer or scraper
Install valve on bucket. Connect oil lines.
operation), the bucket relief valve may be incorrectly
adjusted or in need of servicing. The valve is adjust-
ed by adding or subtracting shims under the relief
valve cap.
Litho in U.S.A.
55-8 Miscellaneous Hydraulic Components TM-11 02 (Nov- 73)
BREAKAWAY COUPLERS
GENERAL INFORMATION
T 3 2 0 76N
1- Ball (12 used) 11-Spring (2 used) 21-Snap Ring (2 used) 31- Spring
2-0-Ring (4 used) 12-Sall (2 used) 22- Piug (2 used) 32- Cap Screw (2 used)
3-Backup Ring (4 used) 13- Backup Ring (2 used) 23-Ball (2 used) 33-Backup Ring (4 used)
4-Drive Screw (4 used) 14-0-Ring (2 used) 24-Spring (2 used) 34-0 -Ring (4 used)
~haln (2 used) 15--Receptacle (2 used) 25-Guide (2 used) 35--Lock ~asher (8 used)
&-Dust Plug (2 used) 1&-0-Ring (2 used) 2&-Snap Ring (2 used) 3&-Gasket (2 used)
7~asket (2 used) 17- Backup Ring (2 used) 27- Piug (2 used) 37- Retalning Ring (2 used)
8-Body 18-Dust Cover (2 used) 28-Cam 38-Spring (2 used)
9-Snap Ring (2 used) 19-Sieeve (2 used) 29-Cap Screw (2 used) 39-Cap Screw
10-Piug (2 used) 20-Snap Ring (2 used) 30-Lock Washer (2 used) 40-Lever
Fig. 11-Breakaway Coupler
Refer to machine operator's manual for use of Remove receptacle assembly from coupler body.
breakaway couplers and to "Quick Disconnect Cou- Remove steel balls (1) and snap ring (20) from re-
plers" in FOS Manual-HYDRAULICS for theory of ceptacle.
operation.
Invert and install receptacle in coupler body and
REMOVAL plac~ coupler body in vise . Press down on receptacle
plug.(10) and remove snap ring (9). Use a brass drift
Disconnect oil lines from couplers and remove
to drive receptacle plug, spring (11). and ball (12)
couplers from unit.
from receptacle.
REPAIR
Inspect all parts of the assembly for wear or dam-
Refer to Fig. 11 and disassemble couplers. age.
Remove retaining rings (37) and springs (38) from INSTALLATION

operating levers and remove levers from receptacles
Install couplers on unit and connect oil lines.
and coupler body.
Litho in U.S. A.
Group 60
TRANSMISSION PUMP
::
I I
II
I
::f I I 1
1 - Gear width .......................... 0.8730 to 0.8735 in.
[22.17 to 22.19 mm]
: I I : I __j_
~~--~11-------4--------~~~~~
I
T320??N
Fig. 1-0uter Gear
T:-----~----:/i I 1 - Gear width .......................... 0.8730 to 0.8735 in.

[22.17 to 22.19 mm]
II II
L---~~/~L___-___-~---------~~~,J____~
I IJ 1
T32078N
Fig. 2-/nner Gear
Litho in U.S.A.
MAIN HYDRAULIC PUMPS

15 GPM Pump
1 - O.D. of pump idler and drive shafts

at bearing area ......................... 0.6850 in. (min.)
[ 17.40 mm]
2 - Pump gear widths ................. ... 1.1070 in. (min.)
[28.12 mm]
3 - I.D. of bearings ..... ... ................ 0.6910 in. (max.)
[17.55 mm )
4 - Back plate gear surface flat
within .. ......................... ... ...................... 0.0015 in.
[0.038 mm ]
5 - Relationship of oil seal to front plate
surface .............................. ... ..... .. ......... .. .... ... Flush
6 - Check springs free length .................... 0.625 in.
[ 15.9 mm]
Check springs test length ................. .... 0.437 in.
[ 11. 1 mm) with 0 .28 lbs. [13.0 kg]
7 - Pump assembly cap screws
TJ2079N
torque ............. .. ............................. 27 to 30 lb-ft.
Fig. 3-Main Hydraulic Pump [3.7 to 4.1 kg-m]
23 GPM Pump
1 - O.D. of pump idler and drive shafts

at bearing area ........... .. ............ 0.8730 in. (min.)
[22. 17 mm]
2 - Pump gear widths ......... .. ......... 1.1660 in. (min.)
[29.62 mm]
3 - I. D. of bearings .. ...................... 0.8790 in. (max.)
[22.33 mm)
4 - Back plate gear surface
flat within .............................................. 0.00 15 in.
[0.038 mm]
surface ..................................... 0. 1560 in. (below)
[3.96 mm]
6 - Check spring free length ...................... 0.875 in.
[22.22 mm]
Check spring test length ...................... 0.562 in.
[ 14.27 mm] with 41 lbs. [ 18.60 kg]
torque ..................................................... .. 40 lb-ft.
[5.5 kg-m]
Litho in U.S.A.
MAIN HYDRAULIC PUMPS

See Fig. 3 28 GPM Pump
1 - 0.0. of pump idler and drive shafts

at bearing area ........................ 0.8730 in. (min.)
(22.17 mm]
2 - Pump gear widths .................... 1.4100 in. (min.)
(35.81 mm]
3 - 1.0. of bearings ....................... 0.8790 in. (max.)
[22.33 mm]
4 - Back plate gear surface
flat within ............................................. 0.0015 in .
(0.038 mm]
surface .................................... 0.1562 in. (below)
[3.97 mm]
6 - Check spring free length ...................... 0.875 in.
[22.22 mm]
Check spring test length ...... ................ 0.562 in .
[14 .27 mm] with 41 lbs. [18.60 kg]
torque ...................................................... .40 lb-ft.
[5.5 kg-m]
WINCH HYDRAULIC PUMP

1 - Distance body needle bearings below pump

machined surface ............... 0.0150 to 0.0200 in.
[0 .381 to 0.508 mm]
Distance cover needle bearings below pump
machined surface ............... 0 .0050 to 0.0150 in.
[0.1 27 to 0.381 mm]
2 - Width of gears .................... 0.3745 to 0.3750 in.

[9.512 to 9.525 mm]
3 - 0.0. of gears ...................... 1.2430 to 1.2435 in.

[31.572 to 31.585 mm]
T 32 080N
Fig. 4-Winch Hydraulic Pump
Litho in U.S.A.
CLUTCH CONTROL VALVE

Fig. 5-Ciutch Control Valve
- Accumulator inner spring test 4 - Detent spring test

length ................ .. ...... ............. 3.00 in. [76.0 mm) length..................................... 0.88 in. [22.5 mmJ
with 90 to 110 lbs. [40.5 to 49.5 kg) with 22.5 to 27.5 lbs. [9.9 to 12.1 kg)
2 - Accumulator outer spring test 5 - Accumulator check valve spring

length .. .. .. ............................... 3.26 in. [82.8 mm] test length ...................... .. ..... 0.88 in. [22.4 mm)
with 150.3 to 183.7 lbs. [68.2 to 83.4 kg] with 5.5 to 7.5 oz. [ 156.0 to 212.6 g]
3 - Accum ulator bypass spring test

length..................................... 1.34 in. [34.0 mm]
with 20.45 to 25.05 lbs. [9.32 to 11 .32 kg)
Litho in U.S.A.
STEERING VALVE
1 - 1.0. of valve bore .. ........ ..... 0.7518 ± 0.0010 in.

[ 19.096 ± 0.025 mm]
T32082N
Fig. 6-Steering Valve
- 0.0 . of valve spool ............ 0.7502 to 0.7508 in.

[ 19.055 to 19.070 mm]
T32083N
Fig. 7-Steering Valve Spool
Litho in U.S.A.
50 Hydraulic System Crawler - J0450-C
60-6 Specification and Special Tools TM-1102 (Nov-73)
LOADER BOOM VALVE

'l'JZOB<JN
Fig. 8-Loader Boom Valve Section
1 - Lift check spring test 3 - Spool spring test

length ......... ............. ..... .......... 1.06 in. [26.9 mm] length ................. .............. ...... 1.44 in. [36.6 mm]
with 1 lb. [0.45 kg] with 50 lbs. [22.68 kg]
2 - System relief valve spring test
length ..................................... 1.34 in . [34.0 mm]
with 15 lbs. [6.80 kg]
LOADER BUCKET VALVE

TJ2085N
Fig. 9-Loader Bucket Valve
- Litt check spring test 2 - Spool spring test length (without return-
length .......................... ....... .... 1.06 in. [26.9 mm] to-dig mechanism) .. .. ............ 1.37 in. [34.8 mm]
with 1 lb. [0.45 kg] with 52 lbs. [23.59 kg]
Litho in U.S.A.
BULLDOZER CONTROL VALVE

T3Z.08611
Fig. 10-Bulldozer Control Valve
- Lift spool spring free 2 - Tilt spool spring free

length ..................................... 1.56 in. [39.6 mm] length..................................... 1.20 in . [30.5 mm]
Lift spool spring test Tilt spool spring test
length..................................... 1.25 in. [31. 7 mm] length..................................... 0.94 in. [23.9 mm]
with 31.5 to 35.1 lbs. [ 14.3 to 15.9 kg] with 27.5 lbs. [ 12.5 kg]
2 - Angling spool spring free 3 - Relief valve spring frE:e

length ............................... ...... 1.19 in . [30.2 mm] length ..................................... 2.81 in. [7 1.4 mm]
Angling spool spring test Relief valve spring test
length ..................................... 0.94 in . (24.2 mm] length ...... .. .. .. ... ...................... 2.31 in. [58.7 mm]
with 21 to 25 lbs. [9.5 to 11 .3 kg] with 243 to 297 lbs. ( 110.1 to 134.7 kg]
Litho in U.S.A.
BACKHOE CONTROL VALVE

T3208?N
1 - Spool spring test 3 - Lift check spring test

length ..... .. .............................. 1.25 in. [31 .7 mm] length..................................... 0.75 in . [19 .0 mm]
with 27 lbs. [ 12.25 kg] with 2 oz. [56. 7 g]
2 - Anti-cavitation check valve spring
test length .. .. .. ............. .......... 0.62 in. [ 15.7 mm]
with 75 lbs. [35.02 kg]
ro
~
0
0
0 0
0
TJ2088N
- Tie bolt torque ................ ......... ..... 25 to 40 lb-ft.

(3 .46 to 5.53 kg-m]
Litho in U.S.A.
TM- 1102 (Nov-73} Specifications and Special Tools 60-9
WINCH CONTROL VALVE

r- - - - - - - - - - - - - .
:@
I
Q
••
•
I
I
z-J•
0
___ _ _ _ ..!
T32089N
Fig. 13-Winch Control Valve
- Detent spring test 2 - Relief valve spring test

length ................................. 0.617 in. [15.67 mm] length .. ................................. 0.75 in. [19.05 mmJ
with 10 lbs. [4.53 kg] with 23 lbs . [ 10.43 kg)
CYLINDERS
6 ~---------- 3 ------~
5
T32090N
Fig. 14-Loader Bucket Cylinder
1 - Loader bucket cylinder bore ................... 3.50 in. 4 - Rod guide torque ···········--------·- 250 to 300 lb-ft.
[88.9 mm] [34.6 to 41.5 kg-mJ
2 - Rod diameter ........................................... 2.00 in. 5 - Set screw torque .. .................................. 40 Ib-in.
[50.8 mm] [0.5 kg-m]
3 - Cylinder stroke ................. ...................... 3 1.10 in. 6 - Special nut torque .................... 600 to 700 lb-ft.
[786.9 mmJ [82.9 to 96.8 kg-m]
Litho in U.S.A.
60-10 Specifications and Special Tools TM- 1102 (Nov- 73)
CYLINDERS
TJ2091N
Fig. 15-Loader Boom Cylinder
1 - Loader boom cylinder bore .................... 4.25 in. 4 - Spanner nut torque ............ ...... 250 to 300 lb-ft.
[ 108.0 mm) [34.5 to 41 .5 kg-m)
2 - Rod diametor .. ... ......... .. ........................... 2.25 in. 5 - Set screw torque ......... .... .. ..................... 40 lb-in.
[57.2 mm] (0.5 kg-m)
3 - Cylinder Stroke .. ...................... .. ............ 28.25 in. 6 - Special nut torque ......... ........... 600 to 700 lb-ft.
[717.6 mm] (82.9 to 96.8 kg-m)
T32092N
Fig 16- Log Grapple Cylinder
- Log grapple cylinder bore ....................... 3.50 in. 4 - Spanner nut torque ............ .... .. . 125 to 175 lb-ft
[88.9 mm) (17.23 to 24.19 kg-m]
5 - Special nut torque .................... 475 to 575 lb-ft.
2 - Rod diameter .. ....................... ......... ......... 1.75 in. [65.67 to 79.50 kg-m)
[44.4 mm)
3 - Cylinder Stroke ... .. ..... .. .............. .. ......... . 16.85 in.
[427.99 mm)
Litho in U.S.A.
CYLINDERS
Fig. 17-Lumber Clamp Cylinder
- Lumber clamp cylinder bore ................... 5.25 in. 4 - Set screw torque ........ ............................ 40 lb-in.
[133.35 mm] [0.46 kg-m]
2 - Rod diameter ....... .................................... 2.25 in. 5 - Rod guide torque ................ ...... 250 to 300 lb-ft
[57.15 mm] [34.56 to 41.48 kg-m]
3 - Cylinder stroke ... .................................... 16.80 in. 6 - Special nut torque .................... 600 to 700 lb-ft.
[426.72 mm] [82.95 to 96.77 kg-m]
0
5
T32094N
Fig. 18-Bulldozer Lift Cylinder
- Bulldozer lift cylinder bore ...................... 3.50 in. 4 - Spanner nut torque ... ................ 125 to 175 lb-ft
[88 .9 mm] [17.3 to 24.2 kg-m]
2 - Rod diameter ............... ... ......................... 1.50 in. 5 - Special nut torque ... ................... 500 lb-ft. (min.)
[38.0 mm) [69.1 kg-m ]
3 - Cylinder stroke ........... ............................ 15.00 in.

[38 1.0 mm)
Litho In U.S.A.
60·12 Specifications and Special Tools TM-1 102 (Nov- 73)
CYLINDERS
5
T32095N
Fig. 19-Bulldozer Tilt Cylinder
1 - Bulldozer tilt cylinder bore ... ......... ........ .. 3.50 in. 4 - Spanner nut torque ..... .. ... .. .. ... .. 125 to 175 lb-ft
(88.9 mm] (17.3 to 24.2 kg-m]
2 - Rod diameter .. ..... ...................... ... ........... 1.50 in. 5 - Special nut torque ......... .. .. .. .. .. .... 500 lb-ft. (min)
(38.0 mm] [69.1 kg-m]
3 - Cylinder Stroke ..... .... .......... ... ....... ........... 3.00 in.
(76.2 mm]
5
~----------- 3 ------------~
T32096N
Fig. 20-Bu//dozer Angling Cylinder
1 - Bulldozer angling cylinder bore .. ............ 3.50 in . 4 - Spanner nut torque ... ............. ......... 125- 175 lb-ft
(88.9 mm] [17.3 to 24.2 kg-m]
2 - Rod diameter .. .... ............... ... .. .. ............... 1.50 in. 5 - Special nut torque .. .... ...... ... ....... .. 500 lb-ft (min)
[38 .0 mm] [69.1 kg-m]
3 - Cylinder stroke .. ........ .. .. ............... .. ..... ... 13.00 in.
(339 .9 mm]
Litho in U.S.A.
TM-1102 (Nov- 73) Specifications and Special Tools 60-13
CYLINDERS
SPECIFICATIONS AND TORQUE VALUE5-Continued
5 ~--------- 3----------~
T32097N
Fig. 21-Backhoe Bucket Cylinder
- Backhoe bucket cylinder bore ................ 3.50 in. 4 - Rod guide torque ...................... 250 to 300 lb-ft
[88.9 mm) [34.56 to 41 .48 kg-m]
2 - Rod diameter ........................................... 2.25 in. 5 - Special nut torque ..................... 600 to 700 lb-ft
[57.15 mm] [82.95 to 96.77 kg-m]
3 - Cylinder stroke ....................................... 27.37 in.
[695.20 mm]
T32098N
Fig. 22-Backhoe Crowd Cylinder
1 - Backhoe crowd cylinder bore ................. 4.00 in. 4 - Set screw torque .................................... 40 lb-in.
[101.6 mm] [0.46 kg-m)
2 - Rod diameter ........................................... 2.00 in. 5 - Spanner nut torque .................... 250 to 300 lb-ft
[50.8 mm) [34.56 to 41 .48 kg-m]
3 - Cylinder stroke ....................................... 33.00 in. 6 - Special nut torque ..................... 600 to 700 lb-ft
[838.2 mm) {82.95 to 96.77 kg-m]
Litho in U.S.A.
CYLINDERS
6
~----------3------------~
T32099N
Fig. 23-Backhoe Boom Cylinder
- Backhoe boom cylinder bore .................. 4.50 in. 4 - Set screw torque ..................................... 40 lb-in
[ 114.3 mm] [0.46 kg-m]
2 - Rod diameter .......................................... . 2.25 in. 5 - Spanner nut torque ................... 250 to 300 lb-ft
[57.15 mm] [34.56 to 41.48 kg-m]
3 - Cylinder stroke ....................................... 34.00 in. 6 - Special nut torque ................. 1000 to 11 00 lb-ft
[863.60 mm] [ 138.2 to 152.1 kg-m]
TJ2100N
Fig. 24-Backhoe Stabilizer Cylinder
- Backhoe stabilizer cylinder bore ............ 4.00 in. 4 - Set screw torque ..................................... 40 Ib-in
[ 101.6 mm] [0.46 kg-m]
2 - Rod diameter ........................................... 2.00 in. 5 - Spanner nut torque ................... 250 to 300 lb-ft
[50.8 mm] [34.56 to 41.48 kg-m]
3 - Cylinder stroke ....................................... 16.62 in. 6 - Special nut torque ................... .. 600 to 700 lb-ft
[422.1 mm] [82-95 to 96.77 kg-m]
Litho in U.S.A.
CYLINDERS
5
~-------------- 3 ----------------~
T32101N
Fig. 25 - Ripper Lift Cylinder
1 - Ripper cylinder bore ................................ 2.50 in . 4 - Spanner nut torque ................... 125 to 175 lb-ft
[63.5 mm]
[ 17.3 to 24.2 kg-m]
2 - Rod diameter ........ .. ................................. 1.25 in.
[31.7 mm] 5 - Special nut torque ..................... 150 to 210 lb-ft
[20.7 to 29.0 kg-m]
3 - Cylinder stroke ....................................... 15.19 in.
L385.8 mm]

- Return line fil ter indicator piston spring

test length .............. ............... 1.50 in. [38.1 mm]
with 23.5 lbs. [10.66 kg]
T32102N
Fig. 26 - Return Line Filter
Litho In U.S.A.
60-16 Specifications and Special Tools TM-1102 (Nov-73}

FLOW DIVIDER
1 - Spool spring free length ... ...................... 1.66 in.

[42.2 mm]
Spool spring test length .......................... 1.00 in.

[25.4 mm] with 15.9 lbs. [7.21 kg]
T32 103N
Fig. 27-Fiow Divider Valve
Litho in U.S.A.
Crawler - JD450-C Miscellaneous Components 60
TM-1102 (Nov-73) Tracks 5-1
Section 60
MISCELLANEOUS COMPONENTS
Page Page
GROUP 5 - TRACKS GROUP 25 - LOADER FRAME, BOOM
General Information ............................................ 5-2 AND BUCKET
Removal ...............................................................5-3 General Information ........................................ 0025-1
Repair .............................................. ,................... 5-3 Removal .............................................................25-2
Installation ............................................................5-8 Repair
Regular Buckets 00 ...... 00 .. 00 00 ........ 00 .................. 25-3
GROUP 10 - TRACK CARRIER Multi-Purpose Buckets ...... 00 .... 00 .... 00 .. 00000000000025-4
ASSEMBLY Boom and Linkage .. 25-5
oo . . oo . . . . . . . . . . . . oo . . . . . . . . oo . . . . . . . .
General Information .. 00 00 00 ............... 00 ................. 10-1 Frame ........ ,.......................................... 00 ........ 25-6
Track Rollers Installation ..... 00 ................................................... 25-6
Removal .......... 00 ........ 00 ................. 00 .. 000000 ........ 10-2 GROUP 30 - DOZER FRAMES AND
Repair ............................................................. 10-2 BLADES
Installation 00 .................................... 00 ............ 001 0-4 General Information .............. 00 ... 00 ..................... 30-1
Track Carrier Rollers Removal .............................................................30-2
Removal ............................ 0000 .. 00 00 ........ 00 00 .. 00 ... 10-4 Repair
Repair ............................................................. 10-4 Frames and Booms ...... 30-2
o o o o . . . . . . . . oo . . . . . . . . . . . . . . . . . .
Installation ...... 00 ................ 00000000 ....... 00 ..... 10-5 oo . . . . . .
Blades ......................................................... 00.30-3

Track Front Idler Installation ..........................................................30-4
Removal ......................................................... 10-5
Repair ............................................................. 10-5 GROUP 35 - LUMBER FORK AND
Installation .......................... 00 .......................... 10-6 PULPWOOD LOADER
Track Idler Recoil Spring General Information ........ 00 ............................ 00 .. 35-1
Removal ......................................................... 10-7 Removal .............................................................35-1
Repair ............................................................. 10-7 Repair ................................................................35-1
Installation ....... 10-8
oo . . . . . . . . oo . . . . . . . . . . . . . . . . oo . . . . . . . . . . . . . . . . .
Installation ..........................................................35-3
Hydraulic Track Tension Adjuster GROUP 40 - BACKHOE FRAME, BOOM
Removal ........ 00 ............................................... 10-8 AND BUCKET
Repair. 00 .......................................................... 10-8 General Information ................. 00 .... 00 .......... 0000 .. .40-1
Installation ...................................................... 10-9 Removal .............................................................40-1
Track Carrier Assembly Repair
Removal ...................................................... 00.1 0-9 9300 Backhoe ............................................... .40-2
Repair ........................................................... 10-10 9250 Backhoe ............................................... A0-4
Installation 00 00 .............................................. 001 0-12 Backhoe Bucket Tooth Assembly ............... .40-6
Installation ......................................................... .40-7
GROUP 15 - WINCH SYSTEM
General Information .................... 00 .................... 15-1 GROUP 45 - SPECIFICATIONS AND
Removal .. 00 00 .............. 00 ....................................... 15-1 SPECIAL TOOLS
Repair ................................................................ 15-2 Tracks
Adjustment ......................................................... 15-9 Specifications and Torque Values .............. .45-1
Installation ........................................................ 15-1 0 Special Tools ... 0000 .... 00 ...... 00 0000 00 .. 00 00 0000 .. 00 00 ...... 45-2
Track Carrier Assembly
GROUP 20 - WINCH FAIRLEAD Specifications and Torque Values 0000 .......... .45-3
ASSEMBLY Special Tools ................................................ .45-5
General Information .................. 0000 ........ 00 ....... 20-1 Winch System
Removal ......................................................... 20-2 Specifications and Torque Values .............. .45-7
Repair .............................................................20-2 Special Tools .............................................. .45-1 0
Installation .... 00 ........................................... 00 ... 20-2 Winch Fairlead Assembly
Special Tools .................................. 00 .......... .45-11
Lumber Fork and Pulpwood Loader
Litho in U.S.A. Specifications and Torque Values .. 00 ........ .45-11
60 Miscellaneous Components Crawler - JD450-C
5-2 Tracks TM-t 102 (Nov-73)
Group 5
TRACK.S
GENERAL INFORMATION
1 -Trac~ 4-Track Carrier Roller 7-Track Frame 1o-Track Rollers

2- Track Drive Sprocket 5-front Crossbar 8-Rock Guard 11-Sprocket Shield
3--Rear Crossbar 6-front Idler 9-Track Adjusting
Cylinder
Fig. 1-Track System
The track system consists of two tracks mounted The track carrie r assembl ies (Fig . 1) keep the
on track frame assemblies, piloted by and connected tracks in position and distribute the weight of the
to two fixed crossbars (Fig. 1). The track frame as- tractor on the tracks.
semblies are mounted on the crossbars to give a
fixed tread of 52 inches [ 13.21 em]. Each assembly includes a frame which forms a
support for the idler wheels and the five track rollers.
Each track is driven from the rear by a hardened A heavy spring and a hydraulic track adjusting cylin-
cast-steel sprocket bolted to a flanged axle shaft and der provide a means of adjusting track tension . Rock
deriving power through a final drive and steering guards greatly reduce the entrance of foreign materi-
clutch-brake mechanism. The tracks are guided at al into the track system and thereby increase track
the front by idler wheels which are hydraulically shift- life. Outer sprocket shields are available as optional
ed forward or rearward to adjust track tension. equipment. Upper and lower front idler shields are al-
so provided as optional equipment.
Track shoes are available in a variety of widths
and types to accommodate various ground and work- The track frame assemblies are held in position by
ing conditions. two fixed crossbars. The front crossbar, is of cast
nodular iron and is fastened to the side frames. The
Track link joints should never be reversed since rear crossbar is a round solid steel bar.
doing so will cause the lugs to contact the ground
backwards and will throw dirt over the track system. Servicing of track carriers is covered in Group 10
of this Section.
Litho in U.S.A.
TM-1 102 (Nov-73) Tracks 5-3
T32408H
1- Track Assembly 5-Left Track Link 9-Snap Ring 13-Track Shoe (36·
2-Right Track Link (35-Dozer, 36-Loader) 10-Track Master Pin Dozer, 37-Loader)
(35-Dozer, 36- 6-Track Pin (35-Dozer, 36- 11- Track Bushing 14-Special Hex. Nut
Loader) Loader) (1 used with (144-Dozer,
3-Spacer (2 used)* 7-left Master Track Link master link) * 148-Loader)
4-Bus hlng (35-Dozer, 8-Right Master Track Link 12- Cap Screw (144 used)
36-Loader)
*Used for link or bushing replacement in center of track chain.
Fig. 2-Track Assembly and Shoes
REMOVAL Using Track Wear Gauge

The track must be split for disassembly of track A track wear gauge (JD268) is available, enabling
links and replacement of pins and bushings. Locate the serviceman to quickly check the condition of a
the master pin (10). Remove snap ring (9) and drive track assembly for use as a guide in replacing the
out ma!)ter pin. track components. The track assembly components
that can be checked are listed below and illustrated
REPAIR in Fig . 3.
Pin and Bushing Wear · Position gauge on track link ·
as shown . Place corner of gauge marked "Pin Cen-
ter" at center of one pin and other end of gauge at
center of next pin. If point of gauge marked " New
place excessively worn bushings and pins as
Chain" falls at center of pin, track chain does not re-
needed. When the forward edge of the front idler quire servicing. If point marked " Recondition'' falls on
pin center, track pins and bushings are probably
track assemblies are in need of reconditioning.
worn.
Link Wear - Position gauge on track link. With top of

gauge (end with hole) against track shoe, check po-
sition of two arrows on gauge in relation to bottom of
link. Link is worn if arrow marked "Replace" is at
bottom edge of link.
Litho in U.S.A.
5-4 Tracks TM-11 02 (Nov-73)
Grouser Wear - To measure amount of wear on Disassembly (Starting At Master Link)

grouser lugs, position gauge upright and against
Install proper saddle and secure it to track press
grouser lug. Point on gauge at which top of lug falls
frame with socket head cap screws.
is amount of wear.
Adjust conveyor extension to desired conveyor
working height.
Remove outside row of cap screws (row away

from work head of press) securing track shoes to link
assemblies.
Install ram end disassembly adapter to work head

of press and secure with attaching nut. Install bush-
ing side cap to disassembly adapter and secure with
socket head cap screw.
Raise the elevating conveyor and manually pull the

track chain assembly toward the press operator until
Pin and Bushing Wear
the link assembly bushing male end is directly over
the top of the saddle.
Lower conveyor so that chain link assembly is in-

dexed into saddle.
Advance work head of track press until the cam

and disassembly adapter come in contact with bush-
ing and pin. Press bushing and pin from right hand
link. Remove right hand link with shoe as an assem-
bly (Fig. 4).
Remove left hand link, with bushing and pin intact,

from saddle.
Link Wear Grouser Wear
To remove pins and bushings from left-hand links,
Fig. 3-Using Track Wear Gauge position saddle bushing spacer (pin side) (5, Fig. 5)
on saddle (5, Fig. 4) as shown in Fig. 5. Advance
Track Disassembly and Assembly work head of track press and remove bushing and
The pins and bushings in the track assembly are pin from left hand link.
made of extremely hard material. They are manufac-
tured to press-fit tolerances. Accordingly, the track
cannot be disassembled without track -p ressing
equipment equivalent to that described and illustrated
in the following instructions.
NOTE: Owatonna track press and tool set are il-

lustrated in the following instructions.
Litho in U.S.A.
TM-1102 (Nov-73) Tracks 5-5
1-40706 Abutment 6-Pin

2- 24282 Rear Abutment 7-Lett-Hand Link
Assembly Adapter 8-24288 Ram End As-
Plate sembly Adapter
3-30194 Pin Side Plate
1-Right-Hand Link 5-40599 Saddle Spacing Post 9-Bushing
2- Pin Remover 6-Left-hand Link 4-40599 Saddle 10-30174 Bushing Side
3-26819 Disassembly Assembly 5-24284 Saddle Bushing Spacing Post
Adapter Plate 7-40706 Abutment Spacer (pin side) 11-21887 Bushing Side
4-Bushing Remover Spacer
Fig. 4-Removing Right Hand Unk Fig. 5-Preparing Press for Track Pin and
Bushing Installation
Continue these steps with each link assembly until
the track is completely disassembled.
Assembly (Starting At Master Link)

Remove ram end disassembly adapter from press
head and install ram end assembly adapter. Install
rear abutment assembly adapter on press as shown
in Figure 5. Do not remove saddle.
Position shims behind rear abutment assembly

adapter blocks to align abutment blocks so that link
assemblies remain loose during assembly.
With pin and bushing in saddle, position left link

with track shoe mounting holes down between sad-
dle and work head of press as shown in Figure 5.
Advance work head of press and press link onto pin
and bushing . 1- Pin Abutment 4-Pin As.sembly Adapter
2-5hims 5-Shims
3--Bushing Abutment 6-Bushing Assembly
Adapter
Fig. 6-/nsta//ing Shims Behind Abutment
Adapter Block
Litho In U.S.A.
5-6 Tracks TM-11 02 (Nov-73)
NOTE: The track shoe mounting holes are in the If a new right link is to be installed, it will be nec-
down position. After the link is pressed onto the pin essary to remove the track bolts securing the track
and bushing, it becomes the left hand link assembly. shoes to the right hand link.
After all left-hand links have been assembled with IMPORTANT: One link assembly should be
pins and bushings, remove the saddle bushing spac- completely assembled prior to assembling vari-
er (pin side) (5, Fig. 5) . ous components. This is recommended because
it may be necessary, depending upon link wear,
to vary the number of adjusting shims behind the
rear abutment assembly adapter blocks.
NOTE: When the right hand link is pressed onto

the pin and bushing, use care to properly align the
track shoe bolt holes with the left hand link.
Continue these steps with each link assembly until

the track is completely assembled.
Disassembly (Starting At Position Other

Than Master Link)
1-Master Links 5-Bushing

2- Bushing 6-Lett-Hand Link
3- Pin 7-26327 Master Bush-
4-Right-Hand Link ing Spacer
Fig. 7-lnstalling Right Link to Left Link
With the conveyor in the raised position, install the

left hand link assembly into the male end of the track
chain. Lower the conveyor positioning the left hand
link assembly into the saddle. 1-40706 Abutment 5-32642 Removable
2-32655 Rear Abutment Forcing Pin
Install right hand link, with track shoes attached, Assembly Adapter Plate 6-32621 Disassembly
into position. Advance track press work head and 3-32649 Pin Side Spacing Adapter Plate
press right hand link onto left hand link (Fig . 7) . Con- Post 7-40599 Saddle
4-22776 Pin Side Spacer
tinue to advance work head until right hand link as-
sembly is properly positioned so that bolt holes in Fig. 8-Track Splitting
track shoes align with boll holes in left link . Other Than Master Link
Litho in U.S.A.
TM-1102 (Nov- 73) Tracks 5-7
To replace a single bushing, pin, or link in the

track system it is not necessary to completely disas-
semble the track. The procedure for this type of re-
placement is as follows.
Rernove cap screws which secure track shoes to

link assemblies that are to be disassembled.
Raise the elevating conveyor. Manually pull the

track chain assembly toward the press operator until
the link to be disassembled is directly over the top of
the saddle.
Lower conveyor so that chain link assembly is in-

dexed into the saddle.
1-40706 Abutment 7-24288 Ram End
Advance ram head of track press until pin remover 2- 24282 Rear Abutment Assembly Adapter
comes in contact with pin to be removed. Push pin Assembly Adapter Plate
Plate 8- Master Bushing
from bushing. Raise track high enough to remove pin 3-30194 Pin Side 9-26327 Master Bushing
from pin side spacing post (3, Fig. 8). After pin has Spacing Post Spacer
been removed from pin side spacing post, lower and 4-40599 Saddle 10-30174 Bus hing Side
advance track into position and remove remaining 5-24284 Saddle Bushing Spacing Post
pin from link. With a cutting torch , cut bushings in Spacer 11-21887 Bushing Side
6-Left-Hand Link Spacer
two to free right- and left- hand links from the rest of
track. Fig. 9-Master Bushing Installation
To remove, cut bushings from track links (if links Secure pin side plunger (22764) to disassembly
are to be re-used), attach disassembly adapter plate adapter plate (32621). Attach pin plu nger and plate
(26819) (3, Fig. 4) to track press ram. assembly to press ram .
Place link with cut off bushing in saddle. Advance Place track chain in saddle in final assembly posi-
ram head slowly until bushing cap comes in contact tion. Raise link high enough to position master bush-
with the bushing to be removed. Push bushing from ing spacers into link counter-bores. Lower link into
link. Repeat procedure until all cut off bushings have alignment with master bushing and press in pin.
been removed from links.
Continue this operation until track is assembled.
Assembly (Starting at Position Other Than
Master Link) Install track shoe and tighten to 110 lb-ft [ 15.21
kg-m].
Press a master bushing (short bushing) into left-
hand link. Turn link and bushing sub-assembly over
180° toward rear abutment and press on right-hand
link. Continue until all cut-off bushings are replaced.
To assemble repaired section into track chain, re-

move ram end assembly adapter (7, Fig. 9), master
bushing spacer (9), and saddle bushing spacer (5).
Litho in U.S.A.
5-8 Tracks TM-1102 (Nov-73)
INSTALLATION
Position track assembly on the unit. Align track and adjust tension (see Section 70,
Group 30).
Drive in master pin and secure with snap ring.
Litho in U.S.A.
TM-1102 (Nov-73) Track Carrier Assembly 10-1
Group 10
TRACK CARRIER ASSEMBL V
GENERAL INFORMATION
1- Front Idler 4-Spring Retainer Plate 7- Drlve Sprocket 10--Track Frame

2-Track Adjusting Cylinder 5-ldler Spring 8-Rock Guard
3-Track Carrier Roller 6-Rear Crossbar 9-Track Rollers
Fig. 1-Track Carrier Assembly
Each track carrier assembly (Fig. 1) consists of The idler springs and caps are compressed by
welded rolled channels of high-strength steel which means of a special bolt which is removed when
support the individual roller assemblies and the front spring is installed on track frame. Track tension ad-
idler with its adjusting mechanism . The assembly is justments are made by hydraulically shifting the en-
fastened to the fixed crossbars which support the tire idler wheel assemblies forward or backward on
tractor. the carrier assemblies.
The individual roller assemblies used on the track The rollers and front idlers are factory lubricated
bolt directly to the lower edges of the carriers and and sealed with metal face type seals.
distribute the weight of the tractor evenly on the
tracks. Each roller assembly consists of a forged- The track carrier roller assembly is located ap-
steel roller with two replaceable bronze bushings proximately in the center of the track frame. Its cast
which rotate on a hardened steel shaft. roller has two replaceable bronze bushings which ro-
tate o n a harde ned steel shaft pressed into the
The front idler assemblies are held in place on the mounting bracket.
track carriers by idler brackets which are shim ad-
justed so they will slide freely on the track frame. .
Litho in U.S.A.
10-2 Track Carrier Assembly TM-11 02 (Nov- 73)
TRACK ROLLERS Bushing and Shaft Wear

Inspect bushings in rollers for scoring or excessive
Removal wear. The 1.0. of the roller bushing is 2.3785 inches
NOTE: Due to the design of the track frame as- to 2.3795 inches [60.41 to 60.44 mm]. If it is neces-
sembly, it is possible to remove the track rollers sary to replace the bushings, use a suitable driver to
individually. press old bushings out. Install a new bushings 1/32
inch [0.76 mm] below face of roller (Fig. 3).
To remove roller, remove outer rock guard, loosen
inner rock guard, and release tension from track.
Place jack or hoist under front and rear crossbar and
raise tractor high enough to allow removal of roller.
Repair
Using Track Wear Gauge
Check wear on track rollers using J 0-268 Track
Wear Gauge (see Fig. 2).
T 3 0262N
1- Bushing 3--Track Roller

2-Locate Bushing Below Face
Fig. 3-Correct Location of Bushing in Track Rollers
NOTE: Replacement roller and idler bushings are

Fig. 2-Measuring Track Roller Wear presized and, therefore, do not need to be sized after
installation.
Track Roller Wear: Roller will wear on the sides
and outer surface of roller flanges. Place gauge be- Check roller (0.0. 2.3745 to 2.3755 inches [60.31
tween roller flanges as shown. Allowable wear on to 60.33 mml) and shafts and thrust plates for dam-
outer surface and side of rollers is shown by arrows age or excessive wear. Make sure oil passages in
on gauge. shafts are open . Note condition of oil seals. Replace
all unserviceable parts.
Litho in U.S.A.
TM-1102 (Nov-73) Track Carrier Assembly 10-3
15
1 13
crot~cb
T30263N
1-Cap Screw 5-Cap Screw (4 per roller) 9-Cap Screw (12 used) 13-Bushing (2 used)
2- Special Washer (2 used) 6--Roller Bracket (2 used) 10-Seal Ring (2 used) 14-Roller Assembly
3-0-Ring (2 used) 7-Pin (1 used) 11- Thrust Plate (2 used) 15-Shatt
4-Lock Washer (4 per roller) 8-011 Seal (2 used) 12-Shim (2 used) 16--Special Cap Screw
17-Piug (2 used)
Fig. 4· Track Roller Assembly
Disassembly Place oil seal into counterbore in roller bracket.

Bore must be degreased with clean solvent prior to
Refer to Fig. 4 and remove the two cap screws
installing seal. Washer with retainer is to be installed
and lock washers which attach the roller brackets (6)
first into seal ring.
to the roller shaft (15). Slide brackets and seals (8)
free from roller assembly. Half of seal will remain
Slip roller bracket (6) onto end of shaft (end with-
with bracket. Remove the six socket head cap
out hole) and install 0-ring (3), cap screw (1) and flat
screws (9) and slip off thrust plate (11) and shims
washer. Tighten finger tight.
(12). Roller shaft can now be pulled free from roller.
Remove thrust plate and shims from outer side of
Degrease sealing surface and install seal into its
roller.
bore. Position pin and slip roller bracket on shaft.
Complete assembly by installing 0-ring, flat washer
Assembly and cap screw.
NOTE: Lubricate bushings in track rollers with oil
before installing roller shaft. Tighten inner bracket cap screw to standard torque
and outer bracket cap screw (16) to 210 lb-ft
Position shaft (15) in roller and install a thrust plate [29.03 kg-m).
(11) on each side, using one shim (12) under each
thrust plate. Install seal rings (1 0) and tighten the Fill assembly with approximately 3/8 pint [170.1 g]
socket head cap screws (9) to standard torque. SAE 30 oil.
Litho in U.S.A.
60 Miscellaneous Components Crawler · JD450-C
10·4 Track Carrier Assembly TM-1102 (Nov-73)
Installation TRACK CARRIER ROLLERS

If track has been disconnected, install rollers be-
fore connecting track. However, roller assemblies
Removal
can be installed by loosening track and raising trac- Remove the cap screws which attach cover to idler
tor. and lift cover and shims free from idler. Take out the
two socket head cap screws and remove the thrust
Using a track roller installation tool (see Special plate. The track carrier roller and half of seal can
Tools), position rollers under track carrier frame. now be pulled from its mounting shaft. Remove track
Make sure that special cap screws (1 6. Fig. 4) are carrier support from track carrier.
facing outward . Install the four attaching cap screws
and lock washers and tighten to standard torque. Repair
Disassembly and Assembly
NOTE: The front and rear rollers usually wear at a
taster rate than the center rollers. Move some of the Examine bushing in track carrier roller for scoring
center rollers to the front and rear to distribute wear or excessive wear. The I.D. of the bushing is 1.377
evenly to all of the rollers and extend track service inches to 1.379 inches [34.98 to 35.02 mm]. Use a
life. suitable driver to install new bushing to bottom of
chamfer on outside of roller bore .
Install rock guards. Tighten hex. nuts on rock
guard spacer bolts and rock guard mounting cap Inspect oil seal in carrier support. Keep seals in
screws to standard torque. pairs as removed. It is recommended the new seal
kit be installed.
2~@
\~ ;~· ()I i(:)~·
~ '
7 9 I
8 10
1
15
T21175N
1- Cap Screw ~ap Screw (2 used) 9---Cap Screw (2 used) 13-0il Seal
2-Washer 6-lock Washer (2 used) 1(}-Thrust Plate 14-Shaft
3-Gasket 7-Cover 11-Bushing (2 used) 15-Support
4-Pipe Plug 8-Gasket 12- Roller 16-Cap Screw (4 used)
17-l ock Washer (4 used)
Fig. S-Upper Track Carrier Roller Assembly
Litho in U.S.A.
TM-11 02 (Nov-73) Track Carrier Assembly 10-5
Inspect track carrier roller shaft (0.0. 1.3745 to TRACK FRONT IDLER (FIG. 6)
1.3750 inches [34.91 to 34.93 mmJ) for damage and
excessive wear. This shaft can be replaced by re- Removal
moving old shaft from support bracket and pressing
Refer to Figure 6 and remove idler brackets (5)
new one into bracket. The shaft dimension should be
from adjusti ng cylinder crosshead . Unscrew cap
5 .850 inches [148.59 mmJ above the face of seal
screws ( 1) from shaft ( 11) and remove idler brackets
bore.
with oil seal (6) .
Installation Remove the six cap screws and slip the thrust
NOTE: Before installing support idler on shaft, lu- plate and shims from the idler shaft. The idler shaft
bricate roller bushings with oil. can now be pulled free from the idler wheel. Remove
thrust plate and shims from other side of idler wheel.
Attach support (15) to track carrier frame making
sure that the horizontal and vertical surfaces of the Repair
support are flush against frame. Tighten cap screws
Using Track Wear Gauge
to standard torque.
Check wear on track front idlers using JD-268
Procedure for installation of oil seal is similar to Track Wear Gauge (see Fig. 7).
that of the track rollers (refer to page 60-10-3). Posi-
tion oil seal (13) in roller support. Slide roller (12) on The front idler has a tendency to wear on the sides
shaft. Install thrust plate (10) and tighten the socket and outer surface of the idler flanges. Place the
head cap screws (9) to 40 lb-ft [5.53 kg-m]. gauge large cutout notch over the idler flanges. Push
the gauge to one side against side of idler flange. Al-
Install gasket (8) under cover (7) and tighten at- lowable wear is shown by arrows on gauge.
taching cap screws securely. Fill assembly with ap-
proximately 1-1/2 pints (340.2 gJ of SAE 30 oil.
1-Cap Screw 6--0il Seal (2 used) 11- Shaft 16-ldler Guide (2 used)
2-Speclal Washer (2 used) 7-Cap Screw (12 used) 12- Bushing (2 used) 17-Lock Washer (12 used)
3-0-Ring (2 used) 8-Seal Ring (2 used) 13-Front Idler 18-Cap Screw (8 used)
4-Pipe Plug (2 used) 9-Thrust Plate (2 used) 14-Pin 19-Wear Plate (2 used)
5-ldler Bracket (2 used) 1G-Shlm (2 used) 15-Shim (Approx. 18 used) 2G-Cap Screw (4 used)
21- Special Cap Screw
Fig. 6-Track Front Idler Assembly
Litho in U.S.A.
10-6 Track Carrier Assembly TM- 1102 (Nov-73)
If wear plates (19) have been removed, assemble

them loosely to idler bracket using the same number
of shims as removed. Refer to paragraph on "Front
Idler" for procedure on checking and adjusting front
idler wear plate and guides.
Attach track adjusting yoke to idler bracket using

same shims as removed . If unit is equipped with
front idler shields, attach them at this time.
Installation
Slip front idler assembly into position on track car-
rier frame assembly. Check for excessive play be-
Fig. 7-Measuring Front Idler Wear
tween idler bracket and track channels. If clearance
Bushing and Shaft Wear is excessive, add shims under wear plates (Fig. 8) .
Tighten cap screws to standard torque. Also check
Inspect bushings in front idlers for scoring or ex- for vertical play in idler brackets. Add or subtract
cessive wear. The 1.0. of the front idler bushings is shims under idler guides to correct excessive clear-
2.6285 to 2.6295 inches [66.76 to 66.78 mm]. If it is ance. Front idler should slide freely on track frames
necessary to replace the bushings, use a suitable but without undue looseness.
driver to press old bushings out. Install new bushings
1/32 inch [.76 mm] below face of roller.
NOTE: Replacement idler bushings are presized

and, therefore, do not need to be sized after installa-
tion.
Check idler shafts (0.0. 2.6245 to 2.6255 inches

[66.66 to 66.68 mm]) and thrust plates for damage or
excessive wear. Make sure oil passages in shafts
are open. Note condition of oil seals. Replace all un-
serviceable parts.

For identification and correct location of parts, refer
to Figure 6.
NOTE: Since the assembly for the front idler is the

same as for the roller assembly, follow roller assem-
bly procedure when assembling front idler. Tighten
the thrust plate-to-idler cap screws to standard 1-ldler Brackets 4-Wear Plates
torque. 2-Shims 5--Shlms
3-ldler Guide
Apply Loctite to threads of bracket-to-idler shaft Fig. 8-lnstalfing and Adjusting Track Front Idler
cap screws. Tighten the inner bracket-to-idler shaft
cap screws to standard torque and tighten outer Move the front idler assembly back and forth
bracket-to-idler shaft cap screws (21 ) to 210 lb-ft through its entire moveable range on the track frame
[29.03 kg-m]. channel, checking to see that the brackets do not
bind on the rails. Remove shims if necessary to cor-
Fill assembly with approximately 3/4 pint [340.2 g] rect binding.
SAE 30 oil.
Install and connect the track (Group 5 of this Sec-
tion).
Adjust track tension and check track alignment

(Section 70, Group 30).
Litho in U.S.A.
TRACK IDLER RECOIL SPRING NOTE: When sliding front idler assembly forward,
do not pull track adjusting piston from cylinder as
Removal scraper seal on cylinder may damage piston seal on
piston.
To remove idler recoil spring, disconnect track
(Group 5) and pull front idler forward. Insert a Spe-
CAUTION : Use care when handling spring
cial Bolt (T 16678) with one-inch [25.4 mm l spacer
through the track spring retainer plate and thread into A as accidental release of spring can cause
serious personal injury. Do not, under any cir-
the rear spring cap (Fig. 9) . Tighten bolt until spring
cumstances, attempt to remove spring without
is free. Lift spring from track frame.
special bolt.
Repair
Check to see that spring (Fig. 10) is in good condi-
tion. Replace if it has taken a permanent set.
If spring has been removed from track frame it

must be compressed to a length of 16 inches [ 406.4
mm} (between outer ends of spring caps). Compress
spring and cap in a press and install a special bolt to
hold the spring at 16 inches.
CAUTION : Always use the special bolt or

A a bolt similar in strength to prevent acci-
dental release of idler recoil spring.
1-Special Bolt 2-Sprlng Retainer Plate
Fig. 9-Removing Track Idler Recoil Spring
1-Rear Cap 2-Spring 3--ldler Auxili ary Spring 4-Front Cap
Fig. 10-Track Idler Recoil Spring
Litho in U.S.A.
10-8 Track Carrier Assembly TM-1102 (Nov-73)
Installation HYDRAULIC TRACK TENSION

ADJUSTER (FIG. 12)
Removal
Remove idler recoil spring (see page 60-10-7).
Remove cap screws from yoke (8, Fig. 12) and lift
adjuster assembly from track assembly.
Repair
IMPORTANT: Do not pull piston from track ad-
justing yoke unless scraper seal and piston seal
are to be replaced or seals will be damaged.
Pull track adjusting piston from yoke. Remove

scraper-type oil seal and discard. Inspect yoke for
damage. Replace if necessary.
1- Special Bolt 3-Front Spring Cap
2- Spring Retainer Plate 4-Pipe Remove piston seal from piston. Examine piston
for evidence of bending or other damage.
Fig. tt-lnstalling Track Idler Recoil Spring
Position preloaded spring between spring retaining Use a JD284 Track Ad juster Tool Set to install pis-
plate and rear mounting pad and remove special bolt ton seal, oil seal and piston in cylinder. Make sure all
and one inch [25.4 mml spacer. Use a 2 by 8-inch parts are clean before starting the following steps:
[50.8 by 203.2 mm] section of pipe to center front
spring cap with track adjuster guide under spring re-
taining plate (Fig. 11 ). Be sure spring is firmly fixed
in place.
2
l
®
T324 16/V
1-Piston 5-Set Screw 9-Shlm (6 used)

2- Scraper Seal 6--Jam Nut 1G--Lockwasher (4 used)
3-Piston Seal 7- Ball 11- Cap Screw (4 used)
4-Grease Fitting 8-Voke
Fig. 12-Hydraulic Track Tension Adiuster
Litho in U.S. A.
Insert the oil seal (1. Fig. 13), metal side up, on Installation
the piston (2). Set the conical seal installation tool (3)
Position piston and cylinder on track frame. Tight-
on end of piston and lubricate tool.
en cap screws (11 , Fig. 12).
Insert the piston seal (4) onto conical tool, groove
side up. Using the seal installation driver (3). drive Install front idler recoil spring (see page 60-1 0-8) .
the piston seal onto recessed area of piston.
Insert approximately two tablespoons of grease in TRACK CARRIER ASSEMBLY
cylinder and lubricate top two inches of cylinder wall.
Removal
Install piston guide (5) on cylinder, with square
Remove track (Group 5) .
flange to the top. Tighten bolts and lubricate inside
diameter of flange.
Place piston with seal end into flange. Force
downward by hand until piston seal clears the flange.
Remove piston guide.
Using a dust seal driver (6). drive the oil seal into
the recess of the cylinder.
NOTE: If grease has been removed from track ad-
justing cylinder or if a new cylinder is installed, bleed
cylinder as follows: (a) With cylinder release screw
loosened, place a small amount of grease (see Sec-
tion 10) in bottom of cylinder. (b) Move piston to bot-
tom of bore without seating oil seal. A small amount
of grease should be forced out bleed hole. If neces-
sary, add grease and repeat procedure until grease
is observed at bleed hole. Seat oil seal as described
above and tighten release screw. 1- Fro nt Attaching Point 4-Shim s
2- Rear Crossbar Cap 5-Retainer Cap Screw s
3-Drive Sprocket
Fig. 14-Removing Track Carrier
Remove track drive sprocket (Fig. 14).
Slide front idler assembly from track frame.
Remove six cap screws from fron t crossbar. Take

out cap screws in rear crossbar retainer and remove
retainer and shims.
Place a jack or hoist under both crossbars and

raise tractor until roller flanges clear the track. Drive
carrier assembly free from rear crossbar and slide
clear of tractor.
IMPORTANT: Do not lose or damage shims

during track carrier removal.
1-011 Seal 4-Piston Seal
2-Piston 5-JD284-3
3-JD284·1 6-JD284-2
Fig. 13-Using Track Adjuster

Toot Set
Litho in U.S.A.
10-1 0 Track Carrier Assembly TM-11 02 (Nov-73)
Due to welded construction of the track frame, no IMPORTANT: Be careful not to pull piston from
further disassembly of the frame should be attempted track adjusting cylinder as piston seal may be
except for the track channel wear strips which can be damaged.
removed if worn.
Grind off the old wear strips on the track frame
Repair channel so that none of the strips or welds remain.
Replacing Track Frame Channel Wear Strips
Install new wear strips.
Inspect front idler wear strips on track frame chan-
nels for wear. If strips are excessively worn refer to NOTE: The wide wear strips fit on top of the track
Figure 15 and replace according to the following pro- channel. The narrow strips fit underneath. See Fig.
cedure. 15.
Recommended Welding Procedure

1. Remove dirt, oil and paint from areas to be
welded.
2. Use 5/32-inch [3.97 mm] diameter low hydro-

gen AWS-ASTM E-7018 covered electrode.
NOTE: Flux covering on low hydrogen electrodes

readily takes on moisture which causes welding
problems. Be sure electrodes are dry. Electrodes
stored in open containers should be suspected of
containing excessive moisture and may require bak-
ing prior to use.
3. Use AC or DC reversed polarity welding current

(E LECTRODE POSITIVE (+ )].
4. The suggested amperage range is 100 to 115

amps.
1- Wide Wear Strip 3-ldler Bracket
2- Narrow Wear Strip Cap Screws
When putting on new wear strips, do not clamp
Fig. 15-Replacing Track Channel Wear Strip wear strips firmly to channel. A secure clamping
which still allows a slight wear strip shift will prevent
IMPORTANT: Disconnect battery ground strap cracking of weld fillet during the cooling process .
before doing any welding on the crawler. Failure
to do so may damage the electrical system. Weld the narrow wear strips to track frame chan-
nel, melting as little as possible of the wear strips by
Release track cylinder pressure to loosen track. starting and maintaining the arc primarily on the track
Rernove master track pin and split track. frame channel. The wear strip is a high carbon steel,
so best results are obtained by washing the weld
The front idler wheel, idler bracket, crosshead, and metal toward the wear strip. This wil l produce a
tube can be removed from the track frame as a unit. slightly convex weld fillet.
However. it may be necessary to loosen or remove
the cap screws that screw into the underside of the Weld the wide wear strips to track frame channel
idler bracket. See Fig. 15. using the same procedure as for the narrow wear
strips.
Litho in U.S.A.
Crawler - J0450-C Miscellaneous Components 60
TM-1102 (Nov- 73) Track Carrier Assembly 10-11
Reinstall front idler and bracket assembly. Adjust

wear plate with the maximum of shims that will still
allow the idler bracket to slide freely on the track
frame. Th is may require removal of some of the
shims.
Join track and install master pin and snap ring.
NOTE: To adjust track tension and to check track

alignment, refer to Section 70, Group 30.
Connect negative battery ground strap.

1- Cap Screw (8 used) 7-Special Washer
Disassembly and Assembly 2-Spacer (8 used) (4 used)
3-Cap Screw (6 used) 8-Cap Screw (2 used
Refer to Figs. 16, 17 and 18 for position of parts 4- Special Washer dozer 4 used loader)
during disassembly and assembly. (6 used) 9-Cap Screw (2 used
5--Tapping Bar (2 used) dozer)
6-Front Crossbar 1o--Spacer (4 used)
Tighten side frame-to-steering clutch housing cap 11-Cap Screw (4 used)
screws (3, Fig. 16) to standard torq ue prior to tight-
ening side frame-to-clutch housing cap screws (11 ) Fig. 17-Front Crossbar
to standard torque.
1-Right Rear Bar Bracket 7- Retainer (2 used)

2-Rear Crossbar 8-Lock washer (4 used)
8 T25080N
3-Cap Screw (4 used) 9-Cap Screw (4 used)
4-Cap Screw (4 used) 1o--Cap Screw (8 used)
1-Left Side Frame 7-Cap Screw (4 used) 5--Left Rear Bar Bracket 11-Speciai Washer
2-Special Washer 8-Lock Washer (6 used) 6- Shim (approx. 6 used) (8 used)
(8 used) 9-Cap Screw (6 used)
3-Cap Screw (8 used) 10-Special Washer Fig. 18-Rear Crossbar
4-Right Side Frame (2 used)
5--Spacer (2 used) 11-Cap Screw (4 used)
6--Speclal Washer 12- Spacer (2 used)
(4 used)
Fig. 16-Side Frames
Litho in U.S.A.
10-12 Track Carrier Assembly TM-1102 (Nov-73)
Installation
Before installing track carrier, be sure that front
and rear crossbar are secure and that front crossbar
extends an equal distance from side frames on both
sides. Add shims between side frames and crossbar
if necessary. Tighten front crossbar-to-side frame
horizontal cap screws and vertica l cap screw to
standard torque. Evenly tighten the rear crossbar
cap-to- bracket cap screws {3, Fig. 18) to 250 lb-ft
[34.56 kg-m).
With the tractor supported under both crossbars,

start the track carrier on the rear crossbar and slide
in place. Position the rear crossbar retainer and
shims and loosely install the cap screws. Note that
spacers are used at front attaching points.
Install the drive sprocket on hub dowels and tight-

en cap screws to standard torque. 1-Sprocket 3-Sprocket Centered
2-Adfustlng Shims
Shift track carrier in or out until drive sprocket is
centered between flanges of rear track roller (Fig. Fig. 19-Centering Drive Sprocket in Track Frame
19). Then install just enough shims to fill space be-
tween retainer and retainer seating surface.
Tighten the retainer cap screws to 170 lb-ft [23.50

kg-m) and the front crossbar horizontal cap screws
and the vertical cap screws to standard torque.
Recheck centering of sprocket between rear track

flanges.
Litho in U.S. A.
TM- 1102 (Nov-73) Winch System 15-1
Group 15
WINCH SYSTEM
GENERAL INFORMATION
The winch system consists of a control valve, hy- The Winch Clutch (disk type) is located inside the
draulic pump, and housing with gear train . clutch and brake drum. A pressure plate hydraulically
engages the clutch. A release spring disengages the
The Winch Pump is of the positive-displacement clutch pack after pressure oil is released.
gear type and is located in the winch housing under
the output shaft. The pump is driven by the pinion The Winch Brake is of the contracting band type
shaft drive gear and supplies pressure oil for clutch- mounted around the winch drum and operated by a
ing and releasing the winch brake. (See Section 50, hydraulic piston and cylinder mechanism. The brake
Group 15 for detailed information on the pump.) band is released by oil pressure and engaged by
spring pressure.
REMOVAL
Detach control cable from winch control lever.
Remove winch fairlead assembly (see Group 20) .
Attach a chain hoist to winch housing. Remove

winch housing-to-steering clutch housing cap screws.
Pu ll winch away from rear of crawler , clearing

studs and dowels. At the same time, disengage PTO
shaft coupler.
1- Winch Housing Cap Screws
Fig. 1-Winch Attaching Points
Litho in U.S.A.
15-2 Winch System TM- 1102 (Nov- 73)
REPAIR
Disassembly
Place winch on a stand or bench for disassembly.
'Q- -1
Drain oil from winch housing.
Removing Brake Band and Clutch Cover
T28J99
1-Eibow 9-0owel (2 used)

2- 0il Line 10- Snap Ring
3-Swivel Fitting 11- Middle Disk (3 used)
4-Ciutch Cover 12- lntermediate Disk
S-Diaphragm (2 used)
6-Diaphragm Ring 13-0rive Hub
7-Pres sure Plate 14-Ciutch and Brake
8-Spring (12 used) Drum
1S-V-Packing
1- Brake Cylinder 6- Lock Nut
2-Anchor Pin 7- Ciutch Cover Fig. 3-Ciutch Pressure Plate Assembly
3-Brake Band Assembl y 8-Adjusting Screw Pin
4-Sprlngs ~Oil Line Remove middle disks (11) and intermediate disks
S-Brake Adjusting Nut 10-Swivel Fitting (12) from clutch and brake drum.
Fig. 2-Removing Brake Band
Removing Main Drive Shaft
Remove left quill from winch housing. Remove right bearing retainer with shims and right
quill from winch housing.
Release brake spring pressure.
Slide the main drive shaft and ring gear assembly
Remove brake springs and adjusting screw. out through right-hand side of winch housing.
Remove anchor pin and brake cylinder from winch Removing Clutch and Brake Drum
housing . Slide brake band assembly off the clutch
and brake drum . Remove the socket head cap screws attaching the
cl utch and brake drum to the winch drum and pull
Removing Clutch Disks brake drum free from winch drum dowels.
Remove two clutch cover attaching cap screws
(Fig. 3) and install two 1/2 x 2-inch [ 12.7 x 50.8 mm]
cap screws to facilitate the removal of the spring-
loaded clutch screws.
Remove diaphragm and diaphragm ring.
Litho in U.S.A.
TM-1102 (Nov-73) Winch System 15-3
Removing Winch Drum Attach a puller to the winch drum and force the
bearing cone off the right-hand end of the winch
drum. Slide the winch drum out the left side of the
winch housing.
Removing Gear Train (Fig. 6)

Remove coupling from input shaft. Remove the in-
put shaft bearing quill and shim pack. Remove gear
cover from front of the winch housing.
NOTE: To facilitate removal of the gear cover,

screw two of the attaching cap screws in the unused
threaded holes and force off gear cover.
Fig. 4-Removing Left Bearing Quill
Remove inner grease retainer secured to left bear-

ing quill. Remove bearing quill cap screws. Attach a
puller to the bearing quill and force the bearing cone
off the end of the winch drum (Fig. 4). Remove the
bearing quill and gasket from the winch housing.
Remove end plate and shim pack (from right side

of winch).
1-Cotter Pin 15--Woodruff Key

2- Siotted Nut 16-Thrust Washer (2 used)
3-Special Washer 17- Roller Bearing (2 used)
4-Bearlng Cone 18-Speclal Washer
5--Bearlng Cup 19---Ciuster Gear
6-Shlms 2G-Rivet (10 used)
7-Tapered Spa cer 21 - Ring Gear and Output Shaft
8-Spacer (2 used) 22- Bearlng Cup (2 used)
9---Drive Gear 23-Bearing Cone (2 used)
1G-Shlms 24-lnput Shaft
11- Bearing Cup 25--ldler Shaft
12-Bearlng Cone 26-Shaft
13-Bearlng Cup 27-Main Drive Shaft Assembly
14-Bearln g Cone 28-Spring Pin
Fig. 5-Removing Winch Drum 29---Coupllng
Fig. 6-0utput Shaft Assembly
Litho in U.S.A.
15-4 Winch System TM- 11 02 (Nov-73)
Using Figure 6, remove parts from idler shaft. Examine thrust washer for wear or damage and
replace if necessary.
Remove cover on bottom of winch housing and re-
move hydraulic pump with bracket from winch hous- Inspect ring gear, pinion shaft, and gears for dam-
ing. age. See Figure 6 for parts identification .
Remove expansion plug from rear of idler shaft NOTE: The ring gear and pinion shaft are fur-
bore and drive out idler shaft. nished in matched sets and are not available individ-
ually for replacement.
Using Figure 6, remove parts from output shaft
and remove shaft from housing. Inspect the bearing cone on the p1mon shaft for
wear or damage. If replacement is necessary press
Checking Brake Cylinder and on new cone with large end toward spiral bevel gear
Brake Band of pinion shaft, using the pinion shaft spacer as a
tool (Fig. 7) .
To disassemble brake cylinder, remove internal
snap ring and slide out piston .
Inspect brake cylinder and piston parts for dam-

age. Replace all 0-rings.
Inspection
Checking Shafts and Bearings
Inspect all bearings, cups and cones for damage.
Inspect the input shaft bearing quill sealing ring.
Inspect the input shaft bearing quill oil seal. If re-

placement is necessary, press in new oil seal, lips in-
ward, to flush with input shaft bearing quill bore using
a 630- 11 Tool.
Inspect the bearing cup in the input shaft bearing

quill. If replacement is necessary, press in new bear-
ing cup until it bottoms.
Inspect the bearing cone on each end of the input

Fig. ?-Pressing Pinion Shaft Bearing Cone
shaft. If replacement is necessary, press on new
bearing cone until bearing bottoms. Inspect the rear bearing cup in the pinion shaft
bore for wear or damage. If replacement is neces-
Inspect idler shaft for damage or bent conditions. sary, drive out the old bearing cup, being careful not
to damage or lose shim pack behind cup. Drive in
Inspect cluster gear (19, Fig. 6) for excessively new bearing cup, with large end facing driver, until it
worn or broken teeth. bottoms in bore
Inspect roller bearings for wear or damage. Examine special washer and spacers for wear or
damage.
Litho in U.S.A.
TM- 11 02 (Nov-73) Winch System 15-5
Inspecting Clutch Assembly (Fig. 5)

Pull clutch cover from pressure plate and inspect
for wear.
Examine diaphragm and diaphragm ring for wear

or damage. Make sure the machined surface of the
pressure plate (7, Fig. 5) which makes contact with
the diaphragm (5) is carefully examined for nicks,
scratches and sharp edges.
To remove or smooth out nicks, scratches or sharp

edges, use a very fine file and an emery cloth.
It is extremely important to remove nicks, scratch-

es or sharp edges, if present, to prevent premature
fail ure of the diaphragm.
Fig. 8-lnstalling Main Drive Shaft Bearing Cone
Inspect the bearing cone on the main drive shaft. If Inspect the clutch and brake drum for oil or grease
replacement is necessary, press on new cone to before installing a new brake band. If a small amount
flush with the end of the shaft. Small end should face of either is indicated, wash drum in an alkaline solu-
driver. Use 630-17 Tool (Fig. 8). tion.
Inspecting Winch Drum Bearing Quills If the drum has been soaked in oil or grease. it is
strongly recommended that the drum be replaced . An
Inspect the oil seal in the bearing quills for dam- oil- or grease-soaked drum will continue to bleed oil
age. Press in new oil seals to flush with bore (lips of and grease under operating conditions, thus ruining
the seals facing driver). another brake band .
Inspect bearing cup in the bearing quills. Drive NOTE: If drum is being replaced because it has
new bearing cup into quill , large end facing driver, been soaked with oil or grease, make sure to correct
until it bottoms. the leakage problems.
Inspect the quill bearing cones for wear or dam- Special care should be taken when installing a
age. Pack cones with John Deere Winch Bearing new band to prevent oil or grease from getting on the
Grease. brake band or drum. Any oil or grease on the brake
band or drum braking surfaces will cause the band to
Inspecting Winch Drum slip in the "Hold" position.
If winch drum needle bearing is damaged, press
new bearing to 0.25 in. [6.35 mm] from end of winch After burnishing a new brake band, the brake band
drum. Pack with John Deere Winch Bearing Grease. adjustment should be rechecked and the powder
substance created during burnishing should be blown
Install new vee packing with lip facing needle bear- out from between brake band and the drum .
ing.
Litho in U.S.A.
60 Mscellaneous Components Crawler - JD450-C
15-6 Winch System TM-1102 (Nov-73}
Assembly Establishing Winch Drum Preload

Installing Winch Drum 1. Place shims under the end plate to induce end
play and attach the end plate to the right-hand end
Install the right bearing quill and gasket at the in-
of winch drum. Tighten attaching cap screws to stan-
ner bore in right-hand side of the winch housing.
dard torque.
Install two guides in the cap screw holes to facili-
2. Check the end play on the drum. Remove the
tate quill installation.
correct quantity of shims to give the desired preload
of 0.001 to 0.005 inch [.03 to .13 mm].
Remove the guides and tighten the attaching cap
screws to standard torque.
3. Install the winch hydraulic pump.
Install the winch drum in the left-hand side of the
Ring Gear and Pinion Adjustment
winch housing. End of drum with six holes and three
dowels should face out to left side. When installing a new winch housing, a new ring
gear and pinion shaft set, or new bearing cones or
Install gasket and left bearing quill in inner bore on cups which support these parts, it will be necessary
left hand side of winch housing. to make certain adjustments. These adjustments are
covered on the following pages and must be made in
Install two guides in the cap screw bores to facili- the sequence given below.
tate quill installation.
Step 1 - Cone point adjustment
Remove the guides and tighten the attaching cap
screws. Step 2 - Pinion shaft bearing preload adjustment
Pack the left and right bearing cones with John Step 3 - Ring gear and pinion backlash adjust-
Deere Winch Bearing Grease and drive cones on ment
winch drum, leaving the bearing cones protruding to
specifications over end of winch drum. Step 1 - Adjusting Cone Point
1. Add the number which is etched on the end of
Position the inner grease retainer on the left bear-
the pinion shaft to the mean dimension (1.93 inch
ing quill and secure with attaching cap screws.
[49.02 mm]) of the output shaft rear bearing cup and
cone.
Installing Clutch and Brake Drum
Position clutch and brake drum on the winch dow- 2. Subtract this figure from the number stamped
els and secure to the winch drum with cap screws. on the right quill bore.
Tighten cap screws to standard torque.
3. The difference is equivalent to the thickness of
the shim pack that must be added behind the rear
bearing cup to obtain the correct cone point setting.
Litho in U.S.A.
TM-1102 (Nov-73} Winch System 15-7
Step 2 - Adjusting Pinion Shaft Installing Idler Shaft and Cluster

Bearing Preload Gear
1. Slide pinion shaft with rear bearing cone and Refer to Figure 6 and the following:
rear spacer into pinion shaft bore. Install drive gear,
spacer. and beveled spacer (flat side to the rear) on 1. Install a WoodruH key in the idler shaft keyway.
the pinion shaft and slide the pinion shaft into the Drive the shaft in flush with the counterbore at the
front bore. Place a 0.090-inch [2.29 mm) shim pack rear of bore in gear cover.
on the shaft and install the front bearing cone, flat
washer, and nut. Install expansion plug in the idler shaft counterbore
in gear cover.
2. Place a thrust washer on the idler shaft.
Place a roller bearing, spacer washer, and roller

bearing in cluster gear and slide onto idler shaft.
3. Place a thrust washer over the idler shaft.
4. Install input shaft assembly.
5. Screw two guides into the cap screw holes in

front of the winch housing. Install gasket and gear
cover on the guides and on hollow dowel. Remove
Fig. 9-Pinion Shaft Preliminary End Play the guides and install the attaching cap screws.
2. Install a dial indicator and measure introduced Establishing Input Shaft Preload
end play in shaft (Fig . 9). If there is no end play, re-
move nut and bearing cone and add enough shims This preload is established by shims under the in-
so there is a measurable amount of end play. put shaft bearing quill and can be determined as
follows:
3. Measure end play and determine the shim pack
required to give the desired preload adjustment of 1. Remove the sealing ring from the groove in the
0.004 to 0.006 inch [.1 to .15 mm). input shaft bearing quill.
4. Tighten pinion shaft nut 100 to 125 lb-ft (13.83

to 17.28 kg-m 1. Advance nut as required to install
cotter pin. Install cotter key, gasket and cover.
NOTE: The winch drum and the clutch and brake

drum must be in place before ring gear backlash can
be determined.
Litho in U. S. A.
15-8 Winch System TM- 1102 (Nov-73)
Step 3 - Ring Gear and Pinion Backlash

Adjustment
Make ring gear and backlash adjustment as fol-
lows:
Fig. tO-Measuring Input Shaft End Play
2. Place shims under the input shaft bearing quill

to induce end play. Install quill and tighten attaching Fig. 11-Measuring Ring Gear and Pinion Backfash
cap screws. Check end play as shown in Figure 10.
Remove the correct quantity of shims to give the de- 1. Check backlash of ring gear at several points
sired preload of 0.002 to 0.004 inch [.05 to .1 mm ]. around ring gear (Fig . 11 ). Due to allowable machine
tolerances, there may be one point where there is
less backlash than at other points. By proper place-
3. When the preload has been determined, re-
move the input shaft bearing quill and instal l the ment of shims, establish 0.006 to 0.012 [. 15 to .3
mm] backlash at the point of least backlash.
sealing ring previously removed. Install the quill and
again tighten the attaching cap screws to standard
torque. 2. Adding the calculated quantity of shims under
the right bearing retainer will increase the backlash.
Installing Main Drive Shaft and Right
Quill Deducting the calculated quantity of shims under
the right bearing retainer will decrease backlash.
Install main drive shaft from the right- hand side in-
to the winch housing. Install quill with gasket. Take 3. When the correct backlash of the ring gear and
care ~ot to damage seals. pinion have been established, remove the right bear-
ing retainer and install sealing ring. Lubricate sealing
Drive in bearing cup to 1/8 inch [3.18 mm] below ring before installing. Install right bearing retainer and
shim surface on the right quill. tighten attaching cap screws to standard torque.
Litho in U.S.A.
TM-11 02 (Nov-73) Winch System 15-9
Installing Clutch Assembly (Fig. 3) Burnishing New Brake Facings

Install clutch drive hub and snap ring on main drive On field installation of repair parts, it is necessary
shaft. to burnish the brake band to obtain full capacity.
Alternately install middle disks and intermediate Burnish new replacement brake bands as follows:
disks into the clutch drive hub.
Tighten brake adjusting nut until there is
IMPORTANT: Place the diaphragm in the clutch 4-11/16-inch [119.06 mm] distance between bottom
pressure plate assembly so that the smooth side edge of spring anchor pin and bottom edge of spring
is facing the clutch cover and the textured side is anchor. Hook on to something solid and drive away
out. with winch brake applied. A short distance (25 to 30
feet [7.62 to 9.14 m]) will bring brake to full capacity.
Use the following torque sequence when fastening
diaphragm and diaphragm ring to clutch cover. In practically all cases this will develop full winch
brake capacity; if not, repeat the above procedure.
1. Snug cap screws down using a criss-cross pat-
tern to 5 lb-ft [.69 kg-m] torque. ADJUSTMENT
2. Tighten cap screws using a criss-cross pattern Adjusting Winch Brake Band
to 30 lb-ft [4.15 kg-m] torque.
Always adjust the winch control lever before ad-
justing the winch brake (see Section 70, Group 25).
3. Retorque cap screws to 30 lb-ft [ 4.15 kg-m]
torque.
If the winch brake band or linkage have been re-
moved or replaced, they must be readjusted to pre-
4. Allow clutch cover assembly to set for 30 min-
vent slippage.
utes and retorque the cap screws to 30 lb-ft [ 4.15
kg-m].
Remove the left quill from winch housing. Loosen
the jam nut (see inset, Fig. 13) and back off brake
Pack bearing cone with John Deere Winch Bearing
adjusting nut until brake band is loose. Tighten brake
Grease.
adjusting nut until there is 4-11 /16 inches [119.06
mm] distance between bottom edge of spring anchor
Install assembled clutch pressure plate.
pin and bottom edge of spring anchor. Tighten jam
nut and install cover.
Installing Brake Band (Fig. 2)
Position brake band on clutch and brake drum. Recheck operation of winch. If brake still slips, in-
spect brake band facings for damage from excessive
Secure top brake anchor to boss in winch housing heat, grease, or oil.
pin. Attach adjusting screw to bottom of brake anchor
with pin. With adjusting screw loose, connect brake
springs.
Litho in U.S.A.
15-1 0 Winch System TM-1102 (Nov-73)
INSTALLATION
Attach a chain hoist to the winch housing and lift it
into position on studs and dowels at rear of tractor.
At the same time, engage PTO shaft coupler.
Attach winch housing to steering clutch housing

pads. Torque cap screws to 150 lb-ft [20.74 kg-m).
Install winch fairlead and drawbar on winch hous-

ing (if equipped) .
Attach control cable to winch control lever.
Refill winch housing with proper oil (Section 10,

Fig. 12-Adjusting Winch Brake Band Group 20).
No " Free Spool" After Winch Brake Band Attaching Cable to Winch Drum
Adjustment
Shifting the position of the brake cylinder a very
small amount sometimes will free the brake band if
difficulty is encountered in getting the winch brake
band to release for free spool after the brake band
has been adjusted for slippage.
The brake cylinder's position can be shifted by

loosening the two cap screws on brake cylinder and
with the aid of a screw driver placed between the
brake cylinder and the anchor pin boss, rnove the
brake cylinder slightly forward until free spool occurs.
When free spool occurs hold the position of the
brake cylinder and tighten cap screws.
rnos \.~---
Fig. 13-Attaching Cable to Drum
Litho in U.S.A.
TM-11 02 (Nov-73) Winch System 15-11
Thread cable through winch drum, fold end of ca-

ble back into drum and pound it in (Fig. 13).
~
/
--
To conform to certain state laws, the winch cable
must be attached to the winch drum so that it can
tl o
come loose if the cable is unwound.
i
1 /\~·l
)
6 ~v
ID
-~ ' r,
' 1.J
Thread the cable through the winch drum as .J 1--;.~
shown in Fig. 14 and wind the cable onto the drum. ,Q
:~j
"''I
Q
Q
IMPORTANT: When the cable is attached to the ~
winch in this manner, unwinding the cable below
five turns on the drum will allow the cable to dis-
,/ \...
connect from the drum. ..18 72 10
Fig. 14-Attaching Cable to Winch Drum
Litho in U.S.A.
15-12 Winch System TM-1102 (Nov-73)
Litho in U.S.A.
TM- 11 02 (Nov-73) Winch Fairlead Assembly 20-1
Group 20
WINCH FAIR LEAD ASSEMBLY
GENERAL INFORMATION
~
t-14
4 3 15
@
1
~
9
11
~
10
12 13\
\v~ 00 / fr-4
1o---1
s-a
9---@
T 11(}52
1-Grease Fitting (2 used) ~Spring Pin (2 used) 11-Shaft Retainer

2- Side Roller Shaft (2 used) 7- Top Roller 12-Cap Screw (2 used)
3-Top Roller Shaft (2 used) 8-Cap Screw (8 used) 13-lock Washer (2 used)
4-Roller Bushing (6 used) 9---Lock Washer (12 used) 14-Cap Screw (4 used)
5-Side Roller (2 used) 1D-Fairlead Frame 15-Grease Fitting
Fig. 1-Winch Fairlead Assembly
Litho in U.S.A.
20-2 Winch Fairlead Assembly TM-11 02 (Nov-73)
The fairlead assembly, mounted under the winch, REPAIR

aids the operator when winching loads from the side.
Examine the top roller and each side roller for ex-
The assembly provides proper winding of the cable.
cessively worn or damaged condition and replace if
necessary.
REMOVAL
Attach strap or chain hoist to fairlead assembly. Inspect the roller bushing in each end of the top
roller and in each side roller. Replace any excessive-
Remove mounting cap screws (8 and 14). Pull as- ly worn or damaged bushing.
sembly away from unit.
Using a JD630-13 tool, press in the new bushing
to the bottom of the counterbore in the top roller and
in each side roller.
Inspect each roller shaft for worn or damaged con-

dition and replace if necessary.
Examine the lubricating hole in each shaft for a

plugged condition.
Inspect and replace all defective grease fittings.
INSTALLATION
Reverse removal procedure for installation of the
fairlead assembly.
Litho in U.S.A.
TM-1102 (Nov-73) Loader Frame, Boom and Bucket 25-1
Group 25
LOADER FRAME, BOOM AND BUCKET
GENERAL INFORMATION
Fig. 1-JD45o-C Crawler Loader
The loader main frame has a low profile and is of

welded steel construction.
The loader boom is of welded construction and at-

taches to the main frame with eccentric pins making
itt 12 98N
several boom adjustments possible.
Fig. 2-Multi-Purpose Bucket
Loaders have either a bucket level indicator or a
solenoid actuated return-to-dig switch mounted on The multi-purpose bucket (Fig. 2) may be used as
the loader frame (see Operator's Manual). a loader, scraper, bulldozer, or clam shell. The buck-
et has a replaceable wrap-around cutting edge which
Loader hydraulic functions are performed by a sin- is equipped with six replaceable steel teeth.
gle control lever.
The boom and bucket are operated by the loader
The regular bucket cutting edge and teeth are control lever, while the clamp action of the bucket is
made of high carbon steel. operated by the attachment control lever.
Two utility rings are welded to the top of the regu- The clam is opened and closed by two double-act-
lar bucket to aid in attaching or removing the bucket. ing hydraulic cylinders.
A single-acting circuit relief valve, located at the

top rear of the bucket provides pressure relief when
the attachment control lever is in neutral.
Litho in U.S.A.
25-2 Loader Frame, Boom and Bucket TM- 1102 (Nov- 73)
REMOVAL
Drain oil from loader reservoir and disconnect Remove cap screws on both sides of loader secur-
loader hydraulic lines from rear tank unit. ing front mounti ng pin to loader frame (Fig. 4).
Disconnect all the necessary wiring, linkage and Remove pins securing loader frame to front cross-
lines between engine and cowl. bar.
Remove air cleaner support and position chains With the aid of a hoist, raise the loade r high
around upper portion of loader frame. Attach chains enough to clear the tractor and remove the loader.
to hoist.
Position floor jack or dolly with wheels under load-

er bucket to aid in removal.
1-Loader Frame 3-Front Crossbar

2- Cap Screw 4-Mountlng Pin
Fig. 4-Loader Front Mounting Points
1- Mounting Frame Dowel 3-0utside Retainer

2-Retaining Cap Screws 4-Rear Crossbar Bracket
Fig. 3-Loader Rear Mounting Points
Remove cap screws on both sides of loader secur-

ing outside dowel retainer to dowel retainer on inside
of loader frame (Fig. 3).
Remove dowels securing loader frame to tractor

right and left rear crossbar brackets.
Litho in U.S.A.
TM- 1102 (Nov-73) Loader Frame, Boom and Bucket 25-3
REPAIR
CAUTION: To avoid possible injury, al- Bucket Teeth
A ways stop tractor and lower or block up
boom and bucket before servicing loader units. Drive out pin and remove old tip (12, Fig. 5) from
bucket tooth shank (13).
Regular Buckets
Hand fit tip on tooth shank.
T21 1 9 6
Fig. 6-/nsta//ing Tooth Tip
Drive tip on tooth shank until pin can be assem-

T21195 bled or until center of hole in shank aligns with cen-
ter of slot in tip (Point "1 " , Fig. 6).
1-Bucket 9-Cap Screw (2 used)
2-cuttlng Edge 10-Piow Bolt (7 used) Secure tip to tooth shank with grooved pin.
3-Ring Hook 11-Groove Pin (7 used)
4-Grease Fitting 12-Tooth Tip (7 used)
5--Pin 13-Bucket Tooth (7 used) IMPORTANT: Pin should not contact front edge
6-Cap Screw (4 used) 14-Cap Screw (5 used) of slot (Point "2", Fig. 6). Point must fit tight with
7-Stop Nut (4 used) 15--lock Nut (14 used) no movement between tooth shank and tip when
8-Pin (2 used)
twisted by hand.
Fig. 5-Loader Bucket
Refer to Fig. 5 when disassembling or assembling

bucket parts.
Inspect bucket pins and cutting edge for damage.

Repair or replace if necessa ry.
IMPORTANT: Because bucket cutting edges

are made of high carbon steel, special welding T 21197 N
techniques are required (See "Special Welding In-
structions," page 60-25-4). 1-1 Inch 2-5/ 16 Inch Bead (all welds)
Fig. 7- Tooth Shank Welded to Bucket
Side impacting or wedging or rocks between buck-

et teeth can sometimes cause the tooth shank at-
taching hardware to loosen or fail. To prevent this,
tooth shanks can be welded to the bucket in the fol-
lowing manner.
Litho in U.S.A.
60 Miscellaneous Components Crawler - J0450-C
25-4 Loader Frame, Boom and Bucket TM-1102 (Nov- 73)
Attach all hardware and tighten to standard torque. Multi-Purpose Buckets
See " Special Welding Instructions" (below) and

weld tooth shank to bucket (Fig. 7).
Do not remove attaching hardware.
Special Welding Instructions

A low hydrogen {with iron powder) electrode
(American Welding Society, Series E7018) is recom-
mended for this type of work. The sizes most easily
hand led in horizontal or out of flat positions are
5/32-inch [3.97 mm] and 3/16-inch [4.76 mm] diam-
eters.
To obtain maximum strength, it is imperative that

all craters at the termination of each weld be filled. 1-Pin (2 used) 12-Cap Screw (6 used)
Because of the cupping action of heavy electrode 2-Grease Fitting (2 used) 13-Tooth Assembly
coating, it is necessary to drag the electrode lightly 3-Cievis Pin (4 used) (6 used)
or hold a very short arc. 4-Cotter Pin (6 used) 15-Cutting Edge-Bucket
5-Bus hing (6 used) 16-Cutting Edge-Clam
6- Pin 17-Cutting Edge-Moldboard
As a second choice. an E701 0 Series Electrode 7-Tip (6 used) 18-Piow Bolt (11 used)
can be used in DC reverse polarity after preheating 8-Sprlng Pin (6 used) 19-Nut (11 used)
the cutting edge to approximately 300 degrees F. 9-Nut (6 used) 2~Biade Assembly
1 ~Tooth Shank (6 used) 21-Cievis Pin (2 used)
[ 148.9°C]. Allow the edge to cool slowly.
11-Cap Screw (6 used) 22-Pin
IMPORTANT: When repairing a small section of Fig. 8-Multi-Purpose Bucltet

the cutting edge, it is necessary to preheat
around damaged area regardless of the electrode
used. This will prevent rapid cooling of the edge
around the weld which could cause the cutting
edge to become brittle.
When cutting edge is cracked, cut completely

through cutting edge. Extend cut 1/2-inch [12.7 mm]
beyond each end of crack.
Weld crack from both sides.
When welding cracks between cutting edge and

bucket, extend weld at least 1/2-inch [ 12.7 mm] be-
yond each end of the crack.
1- Ciam Cutting Edge 5-Compaction Plate

2-Reinforclng Plate 6--Biade Cutting Edge
3-Bottom Plate 7-Biade
4-Support Runner 8-Mo ldboard
Fig. 9-Replaclng Bucket Cutting Edges
Litho in U.S.A.
TM-11 02 (Nov-73} Loader Frame, Boom and Bucket 25-5
Bucket Cutting Edges

Remove worn clam cutting edges from the bucket
using a torch and chisel. The blade cutting edge is
attached with bolts.
Because bucket cutting edges are made of high

carbon steel, special welding techniques are required
(60-25-4).
When replacing cutting edges refer to Fig. 9 and

weld according to the following instructions.
1. Use 1/ 4-inch [6.35 mm] fillet weld on areas A

and C.
2. Use 3/16-inch (4.76 mm) fillet weld on area B.

1- Bushlng 10--Lever Link
Welds are to be 6 inches [152.4 mm] long and cen- 2-Hex. Bolt (10 used) 11- Maln Boom
tered on cutting teeth holes. 3-Nut (6 used) 12-Bus hing (2 used)
4-Rub Bar 13-Bucket Lever
3. Use 1I 4-inch [6.35 mm] bevel weld on area D. ~ rease Fitting 14-Bushing (4 used)
6-Bucket Lever 15--Cylinder Pivot Pin
7-Wave Washer (2 used)
4. Use 1/ 4-inch [6.35 mm) fillet skip weld on area 8-Fro nt Lever 16-Stop Nut (2 used)
E. Welds are to be 6 inches [152.4 mm) long and 12 9-Retalner 11-cap Screw (2 used)
inches [304.8 mm] between centers. 18-Bushing (4 used)
Rg. tO-Boom and Bucket Linkage

5. Use 3/16-inch [4.76 mm) fillet weld on area F.
Welds are 3 inches (76.2 mm) long and centered be-
tween support runners.
Boom and Linkage

Supporting Loader Boom
It is desirable, in servicing some of the crawler
loader components, to raise the boom to its fu ll
height.
L). CAUTION: Be absolutely certain the

. . boom Is then supported before working
underneath ft. This can be accomplished by three
1-Grease Fitting 8-Wave Washer
different methods, as follows: 2-Special Screw 9-Lever
3--Collar 10--Bucket Cylinder Pin
1. Cut a piece of angle iron (4 X 4 inch r101.6 X 4-Co llar 11- 0rilled Pin (2 used)
101 .6 mm] stock or larger) to a length of 24 inches 5--Lever 12-cotter Pin (2 used)
6-Washer 13-Lever
[609.6 mm). Attach it to the boom cylinder piston rod
7- Levellng Link 14-Lever
between the rod end and the cylinder barrel, being
careful to avoid damaging the piston rod. Be sure the Fig. tt-Boom-to-Frame Linkage
angle iron is large enough to rest against the cylinder
barrel and not against the head casting.
2. Use prop under cross member to support boom.
3. Chain bucket to hoist or overhead beam.
Litho in U.S.A.
25-6 Loader Frame, Boom and Bucket TM- 1102 (Nov-73)
Refer to Figs. 10 and 11 during disassembly and Frame

assembly.
Inspect boom, upper links, bucket levers , and

bucket links for damage. Replace parts if necessary.
Inspect all loader pivot points. If pivot points are

loose , worn, or damaged, replace as necessary.
Grease all fittings where new parts have been in-

stalled before resuming operation.
Q/ 15
· ~16
0
...._17
T21194
1- Fender 14-Loader Frame

2-Lock Washer (4 used) 15-Cap Screw (2 used)
3-Cap Screw (4 used) 16-Pin (2 used)
4-Grease Fitting (4 used) 17- Stop Nut (2 used)
5-Pin (2 used) 18-Retainer (2 used)
6--Grease Fitting 19-Dowel (2 used)
7- Special Screw 20-Retainer (2 used)
a-washer 21 - Lock Washer (4 used)
9-Bushing 22-Cap Screw (4 used)
10-Stop Nut 23-Spacer (2 used)
11-Pivot Pin 24-Cyllnder Pin (2 used)
12- Cap Screw (2 used) 25-Washer (2 used)
13-Fender 26-Cap Screw (2 used)
Fig. 12-Loader Frame
Refer to Fig. 12 during disassembly and assembly.
Inspect all loader pivot points. If pivot points are

loose, worn, or damaged, replace as necessary.
INSTALLATION
Install loader by reversing removal procedure.
Litho in U.S.A.
TM-11 02 (Nov- 73) Dozer Frames and Blades 30-1
Group 30
DOZER FRAMES AND BLADES
GENERAL INFORMATION
Three types of bulldozers are available on the
JD450-C Crawler.
All dozers have a one-lever hydraulic control.
Fig. 3-6415 Bulldozer and JD450-C Crawler
The 6415 Bulldozer is outside mounted (Fig . 3).

The tilting and raising of the blade are done hydrauli-
cally.
Bulldozer blades are of reinforced box-welded
The 6405 Bulldozer is inside mounted (Fig. 1). The steel construction. All blades have reversible and re-
tilting, angling, and raising of the blade are all done placeable cutting edges and end bits. Gauge shoes
hydraulically. can be attached to the bottom of the blade to assist
in regulating the depth of blade penetration.
Blades are contoured to move material with an

easy rolling action that reduces power needs and .
clogging at the cutting edge .
The 6410 Bulldozer is outside mounted (Fig. 2).

and is raised and lowered hydraulically. The blade is
angled or tilted manually.
Litho in U.S.A.
30-2 Dozer Frames and Blades TM-1102 (Nov-73)
REMOVAL
Lower blade to the ground and operate dozer con-
trol lever to relieve hydraulic pressure .
Disconnect and plug dozer hydraulic lines.
Attach a chain hoist to rear of boom or frame. Re-

move attaching hardware. Raise dozer assembly
from the crawler.
1-Bushlng 15-Guide Block
Back crawler away from the dozer assembly. Low-
2-Ciamp 16-Bushlng
er rear of dozer assembly to the ground. 3-Ciamp 17-Spacer
4-Cap Sc rew, Lock 18-Sprlng Pin
REPAIR Washer, and Nut 19-Pin
5- Spring Pin 2Q-Angllng Frame
6-Pin 21 - Siotted Nut
Frames and Booms 7- Pin 22-Keeper
8-Sprlng Pin 23- Cotter Pin
A CAUTION : To avoid possible injury and to 9-Bushlng 24-Bushlng
. . insure best results, always stop tractor 10-clamp 25-Pin
operation and lower or block up frame and blade 11-Grease Fitting 26-Cap Screw, Lock
12-Boom Washer, and Nut
before servicing dozer frames and booms.
13-cap Screw and 27- Pin
Lock Nut 28-Pin
Refer to Figures 4 through 8 during disassembly 14-Cap Screw, Lock
and assembly of dozer frames and booms. Washer, and Nut
Fig. 4·6405 Boom and Angling Frame

Inspect lift frame and boom for damage. Replace
parts as necessary.
2~~1
Inspect all pins and bushings. If loose, worn or 3~10 ! 11
damaged replace as necessary. 7, ~ ~ ~13
\ !:--..12 u 14
Tighten all cap screws and bolts to standard
torque.
4 5
\t,. 8
~15
6
~\ 1~~
~ 20
~22 21
T 21 186 2~ v ~23
1-Washer 12-Grease Fitting
2-Sprlng Pin 13-Pin
3-Guard 14-Arm
4-cap Screw and Lock Washer 15-Pin
5-cap 16-Spring Pin
6-Shlm 17-Pin
7-Bushing 18-Cotter Pin
8-Boom 19-Groove Pin
9-Washer 2D-Wedge
1D-Pin 21-clamp Lock
11- Pin 22- Biade Pivot
23-Pin
Fig. 5-6410 Boom and Angling Arms
Litho in U.S.A.
· TM-1102 (Nov-73) Dozer Frames and Blades 30-3
1- Spring Pin 13-Cap Screw

2-cap Screw and lock Washer 14-Pin
3-Cap 15-Spring Pin
4-Shlm 16-Pin
5-Frame 17- lock Nut
6-Bushing 18-Pin
7-Guard 19--Vertical link
8-Washer 2D-Hydraulic line Link T 2118 9
9--Pin 21-Pivot Bracket 1- Bushlng 6-Cap Screw and Lock Washer
1D-Washer 22-Lock Washer 2-Lift Frame 7- Cap Screw and Lock Washer
11- Pin 23-Special Washer 3-Grease Fitting 8-cap Screw and Lock Washer
12--<Jrease Fitting 24-Cap Screw 4-Spacer 9- Bumper
5-lift Frame
Fig. 6-6415 Frame and Angling Arms
Fig. 8-6410 and 6415 Lift Frame
Blades
1-cap Screw and 11- Cap Screw

Lock Washer 12-Mountlng Frame
2- Retainer 13-Pivot Assembly
3-Pin 14-Cap Screw
4-cap Screw, Lock 15-Pin
washer, and Nut 16-Cap Screw and
5-Washer Lock Nut
6-Pin 17-Pin 1-Gauge Shoe 6-Shlm
7-Spring Pin 18-cap Screw 2- Bolt, Lock Washer, 7-Bit
8-0ouble Retainer 19--Pivot Assembly and Nut 8-Piow Bolt, Lock
9--Grease Fitting 2G-Moun1ing Frame 3-Washer Washer, and Nut
10-Support 21-Bushing 4-Cap Screw and 9-cen1er Cutting Edge
lock Washer 1D-End Bit
Fig. 7-6405 Mounting Frames and Pivot 5-Biade Keeper 11-Biade
Assembly
Fig. 9-6405 Blade
Litho in U.S.A.
30-4 Dozer Frames and Blades TM-1102 (Nov-73)
Inspect all blade parts for cracl!;s or other damage INSTALLATION

(Fig. 9). Reverse or replace the blade cutting edge
Install dozer by reversing removal procedure.
when dull or damaged for new cutting action. Re-
verse or replace end bits when they become dull,
damaged or broken.
Protect the polished surface of the blade when

bulldozer is not in use by applying a coat of cup
grease.
Litho in U.S.A.
TM-1102 (Nov-73) Lumber Fork and Pulpwood Loader 35-1
Group 35
LUMBER FORK AND PULPWOOD LOADER
GENERAL INFORMATION REMOVAL
The lumber fork and pulpwood loader use the
same boom and mounting frame as the loader.
Refer to page 60-25-2 for removal of the assem-

bly.
Remove boom attaching pins to remove lumber

fork or pulpwood loader from the assembly.
REPAIR
A CAUTION: To avoid possible injury and to

. . Insure best results, always stop tractor
operation and lower or block up frame before
servicing.
Fig. 1-JD450-C Lumber Fork
The lumber fork is ideal for handling all kinds of Disassembly

cut lumber. It can be used with standard load arms Refer to Figs. 3 through 5 during disassembly and
only or with single or dual clamps. assembly of the lumber fork and pulpwood loader.
Check all parts for wear and damage. Replace

parts as necessary.
Assembly
Lumber Fork
Mount the clamp support on the main frame with
the lower attaching cap screws. Do not tighten these
screws at this time .
Fig. 2-JD45Q-C Pulpwood Loader
The pulpwood loader is an ideal unit for handling

all types of logs. It can be used as a basic log fork or
with grapple arms for positive clamping action .
Litho in U.S.A.
35-2 Lumber Fork and Pulpwood Loader TM- 1102 (Nov-73)
Position the inner surface of the clamp support

against the front surface of the main frame. Insert as
many shims (12, Fig. 3) as possible between the 5
clamp support and the clamp locating strip on the
lumber fork frame. Attach back-up washer (13) with
two cap screws and tighten to standard torque.
0
Tighten lower attaching cap screws to 670 lb-ft
4
I
[83.92 kg-m]. Back nut off to nearest slot and insert
cotter pin.
Lumber Fork and Pulpwood Loader

Tighte n all attaching cap screws and bolts to
standard torque.
T21204
Grease fittings before resuming operation.
1-Grease Fitting (4 used) 9- Spacer (6 used)
2- Boom Pin (4 used) 1O-Spacer (2 used)
1 3-Cap Screw (4 used) 11-Spacer (2 used)
~
4- Stop Nut (4 used) 12-Load Arm Shaft
5--Frame (2 used)
6--Cap Sc rew (4 used) 13---Bolt (2 used)*
7- Retainer (4 used) 14-Load Arm Standard*
J 3
I
•
8-Nut
* With single cla mp

15--Nut (4 used)*
16--Load Arm
Fig. 4-Lumber Fork Frame and Load Arm

\15
2
10
:f •
12
T21203
1-Pin
2-Ciamp
10--Cap Screw (2 used)
11-Lock Nut (2 used)
'/•~<f
T21205
5 10
3---Nut (3 used) 12- Shlm (as required)
4-Ciamp Support 13---Back-Up Washer 1-Bolt, Lock Washer, 7-Cap Screw and Lock
&-Cap Screw (2 used) and Nut Nut (6 used)
6--Pin (2 used) 14-Cap Screw (2 used) 2- Mast End Cover 8-Grapple
7- Cap Screw (2 used) 15--Grease Fitting 3---Bushing (4 used) 9-Main Frame
8-Cotter Pin 16--Washer (2 used) (single 4-Pin (2 used) 10--Pin (4 used)
9-Nut (2 used) clamp only) 5--Grease Fitting (8 used) 11- Cap Screw and Lock
6--Pin (2 used) Nut (4 used)
Fig. 3-Lumber Fork Clamp 12-Pin
Fig. 5-Pulpwood Loader Main Frame and Grapple
Litho in U.S.A.
TM-1102 (Nov-73) Lumber Fork and Pulpwood Loader 35-3
INSTALLATION
Install lumber fork or pulpwood loader on the boom Install loader boom and mounting frames by re-
using attaching pins (2, Fig. 4 and 10, Fig. 5) and versing removal procedure.
hardware.
Litho in U.S.A.
35-4 Lumber Fork and Pulpwood Loader TM-1102 (Nov-73)
Litho in U.S.A.
TM-1102 (Nov-73} Backhoe Frame, Boom and Bucket 40-1
Group 40
BACKHOE FRAME, BOOM AND BUCKET
GENERAL INFORMATION
Double-acting hydraulic cylinders are used in five hookup provides eight operations. Both operating
operations of the 9250 Backhoe and four operations control levers provide normal simultaneous operation
of the 9300 Backhoe. with minimum operator fatigue and effort. Two short-
er levers operate the stabilizers wh ich are individually
A rotary vane-type cylinder is used to swing the controlled.
boom of the 9300 Backhoe during operation.
(See Section 50 for service of hydraulic cylinders
The backhoes operate with a two-lever control. and valves.)
The two-lever control with its universal-joint-type
REMOVAL
1- Bucket Cylinder (Retracted) 3-Maln Frame (Tipped Slightly Forward)

2- Crowd Cylinder (Retracted) 4-Stablllzer Cylinders (Extended)
Fig. 1-Backhoe in Separation Position
Litho in U.S.A.
40-2 Backhoe Frame, Boom and Bucket TM-1102 (Nov-73)
By using the backhoe hydraulic system, the back- REPAIR

hoe can be easily detached to free the crawler for
other jobs. 9300 Backhoe
Refer to Figs. 1 through 5 during disassembly and
Lower the stabilizers until they are supporting the
assembly of backhoe components.
weight of the backhoe. Retract the bucket and dip-
perstick and extend boom cylinder until backhoe is
fully extended and bucket is resting on the ground.
Install swing locking pin in place to prevent tipping.
Remove the cotter pins and mounting pins which

hold the top of the backhoe main frame to the crawl-
er frame.
Use stabilizers to raise backhoe frame off the bot-

tom mounting bracket hooks.
Carefully re·tract the stabilizers until the main frame

T28913N
is resting on the ground tilted slightly forward (Fig. 1).
1- Stabilizer 6-Stabillzer Cylinder Pin
NOTE: The main fra me can be blocked up off the 2- Cotter Pin 7- Lock Nut
ground by blocking across full width of backhoe main 3-Stablllzer Pin &-Cotter Pin
frame. 4-Washer 9-Stabilizer Foot Pin
5-Cap Screw 10--Washer
11-Stabilizer Fo ot
A CAUTION : Shut off the crawler engine be-
. . fore disconnecting the hydraulic lines to Fig. 2-Stabilizer
t he backhoe. If the engine is left running the op-
erator may be sprayed with hot hydraulic oil.
16
Disconnect the pressure and return hoses from the
backhoe main frame at the quick disconnect couplers 9 l
j~! :.~.,._
and connect hoses together.
IMPORTANT: Pressure and return hoses must ,Uo 5

be connected together at all times when backhoe
is removed.
O ~I
t 4/ 6
Wire the hoses to the crawler so they do not drag
on the ground during crawler operations.
T3: 425N 14-/L___.. .;:.: . .
1- Cap Screw (2 used) 9-Cotter Pin (2 used)
Carefully drive the crawler from the backhoe. 2-Stab lllzer Cylinder Pin 10-Cap Screw (2 used)
(2 used) 11-Bushing (2 used)
3-Lock Nut (2 used) 12- Maln Fra me
4-Nut (2 used) 13-Grease Fitting (2 used)
5--Lock Washer (2 used) 14-Bushing (4 used)
6-Pivot Ferru le (2 used) 15--Special Washer
7- Washer (4 used) (2 used)
8-Pivot Pin (2 used) 16--Relief Valve
Fig. 3-Main Frame
Litho in U.S.A.
TM- 1102 (Nov-73} Backhoe Frame, Boom and Bucket 40·3
0- s 1- Bolt, Lock Washer, 8-Cotter Pin

and Nut (6 used) 9-Pin
2-Washer 1(}-Backup Washer
3-Side Cutting Edge 11-Pin
4---Bushing 12- Front Cutting Edge
>-Bushing 13-Tooth Shank
6-Pivot Plate 14---Tooth Tip
7- Backup Washer
Legend for Fig. 4
7
T21591
Fig. 4-Bucket (with straight pivot plates)
26
\ 27
i/ r-29
~
~2~30
e-::... e -28
T32426N
~ I1 2>-Cap Screw (4 used)
1-Dipperstick 11}-Bushing 18-Boom
2-Cap Screw 11- Bushlng 19-Bushing (2 used) 26-Cap Screw (3 used)
3-Lock Nut (2 used) 12-Pivot End 21}-Grease Fitting (2 used) 27-Boom Cylinder Pin
4-Cyllnder Pin 13-Grease Fitting (1 used) 21-Boom Pivot Pin 28-Stop Nut (3 used)
S-Cap Screw 14-Guide L.ink 22- Retaining Washer 29-Cap Screw
6-Bushiog 15-Coupfer Unk (2 used) (2 used) 3o-crowd Cylinder Pin
7-Special Washer (2 used) 16-Special Washer (2 used) 23-Lock Washer (4 used) 31-Boom Wedge
8--Cotter Pin 17- Pin 24-Grease Fitting (3 used) 32-Boom Pivot Pin (2 used)
9--Pin
Fig. 5-Boom and Dipperstick
Litho in U.S.A.
40-4 Backhoe Frame, Boom and Bucket TM-1102 (Nov-73)
1- Stabilizer Pivot Pin 7-Lock Nut (4 used)

(2 used) 8-Nut (4 used)
2-cap Screw (2 used) 9-Lock Washer (4 used)
3-Lock Nut (2 used) 1~Stabilizer Cleat
4-Stabillzer (2 used) (2 used)
5-Cap Screw (4 used) 11-cap Screw (4 used)
6-Stablllzer Cylinder
1-Spring Pin 1~Bushing (2 used) Pin (2 used)
2- Pin 11-cap Screw
3-Lock Nut (2 used) 12- Boom Pivot Fig. ?-Stabilizer
4-Pivot Pin (2 used) 13-Bushlng (2 used)
~ap Screw 14-Dowel (2 used)
6-Grease Fitting (4 used) 15-Lock Washer (4 used)
7-Cap Screw 16-Spacer Ring
8-Pin 17-8haft Coupling (2 used)
9-Lock Nut 18-Cap Screw (4 used)
Fig. 6-Boom Pivot
9250 Backhoe
Refer to Figs. 7 through 9 during disassembly and
assembly of backhoe components. Refer to Fig. 4 for
repair of bucket.
1-Maln Frame 7-Cap Screw (2 used)

2-cap Screw (4 used) 8-Nut (2 used)
3-Stabilizer Cylinder 9-Lock Washer (2 used)
Pin (2 used) 1~Washer (4 used)
4-Lock Nut (4 used) 11-cap Screw (2 used)
5-Lock Nut (2 used) 12-Pivot Ferrule (2 used)
6-Stablllzer Pivot Pin 13-Pivot Pin (2 used)
(2 used) 14-Cotter Pin (2 used)
Fig. 8-Main Frame
Litho in U.S.A.
TM-1102 (Nov-13) Backhoe Frame, Boom and Bucket 40-5
10
26
28 27
~l J 25
u~~~~~~
~
22
T288?SN
1-Pin (2 used) 1 ~oom Assembly with Pivot 19-Pin

2-cap Screw (3 used) and Bushings 20-Dipper End
3-Lock Nut (4 uaed) 11-c&p Screw 21-Dipperstlck Bushing (2 used)
4-Cap Screw 12- Pin 22-Bucl<et Link (2 used)
~Pin 13-Pin 23-Grease Fitting
6-Lock Nut 14-Washer 24-Speciai Washer (4 used)
7-Bushlng (4 used) 1~Cap Screw 25-Cotter Pin (4 used)
a-Grease Fitting (4 used) 16-Wedge Bushing (2 used) 26--R.H. Driver Link
9-Bushlng Pivot Assembly 17- Tapered Pin 27- L.H. Driver Link
18-Dipperstick Assembly 28-Pin
Fig. 9-Boom and Dipperstick Assembly
Litho in U.S.A.
40-6 Backhoe Frame, Boom and Bucket TM-11 02 (Nov-73)
Backhoe Bucket Tooth Assembly

9300 Buckets and 9250
Heavy-Duty Buckets
T2~~14N
1- Tooth Tip 3-Fiex Pin

2- Tooth Shank
Fig. to- Tooth Assembly
To fasten the tooth tip to shank, drive the flex pin

in making sure that the half grooves face toward the
1-Pipe 4-Tapered Bushing
tooth tip as shown in Figure 10. The grooves are the 2-Cap Screw 5--Tapered Pin
locking mechanism . 3-Steel Plate
NOTE: If "back" is stamped on the pin, it should Fig. 11-Pu/ling Tapered Pins and Bushings
face toward the shank.
Removing And Installing Tapered Pins And Bush-

ings
The procedures for removing tapered pins and
bushings are as follows:
Remove cap screw (2. Fig . 11) from tapered pin

(5) .
Place a short piece of pipe (1) around the tapered

bushing (4). Lay a piece of steel plate (3) with a hole
in the center over the pipe (1 ). Insert a long cap
screw (2) through the hole in the steel plate (3).
IMPORTANT: To avoid damaging the threads in

the tapered pin, be sure several threads of the
cap screw are engaged sufficiently before apply-
ing force.
Screw cap screw (2) into tapered pin (5) until the
pin and bushing are pulled from the bore. 1-Pipe Spacer or Washers 3-Tapered Bushing
2-Cap Screw 4-Tapered Pin
F~g. 12-Removing Tapered Pins and Bushings
Whenever it Is not possible to remove tapered pins

and bushings by the method given at left, use the
second procedure outlined as follows:
Litho in U.S.A.
TM-1102 (Nov-73) Backhoe Frame, Boom and Bucket 40-7
Place a pipe spacer or washer (1, Fig. 12) be- C. Tighten bolts to full torque.
tween the cap screw (2) and tapered pin (4). This will
transfer the force applied at the cap screw to the ta- D. Repeat step B.
pered pin and not the bushing.
E. Check torque.
Tighten cap screw to standard torque.
F. Repeat steps B and C alternately until shocking
Strike head of cap screw to drive tapered pin and ing the assembly does not reduce the torque
bushing from bore. reading on bolts.
If neither of the above procedures will remove ta- G. Recheck for centered position.
pered pin and bushings, use both procedures simul-
taneously. INSTALLATION
Attach the pressure and return hoses to the back-
When installing tapered pins use the following pro-
hoe main frame at the quick disconnect couplers.
cedure:
Carefully raise the backhoe main frame with the
1. Before inserting pins and bushings, be sure
hydraulic system by extending the stabilizers.
bushing bores are clean, dry and unpainted.
Carefully back the crawler to align the mounting
2. Assemble parts loosely. Center pin assembly in bracket hooks with the lower pins on the backhoe
pin joint within 0.12 inch [3.05 mm].
main frame. Retract the stabilizers until the bottom
pins rest in the mounting bracket hooks on the crawl-
3. Tighten bolts as follows: er.
A. Tighten all bolts associated with the tapered pin Secure the top of each side of main frame to
assembly to a minimum of one-half the crawler with mounting pins and cotter pins.
standard torque.
B. Shock both wedge bushings with a brass, lead,

or aluminum hammer.
a. If the washers are accessible and large

enough, strike both washers in three places.
b. If the washers are not accessible or are too

small to strike directly, place a spacer over
the bolt head or bolt nut and strike the spac-
er three times.
NOTE: Do not pound on bolt head or nut.
Litho in U.S.A.
40-8 Backhoe Frame, Boom and Bucket TM-11 02 (Nov-73)
Litho in U.S.A.
Group 35
TRACKS
1 - Track shoe cap screws ............. 11 0 lb-ft torque
[ 15.21 kg-m]
5 2 - Rubber shoe width ..................................... 13 in.
[330.2 mm)
3 - Triple semi-grouser ...........................13 or 14 in.
[330.2 or 355.6 mm)
4 - Grouser or open center
grouser ........................... ............ 14, 16 or 18 in.
[355.6 or 406.4 or 457.2 mm)
5 - Notched grouser, open center.........14 or 16 in.
[355.6 or 406.4 mm)
6 - Grouser height.. .......................... 1.83 to 1.95 in.
[46.48 to 49.53 mm)
Wear tolerance ................... 0.78 in. [ 19.81 mm]
Track shoes per track (loader) ........................ 37
(dozer) ................. ........ 36
- Center of pin hole in link to center line of
T32412N bushing hole ..... ...................... 6.288 to 6.292 in .
Fig. 1-Track Shoes [ 159.72 to 159.82 mm)
2 - Link height .................................. 3.37 to 3.39 in.
[85.6 to 86.1 mm)
Wear tolerance ................... 3.22 in. [81.79 mm]
3 - Pin and bushing clearance (factory
parts) ...... 0.0035 to 0.0245 in. [.09 to .72 mm)
4 - Pin , dia. (replacement) (identify by
step on end) ................ ..... .. 1.3740 to 1.3790 in .
[34.9 to 35.03 mm )
Pin, dia. (factory) ................ 1.3715 to 1.3765 in.
[34.83 to 34.95 mm)
5 - Master pins, dia .................. 1.3680 to 1.3690 in .
[34.75 to 34.77 mm]
6 - Bushing outside dia. (replace-
ment) ................................... 2.0075 to 2.0085 in.
[50.99 to 51.02 mm)
Bushing outside dia.
(factory) ............................... 2.0055 to 2.0065 in.
[50.95 to 50.97 mm)
7 - Bushing inside dia. (replace-
Fig. 2-Track Chain ment) ....................................... 1.382 to 1.398 in.
[35.1 to 35.5 mm)
Bushing inside dia.
(factory) .. .. ............................... 1.380 to 1.396 in.
[35.1 to 35.46 mm)
8 - Diameter of pin hole in
link ............................. .. ........ 1.3660 to 1.3690 in.
[34.70 to 34.77 mm)
9 - Diameter of bushing hole in
link .................................. ..... 1.9985 to 2.0015 in .
[50.76 to 50 .84 mm]
10 - Pin boss clearance ............. 0.30 in. [7.62 mm 1
Litho in U.S.A. Wear tolerance ................... 0.00 in. [0.00 mm]
TRACKS
SPECIFICATIONS AND TORQUE VALUES-CONTINUED
- Track pitch .............. .......... 6.29 in. [159.77 mm]

Wear tolerance ...... ........... 6.45 in. [ 163.83 mm]
Fig. 3-Track Pitch
SPECIAL TOOLS
Essential Tools
Tool Tool No. Use
1 - Y-760* Owatonna Track Press - Track

disassembly and assembly
P31823 N
Fig. 4-Y760 and Tooling Set
J D268* Track Wear Gauge - Check track

component parts for wear
T32407N
Fig. 5-JD268 Wear Gauge
*Order from:
Service Tools, Inc.
1901 Indiana Avenue
Litho in U.S.A.
Crawl~r- JD450-C Miscellaneous Components 60
TRACK CARRIER ASSEMBL V

- Roller bracket-to-shaft outer

cap screw ............................................... 210 lb- ft
[29.03 kg-m] torque.
2 - Roller radius ................................3.59 to 3.62 in
(9 1.19 to 91 .95 mm)
Wear tolerance ................... 3.49 in . [88.65 mm)
3 - Roller shaft outside dia .....2.3745 to 2.3755 in.
[60.31 to 60.34 mm)
4 - Roller bushing inside dia ... 2.3785 to 2.3795 in.
[60.41 to 60.44 mm)
5 - Roller bushing location below face of
roller .................. ...................... 1/32-in. [. 79 mm]
6 - Roller rebuild lubrication ..... SAE 30 oil, approx.
3/ 8 pt. [170.1 g]
Fig. 6-Track Roller
1 - Track carrier roller flange

height ................................... 0.58 in [ 14.73 mm]
Wear tolerance ................... 0.64 in. [ 16.26 mm]
2 - Track carrier shaft outside
dia .................................. ... ...1.3745 to 1.3750 in.
(34.91 to 34.93 mm)
3 - Track carrier bushing inside
dia . ...... .................................... 1.377 to 1.379 in .
[34.98 to 35.03 mm]
4 - Track carrier roller shaft dimension above face
of seal bore ...................... 5.85 in. [148.59 mm]
5 - Track carrier roller rebuild
lubrication .. .................... ....... SAE 30 oil, approx.
1-1 / 2 pt. [510.3 g)
6 - Track carrier roller thrust plate attaching
cap screws ......................... .40 lb-ft [5.53 kg- m]
Fig. 7- Track Ca" ier Roller
Litho in U.S.A.
TRACK CARRIER ASSEMBLY

SPECIFICATIONS AND TORQUE VALUEs-CONTINUED
1 - Idler flange height ...... ................ 0.76 [ 19.3 mm]
Wear tolerance ................... 0.88 in. [22.35 mm]
2 - Idler bracket-to-shaft outer attaching cap
screw ................................ 21 0 Ib-It [29.03 kg-m)
3 - Idler shaft outside dia........ 2.6245 to 2.6255 in.
[66.66 to 66.69 mm)
4 - Idler bushing inside dia ..... 2.6285 to 2.6295 in.
[66.76 to 66.79 mm)
5 - Front idler bushing location below face of
front idler ................................. 1/32-in. [.79 mm]
4 6 - Front idler rebuild
lubrication ........ ..................... SAE 30 oil, approx.
'•' (i)q· @~/'

'@f ' : • 6 1-1 /2-pt. (680.4 g]
r..
I
fd
'132429N
Fig. 8-Front Idler
1 - Track idler recoil spring compression for

assembly (cap to cap) .......... 16 in. (406.4 mm]
T32430N
Fig. 9-Front Idler Recoil Spring
Litho in U.S.A.
TRACK CARRIER ASSEMBLY

- Rear crossbar cap to bracket ...... ......... 250 lb-ft

[34.56 kg-m)
T324 17N
Fig. tO-Rear Crossbar
SPECIAL TOOLS
Essential Tools
Tool Tool No. Use
JD268* Track Wear Gauge - Check track

system component parts for wear
T32407N
Ag. 11-JD268
T16678** Special Bolt - To compress track

idler recoil spring
r----- -----]
D ~-- -r------ *Order from:
Service Tools, Inc.
1901 Indiana Ave.
T32432H
Chicago, Iff. 60616
Fig. 12-T16678
**Order from your John Deere dealer.
Litho in U.S.A.
TRACK CARRIER ASSEMBLV

SPECIAL TOOLS-CONTINUED
Tool Tool No. Use
JD284* Track Ad juster Tool Set- to install

piston seals, oil seals and piston
in track tension adjuster cylinder.
1 - JD284-1 * Seal Installation Tool - To install

piston seal.
2 - JD284-2* Dust Seal Driver - To install oil

seal.
3 - JD284-3* Piston Guide - To install piston in

cylinder.
Fig. 13-JD284
Track Roller Installation Tool -

To install roller in track carrier.
This tool is used with a large floor jack with lift pad
removed . To make the tool, weld two quarter-inch
rods or angle irons {2, Fig. 14), approximately 24
inches long, to a pulley (3) that has a flange that will
fit into the jack lift pad hole. A 2010 Crawler crank-
shaft pulley is suggested as sufficient size.
Weld a rod {6) across the top of the quarter inch

T2832SN rods or angle irons (opposite end of pulley) to pre-
1- Track Roller 4-Weld vent roller from sliding off. Rods or angle irons
2-Rods or Angle Irons 5-Modified Floor Jack should be placed close enough together to prevent
3-Pulley 6-Rod roller from falling through.
Fig. 14- Track Roller Installation Tool
*Order from:
Service Tools, Inc.
1901 Indiana Avenue
Litho in U S.A.
WINCH SYSTEM
1. Distance bearing cone protrudes over ecge of

winch drum...1/ 16-inch [1 .587 mm].
2. Distance needle bearing is pressed in from left

end of winch drum . .. 1/ 4-inch [6.350 mm].
T32536N
Fig. 15-Bearings Assembled On

Winch Drum
1. Distance bearing cup is pressed in below shim

surface of right quill... 1/ 8-inch (3.175 mm].
T27917N
Fig. 16-Bearing Cup Assembled

In Right Bearing and Seal Quill
1. Snug cap screw using a criss-cross pattern to 5

lb-ft [0.69 kg-m].
ft4
.y
O 0
T27918N
1
Tighten cap screw using a criss-cross pattern to
30 lb-ft [ 4.15 kg-m].
Retighten cap screws to 30 lb-ft [ 4.15 mm).
Fig. 17-Diaphragm-to-Ciutch Cover Torque Allow clutch cover assembly to set for 30 minutes
and retighten cap screws to 30 lb-ft [4.15 kg-m].
Litho in U.S.A.
WINCH SYSTEM
Winch housing-to-steering clutch
housing .................................. 150 lb-ft [20.74 mm]
Fig. 18-Winch housing torque
1 - Pinion shaft nut.. ....................... 100 to 125 lb-ft

[13.83 to 17.28 kg-m]
T32437N
Fig. 19-Pinion Nut Torque
Litho in U.S.A.
WINCH SYSTEM
Fig. 20-Cross Section View of Assembled Winch
1. Winch drum bearing adjustment.. ............ 0.001 to 5. Location of number etched on the end of the pin-
0.005-inch preload [0.02 to 0. 13 mmJ. ion shaft that is to be added to the mean dimen-
sion of the output shaft rear bearing cup and cone
2. Ring gear and pinion backlash adjustment.. ........ for cone point adjustment.
0.006 to 0.012 inch [0.15 to 0.30 mm].
6. Mean dimension of output shaft rear bearing cup
3. Input shaft bearing adjustment.. ... 0.002 to 0.004 and cone for cone point setting ........... 1.1 93 inch
inch preload [0.05 to 0.10 mm]. [30.30 mm].
4. Pinion shaft bearing adjustment... 0.004 to 0.006 7. Location of number in right quill bore that is to be
inch preload [0.1 0 to 0. 15 mm]. subtracted from 5 and 6.
8. Location of shims for cone point adjustment.
Litho in U.S.A.
45-1 0 Specifications and Special Tools TM-1102 (Nov-73)
WINCH SYSTEM
1 - Distance between bottom edge of spring
anchor pin and bottom spring hook edge of
spring anchor ............ 4-1 1/16 inch [ 119.06 mm)
Rg. 21 -Brake Band Adjustment
SPECIAL TOOLS
Convenience Tools
Tool Tool No. Use
630-17* Driver - To press bearing cone on

main drive shaft
t--- 3 - l/2 " --~
630-11 * Driver (Not illustrated) - To press

oil seal in input shaft quill
T 2 7 920N
Fig. 22·630-17
* Order from :
Service Tools, Inc.
1901 Indiana Avenue
Litho in U.S.A.
WINCH FAIRLEAD ASSEMBLY

SPECIAL TOOLS
Convenience Tools Tool No. Use
630-13* Driver - To press bushings in fair

lead rollers
* Order from :
Service Tools, Inc.
1901 Indiana Avenue
Chicago, Illinois 606 t 6
LUMBER FORK AND PULPWOOD LOADER

Clamp support to frame (lower cap

screws) ... ......... .. ............ ....... 670 lb-ft [92.63 kg-m]
T32439N
Fig. 23-Lumber Fork Torque
Litho in U.S. A.
Litho in U.S.A.
Crawler - JD450-C System Testing 70
TM-1102 (Nov-73) General Information 5-1
Section 70
SYSTEM TESTING
Page page
GROUP 5 - GENERAL INFORMATION - GROUP 25 - HYDRAULIC SYSTEM
SEVEN BASIC STEPS OF General Information .......................................... 25-1
DIAGNOSIS AND TESTING .......... 5-2 Diagnosing Malfunctions ................................... 25-8
Testing and Adjustment... ............................... 25-11
GROUP 10 - ENGINE
General Information .......................................... 10-1 GROUP 30 - MISCELLANEOUS COMPONENTS
Diagnosing Malfunctions ................................... 10-3 Adjustment .........................................................30-1
Visual Inspection ............................................... 10-6
Testing and Adjustment.. .................................. 10-8 GROUP 35 - SPECIFICATIONS AND
SPECIAL TOOLS
GROUP 15 - ELECTRICAL SYSTEM Engine ................................................................35-1
General Information .......................................... 15-1 Electrical System ............................................... 35-6
Visual Inspection ............................................... 15-5 Power Train .....................................................35-11
Diagnosing Malfunctions ................................... 15-6 Hydraulic System ............................................ 35-13
Testing and Adjustment.. ................................ 15-12 Miscellaneous Components ............................ 35-1 6
GROUP 20 - POWER TRAIN

General Information ..........................................20-1
Diagnosing Malfunctions ...................................20-7
Visual Inspection ...............................................20-9
Testing and Adjustments ................................ 20-10
Litho in U.S.A.
70 System Testing Crawler - JD450-C
5-2 General Information TM-11 02 (Nov-73)
Group 5
GENERAL INFORMATION
SEVEN BASIC STEPS OF DIAGNOSIS AND TESTING
To prevent the unnecessary loss of time and mon- 4. Inspect The Crawler
ey, use the following seven steps for a quick and ac-
Get off the crawler and make a visual check. Use
curate method of locating crawler troubles:
your eyes, ears, and nose to spot any signs of
trouble.
1. Know The Crawler
In other words, "Do your Homework." Study this Look closely at the components. Inspect for
manual to know how the individual components work cracked welds, loose tie bolts, damaged linkages,
and what their function is in the over-all system. worn or broken lines, etc.
Keep up with the latest service information. Infor-
During the inspection, make a note of all the trou-
mation received today may have the cause and rem-
ble signs.
edy of a problem being encountered.
2. Ask The Operator 5. List The Possible Causes

With the information obtained during steps 1
Question the operator as to how the crawler acted
through 4, make a list of the possible causes.
when it started to fail. Find out what was unusual
about it.
What were the signs you found while inspecting
Also find out if any do-it-yourself service was per- the crawler? What is the most likely cause?
formed. (You may find out later that the trouble is
somewhere else, but you should know if any compo- 6. Reach A Conclusion
nents were tampered with.)
Look over the list of possible causes and decide
Ask how the crawler is used and when it is serv- which are most likely and which are easiest to verify.
iced. Many problems can be traced to poor mainte-
nance or abuse. "Diagnosing Malfunctions" given in the following
groups will be a helpful guide.
3. Operate The Crawler
Reach your decision on the leading causes and
Get on the crawler and operate it. Warm it up and
plan to check them first.
put it through its paces. Don't completely rely on the
operator's story - check it yourself.
7. Test Your Conclusion
Are the gauges reading normal? (If not, it may be Before repairing components in the system, test
that the component being monitored is not function- your conclusions to make sure they are correct.
ing correctly or it may mean that the gauge is faulty.
How's the performance? Is the action slow, erratic, Some of the possible causes can be verified with-
or nil? out further testing. Check these possibilities first.
Do the controls feel solid or "spongy"? Do they
Tests will soon narrow the remaining list of possi-
seem to be "sticking"?
ble causes and soon the actual source of trouble will
Smell anything? Any signs of smoke? be pin pointed.
Hear any funny sounds? Where? At what speeds
With the trouble accurately located, it is now a
or during what cycles?
simple matter to remove and repair the component at
fault.
Litho in U.S.A.
TM-1102 (Nov-73) Engine 10-1
Group 10
ENGINE
GENERAL INFORMATION
Basic Engine Engine Cooling System

The JD450-C Crawler has a 4 cylinder 219 cubic The components of the cooling system are the ra-
inch [3688.9 cm 3 ] diesel engine. diator, water pump, fan and thermostat and housing.
The engine is a valve in-head vertical in-line four The radiator is equipped with a pressure cap which
cycle engine. The engine consists of a lubrication acts as a relief valve to keep pressure at a specified
system, cooling system, fuel system and air intake level in the system.
system.
The water pump draws coolant from the radiator
Engine Lubrication System and sends it into the coolant gallery and engine oil
cooler. Coolant from the gallery circulates through
The components of the lubrication system are the
the engine to cool the block, cylinder liners, and
oil pump, oil filter, oil pressure regulating valve and
head, and then flows into the water manifold into the
oil cooler.
thermostat housing. The coolant going to the engine
oil cooler flows through the cooler then back to the
The oil pump draws lubricant from the oil pan
intake area of the water pump.
through a system of gears and sends it through an
internal passage to the oil cooler.
If the thermostat is closed (as during engine warm-
As the oil moves through the cooler the tempera- up) the coolant is sent directly to the water pump for
recirculation and bypasses the radiator. This allows a
ture is lowered by engine coolant flowing through the
cooler. The oil then goes to the oil filter. faster and more uniform warm up.
The oil filter is a spin on replaceable element

Fuel System
which mounts on the oil cooler. The filter removes The components of the fuel system are the fuel
contaminants from the engine oil. From the filter the tank, fuel supply pump, the fuel filter, the fuel injec-
oil goes to the oil pressure regulating valve. tion pump and the fuel injection nozzles.
The oil pressure regulating valve is used to main- The fuel tank has a strainer in the tank neck and a
tain and regulate oil pressure. From the regulating small finger shaped filter and a fuel shut-off valve lo-
valve the oil goes to the oil gallery and turbocharger. cated near the bottom of the tank.
The fuel supply pump operates off a cam lobe of

the camshaft. It draws fuel from the tank and delivers
it to the fuel injection pump through the fuel filter.
The filter removes impurities from the fuel before it

enters the injection pump.
The injection pump pressurizes the fuel and sends

it through high pressure lines to the injection nozzles.
The injection nozzles open when the fuel reaches

a specified level and inject the fuel into the combus-
tion chambers.
Litho in U.S.A.
10-2 Engine TM-11 02 (Nov-73)
Air Intake System Speed Control Linkage

The components of the air intake system are the The speed control linkage consists of the hand and
air cleaner and an optional turbocharger. foot throttles and various linkages which are connect-
ed to the injection pump. Through common move-
Air enters the air cleaner. The two air cleaner element of the throttles and linkages speed control is
ments remove impurities from the ambient air. The maintained.
air cleaner has a restriction indicator switch which
warns the operator of excessive restriction in the
system.
The turbocharger receives air from the air cleaner,

pressurizes it and sends it through the intake mani-
fold to the combustion chambers. During engine op-
eration, exhaust gases enter the turbine housing of
the turbocharger rotating the turbine wheel and com-
pressor. The compressor draws in and compresses
ambient air. As engine speed increases, the flow of
exhaust gases increases, and the speed of the rotat-
ing assembly increases, thus the amount of air enter-
ing the intake manifold.
The turbocharger is lubricated by engine oil from

the oil gallery.
Litho in U.S.A.
TM-1102 (Nov-73) Engine 10-3
DIAGNOSING MALFUNCTIONS
Engine Will Not Start or Engine Misses

Starting Hard
Basic Engine Malfunction
Fuel System Malfunction Weak valve springs
Fuel tank empty Incorrect valve clearance
Improper type of fuel Burned, warped, pitted or sticking valves
Foreign material in fuel Low compression
Fuel lines clogged or restricted Worn camshaft lobes
Air leak on suction side of fuel system Engine overheating
Fuel transfer pump malfunction Fuel System Malfunction
Fuel filter restricted Water, air or dirt in fuel
Restricted air intake system Faulty injection nozzles
Faulty injection pump Faulty injection pump
Faulty injection nozzles Faulty transfer pump
Water, dirt, or air in fuel system Detonation
Electrical System Malfunction Mixture of gasoline and diesel fuels
Corroded or loose battery cables
Weak or dead battery Lack of Power
Cranking speed too slow
Basic Engine Malfunction
Uneven Running or Frequent Blown cylinder head gasket
Stalling Worn camshaft lobes
Incorrect valve clearance
Basic Engine Malfunction Incorrect valve timing
Improper valve clearance Burned, warped, pitted, or sticking valves
Cylinder head gasket leaking Weak valve springs
Valves sticking or burned Low compression
Worn or broken compression rings Dirty air intake system
Low compression Incorrect timing
Incorrect timing Engine overheating
Dirty air intake system Fuel System Malfunction
Exhaust system restricted Improper type of fuel
Engine overheating Air leak on suction side of fuel system
Fuel System Malfunction Fuel line clogged or restricted
Improper type of fuel Fuel transfer pump malfunction
Air leak on suction side of fuel system Speed control linkage not adjusted properly
Fuel line clogged or restricted Fuel filter restricted
Fuel transfer pump malfunction Fuel injection pump malfunction
Fuel filter restricted Fuel injection nozzle faulty
Faulty injection pump Water, dirt or air in fuel system
Faulty injection nozzles Injection nozzle leak-off line clogged
Water, dirt, or air in fuel system Injection pump out of time
Injection nozzle leak-off lines clogged Clogged manifold system
Injection pump out of time
Exhaust system restricted
Litho in U.S.A.
10-4 Engine TM-11 02 (Nov-73)
Black or Gray Exhaust Smoke Abnormal Engine Noise
Basic Engine Malfunction Basic Engine Malfunction

Incorrect engine timing Excessive valve clearance
Engine overloaded Worn cam followers
Restricted air cleaner Bent push rods
Defective muffler Worn rocker arm shafts
Dirty air intake system Worn main or connecting rod bearings
Fuel System Malfunction Foreign material in combustion chamber
Improper grade of fuel Worn piston pin bushings and pins
Excessive fuel delivery Scored piston
Faulty injection nozzles Incorrect engine timing
Injection nozzle leak-off line clogged Excessive crankshaft endplay
Injection pump out of time Loose main bearing caps
Worn timing gears
White Exhaust Smoke Worn oil pump gears
Broken oil pump shaft
Basic Engine Malfunction Low engine oil level
Low compression Camshaft oil pump gear worn or broken
Fuel System Malfunction Gears worn or broken
Faulty injection nozzle Turbocharger bearing failure
Improper fuel
Injection pump out of time Excessive Oil Consumption
Slow Acceleration Basic Engine Malfunction

Restricted crankcase breather
Fuel System Malfunction Worn valve guides or valve stems
Faulty injection nozzle Piston rings worn or broken
Improper fuel Scored liners or pistons
Excessive ring groove wear in piston
Detonation Rings sticking in grooves of piston
Oil return slots in piston clogged
Fuel System Malfunction Insufficient piston ring tension
Injection pump out of time Piston ring gaps not staggered
Faulty injection nozzles Excessive main or connecting rod bearing clear-
ance
Worn crankshaft thrust bearing (misaligned pis-
ton and rod)
Front or rear crankshaft seal faulty
Crankcase oil too thin (wrong viscosity)
Oil level too high
Restricted air intake system
Litho in U.S.A.
TM-1102 (Nov-73) Engine 10-5
Low Oil Pressure Water Pump Leaks
Basic Engine Problem Basic Engine Malfunction

Excessive main and connecting rod bearing Worn seal and/or shaft in water pump
clearance Worn or broken water pump gasket
Low oil level Water pump damaged
Leakage at internal oil passages Water pump impeller broken
Faulty oil pump
Improper regulating valve adjustment Engine Runs Cold
Improper oil (wrong viscosity)
Defective oil pressure indicator light Basic Engine Problem
Faulty thermostat
High Oil Pressure Defective temperature gauge
Basic Engine Problem Water Pump Making Noise

Stuck regulating valve
Regulating valve spring worn or broken Basic Engine Malfunction
Worn water pump shaft
Engine Overheats Water pump impeller broken
Bent or broken fan blade
Basic Engine Malfunction Loose fan belt
Defective head gasket Fan hitting
Incorrect engine timing
Low coolant level Oil in Coolant or Coolant in
Radiator dirty or plugged Crankcase
Loose or broken fan belt
Faulty thermostat Basic Engine Malfunction
Cooling system limed up Leaking head gasket
Defective radiator pressure cap Cylinder liner packings leaking
Faulty water pump Cylinder block water jacket cracked
Scored piston Cylinder liner cracked
Air in coolant
Engine overloaded
Crankcase oil level low
Fuel System Malfunction
Improper fuel
Excessive fuel delivery
Improper injection pump timing
Litho in U.S.A.
10-6 Engine TM-1102 (Nov-73)
VISUAL INSPECTION
By visually inspecting the engine before you tune Fan Belt

it, you can learn a lot about its general condition.
The fan belt should be neither too tight nor too
loose.
For example, if the engine has been using too
much oil, this often means an external oil leak. If the
A belt which is too tight puts extra load on the fan
engine overheats, look for leaks in the cooling sys-
bearings and shortens the life of the bearings as well
tem.
as the belt.
Oil and Water Leakage
A belt which is too loose allows slippage and low-
Look for water leaks at the radiator, water pump, ers the fan speed, causes excessive belt wear and
and hoses around the cylinder head gasket and wa- leads to overheating of the cooling system.
ter manifold.
The condition of the belts and their tension should
Check coolant for proper level and examine visible be checked periodically. Adjust fan belt tension as
portion inside top of radiator for evidence of rust or shown in 'Testing and Adjustments" in this group.
scale.
Fuel Tank
Check crankcase oil level and for coolant in oil.
Check all seams and connections for fuel leakage.
Look for oil leaks at the oil pan, drain plugs and
gaskets.
Fuel Supply Pump
Check fuel inlet and outlet connections for leaking
Hoses fuel.
Inspect upper and lower radiator hoses and by-
pass hose for hardening or cracking, and softening
Fuel Injection Pump
and swelling. Examine hoses at least twice a year for CAUTION: Escaping diesel fuel under
possible replacement and tightening. A pressure can have sufficient force to pen-
etrate the skin causing serious personal injury.
Oil Cooler Fuel escaping from a very small opening can
be almost invisible. Use a piece of cardboard or
Check around base of cooler for oil leakage.
wood, rather than a hand, to hold near connec-
Check water inlet and outlet for leakage.
tions to check for fuel leaks.
If injured by escaping fuel, see a doctor at
Radiator
Inspect the radiator for bent fins, kinks, dents, frac- proper medical treatment is not administered at
tured seams, and tubes for cracks. once.
Fan Check fuel inlet and outlet connections and high

pressure fuel supply connections. If any of the lines
The only service on the fan is to be certain the fan
are twisted, kinked or broken, repair or replace as
blades are straight and are far enough from the radi-
necessary.
ator so they do not strike the core.
Bent blades reduce the efficiency of the cooling

system and throw the fan out of balance.
Litho in U.S.A.
Crawler - J0450-C System Testing 70
TM-1102 (Nov-73) Engine 10-7
Fuel Filter Air Cleaner

Check fuel inlet and outlet connections. Check ele- Check all air intake and outlet connections to be
ment cover daily for deposits. Clean if necessary. sure they are tight. Check level of dirt in pre-cleaner
Replace filter element as required. and empty if necessary. Check air restriction indica-
tor daily. Clean element when indicator shows red
Be sure primer lever is in its farthest downward with engine shut off, or when excessive smoke or
position. loss of power is noted.
Fuel Injection Nozzles Replace air cleaner elements every 1000 hours.
h CAUTION: Escaping diesel fuel under Turbocharger
. . pressure can have sufficient force to pen-
etrate the skin causing serious personal injury. Check all air inlet and outlet connections and all
manifold and turbocharger gaskets. Be sure oil inlet
Fuel escaping from a very small opening can and drain lines are not twisted, kniked, or broken.
be almost invisible. Use a piece of cardboard or Replace or repair as necessary.
wood, rather than a hand, to hold near connec-
tions to check for fuel leaks. Be sure there is no strain on the connector be-
tween the turbocharger and intake manifold.
If injured by escaping fuel, see a doctor at
proper medical treatment is not administered at
once.
Check each delivery and leak-off line. Repair or

replace lines if necessary.
Litho in U.S.A.
10-8 Engine TM- 1102 (Nov-73)
TESTING AND ADJUSTMENT
Basic Engine Engine Lubrication System

Compression Pressure Test Checking Engine Oil Pressure
Engine oil pressure should be checked before and
1 - Clean t he eng ine thoroughly , preferably by
after a major overhaul or anytime it is necessary to
steam cleaning.
remove the oil pump.
2 - Warm the engine to operating temperature.
3 - When engine has reached operating tempera-

ture, turn ignition switch off.
Disconnect the electrical solenoid shut-off wire

from the injection pump. This will keep the injection
pump from pumping fuel under high pressure to the
nozzles during the test.
h CAUTION: The above step is Important

. . because fuel under high pressure from
the injection will have sufficient force to pene-
trate skin. Do not, at any time, while the engine is
cranking , place hands or arms In front of the in-
jection nozzles.
Fig. 1-0i/ Pressure Test Connection Point
Remove all four injection nozzles and seal gaskets
from the head (see Section 20). To check oil pressure, remove oil pressure indica-
tor switch f rom engine. Connect an oil pressure
Clean the injection bores. Blow loose carbon out gauge at area shown in Fig . 1.
with compressed air.
With engine at normal operating temperature and
Install a 70-314 Compression Gauge Adapter in running at 2500 rpm, oil pressure reading should be
bore to be tested. A new seal gasket should be in- 45 to 65 psi [3 .16 to 4.56 kg /em~ .
serted before the adapter is installed.
Connect a 70-7003 Compression Gauge to the

adapter.
Crank engine at approximately 200 rpm with the

starting motor.
Observe the pressure reading on the compression

gauge. The reading should be 300 psi [2 1.09 kg/
em~ for diesel.
Litho in U.S.A.
TM- 1102 (Nov- 73) Engine 10-9
Adjusting Engine Oil Pressure Engine Cooling System

Under normal conditions, there should be no need Since efficient operation of pressure cooling de-
to adjust engine oil pressure. pends on a system that is free from leaks, the entire
cooling system should be tested prior to servicing.
If an adjustment is necessary, use the following
procedure : Checking Radiator for Leaks
Install a pressure tester on the radiator according
To increase pressure, with a large alum inum
to the manufacturers instructions.
washer under the head of the regulating valve plug ,
insert small shims in the counterbore of the plug (to-
tal not to exceed four) until oil pressure of 45 to 65
psi [3.16 to 4.57 kg/cm2 ] at 180° to 220°F. [82.2° to
104.4° C.] is reached.
TJ26 61N
1-Valve Plug 4-Regulatlng Spring

2-Aiuminum Washer 5-Regulating Valve
Fig. 3-Testing Radiator
3-Adjustlng Shim (if used)
Fig. 2-0il Pressure Regulating Valve Assembly With the tester installed, carefully inspect the radi-
ator, water pump, hoses, drain cocks and cylinder
To decrease pressure, remove any adjusting shims block for leakage.
from counterbore of valve plug. To further decrease
pressure, add a second large alum inum washer un- Mark all leaks plainly to help locate them when
der head of plug. repairing.
If you cannot find any leaks but leaking persists,

remove the radiator and test as described in Section
20, Group 20.
For additional information on testing and
E] maintai ning the cooling system refer to

" Cooling System" in FOS Manual - En-
gines.
Litho in U.S.A.
10-10 Engine TM- 1102 (Nov- 73)
Fan Belt Tension Adjustment Fuel System

A CAUTION : Live sparks, smoking or fire of
.._ any nature should not be permitted when
testing the fuel system.
Fuel Supply Pump Pressure Test
Fig. 5-Fuel Supply Pump Pressure Test Connection Point
1- Aiternator Bracket 2- Belt Tension Gauge Tee a low-pressure gauge (0 to 100 psi) [0 to 7.0
Fig. 4-Checking Fan Belt Tension kg/cm2 ] between the fuel supply pump and fuel line
to fuel filters.
Adjust fan belt tension by loosening the alternator
bracket and adjusting cap screws and apply outward Start the engine. Let it run at low idle and observe
pressure to the front alternator frame to determine if the low pressure gauge . Read ing on the gauge
the fan belts are adjusted properly, apply approxi- should be 2 to 2.5 psi [0.14 to 0.17 kg/crrr].
mately 20 pounds [9.072 kg] of force on the belt with
the thumb about midway between the pulleys. The Remove pressure gauge and connect fuel line to
belt deflection should be 0.75 inch [ 19.05 mm ]. supply pump alter test has been completed .
More consistent belt tension will result and the

belts will last longer if the tension is set with a belt
tension gauge. When a belt tension gauge is used ,
the initial reading should be 100 to 110 pounds [ 45.4
to 49.9 kg] strand tensions. After 3 minutes of opera-
tion recheck the belt tension. The gauge should read
a minimum of 80 pounds [36.29 kg] strand tension.
Litho in U.S.A.
TM- 1102 (Nov-73) Engine 10-11
Adjusting Injection Pump Cam Advance 4 - Check cam advance according to following spec-
ifications:
1 - Be sure Injection pump is static timed to engine
(see Group 15. Section 20).
JDB435AL2442
Total advance movement ....................... 7° ::t: 1/2°
2 - Remove timing hole cover and install timing win-
Advance at 1900 rpm
dow (JD259-13366).
(full load) ............................... so (check so ::t: 1°)
Advance at 1100 rpm (no load) .......................... 4°
Note the location of the cam timing line. Due to
Advance by 2SOO rpm (full load) ........ 6-1/2° min.
slight variations in windows and hole locations, cam
line may not be exactly behind window line. Adjust
NOTE: Marks on timing window are two pump de-
timing window to get best possible line up.
grees apart.
S - If cam advance must be adjusted loosen lock nut

and turn advance trimmer screw.
Turn screw in {clockwise) to retard timing; turn

screw out (counterclockwise) to advance timing.
6 - Secure trimmer screw with lock nut and install

seal cap.
7 - Remove timing window and install timing hole

cover.
1-Timing Window 3- Advance Trimmer Screw

2- Lock Nut 4-Seal Cap
Fig. 6-Adiusting Cam Advance
3 - Bring engine to operating temperature.
Litho in U.S.A.
10-12 Engine TM-1102 (Nov-73)
Speed Control Linkage

Repair
Refer to Fig. 7 for relative position of speed control
linkage parts.
Inspect linkage for bent or cracked rods and arms.
Examine linkage for binding, looseness, and any

condition that might cause poor engine performance.
T20940N
1-Hand Throttle Lever 5-Adjustable Yoke &-Adjustable Yoke

2-Lever-to-Bell Crank Link 6-Speed Control Cable 9-Pump Slow-Idle Stop Screw
3--Frlction Adjusting Nut 7- Bracket 10-Pump Fast-Idle Stop Screw
4-Bell Crank
Fig. 7-Speed Control Linkage
Litho in U.S.A.
TM- 11 02 (Nov- 73) Engine 10-13
Speed Control Adjustments Air Intake System

Make all speed control adjustments in the exact Intake Manifold Vacuum Test
order given here. Refer to Fig. 7 as a guide to ad-
Remove pipe plug from intake manifold (see Fig.
justing points.
7).
IMPORTANT: Be sure engine is at operating
temperature before making speed adjustments.
Use a master tachometer. All speeds given are
for engine at no load.

pump arm . Loosen cable clamp (7).
2. Run engine and rotate pump throttle arm until

fast-idle stop screw (10) contacts its stop. Engine
speed should be at fast idle of 2650 rpm . If not, ad-
just pump stop screw (1 0) to correct. Lock screw with
sealing wire.
3. Lightly rotate pump throttle arm to slow-idle po-

sition. Engine speed should be at slow idle of 800
rpm . If not, adjust slow-idle stop screw (9) on top of
injection pump.
4. With speed control cable disconnected, move

Fig. 8-Pipe Plug in Intake Manifold
hand lever forward to the high idle position . Adjust
cable yoke (8) to provide for 1/8-inch [3.175 mm] Install a mercury vacuum gauge to intake manifold.
overtravel of the pump arm. (For more travel, adjust Run engine at 2650 rpm high idle. The gauge should
cable at yoke (5) under dash.) Check slow idle. read 15 to 20 inches [381 to 508 mm] of mercury.
5. Move hand throttle fully rearward and turn off Shut off engine and remove gauge. Apply perma-
ignition. tex to threads of pipe and reinstall in intake manifold.
6. Move hand throttle bacll; and forth to check fric-
tion on lever. Check for 5 to 11 lbs . [2.3 to 5.0 kg]
drag with a spring scale. Adjust, if necessary, at nut
(3) .
Litho in U.S.A.
10-14 Engine TM-11 02 (Nov- 73)
Testing Air Restriction Indicator Install a 'T' fitting into restriction indicator. Install
restriction indicator on one end of "T" and JDST-11
Remove right engine side shield from unit. Re-
water vacuum gauge on other end.
move air restriction indicator (Fig. 8).
Start the engine and slowly cover air intake pipe.
Observe reading on water vacuum gauge. Restriction
indicator should show red when water vacuum gauge
reads 14 to 25 inches [355.6 to 635 mm] of water.
Remove water vacuum gauge, restriction indicator

and " T" fitting. Install indicator and side grille.
Fig. 9-Air Restriction Indicator
Litho in U.S.A.
TM-11 02 (Nov- 73) Electrical System 15-1
Group 15
ELECTRICAL SYSTEM
GENERAL INFORMATION Starting Circuit
This group contains trouble shooting tips, wiring The starting circuit consists of the batteries, start-
diagrams and test specifications necessary to locate ing motor with solenoid switch, start-safety switch,
trouble in the system. By following the tests as given, start switch, key switch, ammeter, circuit breaker and
the faulty component may be located and removed connecting wires.
for further testing, repair, or replacement.
Tests and service instructions for system compo-

nents, when removed from the unit, are provided in
Section 30.
A 12-volt negative system is used to supply the

electrically-operated components of this unit. Current
is supplied by two 12-volt batteries connected in par-
allel for cranking the engine and operating the acces-
sories when the engine is not running. -,
I
The electrical system is a combination of four elec- \
tric circuits: the charging circuit, the starting circuit, 0 : 1
accessory circuit and lighting circuit.
""'
Batteries
'---JL1..:I ______
' ____ J( /J
TJ1 OON T 10
The batteries are the heart of the electrical system.
During operation , the storage batteries function as an
1- Shift Lever 7-Battery Terminal
electrochemical device for converting chemical ener- 2-Piunger 8- Motor Terminal
gy into electrical energy required for cranking the en- 3-Solenold 9- Battery Posltlve Cable
gine or operating the accessories when the engine is 4-Hold-ln Winding 10-Starting Motor
shut-down. 5-Pull-ln Winding 11-0verrunning Clutch
6-Key Switch 12-contact Disk
The batteries do not actually store electricity as is Fig. 1-So/enoid Circuit
commonly believed, but it does convert electricity into
chemical energy which is stored until the battery is When the key switch is turned to the "start" posi-
converted to an external circuit, at which time the tion and the start switch is pressed, the battery cur-
chemical energy is transformed back into electrical rent flows into the hold-in winding and also to the
energy and current flows through the circuit. armature coils through the pull-in and field windings,
and brushes.
For good operation , the batteries must do three
jobs: Then the plunger is pulled in by means of magnet-
ic pull produced by pull-in and hold-in windings, and
1. Supply current for starting the engine. the overrunning clutch is pushed out on the armature
shaft by the drive lever to engage the pinion with the
2. Supply current when the demand excee:ls the flywheel ring gear. At this time. the pinion is partially
output of the charging system. engaged with the ring gear before the contact plate
closes between the contacts.
3. Stabilize the voltage in the system during oper-
ation.
Litho in U.S.A.
15-2 Electrical System TM-1102 (Nov-73)
When the contacts are fully closed, a huge battery The charging system consists of the batteries, al-
current flows directly into field windings and to the ternator, regulator, ammeter, starting motor, key
armature coils through the contact plate, and ener- switch and connecting wires.
gizes the armature to spin creating a large torque.
This pushes the clutch pinion further to engage com- The purpose of the charging circuit is to provide
pletely with the ring gear. As the armature rotates, operating power when the machine is running and to
the overrunning clutch also rotates, and the rollers keep the batteries fully charged.
between the clutch shell and pinion collar are moved
into the narrower portion of the notches in the shell. The alternator is an electric generator that pro-
This action locks the pinion to the armature shaft and duces alternating current. An alternator has a high
permits the transfer of torque to the pinion for engine current output at low speeds.
cranking.
In an alternator, the magnetic field of the rotor is
Once the solenoid switch plunger is pulled in, less moved across stationary conductors in the stator.
magnetism is needed to hold it in. Thus the pull-in This permits permanent connection between the sta-
winding is shorted with the contact plate, and only tor windings and the output terminal. Slip rings are
the hold-in winding operates to hold the plunger in used to transmit the field current to the rotor field
place as long as the start switch remains closed. winding.
Once the engine has started, the flywheel gear will The alternator produces power in the form of three
tend to drive the armature through the pinion faster phase alternating current and voltage. The alternat-
than the armature is running. The pinion, rotating ing current is rectified to direct current by a three
faster than the clutch shell, turns the rollers back into phase full wave rectifier circuit using six silicon recti-
the larger portion of the notches against spring ten- fier diodes. Since the diode will pass current in only
sion. This permits the rollers to unlock and turn freely one direction (from alternator to battery or load), the
so that the pinion will overrun the clutch shell but not alternator does not require the use of a cutout relay.
drive the armature.
The alternator output current is controlled by the
With the start switch released after engine starting current flow through the field coil (rotor). The amount
the current flows from the contact plate to both the of current required is determined and controlled by
pull-in and hold-in windings in the same direction. As the regulator. Since there is very little residual mag-
these windings are wound to have their magnetic netism in the alternator, it is necessary to supply a
fields act in opposite directions so that they cancel small amount of excitation current to the field (rotor)
each other. The plunger returns to the rest position to start the process of current generation. The excita-
by means of the return spring, demeshing the pinion tion resistor supplies this starting current when the
from the flywheel. key switch is turned on. This resistor is enclosed in
the sealed regulator case. Once the alternator is ex-
For additional information on starting cir- cited, a voltage is developed at the regulator terminal
EJ a
cuits, refer to "Starting Circuits" in FOS
Manual - ELECTRICAL SYSTEMS.
Charging Circuit
and the voltage regulator takes over control of the
system voltage.
The regulator features a silicon controlled rectifier

as the current controlling device for the field. There is
no isolation diode or reed switch used to isolate the
For information on fundamentals of an al-
EJ
regulator from the batteries when the engine is not
ternator charging circuit, refer to "Charging
running.
Circuits" in FOS Manual - ELECTRICAL
SYSTEMS.
Litho in U.S.A.
TM-11 02 (Nov-73) Electrical System 15-3
The following is the operation of the regulator. With key switch on, engine running and output
voltage is below 14.4 volts.
During each positive half cycle of the stator wind-

ing, current flows from the "STA'' terminal through a
slip ring , the rotor, another slip ring and the silicon
controlled rectifier. Some current also flows into the
field compacitor, charging it. Current from the key
switch flows through the bias resistor and the silicon
controlled rectifier as gate current.
During each negative half cycle of the stator the

silicon controlled rectifier does not conduct. However
the field capacitor discharges keeping current flowing
in the same direction through the field windings.
With key switch on , engine running and output

voltage is above 14.4 volts.
Current flows from the alternator output terminal

through the set resistor, series set resistor, tempera-
ture compensated Zener diode and the driver bias
resistor to ground. Current also flows from the Zener
diode through the base and emitter of the milliwatt
transistor. With base to emitter current flow the mil-
liwatt transistor conducts current from the bias resis-
tor through its collector, base and emits to ground.
1- Batteries 12- Field Capacitor This removes the positive gate voltage at the silicon
2- Starting Motor 13-Silicon Controlled controlled rectifier and consequently it will not con-
3-Solenoid Rectifier duct during the stator voltage positive half cycle.
4-Ammeter 14-Field Diode
~Circuit Breaker 1~Excitation Resistor
6-Key Switch 16-Bias Resistor System voltage will not remain at 14.4 volts with-
7-Posltive Diodes 17-Milliwatt Transistor out some alternator output. Therefore current flow
8-Negative Diodes 18-Set Resistor through the zener diode circuit is not constant and
9-Stator 19-Series Set Resistor the silicon controlled rectifier cut-off is only momen-
10-Rotor 20-Temperature Compen -
11- SIIp Rings sating Zener Diode tarily.
21-Driver Bias
Fig. 2-Charging Circuit Schematic
With the key switch off, engine not running, battery

power is blocked by the positive diodes and by the
open contacts of the key switch.
With the key switch on, engine not running, current

flows from the key switch "ACC" terminal through the
excitation resistor, a slip ring , the rotor, another slip
ring , the silicon controlled rectifier and fina ll y to
ground . A very small amount of current also flows
through the bias resistor and the silicon controlled
rectifier as gate current which allows the field current
to conduct through the silicon controlled rectifier.
Litho in U.S.A.
Block Diagram (Fig. 3) For explanation of basic symbols of an

A block diagram is a simple picture of the power
flow in the electrical system. It provides an easy to
follow description of the system components and
their relationship to other components.
EJ Cl
electrical schematic, refer to FOS Manual -
"ELECTRICAL SYSTEMS", page IV.
To use the electrical schematic, you must think of

the electrical current as flowing from the positive ( +)
Use the block diagram (Fig. 3) to follow the basic
terminal of the batteries through the various circuits
power distribution to the various circuits.
and components to ground, and from ground back to
the negative (-) terminal of the battery.
Trace the current by starting at the battery positive
terminal and follow the connecting lines from box to
If circuit is complete to ground, positive current
box. Current flows from the batteries to the starting
flow is from the batteries to the starting motor sole-
motor and then to the alternator and key switch. As
noid "BAT" terminal, to the alternator and on to the
you can see this provides a very basic and simple
key switch.
picture of the current or power distribution in the
system.
Now let's use the schematic to solve a problem.
By looking at the output of the key switch, you can
Problem: Gauges do not work but the lights work.
see that the current flow is further distributed out of
two terminals: "ACC" and "IGN."
Solution: By referring to the schematic diagram
(Fig. 4) you can see there is power to the
The components in each of these circuits can be
"ACC" terminal of the key switch. So the
determined very easily by following the connecting
problem is probably an open wire from
lines from box to box.
the key switch to the engine oil pressure
gauge.
Now let's use the block diagrams to solve a prob-
lem.
Precautions
Problem: Engine starts but the hour meter does Certain precautions should be followed when test-
not work. ing or servicing the electrical system.
Solution: By referring to the block diagram (Fig. 3) CAUTION: To avoid injury from a spark or
you can see that there is power to the in-
jection pump solenoid. Therefore the
A short circuit, DISCONNECT THE BAT-
TERY GROUND STRAP when working on any
problem must be in the hour meter or the part of the electrical system. This will also pre-
wiring to the hour meter. vent accidental starting.
Schematic Diagram (Fig. 4) Disconnect the battery cables before fast charging
the battery in the machine. This is especially impor-
The schematic diagram is a detailed "How It
tant to prevent damage to the alternator.
Works" picture of the electrical system. It provides
the theory of operation in a simple, easy-to-under-
When removing the batteries, disconnect the bat-
stand manner. The schematic is especially helpful in
tery ground strap first. When installing the battery,
trouble-shooting to isolate a problem to a given com-
connect the ground strap last.
ponent.
NEVER REVERSE THE POLARITY OF THE BAT-
To use a schematic diagram, it is essential that
TERY CONNECTIONS. Reversing the polarity may
you know and understand the basic symbols used in
damage some components and wiring in the system.
an electrical schematic.
Litho in U.S.A.
DO NOT ATTEMPT TO POLARIZE THE ALTER- VISUAL INSPECTION

NATOR after connecting the battery. No polarization
Carefully inspect the electrical system for tips on
is needed. Any attempt to do so may damage the al-
the malfunction. Check to see if the unit can be oper-
ternator, regulator, or circuits.
ated without further damaging the system.
If booster batteries are used to help start the en-
Always check these items before turning on
gine, be sure to connect them properly. Connect the
switches or running the unit.
negative (-) terminal of the booster battery to the
negative (-) terrninal of the machine battery, and
1. Look for bare wires that could cause grounds or
connect the positive ( +) terminals to each other.
shorts and dangerous sparks. Shorted wires can
damage the charging system.
When using booster batteries, prevent fire hazards
as follows:
2. Look for loose or broken wires. They can damage
the regulator.
1. When possible, use equipment with a switch in
the line connecting the booster battery to the ma-
3. Inspect all connections, especially battery con-
chine battery.
necting points. Acid film and dirt on the battery may
cause current flow between the battery terminals, re-
2. Always "rock" the connector clips to make sure
sulting in current leakage. Check the battery ground
they are secure.
strap for proper operation.
3. If only jumper cables are available, always con-
4. Check the battery electrolyte level. Continued loss
nect the machine battery first; then when connecting
of electrolyte indicates overcharging. Check for acid
the booster battery, be very careful in handling the
film and dirt on top of battery.
cable clips. When disconnecting always break the
connection at the booster battery first.
5. Check the alternator drive belt tension.
When connecting a fast charger to a battery in a
6. Inspect for overheated parts after the unit h.as
machine, be very careful. First remove the battery
been stopped for a while. They will often smell like
ground strap to prevent fire hazards and damage to
burnt insulation. Put your hand on the alternator or
the alternator.
regulator. Heat in these parts when the unit has not
been operated for some time is a sure tip-off to
Do not lay metal tools or other objects across the
charging circuit problems.
battery as they may create a short circuit.
If your visual inspection does not indicate the pos-
A CAUTION: GAS FROM BATTERY ELEC-
sible malfunction, but your inspection does indicate
. . TROLYTE IS FLAMMABLE. Keep all
that the machine can be run, first turn the key switch
sparks and fires away from the battery. ~hen
to the "accessory" position. Try out the accessory
charging the battery gas is created more rap1dly.
circuits - Gauges, cigar lighter and lights. How do
Be sure the room where the battery is charged is
each of these components work? Look for sparks or
well ventilated.
smoke which might indicate shorts.
CAUTION: BATTERY ACID IS HARMFUL
A ON CONTACT with the skin or most mate-
Turn the key switch to the "start" position. Now
start the machine. Check all gauges for good opera-
rials. See Group 5, Section 30 for first aid tips
tion, and check to see if the system is charging or
when acid comes in contact with skin.
discharging.
Never operate the alternator in an open circuit.
In general, look for anything unusual.
Never short or ground the alternator terminals.
Many electrical failures cannot be detected even if
the machine is started. Therefore, a systematic and
Do not disconnect the voltage regulator while the
complete inspection on the electrical system is nec-
alternator is running.
essary. See "System Testing" in this section.
Litho in U.S.A.
15-6 Electrical System TM-11 02 (Nov-73)
DIAGNOSING MALFUNCTIONS Engine Cranks Slowly

Burnt or poor solenoid switch contacts.
Batteries
Poor contact of brush or worn out brushes.
Undercharged Battery Burnt commutator.
Commutator mica too high.
Excessive loads from added accessories.
Shorted or grounded armature coil.
Excessive engine idling.
Poor tension on brush spring.
Accessories left on.
Armature rubbing pole core.
Low charging system voltage.
Low battery charge.
Low charging system output.
High resistance in battery cables.
Continuous drain on battery.
Starting Motor Keeps Running
Low Battery Output
Defective starting motor solenoid.
High resistance in circuit.
Defective start switch
Low electrolyte level.
Short in wiring.
Low specific gravity.
Defective battery cell.
Noise Produced At Engine Cranking
Cracked or broken battery case.
Low battery capacity. Armature interfering with stationary components.
Starting motor drive gear worn.
Battery Uses Too Much Water
Starting Motor Will Not Spin,
Cracked battery case.
Engine Will Not Crank
Battery being overcharged.
Defective battery. Burnt or poor solenoid switch contacts.
Open, shorted, or grounded solenoid switch pull-in
Starting Circuit windings.
Open, shorted, or grounded solenoid switch hold-
Solenoid Switch Chatters
in winding.
Low battery. Poor contact of brush or worn out brushes.
Poor connection. Burnt commutator.
Open in solenoid hold-in circuit. Commutator mica too high.
Open or grounded field winding.
Starting Motor Spins But Will Not Open, shorted, or grounded armature coil.
Crank Engine Poor tension on brush spring.
Grounded positive side brush holder.
Damaged overrunning clutch pinion.
Broken drive lever.
If starting motor does not operate connect a volt-
Broken drive lever pivot bolt.
meter to the solenoid "S" terminal and a good
Broken solenoid switch plunger hook.
ground. Turn key switch on and press start switch.
Defective overrunning clutch.
Voltmeter Indicates Battery Voltage
Defective starting motor.
Defective solenoid switch.
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Voltmeter Does Not Indicate Battery Voltage If A Gauge Consistently Registers Too High
Defective key switch. Poor connection between gauge and
Defective start switch. connecting wire.
Defective start-safety switch. Broken connecting wire.
Maladjusted start-safety switch. Poor ground at sending unit.
Defective wiring between battery and Failure of gauge or sender, usually the sender
solenoid "S" terminal.
Cigar Lighter
Charging Circuit
Cigar Lighter Does Not Function
Low Charging System Voltage
Circuit breaker in lighter tripped.
High resistance in circuit connections. Faulty lighter element or lighter shell.
Defective wiring. Defective wiring.
Low amperage output of alternator.
Defective regulator. Injection Pump Solenoid
Defective batteries.
High Current Draw
Low Charging System Output
Shorted windings.
Slipping drive belts.
Excessively worn or sticking brushes. Low or No Current Draw
Dirty or out-of-round slip rings.
High resistance at internal connection.
Grounded, shorted, or open field circuit.
High resistance in connector or wire.
Defective diodes and alternator.
Open circuited windings.
Defective regulator.
Lights
High Charging System Voltage
High resistance at regulator connections. Dim Lights
Defective regulator.
High resistance in circuit or poor ground
on lights
Noisy Alternator
Low battery charge.
Defective drive belt. Defective key switch or light switch.
Worn or defective bearings.
Loose mounting or drive belt. Lights Will Not Light
Pulley not aligned.
Defective light switch.
Diodes shorted or open.
Defective wiring.
Poor ground on lights.
Gauges
If A Gauge Does Not Register

Lack of current to the gauge.
Poor ground connection.
Connecting wire grounded to unit.
A defective sending unit or gauge.
Litho in U.S.A.
15·8 Electrical System TM-1102 (Nov- 73)
KEY
SWITCH
ACC ~~--~--------~----------~------------------------------~
BAT.
I GN ~-----------.,
CIR CUIT
BREAKER
T32110N
0 TE ST POI NT
Fig. 3-Eiectrical System Block Diagram
Litho in U.S.A.
r- ~R
s
0
,lb
- ~
-<b
s· o ...
!\;),
~ -<-
~52
(J)
):..
"'
'C OJ
""'
~()
Q 0
N __L_- - '-'----
~® DK6l
PU B
Y IP
Pli
PR
@
p
Po
@ @
7" -;-' 7 -::- -=- -=- -=- - - -=- -::- -::- -=-
TJ2111N
0 TEST POI NT
1- Battery f 1- Buc ket Switc h B-Biack P- Pink rn

2- Starting Motor 12-Spool Switch BR- Brown PU-Purple Ci>(J)
3-Solenokf 13-Spool Solenoid DKBL- Dark Blue R- Red Q.~
~.-..
~~
4-Start-Safety 14-Sendlng Units DKGR- Oark Green W- White
Switch 15--light Switch GY--Gray W/ B-White/Biack
5-Start Switch 16-Gauge Lights LTGR-Light Green Y- Yellow ~q;r
6-Key Switch 17--Grille light N- Neutral (/) (/)
(i) ~.
7- Fuel Shut-Off Solenoid 18---Front Light
8---Circuit Breaker 19-Side lights
3t5
9-Aiternator 20--Rear light ....
t O-Regulator Cf~
Fig. 4-E/ectrica/ Schematic coo
15- 10 Electrical System TM-1102 (Nov-73)
10
58
~7
7B_.;rvu
4
STARTIHG MOTO R SA AM f~ETER START SW ITCH

KEY SWITCH AlTERNATOR
AN[) SOLENO ID
WIRE HARNESS START - EN GIN E OIL ENGINE WATER TRAN SMI SSION
REGU LATOR CON NECT OR SWITCH PR ESSURE GAUG E TEMPERATURE GAUGE TEMPERATURE GAUGE
14A 3A 2A
TRA NSMI SS ION ENGINE WATER EN GINE OIL HOUR METER CIGA R
TEMP ERATURE TEMP ERATUR E PRESSURE LIGHTER
SEN DER SE NDER SEN DER
9K~
9u~ ~~ 9L~ 9K~ 9K~ ~~

9N 9M--::h
LIGHT 98 LOADER REAR GRIL LE FRON T DOZER FUEL HI JECTI ON

SWITCH SIDE LIGHTS LIGHT liGHTS LIGHT SI DE PU t~ P SO LENOID
LIGHTS
14
~9K
2~ 2y-yss ~
~9C
t1A I N WIRE
90 ~2SA ~ GA UGE AND gA
llC BU CKET SPOOL TAC HONETER LIGHTS
HARN ESS SINGLE SWITCH SWITCH
CONNEC TOR
~
9Q 9N
0258
j\
LIGHT \~IR E MAIN lHRE
SPOO L
SOLENO ID
GRIL LE AND FRONT
LIG HT
CONNECTORS
HAR NES S CONNECTOR CO NNECTOR

T 3 8112N .
Fig. 5-Component Wire Routing
Litho in U.S.A.
Crawler· - JD450-C System Testing 70
TM-1102 (Nov-73) Electrical System 15-11
The following is an explanation of Fig. 5 - Compo- No. Color Routing

nent Wire Routing.
90 OkBI Instrument panel wire harness con-
No. Color Routing nector to light wire harness connec-
tor.
Neutral Instrument panel wire harness con- 9E OkBI Instrument panel wire harness con-
nector to instrument panel wire har- nector to light wire harness connec-
ness connector. tor.
1A Neutral Safety switch and hour meter wire 9G Pink Light switch to key switch "ACC" ter-
harness connector to start-safety minal.
switch. 9K Pink Main wire harness single connector
1B Neutral Main wire harness single connector to grille and front light connector.
to solenoid "S" terminal. 9L OkBI Safety switch and hour meter wire
2 OkGr Instrument panel wire harness con- harness connector to rear light.
nector to engine oil pressure gauge. 9MOkBI Rear light to dozer left-hand side
2A OkGr Main wire harness connector to en- light.
gine oil pressure sender. 9N OkBI Light wire harness connector to load-
3 Brown Engine temperature gauge to instru- er side lights.
ment panel wire harness connector. 9QOkBI Light wire harness connector to doz-
3A Brown Main wire harness connector to ener right-hand side light.
gine coolant temperature sender. 10 Purple Key switch "ACC" terminal to engine
4 Black Ammeter to instrument panel wire oil pressure gauge.
harness connector. 11 Gray Key switch "IGN" terminal to instru-
4A Black Main wire harness single connector ment panel wire harness connector.
to starting motor solenoid "BAT" ter- 11 A Purple Safety switch and hour meter wire
minal. harness connector to hour meter.
5 Red Ammeter to instrument panel wire 11C Purple Instrument panel wire harness con-
harness connector. nector to instrument panel wire har-
SA Red Main wire harness connector to alter- ness connector.
nator output terminal. 11 F Gray Main wire harness connector to fuel
58 Red Circuit breaker to key switch "BAT" injection pump solenoid.
terminal. 14 W/B Transmission temperature gauge to
5CRed Ammeter to circuit breaker. Stripes instrument panel wire harness con-
6 Red Starting motor solenoid "BAT" termi- nector.
nal to wire harness regulator connec- 14A N/B Safety switch and hour meter wire
tor. Stripes harness connector to transmission
6CYellow Circuit breaker to cigar lighter. temperature sender.
7 Neutral Start switch to instrument panel wire 18 LtGr Wire harness regulator connector to
harness connector. alternator "FLO" terminal.
7A Neutral Safety switch and hour meter wire 19 Black Wire harness regulator connector to
harness connector to start-safety alternator "GRO" terminal.
switch. 23 Yellow Wire harness regulator connector to
78 Neutral Start switch to key switch "IGN" ter- alternator "ST A" terminal.
minal. 24 Black Alternator "FLO" terminal to alterna-
8 Purple Engine temperature gauge to instru- tor "STA" terminal.
ment panel wire harness connector. 25 White Key switch "IGN" terminal to bucket
8A Purple Main wire harness connector to wire switch.
harness regulator connector. 25A White Bucket switch to spool switch.
8C Purple Engine temperature gauge to trans- 258 White Spool switch to spool solenoid.
mission temperature gauge.
9 Purple Engine oil pressure gauge to engine
temperature gauge.
9A Black Light switch to gauge lights.
98 Pink Light switch to instrument panel wire
harness connector.
9C Pink Main wire harness connector to main
wire harness single connector.
Litho in U.S.A.
15-12 Electrical System TM-11 02 (Nov- 73)
TESTING AND ADJUSTMENT 5. By disconnecting and reconnecting each electrical

circuit, one at a time, the shorted circuit can be locat-
The circuits tested in this group are the charging
ed .
circuit, starting circuit, accessory circuit and light cir-
6. When a disconnected circuit causes the test lamp
cuit.
to go out, you've found the culprit. Now all that re-
mains is to trace that circuit, then locate and correct
Failure of the engine to crank may be due to one
the cause of the short.
of a number of causes. Any one of several units in
the starting circuit may be at fault, or the cause of
Testing The Batteries Voltage
failure may be due to a weak battery. Another reason
for failure could be broken, disconnected or loose
leads or corroded connections.
Therefore, both a visual and an electrical check

should be made to isolate trouble before removing
any unit, otherwise a component may be removed
needlessly, only to find it is not the cause of cranking
failure.
Always use accurate electrical test equipment

when making electrical tests. Faulty equipment will
prevent the servicemen from doing thoroug h work
and may damage the electrical system.
Before you start the circuit tests, quickly review the

precautions on page 70, 15-4 and make the following
checks:
1. Check battery electrolyte level.

Fig. 6-Checking Battery Voltage
2. Look for corroded terminals.
3. Check for acid film and dirt on top of battery. Battery condition should be determined first. It is
4. Check battery polarity. vital to the testing of the starting circuit problem to
5. Test the charge of the battery (nine volts minimum have the battery fully charged and free of shorted or
for testing system). dead cells Use the following test to determine volt-
age available at battery.
System Short Test
Following is a simple method to locate an electrical 1. Attach positive ( + ) voltmeter lead to positive
system short quickly: ( +) battery post At1ach negative (- ) voltmeter lead
to negative (- ) battery post (Fig. 11).
1. Be sure battery is fully charged.
2. Disconnect the negative cable from the battery. 2. Crank engine.
3. Connect a 12-volt test lamp between the negative
battery post and the disconnected cable. 3. Voltmeter should read at least nine volts. If
4. If there is a short, the test lamp will glow with all above the minimum, continue testing . If below mini-
accessories turned off. mum replace or recharge battery .
Litho in U.S.A.
TM- 11 02 (Nov-73) Electrical System 15-13
Testing the Starting Circuit 3. The starting motor is running, but the engine
does not turn over.
When making tests, the battery voltage should not
drop below 9 volts. Never run the starting motor
4. The starting motor turns over the engine slowly
more than twenty seconds at a time or overheating
or erratically.
will result. Allow motor to cool at least two minutes
before running it again.
5. The engine starts but the starting motor drive
does not disengage from the flywheel.
You can check out these five problems as follows.
- Nothing Happens
Test No. 1
T J2 1 1 4N
0 TE ST POIIH
1- Batteries 5-Start Switch

2-Starting Motor 6-Key Switch
3-Solenoid 7-lnjection Pump Fig. 8-Voltmeter Connected to Solenoid
4-Start·Safety Switch Solenoid "S" Terminal
8- Circuit Breaker
Connect voltmeter to solenoid "S" terminal and to
Fig. 7-Starting Circuit ground (Fig. 8) . With H-L-R lever in neutral position,
turn key switch on and press start switch . Voltmeter
With the H-L-R lever in neutral position, turn key should read 9 to 12 volts.
switch on and press start switch. You can expect one
of five things to occur if the starting circuit is defec- If there is a voltage reading of 9 to 12 volts, the
tive: problem is in the solenoid . See Section 30, Group 15
for "Solenoid Tests."
1. Nothing happens - there is no "click" indicating
that the solenoid contacts did not close. If there is no voltage reading connect voltmeter to
solenoid "BAT" terminal. Voltmeter should read 9 to
2. An audible "click" in the solenoid is heard, but 12 volts.
the starting motor does not operate .
Litho in U.S.A.
15-14 Electrical System TM-11 02 (Nov- 73)
If there is a reading of 9 to 12 volts proceed to If there is a voltage reading of 9 to 12 volts, check

Test No. 2. fo r a de fect ive c ircuit breaker. key switch . sta rt
switch, or open wires. Replace as necessary.
If there is a low voltage reading or no voltage
reading, check for a defective battery cables or poor If there is no voltage reading at the ammeter and
and corroded connections. there was a voltage reading at the solenoid " BAT"
terminal in Test No. 1, there must be an open wire
Test No. 2 between the solenoid " BAT" terminal and the amme-
ter.
Remove engine shields, pre-cleaner, muffler ex-
tension and hood.
Test No. 3
Fig. tO-Voltmeter Connected to Instrument

Rg. 9-Voltmeter Connected to Instrument Panel Wire Harness Connector
Panel Wire Harness Connector
Connect voltmeter to the neutral colored wire at
Insert a straightened paper clip into the instrument the instrument panel w ire harness connector (Fig.
panel wire harness connector as shown in Fig. 9.
10). With H-L-R lever in the neutral position, turn key
With H-L-R lever in neutral position, turn key switch
switch on press start switch. Voltmeter should read 9
on and press start sw itch. Voltmeter should read 9 to
to 12 volts.
12 volts.
If there is a reading of 9 to 12 volts, you know the
If voltmeter reads 9 to 12 volts you know the circuit
start-safety switch is functioning okay, and the prob-
is okay from "BAT" terminal on the solenoid through
lem is in the neutral colored wire from the instrument
the ammeter, circuit breaker, key switch and start panel wire harness connector to the solenoid " S"
switch is okay. Proceed to Test No. 3.
terminal.
If there is no voltage reading, remove the instru- If there is no voltage reading, check the terminals
ment panel and check the ammeter terminal with the of the start-safety sw itch w ith an electrical test probe.
black lead for a voltage reading. If probe lights on only one terminal, either the trans-
mission is not in neutral, the connection is loose, or
the start-safety switch is faulty or maladjusted. See
Section 70, Group 20 for start-safety switch adjust-
ment.
Litho in U.S.A.
TM-1102 (Nov-73} Electrical System 15-15
2. Solenoid Contacts "Clicked" but the Starting

Motor Did Not Operate
This indicates that the circuit problems lie within
the starting motor. If the solenoid switch contacts
close, and the switch begins to "chatter" an open cir-
cuit exists in the hold-in winding of the solenoid. In
any case, the starting motor should be removed and
tested as covered in Section 30, Group 15. N
3. Starting Motor Ran but Did Not Turn the En- GY

gine Over.
We know that the starting motor is getting enough GY
current to operate. The problem, then, is either in the
-- 7
shifting of the drive assembly into mesh, a broken ar-
mature shaft, or a dirty or faulty drive assembly.
PR
These causes require disassembly of the starting
motor for proper service or repair. See Section 30,
Group 15.
4. Starting Motor Turned the Engine Over Slowly

or Erratically
With slow sluggish starting motor operation, con-
nect a voltmeter across the battery terminals and T32118N
operate starting motor. With a slow running starting 1- Batteries 5-Start Switch
motor the voltage should be less than 9 volts. If more 2-Startlng Motor 6-Key Switch
than 9 volts, check for high resistance between the 3--Solenold 7-lnjectlon Pump Solenoid
4-Start-Safety Switch 8-Circuit Breaker
batteries and the starting motor. See " High Resis-
tance Test". Fig. 11-High Resistance Test Points
If voltage reading is less than 9 volts, cause is ei-

ther the batteries or the starting motor. Check battery RESISTANCE TEST VALUES
condition first. See Section 30 for testing batteries
and starting motor. Test Points Maximum Voltmeter Reading
High Resistance Test A-F 0.2

B-C 0.2
Disconnect wire from injection pump solenoid shut- C-D 1.0
off terminal. C-E 0.2
Connect voltmeter to ground and to solenoid bat- 5. Engine Starts But the Starting Motor Drive
tery terminal. Operate starter and compare voltage Does Not Disengage From the Flywheel
with a similar reading at battery. Always use a pin
connector at battery post. If difference is more than This indicates a defect in the drive mechanism, or
0.8 volt, make the tests indicated in Fig. 11. Check solenoid pull in windings, or solenoid contacts, or so-
for defective wires or faulty connections. lenoid control circuit which will not allow the drive to
disengage.
The starting motor or solenoid needs repair. See

Litho in U.S.A.
Testing The Charging Circuit
R B 4
Fig. 13-Vottmeter Connected to Stator Terminal
-Q TEST POINT
Test No. 2
1-Batteries 5-Circuit Breaker With key switch on and engine not running, con-
2-Starting Motor 6-Aiternator nect voltmeter to stator terminal (Fig. 13). The read-
3-Solenoid 7- Regulator
4-Key Switch ing should be approximately 2 volts.
Fig. 12-Charging Circuit If no voltage is indicated, the cause is either an

open in the wiring to the regulator or short to ground
Before you start the circuit tests, quickly review the in the field circuit.
precautions listed on page 70-15-4.
To isolate check voltage on the purple lead termi-
Make the following tests to isolate a faulty compo- nal in the regulator connector (Fig. 14). It should be
nent in the charging circuit. 9.0 to 12 volts. If voltage is at regulator connector,
remove black wire from stator-to-field terminal. Now
Test No. 1 if voltage goes to 12 volts at the stator terminal,
With key switch off, connect voltmeter to alternator check brushes and rotor for a short to ground condi-
stator terminal (Fig. 13). Voltage reading should be 0 tion .
volts.
If you get a 12 volt reading , the f ield circuit is
If 12 volts is indicated one or more of the positive open , either in the alternator or in the regulator. To
diodes is shorted. If the reading is approximately 2 isolate proceed to Test No. 3.
volts, the key switch contacts are not opening.
Litho in U.S.A.
TM-1102 (Nov-73} Electrical System 15-17
With key switch on and engine not running, con-

nect voltmeter to field terminal with the green wire
(Fig. 15).
If you get a 12 volt reading, the regulator field cir-

cuit or ground circuit is open.
To isolate connect a jumper wire to black lead in

regulator connector and to ground. Now if you get a
2 volt reading at the stator terminal you know the
ground circuit is open. Check black lead to alternator
for an open. If a 12 volt reading is still obtained at
the stator terminal, replace regulator.
If reading is 0 volts the alternator field circuit is

shorted to ground. Check the brushes and rotor.
Test No. 4
Fig. 14-Vol/meter Connected to Purple Lead

in Regulator Connector
Test No. 3
Fig. 16-Voltmeter Connected to Output Terminal
With key switch on, engine running at fast idle,

connect voltmeter to the output terminal (Fig. 16).
Fig. 15-Voltmeter Connected to Alternator

Field Terminal
Litho in U.S.A.
15-18 Electrical System TM-1102 (Nov- 73)
Initially the ammeter (on the dash) reading should In summary, the solution to most problems in the
be 20 amps. or more and the voltmeter should read charging circuit can be obtained if you can accurately
approximately 13.0 volts in a fully charged battery. answer these questions:
After a few minutes of operation the voltage read- 1. Is system voltage being blocked in the key off
ing should start to rise. When the reading is approxi- condition?
mately 14.2 volts, the ammeter indicator should start
to decrease. The voltage should continue to rise 2. Is there excitation voltage to the alternator field
slowly to approximately 14.4 volts and then level off. in the key on condition?
The ammeter should drop to approximately 10 to 3. Is the field current functional?

15 amps.
4. What is the alternator output w ith full field?
Since temperature does affect the controlled volt-
age level, Test No. 4 should be run at approximately 5. At w hat voltage does the regulator limit alterna-
70°F (21.1°C) ambient temperature. tor output?
W ith a cold ambient temperature the voltage will High Resistance Test
go up and with a hot ambient temperature the volt-
age w ill go down. See chart.
Temperature• Voltage
40°F [4.4°C] 14.4 - 14.9 volts

60°F [ 15.6°C] 14.3 - 14.7 volts
80°F [26.7°C] 14.2 - 14.6 volts
100°F [37.8°C] 14.0 - 14.4 volts
120°F [48.9°C) 13 .8 - 14.3 volts
140°F [60.0°C) 13.6 - 14.1 volts
*Measured 1 inch from regulator.
If the alternator output current is low the probable

causes are in the alternator, open positive diodes,
shorted negative diodes, or a defective stator.
If the voltage does not level off and the current

level remains high, the voltage regulator is faulty and
should be replaced .
Since these a re only p robable causes , a lways

check the alternator output voltage whenever you
have a low ammeter reading. You could have a sulf- T 3 2124N
0 TEST POI IH
ated battery causing high resistance to curren t flow, 1-BaHeries 5-Circuit Breaker
or a high resistance connection in the charging circuit 2- Starting Motor 6-Aiternator
which would cause a rise in system voltage to 14.4 3- Solenold 7-Regulator
volts and consequently the regulator would reduce 4-Key Switch
the alternator output. See " High Resistance Test" .
Fig. 17-High Resistance Test Points
Litho in U.S.A.
TM-1102 (Nov- 73) Electrical System 15-19
With battery ground disconnected, connect the am- Testing Gauges, and Return-To-Dig
meter (Fig. 17). Obtain 10-amp charge rate. Check Circuits
the voltage between the points indicated in the chart
below. Always use a pin connector to connect volt-
meter to battery posts.
R
If voltmeter readings exceed the maximum listed in
the chart, high resistance usually exists in a poor
connection.
4-f;.J;-1
J • ~ I
y
L •• - - - · I
When there is a high resistance present in the 8

charging system, the regulator cannot control alter-
nator voltage and maintain the battery in a fully y
charged condition.
Test Points Maximum Voltmeter Reading*
A - D 0.3 volt
B- E 0.3 volt
B- C 1.3 volts
*10-amp charging rate
Test No. 5 - Ammeter Test

T 3 2 125N
Remove screws from instrument panel and pull
panel back away from cowl. 1-Batteries 6-Bucket Switch
2-Starting Motor 7-Spool Switch
3-Solenoid 8-Spool Solenoid
Start engine. 4-Key Switch 9-Sending Units
&-Circuit Breaker
Remove red lead from ammeter. Check for volt-
age, at disconnected red lead, black lead (connected Fig. 18-Gauges and Return-to-Dig Circuits
to ammeter) and red lead terminal. Voltage reading
Testing Engine Temperature Gauge
should be battery voltage 9.0 to 12.0 volts at all
readings. Test No. 1 - Gauge Not Operating
Remove the brown lead wire from the engine tem-
If you have a voltage reading at the red lead and
perature sending unit and check for corriosion or a
the black lead (connected to ammeter) but no read-
poor connection at the sender terminal.
ing at red lead terminal, ammeter is defective. Re-
place ammeter.
With brown lead wire disconnected from sender,
turn key switch on.
If either lead wire has no voltage reading, check
for defective lead wire. Replace if necessary.
Litho in U.S.A.
15-20 Electrical System TM-11 02 (Nov-73)
With the brown lead wire not touching anything the Check the gauge mounting and be sure mounting
gauge needle should go to the full left, the cold screws are tight and that there is good contact be-
position. tween the gauge mounting bracket and instrument
panel. Repeat Test No. 1.
With the brown lead wire touching ground the
gauge needle should be to the full right, the hot Now if gauge needle goes to the maximum cold
position. position as soon as the brown lead is removed from
ground, you have found the problem.
If the gauge operates as described above, it can
Test No. 4 - No Needle Movement
be considered good and the sending unit needs to
be replaced. If there is no gauge needle movement under any
condition, check for voltage at the gauge.
Test No. 2 - Gauge Remains in Cold Position
There should be 9.0 to 12.0 volts at the gauge ter-
If the gauge needle is in the maximum cold posi-
minal with the purple lead.
tion all the time regardless of what the sending unit
brown lead wire is touching in Test No. 1, the cause
If no voltage at the gauge, check the purple lead
could be a break or poor connection in wiring from
(gauge to engine oil pressure gauge) for a crack or
the gauge to the sender.
poor connection.
Remove instrument panel with engine temperature
With voltage to the gauge, gauge grounded, wiring
gauge installed in it. Use a jumper wire to ground in-
from gauge to sender good and the gauge still not
strument panel to unit.
working correctly, the problem then must be in the
gauge. Replace gauge.
Take a short jumper wire and connect it to the
gauge terminal with the brown lead wire and to
Testing Engine Oil Pressure and
ground. Turn ignition switch on.
Transmission Temperature Gauges
If gauge needle goes to maximum hot position, the Engine oil pressure and transmission temperature
problem is in the wiring. Check for a defective wire or gauges can be checked in the same manner in
poor connection and repeat Test No. 1. which engine temperature gauge was tested.
Test No. 3 - Gauge Remains In Hot Position Testing Return-To-Dig Circuit

If the gauge needle goes to maximum hot position If return-to-dig fails to work, check lights to see if
with the brown lead touching ground but does not go they work. If lights work, check for voltage at bucket
to the maximum cold position as soon as the lead is switch (16, Fig. 18), spool switch (7) and spool sole-
removed from ground, the cause could be a poor noid (8). If electrical circuit checks out okay, refer to
gauge ground connection. Section 70, Group 25 and check that bucket switch is
properly adjusted.
Litho in U.S.A.
TM-1102 (Nov-73) Electrical System 15-21
Testing light Circuit Co nnect voltmeter to lamp terminal and lamp

frame.
Voltmeter Reads Battery Voltage
Defective bulb
\ 5 High resistance at an internal connection
B
If voltmeter reading is 0.5 volt or more below bat-
tery voltage, connect voltmeter between lamp frame
B and a good ground.
Voltmeter Reading Exceeds 0.1 Volt
Defective lamp ground.

7-
If voltmeter reading to ground is lower than 0.1
volt, connect voltmeter between lamp terminal and
9 battery positive post that is connected to the starting
. ·¢ rES! P~ l.l .,. motor.
T 3 213611
1-Batterles 7-Gauge Lights Voltmeter Reading Exceeds 0.5 Volt

2-Starting Motor 8-Grille Lights
3-So leno ld 9-Front Light Defective light switch or key switch.
4-Key Switch 1D-Side lights
s-<:lrcult Breaker 11-Rear light Defective or disconnected wiring.
6--Light Switch
If voltage is excessive, use voltmeter across vari-
Fig. 19-Light Circuit ous points between the lamp terminal and the battery
post to locate the point of excessive resistance. Indi-
If all lights will not light, check for voltage at light vidual unit resistance should not exceed 0.1 volt.
switch.
If voltmeter reading is under 0.5 volt between lamp
If individual lights will not light, use the following terminal and the battery post, connect voltmeter to
procedure. lamp frame and the grounded battery post. A voltage
reading above 0.5 volt indicates there is a high resis-
tance somewhere in the ground circuit. Connect the
voltmeter across various places where a high resis-
tance might be present such as a battery box to the
crawler frame.
Litho in U.S.A.
Litho in U.S.A.
TM-1102 (Nov-73) Power Train 20-1
Group 20
POWER TRAIN
GENERAL INFORMATION
Engine Clutch Assembly The clutch controls and pedal shaft are mounted in
the center portion of the clutch housing. Movement of
The engine clutch mechanism is located on the
the clutch pedal is transmitted through the clutch
rear of the engine flywheel and is enclosed by the
linkage to the throw-out bearing.
clutch housing. A pedal mechanically controls the
clutch throw-out bearing which engages or disen-
The front input shaft transmits engine power from
gages the driven disk by means of a spring-loaded
the flywheel through the splined hub of the driven
pressure plate. On units with H-L-R transmissions,
clutch disk directly to the transmission. The front end
an 11-inch driven disk is used.
of the front input shaft is supported by the clutch pilot
bearing located in the flywheel.
Partially depressing the clutch pedal stops tractor
motion but does not stop powershaft rotation. Thus
The engine clutch also serves as the PTO or
"live power" is available at all times for PTO or winch
winch drive clutch. The powershaft drive gear,
drive operations.
splined to the input shaft under the front cover,
drives the PTO driven gear and shaft or the winch
The clutch pressure plate is bolted directly to the
drive shaft. Power is transmitted only when the en-
engine flywheel.
gine is running and the clutch is engaged. "Live pow-
er" operation is provided by partially depressing the
When the clutch pedal is depressed, the clamping
clutch, stopping tractor motion but not stopping pow-
action of the pressure plate is released, allowing the
er to the powershaft.
clutch driven disk to stop rotating with the pressure
plate and flywheel. This is the disengaged position.
H-L-R Transmission
When the clutch pedal is released, coil springs The H-L-R transmission is basically a collar shift
within the pressure plate mechanism act against the transmission plus a hydraulic reverser and under-
pressure plate disk and clamp the friction surfaces of drive unit. The two features work as follows:
the driven disk between the pressure plate and the
clutch surface of the flywheel. This causes the clutch 1. Manual Shifting of Gears. Shift lever beside op-
driven disk to rotate with the pressure plate assembly erator's seat is used to select one of four shift sta-
and the flywheel, thereby transmitting engine power tions by manual shifting of collars on gears in the
to the transmission. This is the engaged position. speed change compartment.
The clutch and clutch control linkages have been 2. Shifting "On the Go." Reverser lever on plat-
so designed that the minor adjustment of the clutch form is used to reverse the gear train or to shift from
is made externally, thereby eliminating disassembly high to low gear under load without clutching by
of the clutch except at time of major overhauls. means of hydraulic cluthes in the range change com-
partment.
The reverser lever can select a high, low, or re-

verse gear for any of the four shift stations, making
available eight forward gears and four reverse gears.
Litho in U.S.A.
20-2 Power Train TM-11 02 (Nov-73)
The transmission case contains three separate Both brake bands can be actuated by pressing the
compartments. From front to rear they are: brake pedal. The steering clutches are not disen-
gaged when the brake pedal is depressed. The
1. Range Change Compartment. A control valve brake pedal can be locked to hold the tractor when it
unit operates the three hydraulic clutches-high, low, is parked.
and reverse-mounted on the clutch shaft. Two
countershafts transmit rotation to the clutch shaft. Final Drive Assembly
The final drive system transmits power from the
2. Speed Change Compartment. The rear input
steering clutches to the rear track drive of the tractor.
shaft carries drive teeth which mesh with gears on
Each final drive unit contains one rear axle mounted
the pinion shaft. The pinion shaft carries the shifters,
on two tapered roller bearings and driven off the final
shifter collars, and driven gears which transmit a
drive pinion by a large gear.
specific speed through the pinion to the ring gear.
3. Ring Gear and Hub Compartment. This com-

Power Take-Off and Winch Drive
partment houses the ring gear and hub which receive JD450-C Crawlers can be equipped with a 1000
rotation from the pinion and transmit it to the rear rpm power take-off or winch drive unit. The powers-
axle. haft is the same in both applications and drives
equipment from the rear of the crawler.
The transmission shifter mechanism is actuated by
the shift lever and the reverser lever. The shift lever The powershaft gives a standard speed of 1000
is used to select the four shift stations by means of rpm when operated with the engine at the recom-
collars in the speed change gear box. The reverser mended PTO speed of 1900 rpm.
lever is used to select high, low, or reverse oears
within each station by means of hydraulic clutches in The powershaft is continuous running, that is, it is
the range change box. possible to stop tractor movement without stopping
powershaft rotation. By depressing the clutch pedal
Steering Clutch and Brake Assembly 3-1/2 inches (or until resistance is felt), crawler
movement is stopped, but the powershaft will still ro-
Steering is controlled by multiple-disk steering
tate if the control lever is in the engaged position.
clutches and contracting band-type brakes located in
housings between the transmission case and the fi-
The front drive shaft carries the powershaft drive
nal drive housings. Because the flow of power to ei-
gear which is in constant mesh with the powershaft
ther track can be interrupted by the steering clutches,
driven gear. A shifter fork controlled by the PTO con-
a differential is not required.
trol lever moves the drive gear internal splines in and
out of mesh with splines on the front drive shaft. The
When a steering lever is pulled to the rear, it
shifter and PTO gears are housed in the transmis-
moves a valve spool to block the pressure oil pas-
sion front cover.
sage and opens the pressure port to sump releasing
the clutch pack. Any further rearward movement of
The powershaft driven gear is splined to the pow-
the steering lever contracts the brake band which
ershaft which extends from the front wall of the
grips the brake drum and retards or stops its rotation.
transmission case out to rear of the transmission.
Since the track drive sprocket is geared to the brake
The shaft is supported on the front by a roller bear-
drum, the track is also retarded or stopped.
ing and on the rear by a ball bearing in the rear
powershaft housing.
Litho in U.S.A.
TM-11 02 (Nov-73) Power Train 20-3
Pulling the PTO control lever to the rear moves the

powershaft drive gear rearward into mesh with
splines on the front shaft. Power is picked up from
the powershaft drive gear by the powershaft driven
gear which turns the powershaft. The engine clutch
must be fully disengaged before powershaft can be
engaged or disengaged by the lever. The powershaft
drive gears and bearings are lubricated by oil in the
transmission reservoir.
Litho in U.S.A.
20-4 Power Train TM-1102 (Nov-73)
Clutch Slips Clutch Drags (While Disengaged)
Worn or burned clutch disk facings. Excessive pedal free travel.
Replace clutch disk. Check pressure plate. Adjust pedal linkage.
Oil or grease on clutch disk facing. Distorted or rough clutch shaft splines.
Clean or replace disk. Repair or replace shaft and disk.
No clutch free travel. Disk hub tight on clutch shaft.

Adjust pedal linkage. Repair or replace shaft and disk.
Clutch levers out of adjustment. Disk facing broken.

Adjust clutch levers. Replace clutch disk.
Weak clutch springs. Clutch disk warped or bent.

Check springs to specifications. Replace clutch disk.
Clutch Chatters High spots on disk.

Replace clutch disk.
Loose clutch disk facings.
Replace clutch disk. Excessive clutch face run-out (flywheel not seated
properly).
Clutch disk loose at hub. Remove flywheel and seat correctly.
Repair disk.
Clutch disk frozen to flywheel.
Cracked or broken pressure plate. Clean or replace disk.
Replace pressure plate.
Clutch Pedal Pulsates
Worn clutch throw-out bearing.
Replace and lubricate periodically. Broken or missing clutch pedal spring.
Replace spring.
Clutch Makes Noise (While Engaged)
Clutch shaft or disk splines worn. Clutch levers out of adjustment.
Replace shaft and disk. Adjust levers.
Clutch disk loose at hub rivets. Flywheel not seated correctly.

Replace disk. Remove flywheel and seat correctly.
Flywheel loose on crankshaft. Bent crankshaft flywheel flange.

Replace crankshaft.
Bent clutch shaft.

Replace shaft and disk.
Litho in U.S.A.
TM-1102 (Nov-73} Power Train 20-5
H-L-R TRANSMISSION
Transmission Continually Runs Hot Shifts Too Slow
Obstruction in cooler lines or cooler. Adjust clutch and H-L-R shifter linkage.
Check lines for mushy or collapsed condition and Adjust needle valve orifice.
cooler restriction. Check bypass valve for broken spring or valve
in backwards.
Cooler fins filled with trash. Check screen or pilot valve orifice for clogging.
Clean and straighten fins.
Clutches Slip or Fail to Take Hold
Oil level too high.
Check level. Check clutch pressure.
Drag or interference caused by failed bearings. Pressure gradually decreases as pedal is depressed.
Replace worn or damaged transmission parts. Adjust clutch pedal and shifter linkage.
Low oil pump capacity. Pedal moves away from its stop.
Inspect pump for damaged or worn parts. Replace clutch pedal return spring.
Low flow through cooler; check cooler flow.
Excessive Gear Clash When Shifting
Weak cooler relief valve spring.
Replace spring and adjust system pressure. Disconnect clutch out of adjustment or clutch
pedal not depressed far enough.
Shuttle Shift Too Abrupt
Excessive Transmission Noise
Check clutch valve adjustment.
Transmission parts worn or damaged.
Overhaul and repair transmission.
Transmission low on oil.

Fill to proper level.

Loss of Power Transmitted Brakes Not Releasing
Brake out of adjustment. Linkage over-center.
Adjust brake linkage. Adjust brake lever stop screw.
Steering Effort High Jerky Steering

Brake too tight. Clutch overlaps brake.
Adjust brake linkage. Adjust linkage.
Low Brake Effect Housing Filled With Oil
Self adjuster not functioning. Manifold oil seal leaks.

Remove plug and manually adjust brakes. Leak in pressure oil line.
Clutch piston seal leaks.
Tear down and repair.
Litho in U.S.A.
20-6 Power Tra in TM-1102 (Nov-73)
TESTING AND ADJUSTMENTS
Engine Clutch Assembly Back off (turn counterclockwise) the H-L-R linkage
stop nut (2, Fig. 1) while observing the pressure
gauge. Continue turning the nut until the pressure
2
drops to a reading 30 to 50 psi (2.11 to 3.52 kg / cm ]
lower than the recorded reading.
While observing the pressure. turn down (clock-

wise) the H-L-R linkage stop nut at a slow rate. As
the nut is turned the pressure at the gauge will in-
crease to a maximum and then drop as the nut is
turned further. From the point where a 5-10 psi [0.35
to 0.70 kg/cm2) pressure drop occurs, continue to
turn the nut one complete turn clockwise.
When properly adjusted, pressure at the gauge

2
should rise 5 to 10 psi [0.35 to 0.70 kg / cm ] when
clutch pedal is depressed 1/ 2 to 3/ 4 inch [ 12.70 to
19.05 mm].
H-L-R Transmission
The H-L-R oil pressure test and speed of shift ad-
justment are covered in Section 70, Group 25.
1-Free Travel 3-Pedal Detent Adjusting
2-H-l-R linkage Stop Nut Screw
Proceed as follows to make the H-L-R lever ad-
justment:
Fig. 1-Adjusting H-L-R Linkage
1. Shift H-L-R lever (11 , Fig. 47, page 40- 10-28)
Whenever the clutch and H-L- R linkage have been in neutral detent (between high and reverse).
removed. or clutch pedal free travel becomes less
than 3.250 inch r88.900 mm] or whenever H-L-R 2. Hold H-L-R lever against back edge of slot in
shifts from high to reverse too aggressively, the link- neutral lock (7, Fig. 46, page 40-10-27). Apply pres-
age must be readjusted . Be sure to make both ad- sure to take play out of neutral lock.
justments in the sequence given below.
3. Starting with the H-L-R rod yoke (15, Fig. 47,
First adjust clutch pedal free travel to 3.750 inch page 40-1 0-28) adjust long . Shorten the H-L-R rod
[95.250 mm] at the clutch pad as follows: Remove yoke until pin (8) slips through the yoke and pivot
left footres t from tractor. Observe detent set screw arm (22). Turn yoke 1/2 additional turn but not so
on clutch pedal arm on left side of clutch housing short that the pin will not slide freely into yoke and
(Fig. 1). Loosen detent screw to increase free travel pivot arm.
or tighten screw to decrease free travel. Always end
up with screw in the detent (locked position). 4. Install pin and cotter pin. Tighten the yoke jam
nut.
Refer to Section 70, Group 25 and install pressure
gauge as instructed. To test H-L-R lever adjustment proceed as follows:
With the foot brakes on, start the engine. Place the 1. With the H-L-R control lever locked in neutral
speed selector lever in a neutral position and the H- and the speed selector lever in the 4th speed posi-
L-R range selector in high. Slowly release the clutch tion, depress the clutch pedal and start the engine.
pedal and set the engine speed at slow idle. Record
pressure reading. 2. Make certain the area around the crawler is
cleared to allow some travel of the machine.
Litho in U.S.A.
TM- 1102 (Nov-73) Power Train 20-7
3. Adjust the engine throttle lever to obtain an en- Refer to Fig. 2 and adjust the steering brake rod
gine speed of approximately 1900 rpm . yokes. Adjust so that the top of the steering levers
move 10 :t 0.25 inches [254.00 :t 6.350 mm] when
4. While holding the foot brake firmly and with the
the brake lever (4, Fig. 7, page 40-15-7) contacts the
clutch fully depressed. lift the H-L-R neutral lock and
brake lever adjusting screw (1) . Tighten steering
shift the lever to reverse.
brake rod yoke jam nuts (Fig. 2).
5. With the brake pedal firmly depressed, slowly
release the clutch pedal to such a degree that the
engine starts to load in reverse.
6. Again fully depress the clutch pedal and move
the H- L- R co ntrol lever toward neutra l just far
enough that the neutral lock can be placed over the
lever in the locked position . Now slowly relea.se the
clutch pedal to its maximum engaged position.
NOTE: If the crawler begins rearward movement
while releasing the clutch pedal, shut the engine off,
recheck the adjustment of the linkage and if neces-
sary, adjust the linkage yoke an additional 112 turn
clockwise. Retest as outlined in steps 1 through 6 of
the testing procedure.
7. After establishing that the unit will not operate
rearward with the lever locked in neutral, repeat the
testing procedure (step,s 1 through 6) from the high
to neutral position and readjust as required until no
movement of the crawler can occur in either direction
with the H-L- R lever locked in neutral.
1- Steering Valve Rods 3--Jam Nuts
Steering Clutch and Brake Assembly 2-Steering Valve Spool 4-Steering Valve
Eye Bolts

rods (1) will just slip through the eyebolts. Tighten
one additional turn and tighten jam nuts (3) .
Adjust brake pedal with pedal back against the

stop. Pull brake rods forward to take up pin clear-
ance. Adjust brake rods to align holes and install
pins. Tighten jam nuts.
Reach through the access ho le in the side of

nuts until 60 pounds [22.68 kg] pull at the base of
the steering lever hand grip will just move the lever
to the stop.
TJJ9921i
1- Steering Brake Rods 2-Steering Valve Rods
Fig. 2-Steering Levers and Rods Adjustment
Litho in U.S.A.
20-8 Power Train TM-11 02 (Nov-73)
Litho in U.S.A.
TM-1102 (Nov-73) Hydraulic System 25-1
Group 25
HYDRAULIC SYSTEM
GENERAL INFORMATION
The hydraulic system for all crawler functions is of The foll owing hydraulic circuit diagrams give a brief
the open center type. description of each hydraulic system and its compo-
nents.
Basic crawler hydraulic systems consist of an en-
gine driven gear type hydraulic pump, oil reservoir, Study the circuit diagrams when diagnosing hy-
filters, control valve anq cylinders. draulic system difficulties .
1- System Relief 4-Circuit Relief (Bucket) 7-Control Valve

2--Circult Relief (Boom) &-Hydraulic Pump 8-Reservolr
3-Circuit Relief (Bucket) &-Pressure Tap 9-Boom Cylinder
1G-Bucket Cylinder
Fig. 1-Crawler Loader Circuit
Litho in U.S.A.
25-2 Hydraulic System TM-1102 (Nov- 73)
1- System Relief 4-Circuit Relief (Bucket) 8-Reservoir

2-Circult Relief (Boom) 5--Hydraulic Pump 9-Boom Cylinder
3-Circult Relief (Bucket) ~Pressure Tap 1G-Bucket Cylinder
7-Control Valve 11- Ripper Cylinder
Fig. 2-Crawler Loader with Ripper
T32 128!1
1- System Relief 5--Hydraulic Pump 1G-To Ripper Cylinder

2-Circuit Relief (Boom) 6-Pressure Tap 11-Selector Valve
3-Circuit Relief (Bucket) 7-Ciam Circuit Relief 12-Boom Cylinders
4-Circuit Relief (Bucket) 8-Control Valve 13- Bucket Cylinders
9-Reservoir 14-Cam Cylinders
Fig. 3-Crawler Loader with Ripper and DroH Bucket

Litho in U.S.A.
TM-11 02 (Nov-73) Hydra ulic System 25-3
1-System Relief ~ydraulic Pump 9---Return from Rear Function

2-Circu lt Relief (Boom) &-Pressure Tap 1o-contro1 Valve
3-Circu lt Relief (Bucket) 7-Retum OH 11- Aeservoir
4-Circult Relief (Bucket) ~Power Beyond (Backhoe) 12-Boom Cylinders
13-Bucket Cylinders
Fig, 4-Crawler Loader with Backhoe
1- Hydraullc Pump 4-Lift Cylinder 7- Return Line

2- Pump Pressure Line ~System Relief Valve 8-Restrlcted Union
3-Pump Inlet Line ~Control Valve (2 used) 9---Reservoir
Fig. 5-Mechanical Bulldozer Circuit
Litho in U.S.A.
25-4 Hydraulic System T~-1102 (Nov-73)
1-Hydraulic Pump ~Tilt Cylinder 9-Return Line

2- Pump Pressure Line 6-Lift Cylinder 1~Reservoi r
3-Pump Inlet line 7-System Relief Valve 11-Restricted Union
4--Angling Cylinders 8--Control Valve (3 used)
Fig. 6-A/1-Hydraulic Bulldozer Circuit
T21491
1- Hydraulic Pump 6---Fiow Divider 11- 0ozer Control Valve (3 spool)

2-Pump Pressure Line 7-Return Line 12-0ozer Valve Return Line
3-Pump Inlet Line 8-0ozer Valve Inlet Line 13-Return Line from Function
4--Selector Valve ~zet' Control Valve (2 spool) 14--Auxlliary Valve Inlet Line
~Selector Valve Relief 1~Dozer System Relief Valve 15-Reservoir
Rg. 7-Bu//dozer Equipped with Backhoe

Litho in U.S.A.
T21143
1-Hydraullc Pump ~zer Valve (2 spool) ~Dozer Valve (3 spool)

2- Pump Pressure Une &-To Function 1G-Auxlllary Valve (2 spool)
3-Pump Inlet line 7-Auxiliary Valve (1 spool) 11- Return from Dozer Valve
4--Reservol r 8-System Relief 12- Pressu re to Auxiliary Valve
Ag. 8-Bulldozer Equipped with Auxiliary Valves
1- Hydraulic Pump 4-Lift Cylinder 7-Return Line

2-Pump Pressure Une 5-System Relief Valve 8-Restrlcted Union
3-Pump Inlet Line 6-Control Valve ~Reservoir
1G-Tilt Cylinder
Fig. 9-Mechanical Bulldozer with Hydraulic Tilt
Litho in U.S.A.
25-6 Hydraulic System TM-1102 (Nov-73)
BUCKET BOOM
CYLINDERS CYLINDERS
t
I
MAIN
HYDRAULIC 1-
PUMP
CONTROL
VALVE
I RETURN I
I LINE :
I _______
:_ FILTER JI
RESERVOIR
RIPPER
TJ2129N
Fig. tO-Block Diagram of Hydraulic System (Loader and Ripper Shown)
Litho in U.S.A.
Crawlers - JD450-C System Testing 70
1- Pressure 011 5-011 Cooler 9--Shlms 13-Lub. 011 to Clutches and

2-lntermediate Pressure Oil 6--011 Alter 10-Cooler Bypass Valve Output Shaft
3-Low Pressure Oil 7-Protective Filter Bypass 11--Ciutch Lubricating Bypass 14-Engaging Oil to Clutches
4-Pressure Free Oil &-Pressure Regulating Valve Valve 15-0il From Reservoir
12- Excess Oil to Reservoir 16-Ciutch Oil Pump
17- To Steering Clutches
Fig 11-Transmission Oil Supply System
OPERATION OF TRANSMISSION up pressure further opens the regulating valve and

OIL SUPPLY SYSTEM diverts excess incoming oil to the cooler. If the pres-
sure differential between oil cooler inlet oil and clutch
The transmission oil supply system cools and fil-
lubricating oil rises above 80 to 100 psi [5.62 to 7.03
ters the oil and delivers it as needed for all functions
kg/cm2], the oil cooler bypass valve opens and di-
of the transmission and steering clutches. Flow of oil
verts excess oil to the clutch lubricating oil circuit.
in the system is shown in Fig. 11.
Excess lubricating oil is in turn relieved as the clutch
lubricating oil bypass valve opens and dumps it to
Oil is sucked from transmission case reservoir by
the reservoir.
the clutch oil pump and constantly delivered to the
pressure regulating valve. This valve sends the oil
Initial oil pressure for the oil supply circuit is set by
"on demand" to the H-L- R clutches and steering
the pressure regulating valve, adjustable by shims.
clutches for engagement or to the oil cooler to be
The other valves work in series to regulate oil pres-
cooled and filtered and returned for clutch lubrication. <
sure.
During clutch engagement, pressure oil from the
If the oil filter clogs, the protective relief valve
pump is sent to the engaging clutch pack. As the
opens, allowing oil to bypass the filter and return di-
clutch engages and oil is no longer demanded, back-
rectly to the clutch lubricating circuit.
Litho in U.S.A.
70 System Testing Crawler - J0450-C
25-8 Hydraulic System TM-11 02 (Nov-73)
MAIN HYDRAULIC PUMP Functions Fail To Stay Raised
No Pump Output Or Low Flow Leaking or broken oil lines or fittings from control
valve to cylinder.
Pump worn or damaged.
Check for leaks. Tighten or replace lines.
Test pump against specifications.
Oil leaking past control valve spool(s).
Repair or replace valve spool(s).
Shaft Seal Leaking Oil leaking past cylinder seals.
Worn shaft seal. Replace worn parts in cylinder.
Replace shaft seal.
Broken diaphragm "vee" seal or backup gasket. Functions Fail To Work
Repair pump.
Excessive internal leakage. Insufficient oil in reservoir.
Repair pump. Add recommended oil.
Relief valve not functioning.
Noisy Pump Replace relief valve.
Insufficient relief valve pressure.
Pump worn or damaged. Clean or replace relief valve.
Test pump against specifications. Pump badly worn or damaged.
Low oil supply or oil of wrong viscosity. Repair or replace pump.
Fill reservoir with proper oil Broken oil line.
Suction line plugged or pinched. Check for leaks o:nd repair.
Clean or replace line. Obstruction in oil lines or valve.
Check flow of oil through system.
HYDRAULIC SYSTEM Worn control valve.
Repair or replace valve.
Functions Lift Slowly Oil leaking past cylinder seals.
Replace worn parts in cylinder.
Cold oil.
Allow oil to warm up. Oil Heats
Oil viscosity too heavy.
Use recommended oil. Operator holds valves open too long causing relief
Insufficient engine speed. valve to open.
Open crawler throttle. Return levers to neutral position when not in use.
Air leak in suction line. Incorrect system relief valve pressure.
Check and tighten. Replace relief valve.
Badly worn pump. Using light oil in very hot weather.
Replace or repair pump. Use recommended oil.
Oil leaking past cylinder packings. Dirty oil.
Replace worn parts. Drain and refill with new oil.
Oil leaking past control valve. Tractor engine running too fast.
Replace or repair valve. Reset speed control linkage or reduce throttle.
Restriction in suction line.
Check and replace suction line.
Dirty oil filter (if used).
Replace or clean filter
System relief valve dirty or leaking.
Clean or replace relief valve.
Litho in U.S.A.
TM-1102 (Nov-73} Hydraulic System 25-9
Oil Foams CLUTCH CONTROL VALVE
Air leak in line from reservoir to pump. Transmission Continually Runs Hot
Tighten or replace suction line.
Kink or dent in oil lines. Obstruction in cooler lines or cooler.
Replace oil lines. Check lines for mushy or collapsed condition and
Worn seal around pump shaft. cooler restriction.
Replace seal.
Wrong oil used. Cooler fins filled with trash.
Use recommended oil Clean and straighten fins.
Control Valve Sticks Or Works Hard Oil level too high.

Check level.
Return spring binding or broken.
Replace spring. Drag or interference caused by failed bearings.
Dirty valve. Replace worn or damaged transmission parts.
Clean valve. (See Section 40, Group 10).
Scored valve bore or bent spool.
Replace valve. Low oil pump capacity.
Misalignment of control linkage. Inspect pump for damaged or worn parts.
Foreign matter in spool bore. Low flow through cooler; check cooler flow.
Clean control valve and hydraulic system.
Weak cooler relief valve spring.
Engine Stalls While Working Replace spring and adjust system pressure.
Load beyond crawler or hydraulic system capacity. Shuttle Shift Too Abrupt
Move smaller loads. Check clutch valve adjustment.
Incorrect relief valve pressure.
Replace or clean cartridge. Shifts Too Slow
Check screen or pilot valve orifice for clogging.
System Pressure Is Low
WINCH SYSTEM
Relief valve ball held open by foreign material or bro-
ken valve spring. Allows oil to return to reservoir be- Brake Band Slippage
cause valve will not seat.
Replace or clean relief valve. Brake band out of adjustment.
Brake lining not fully contacting braking surface.
BREAKAWAY COUPLERS Burnish lining or replace brake band.
Oil on lining.
Cylinder Will Not Extend Inspect diaphragm or swivel fittings.
Check brake cylinder 0-rings and connectors.
Breakaway coupler valve closed. Excessive heat in brake band.
Turn breakaway coupler operating handles 90 de- Let cool for one hour and recheck.
grees. Brake band spring broken.
Mechanical binding in control linkage.
Cylinders Will Not Retract
Brake Does Not Disengage
Breakaway coupler valve closed.
Turn breakaway coupler operating handles 90 de- Low oil pressure - Check pressure.
grees. Oil leaks - Replace cracked lines.
Litho in U.S.A.
Clutch Slips or Does Not Engage Excessive "Free Spool" Effort Only
Low oil pressure - Check pressure. Low oil pressure - Check pressure.
Oil on clutch facings. Brake dragging - Readjust brake.
Inspect diphragm or swivel fitting. Excessive preload in winch drum.
Excessive oil leakage out small hole in left quill. Cable binding against winch housing.
Too much cable.
Clutch Does Not Disengage Snarled cable - Straighten or replace cable.
Middle or intermediate disk hanging up. Noisy Pump Caused by Cavitation

Repair clutch pressure plate assembly.
Damage to clutch release bearing or spring. Oil supply low. (See Section 10.)
Repair and replace spring. Contaminated oil.
Pressure plate not retracting. Oil filter plugged.
Suction line plugged.
Hydraulic Failure
Oil Heating
Low oil pressure - Check pressure.
Low oil supply. (See Section 10.)
Leakage of piston seals.
Contaminated oil.
Low oil supply. (See Section 10.)
Oil in system too light. (See Operator's Manual.)
Oil leaks - Replace cracked lines.
Failure to lock in "Free Spool" Position.
Inspect detent ball and spring. Add shims.
Foaming Oil
Low oil level.

Excessive "Free Spool" Effort
Air leaking into suction line.
(Clutch Dragging and Cable Winding
Wrong kind of oil. (See Operator's Manual.)
In "Free Spool" Position)
See "Clutch Does Not Disengage."

Clutch hub rubbing on brake drum to winch screws.
Left drive shaft bearing dragging.
Replace bearing.
Foreign material between facings.
Repair linkage.
Litho in U.S.A.
VISUAL INSPECTION
Slow function operation may be an indication that Wash inside and outside of oil lines and fittings
the hydraulic system is leaking. Check all oil lines with clean diesel fuel or petroleum solvent to remove
and connections for leaks. dirt before installing them on the machine.
Leaks in the pressure side of the system can be When tightening connections, always use two
located by carefully inspecting the external area of wrenches to prevent damage to hoses, tubing and
the components, fittings and hoses. fittings.
Check the suction side of the system for leaks by IMPORTANT: Tighten fittings only tight enough
examining the oil in the reservoir. If air is being to eliminate leaks. Do not overtighten connec-
drawn into the system, the oil will contain air bubbles tions.
and will appear to foam.
Dented tubing can cause oil foaming, heat, faulty

function operation or pump failure. Replace damaged
tubing immediately.
TESTING AND ADJUSTMENT
Flow Meter Tests Second is the "circuit test" which checks the effi-
ciency of the control valves, relief valves and cylin-
Before proceeding with these tests, read the oper-
ders.
ating and instruction manual furnished with each hy-
draulic tester and review the machine hydraulic
A preliminary check of the hydraulic system oil
system. A thorough understanding of the tester and
supply, oil lines and cylinder rods as well as for ex-
the hydraulic system will enable you to obtain more
ternal leaks, should be made prior to hydraulic tester
exact and helpful data when performing the test. Also
installation.
refer to "Diagnosing System Malfunctions" for an or-
derly process of eliminating the most likely trouble
When making test connections according to Figure
first.
12 use either all OTC fittings ("Y" prefix) with OTC
tester and hoses or all Nuday fittings ("D" prefix) with
There are two basic flow meter tests used to check
Nuday tester and hoses.
out the loader hydraulic system:
First is the "pump test" which checks the pump

r:;-, Refer to FOS Manual-HYDRAULICS for
~additional information on Hydraulic testing.
flow at rated pressure.
Litho in U.S.A.
25-12 Hydraulic System TM-1102 (Nov-73)
@
t I
l
~---@
\ I
\ I
I
\ \
"
T ZJ 147
--- - - - -- ::.--~
1- Pressure Line to Control 4-Pump 8-0-94, V3020 13-To Loader Control
Va lve 5-0·91 , Y21-10 9-0·96, Y3018 Valve Return Line
2-0ozer 0·88 6-Use with Pump Test 1Q-0-92, V3013 14-To Dozer Control
Loader 0 -98, Y3011 To Plug Hose and Tee 11- Hydraullc Tester Valve or Tee into
3-0ozer 0·99, Y3016 7-0·93, Y3019 12-0-101, Y3012 Return Line
Loader 0-97, Y3010
Fig. 12-lnstalling Hydraulic Tester
Hydraulic Pump Test Open pressure loading valve to read maximum

pump flow at zero pressure.
Connect hydraulic tester for pump test as shown in
Fig. 12.
Close loading valve slowly to increase pressure
and record flow at 250 psi [17.58 kg/crrr] increments
Open hydraulic tester pressure loading and oper-
from zero psi to maximum system pressure.
ate engine at fast idle.
Open hydraulic tester pressure loading valve until
Slowly close pressure loading valve to system
maximum pump flow is again at zero pressure.
operating pressure until normal operating tempera-
ture is reached .
Pump Test Diagnosis
NOTE: Mal{e all tests at operating temperature be· The decrease in flow from zero pressure to maxi-
cause as oil heats it becomes thinner and will dis- mum pressure is used to determine the pump condi-
close any internal leakage; however, never exceed tion (efficiency). A pump that delivers a constant low
210°F. {98.9°C]. flow at zero pressure and at maximum pressure indi-
cates suction problems.
Litho in U.S.A.
TM-11 02 (Nov-73) Hydraulic System 25-13
Hydraulic Circuit Test Circuit Test Diagnosis

Remove plug from goo side of tee at inlet side of If all components are in good operating condition,
hydraulic tester. Connect hose from control valve circuit flow measurements at each recorded pressure
pressure line (located along right side of tractor) to will be the same as made during the hydraulic pump
goo side of tee. Quick disconnect couplers may be test.
used at this point if desired.
If a continuous decrease in flow is noted in any of
NOTE: If flow divider is used in the hydraulic sys-
the control valve positions, leakage is indicated either
tem, the hydraulic tester must be installed between
within the control valve or in the cylinder.
the flow divider and bulldozer or loader control valve
in order to test the bulldozer or loader circuit. Basic
To determine whether leakage is in the control
test (same as pump test) is made on flow divider to
valve or in the cylinder, remove cylinder return line
compare with bulldozer or loader circuit tests. This
with the control valve in a power position. If no oil is
applies to the Sideboom, 345 Rotoboom and all
leaking from cylinder return port, the control valve is
backhoes used with dozers. This also applies to the
at fault. If leakage is noted, the cylinder is defective.
3400 Rotoboom when used with loaders.
Open hydraulic tester pressure loading valve and If the decrease in flow is the same with the control
operate engine at fast idle. valve in all positions, the system relief valve may be
at fault.
Slowly close pressure valve to load system until
normal operating temperatures (160°F) [71.1 °C] are
NOTE: This can also indicate some other leak is
reached.
present in the control valve such as a defective cast-
Open pressure loading valve to read maximum ing; however, always check the relief valve first.
system flow at "0" pressure.
If equipment with circuit relief valve is being
Operate function control valve and hold valve in a
checked, cracking pressure would be indicated by a
power position (piston in cylinder at the end of its
sudden decrease of approximately 3 gpm [ 11.36 I]
stroke).
(or more) or a drop of "0" gpm depending on wheth-
NOTE: Only one control valve should be in a power a full flow relief valve is used.
er position at any one time.
Relief Valves
With control valve held in a power position, slowly
close hydraulic tester loading valve and record flow Often relief valves will start to open before they
at 250 psi [17.58 kg/crrfJ increments from "0" psi to reach their full pressure flow settings. This can be
maximum system pressure. noted by comparing the pressure and flow rate read-
ing made in the circuit test. Any great decrease in
NOTE: Readings should be made at the same in-
flow rate indicates a faulty relief valve.
crements as recorded during the pump test.
Open hydraulic tester pressure loading valve until Falty system relief valves will affect pressure read-
maximum flow is again at "0" pressure. ings in all tests.
Repeat all power positions for all control valve
Faulty circuit relief valves will affect only pressure
circuits.
readings in individual circuits.
NOTE: Make all tests at normal operating temper-
ature (160°F) [71.1°C], if temperature is too hot (over
21 0°F) [98.9°C] from previous circuit test, keep load-
ing valve closed and work function control valve to
circulate oil through the system.
Litho in U.S.A.
70 System Testing Cra wler - JD450-C
Checking Control Valve for leaks

After long use, the valve spools may become
worn, allowing oil to leak past them . Check the valve
leaks as follows:
NOTE: Use loaded bucket to perform checks on

crawler loader machines.
1. Raise the function a few feet off the ground and

shut off the engine. Disconnect the return line be-
tween control valve and reservoir.
2. If the function settles because of valve spool

leakage, oil will seep frorn the disconnected return
line. Connect the return line and lower the blade to
the ground.
If the control valve check valves appear to be leak-

ing, proceed as follows: Rg; 13-Pressure Tap Loc13tion
1. Start engine. Raise the function a few feet off

the ground and return the control lever to the neutral If the control valve is not leaking and the function
position. continues to settle with the control valve in neutral ,
oil is probably leaking past the packings in the cylin-
2. Slowly move the control lever back to the raise ders. Check each cylinder individually to determine
position. If the function settles before it begins to which one is leaking.
rise, the check valve is probably leaking. Lower the
function to the ground and, if necessary, remove With the cylinder to be checked either fully extend-
control valve for service. ed or retracted, remove a hydraulic hose from one
end of the cylinder. (If the cylinder is extended, re-
Checking System Relief Valve move hose from rod end ; if the cylinder is retracted,
Install pressure gauge in pressure tap (1 /8 in-27 remove hose from the head end) . Cap end of hose
NPT) (Fig. 13). removed and operate the cylinder. Because the cyl-
inder piston is at the end of its stroke, the relief valve
With hydraulic oil at normal operating temperature will open.
and engine at fast idle, lower the function to the
ground . IMPORTANT: To prevent oil discharge from the
disconnected hose, be sure to operate cylinder in
Continue to hold the control valve open. This will the same direction as chosen above. For exam-
cause system pressure to build and the system relief ple, if hose is disconnected from the end, operate
valve to open. the valve lever to extend the cylinder.
Observe reading on pressure gauge at this time. Examine the open port on the cylinder. If any oil is
Refer to "Specifications" for relief valve operating leaking from the port, cylinder packings are defective
pressure. and should be replaced.
Checking Cylinders for Leaks Be sure to replace any oil lost during each test.
NOTE: Before checking the cylinders for leaks, in-

spect the control valve and relief valves.
Litho in U.S.A.
Checking Pump Efficiency

Check oil lines, control valve and cylinders before
checking the pump. To obtain correct timing, the hy-
draulic oil should be at normal operating temperature
and the engine at fast idle.
Check cycle times with a stop watch and refer to

Specifications for correct times.
If the cycle times are above the maximum times

given in specifications. the pump is probably faulty
and should be serviced.
Transmission Test
H-L-R Shifting 1- Drum Plug Location 2-Rubber Plug
Fig. 14·Checklng 011 Pressure

First adjust clutch pedal free travel and H-L- R link-
age (refer to Section 70, Group 25) .
H-L-R Pressure Test Adjust pressure if necessary as follows. Remove

rubber plug from top right side of the clutch housing
Start engine, warm it up to normal operating tem-
(Fig. 14). Then remove large plug from transmission
perature and set engine speed to fast idle. Warm up
front cover and add or subtract shims inside plug.
H-L- R oil to normal temperature by cycling reverser
(Grease may be used to retain shims.)
lever.
Read oil pressure on gauge. When pressure is
Remove large drum plug from transmission top
correct, reinstall plugs.
cover (Fig. 14). Remove small pipe plug from top of
accumulator housing and attach a pressure gauge in
Speed of Shift Adjustment
the hole as shown.
To make speed of shift adjustment, remove needle
Run engine at 1800 rpm and record oil pressure. valve access plug from right wall of transmission
Correct engaging oil pressure to H-L-R clutches is case (Fig. 15).
170 to 180 psi [11.9 to 12.6 kg/ crrfJ with oil at 150
to 180° F l65.6° to 82.2°C). NOTE: Needle valve should not need adjusting
unless manifold has been changed.
When shifting from reverse to high or high to re-
verse, the oil pressure at the by-pass valve in the Loosen jam nut and screw in on needle valve until
accumulator housing should drop from and return to shuttle shifting becomes sluggish. (If this cannot be
engaging oil pressure in 1 .5 seconds average. If de- done, recheck clutch pedal and shifter linkage adjust-
viation from this time is observed, readjust clutch oil ment.)
manifold needle valve. Always check clutch adjust-
ment before attempting to readust the needle valve. Screw out needle valve gradually until shuttle shift-
ing is as rapid as desired , without jerking (1.5 second
When shifting rapidly from high to low or low to average) .
high, the oil pressure at the by-pass valve in the ac-
cumulator housing should be 170 to 180 psi [ 11.9 to
12.6 kg/cm2 ) in 1 second maximum time after start of
shift.
Litho in U.S.A.
25-16 Hydraulic System TM- 1102 (Nov-73)
1- Needle Valve Access Plug T20983
Fig. 15-Adjusting Time Span of Shifting 1-Pressure Gauge 3- lnlet Line

2- 0il Cooler 4-Return Line
Fig. 16-Testing Bypass Valves

Hold needle valve in place and lock with jam nut.
Reinstall plug in case .
IMPORTANT: Do not allow shuttle shifting to Run transmission at 1800 rpm and the range
become sluggish. If shift Is too slow, excessive change (H-L-R) in gear position.
heat will be generated while clutch is slipping,
and clutch friction disks will become glazed. As a Pressure at the gauge on the cooler return line
result, the clutch may slip under load and tractor (Fig. 16) should be 58 to 72 psi [ 4.1 to 5.1 kg/cnf].
will lose power. Keep clutches adjusted for a The differential between gauges in the cooler inlet
snappy shift. line and the cooler return line should be 80 to 100
psi [5.6 to 7.0 kg/cm2 ]. If deviation from these pres-
If correct shift time cannot be obtained , recheck sures is observed, check the valves and springs .
linkage adjustments.
Run engine at 2500 rpm . Engage clutch with the
Oil Cooler Bypass Valve and Clutch Lu- H-L-R in neutral position. Flow through the cooler
bricating Bypass Valve Test should be 10 gpm [37.8 I] minimum.
Detach the cooler inlet line and return line at cool- Remove gauges and reinstall inlet and return lines
er elbows. Attach a pressure gauge to both the inlet after this portion of the test.
line and return lines.
Litho in U.S.A.
Winch System Tests Adjust engine speed to 800 rpm.
NOTE: Brake band must be correctly adjusted and Again move winch control lever from hold to wind
if new brake facings have been installed, they must position and observe reading on pressure gauge.
be burnished before the following tests are per- Pressure should rise rapidly to at least 850 psi
formed (see Section 60, Group 15). [59.76 kg/cm2 ).
Pressure Tests Repeat test a mmrmum of ten times. Pressure

must repeat and be stable.
High pressure indicates that relief valve is out of

adjustment.
Low pressure indicates that the relief valve is out

of adjustment, winch pu ~np is faulty or damaged or
oil is leaking past the control valve, brake piston or
clutch pressure plate.
Leakage Checks
Brake Piston Seals and Clutch Pressure

Plate Diaphragm
Remove left quill from the winch housing. If oil is
found behind this quill , the brake piston or clutch
pressure plate is leaking and should be repaired.
Fig. 17-Checking Relief Valve Control Lever Adjustment
Install a 0 to 1500 psi [ 105.46 kg/cnfJ pressure Push control lever forward (with a force not to ex-
gauge in winch housing as shown in Fig. 17. ceed 50 lbs. [22.7 kg]) until the internal stop inside
the control valve is contacted.
Start and run unit until oil temperature reaches
155° to 165°F [68.3° to 73.9°C]. NOTE: If you cannot contact the internal stop in-
side the control valve adjust yoke accordingly.
Adjust engine speed to 1900 rpm.
When the internal stop inside the control valve has
Move the winch control lever from hold to wind po- been contacted , adjust lever stop cap screw to con-
sition and observe reading on pressure gauge. Pres- tact control lever. Then adjust control lever stop cap
sure should rise rapidly to 950 to 1050 psi [66.8 to screw 1/2 turn long and tighten nut.
73.8 kg/em~.
Repeat test a minimum of ten times. Pressure

must repeat and be stable.
Litho in U.S.A.
Litho in U.S.A.
TM-1102 (Nov-73} Miscellaneous Components 30-1
Group 30
TRACKS 2. Drifting of tractor to right or left, depending on
which track is the tighter.
Possible results of improper track adjustment are
listed below.
3. Fast wear on pins, bushings, and track links.
Loose Track
4. Excessive and rapid wear on drive sprockets
If this condition exists, the following may result: and idler wheels. Undue strain on entire track system
because track flexibility is lost.
1. Extremely fast wear on pins, bushings, and
track links. 5. Unnecessary wear on final drive bearings and
oil seals.
2. Unnecessary and rapid wear on sides of drive
sprocket teeth and idler wheel flanges. 6. Abnormal steering clutch wear.
3. Possible damage to, or breakage of, drive Misaligned Track

sprocket, idler wheel and idler wheel bracket, fend-
If this condition exists, the following may result:
ers, side frames, and rollers.
1. Drifting of tractor from a direct course.
4. Track may jump sprocket in both forward and
rearward operation. Track may be thrown off when
2. Abnormal wear on idler wheel flanges and front
tractor is turned.
idler flanges.
5. Noisy track.
3. Excessive track link and drive sprocket wear.
6. Frequent accumulation of trash in track.
4. Rapid steering clutch and brake wear.
Tight Track 5. Operator annoyance and fatigue caused by the
If this condition exists, the following may result: constant necessity of steering the tractor to keep it
from drifting.
1. Extreme loss of drawbar power and ground
speed. Tractor will not handle rated working load.
Litho in U.S.A.
30-2 Miscellaneous Components TM-11 02 (Nov-73)
WINCH Excessive "Free Spool" Effort

(Clutch Dragging and Cable Winding
Brake Band Slippage In "Free Spool" Position)
Brake band out of adjustment. See page 60-15-10.

Brake lining not fully contacting braking surface. Clutch hub rubbing on brake drum to winch screws.
Burnish lining or replace brake band. Left drive shaft bearing dragging.
Oil on lining. Replace bearing.
Inspect diaphragm or swivel fittings. Foreign material between facings.
Check brake cylinder 0-rings and connectors. Mechanical binding in control linkage.
Excessive heat in brake band. Repair linkage.
Let cool for one hour and recheck.
Brake band spring broken. Excessive "Free Spool" Effort Only
Low oil pressure - Check pressure. (See Section 70,
Brake Does Not Disengage Group 25.)
Brake dragging - Readjust brake.
Low oil pressure - Check pressure. (See Section 70, Excessive preload in winch drum.
Group 25.) Cable binding against winch housing.
Oil leaks - Replace cracked lines. Too much cable.
Snarled cable - Straighten or replace cable.
Clutch Slips or Does Not Engage
Noisy Pump Caused by Cavitation
Low oil pressure - Check pressure.
Oil on clutch facings. Oil supply low. (See Section 10, Group 15.)
Inspect diaphragm or swivel fitting. Contaminated oil.
Excessive oil leakage out small hole in left quill. Oil filter plugged.
Suction line plugged.
Clutch Does Not Disengage
Oil Heating
Middle or intermediate disk hanging up.
Repair clutch pressure plate assembly. Low oil supply. (See Section 10, Group 15.)
Damage to clutch release bearing or spring. Contaminated oil.
Repair and replace spring. Oil in system too light. (See Operator's Manual.)
Pressure plate not retracting.
Foaming Oil
Hydraulic Failure
Low oil level.
Low oil pressure - Check pressure. (See Section 70, Air leaking into suction line.
Group 25.) Wrong kind of oil. (See Operator's Manual.)
Leakage of piston seals.
Low oil supply. (See Section 10, Group 15.)
Oil leaks - Replace cracked lines.
Failure to lock in "Free Spool" Position.
Inspect detent ball and spring. Add shims.
Litho in U.S.A.
TM- 1102 (Nov-73) Misce!faneous Components 30-3
ADJUSTMENT
Track Tension To loosen track, first loosen jam nut on set screw
of track adjusting cylinder. Then turn set screw coun-
For proper track and tractor operation, it is neces-
sary that track tension and track alignment adjust-
ments be properly made.

When operating track in conditions where extreme

soil packing occurs in track system, check track ten-
sion often as tens ion may increase when soil is
coil mechanism, and final drive components.
1-Track Sag 3-0ecrease Tension
2- Pin Centered 4-lncrease Tension IMPORTANT: When forward edge of track front
Fig. 1-Track Tension Adjustment the end of the track frame, track bushings and
When measuring track sag, a pin and bushing place excessively worn bushings and pins as
must be lined up over center of track carrier roller. needed. When the forward edge of the front Idler
Adjust track sag so there is 7/8 to 1-1/8 inch [22.23 and forward end of the track frame are in line,
to 28.58 mm] sag in center of track between rear track assemblies are In need of reconditioning.
sprocket and carrier roller (Fig. 1).
After adjusting for proper tension, check alignment
Track tension is adjusted by attaching flexible hose and adjust if necessary.
with special adapter furn ished with crawler on a
grease gun that has a maximum capacity of 8000 psi Track Alignment
[562.46 kg/cm2].
The importance of proper track alignment cannot
To tighten track, apply grease with gun until the be too greatly emphasized. If the sides of the drive
proper tension is achieved (Fig. 1). sprockets and front idler flanges show heavy wear,
the track is probably out of alignment.
IMPORTANT: Never, under any circumstances,
use a grease gun to adjust track having a capaci- Check track alignment by driving forward on level
ty higher than 8000 psi [562.46 kg/cmZJ. Tee a ground for about 25 feet [7.62 m]. Stop tractor with-
pressure gauge (0 to 10,000 psi [0 to 703 .07 out touching steering levers and examine location of
kg/cm 2 ] capacity) In grease gun tube to check track link in relation to the front idler flanges (Fig. 2) .
pressure. If piston cannot be moved with this {In the illustration one shoe has been removed for
type grease gun, disassemble track adjuster and better visibility.)
free seized parts.
Litho in U.S.A.
70 System Testing Crawler - J0450- C
30-4 Miscellaneous Components TM-11 02 (Nov-73)
Loader Boom Alignment

The loader boom is attached to the loader frame
with eccentric pins, making several boom ad just-
ments available .
By turning the eccentric pins so the offset portion

of one is facing forward and the other facing to the
rear, approximately 1/2 inch [12.7 mm] of side ad-
justment is possible.
NOTE: A lesser degree of adjustment is possible

by turning the pins so the offset portions are only 90
degrees apart instead of 180 degrees.
The eccentric pins are in a neutral position when

the low side of the pins are in the down position.
To adjust the boom, proceed as follows:

1- Track Shoe 2-Track Idler
Fig. 2-Checking Track Alignment

properly aligned.
Fig. 4-Loader Boom
Raise the loader boom five feet and secure with a

hoist. Remove the cap screws and retaining wash-
ers .
1-Adjusting Shims 2- Track Adjusting Cylinder
Shims are provided on each side at the rear of

rear of idle r bracket (Fig . 3) on the side of idler
move one shim, then test by running the tractor in
Litho in U.S.A.
TM-1102 (Nov- 73) Miscellaneous Components 30-5
Drive the eccentric pins out 1/2 inch [12.7 mm) to Angling Bulldozer Blades
clear retaining blocks.
The bulldozer blades (except the 6415) can be an-
gled 25 degrees to the right or the left.
6410 Bulldozer
Raise the blade off the ground before attempting to
change the angle.
Reinove both angling pins. Set blade at desired

angle and replace pins.
Tilting and Leveling Bulldozer Blades

6410 Bulldozer
Drive wedges loose and adjust the tilt of the blade.
Fig. 5-Eccentric Pin
The boom is in neutral position when both pivot The blade is level when the top of the clamp lock
pins have the low side of eccentric in the down posi- is even with the dot on the track.
tion (Fig. 5).
6405 Bulldozer
One-half inch side adjustment can be obtained by The blade is level when the indicator on the an-
positioning the low side of eccentric of one pin for- gling frame and the second cap screw retaining the
ward and the low side of eccentric of the opposite blade keeper are aligned.
pin rearward .
6415 Bulldozer
One-fourth inch side adjustment can be obtained
by positioning the low side of eccentric of one pin in The blade is level when the boom guide plates are
forward or rearward position and the low side of ec- even with the blade keepers.
centric of the opposite pin in the down position.
Maximum tilt on each dozer is as follows. 6405
Bulldozer - 14 in. [355.6 mm]; 6410 Bulldozer - 11
in. [279.4 mm]; and 6415 Bulldozer - 11.5 in. [292.1
mm).
Regulating Blade Depth

Gauge shoes can be attached to the bottom of the
blade to assist in regulating depth of blade penetra-
tion. Adjust the shoes up or down by loosening the
bolts holding them to the blade.
T$2131 IV.
1-0ffset Down 3-0ffset Fro nt (Right Pin)

2-0ffset Rear (Right Pin) Offset Rear (Left Pin)
Offset Front (Left Pin)
Fig. 6-Eccentric Pin Positions
Litho in U.S.A.
30-6 Miscellaneous Components TM-11 02 (Nov- 73)
Lumber Fork Tines

The tines on the fork may be adjusted from 70 to
15 inches [ 1,778 to 381 mm].
Fig. 7-Adjusting Tines
To adjust tines, remove collar from shaft and pull

shaft out. Place spacers on either side of tine to ob-
tain desired position.
Litho in U.S.A.
Group 35
ENGINE
Basic Engine Minimum compression reading ...................... 350 psi

[24.61 kg/em~
The most important factor in compression readings

is the difference between cylinders. This difference
should be no more than 50 psi [3.5 kg/crrf J.
Engine Lubrication System Oil pressure at 2500 rpm with engine at normal
operating temperature .... 45 to 65 psi [3.16 to 4.51
kg/cm 2 ]
Engine Cooling System Fan Belt Adjustment:
With Gauge
(initial) ............................................. 100 to 110 lbs.
[ 45.4 to 49.9 kg] tension
(after 3 minutes of
operation) ...................................... 80 lbs. minimum
[36.3 kg]
Without gauge ..................... 3/4-inch [19.0 mm] flex

at 25 lbs. force
[11.3 kg]
Fuel System Fuel supply pump at low idle

Pressure ................................................... 2 to 2.5 psi
[0.14 to 0.17 kg/cm2]
Injection pump cam advance

JDB435AL2442
Total advance movement.. ..................... r ± 1/2°
Advance at 1900 rpm
(full load) ............................... 5° (check 5° ± 1°)
Advance at 1100 rpm (no load) ........................ .4°
Advance by 2500 rpm (full load) ........ 6-1/2° min.
Litho in U.S.A.
35-2 Specifications and Special Tools TM-1102 (Nov-73}
ENGINE
Speed Control Linkage Fast idle ....................................................... 2650 rpm

Slow idle ........................................................ 800 rpm
Overtravel at throttle lever ............................... 1/8 in.

[3.175 mm]
Drag friction on throttle lever ................. 5 to 11 lbs.

[2.3 to 5.0 kg.]
Air Intake System Air restriction indicator shows red when water vacuum
gauge reads ....................... 14 to 25 inches of water
[1.05 to 1.41 kg/cm2 ]
Intake manifold vacuum
at high idle (2650 rpm) ......................... 15 to 20 psi
[1.05 to 1.41 kg/cm 2]
Litho in U.S.A.
TM-1102 {Nov-73) Specifications and Special Tools 35-3
ENGINE
SPECIAL TOOLS
Essential Tools
Basic Engine
Tool Tool Number use
70-314"' Compression Gauge Adapter - To
check diesel engine compression.
:i.'3182BNV
Fig. 1-Compression Gauge Adapter
70-7003* Compression Gauge - To check

diesel engine compression.
T27985N
Fig. 2-Compression Gauge
*Available from: Bacharach Instrument Co.

625 Alpine Drive
Pittsburgh, Pennsylvania 15238
Litho in U.S.A.
ENGINE
Engine Lubrication System
Pressure Gauge - To check oil

and fuel pressures.
Fig. 3-Pressure Gauge
Engine Cooling System

(Not Illustrated) Radiator Pressure Tester - To check
radiator for leaks.
Fuel System
JD-259 (13366)* Timing Window - To adjust injec-
tion pump cam advance.
T 3 19 20N
Fig. 4-lnjection Pump Timing Window

1901 Indiana Ave.
Chicago, 1/linois 60616
Litho in U.S.A.
ENGINE
Speed Control Linlf.age
Tool Tool No. Use
(Not Illustrated) Tachometer To check engine

speeds while adjusting speed con-
trol linkage.
Convenience Tools
Engine Cooling System (Not Illustrated) Fan Belt Tension Gauge - To check
fan belt tension.
JDST-11 * Water Vacuum Gauge - To check fuel

and air vacuum.
T2?630N
Fig. 5-Water Vacuum Gauge and Finings

1901 Indiana Ave.
Litho in U.S.A.
ELECTRICAL SYSTEM
Starting Circuit Test Values

Test No. 1.............. .. .................... 9.0 to 12.0 volts
Test No. 2 ........ ............................ 9.0 to 12.0 volts
Test No. 3 .................................... 9.0 to 12.0 volts
High Resistance Test Values

Test Point Maximum Voltage Reading
A-F 0.2
B-C 0.2
C-D 1.0
C-E 0.2
TJ213 2N
1- Batteries s-s tart Switch

2-Starting Motor 6-Key Switch
3-Solenold 7- lnjection Pump
4-Start-Safety Solenoid
Switch 8-Circuit Breaker
Fig. 6-Starting Circuit Test Points
Charging Circuit Test Values

Test No. 1 ............................... .. ...... .............. 0 volts
Test No. 2 ....................................... .. ......... 2.0 volts
R Regulator Connector Purple wire .... 9.0-12.0 volts
Test no. 3
Regulator field circuit or ground
circuit is open .......... .. .......................... 12 volts
Field circuit shorted to ground ................. 0 volts
Test No. 4
Initially .................... .......... 20 arnps at 13.0 volts
After fifteen minuts of operation
at 70°F [21 .1°C] (See chart below for dif-
ferent temperature values) . 10 to 15 amps at
14.4 volts
Temperature* Voltage
~ T3 8 133N
0 1ES1 PO! Hl
40°F
60°F
[4.4°C]
[ 15.6°C]
14.4
14.3
-
-
14.9
14.7
volts
volts
80°F [26.7°C] 14.2 - 14.6 volts
1-Batterles s-circult Breaker 100°F [37.8°C] 14.0 - 14.4 volts
2- Starting Motor 6-Aiternator
3-Solenoid 7-Regulator 120°F [ 48.9°C] 13.8 - 14.3 volts
4-K-ey Switch 140°F [60.0°C] 13.6 - 14.1 volts
Fig. ?-Charging Circuit Test Points *Measured one inch from regulator.
Test No. 5 ........................... ......... 9.0 to 12.0 volts

Litho in U.S.A.
Cra wler - JD450-C System Testing 70
ELECTRICAL SYSTEM
Charging Circuit High Resistance Test
Values
Test Points Maximum Voltmeter Reading *
\
itx~ 7 A-D
B-E
0.3 volt
0.3 volt
B-C 1.3 volt
*10-amp charging rate
1-Batteries 5-Circuit Breaker

2- Starting Motor 6-Aiternator
3-Solenoid 7-Regulator
4-K:ey Switch
Fig. 8-Charging Circuit High Resistance Test Points
Gauges and Return-to-Dig Circuit

Test No. 4 - Engine water temperature engine oil
pressure and transmission tempera-
ture gauges purple
lead ............................ 9.0 to 12.0 volts
Test No. 5 - Return-to-dig bucket switch, spool

switch and spool
solenoid ..................... 9.0 to 12.0 volts
Light Circuit Test Values
Voltage reading at lamp terminal...... Battery voltage

Maximum voltage drop between battery
and lamp ...................................................... 0.5 volt
Maximum voltage drop between lamp frame and
ground ; across switch or connection .. ...........0.1 volt
Litho in U.S.A.
70 System Tes ting Crawler - JD450-C
ELECTRICAL SYSTEM
SPECIAL TOOLS
Essential Tools
Voltmeter - Check starting circuit,

charging circuit, accessory circuit
and light circuit.
Ammeter - Check alternator out-

put.
Fig. 9-Voltmeter and Ammeter
Litho in U.S.A.

1. Clutch pedal free travel ............... ............ 3.750-in.
[95.250 mm]
Fig. to-Clutch Pedal Free Travel

1. Top of steering lever full

travel ........... 10 ± 0.25-in. [254.00 ± 6.350 mm]
Fit. It-Steering Clutch Lever Travel
Litho in U.S.A.
70 System Testing Crawler - J0450-C
35-10 Specifications and Special Tools TM- 11 02 (Nov-73)
STEERING CLUTCH AND BRAKE ASSEMBL V

1. Force to pull brake lever to

the stop .. ..... ............................................. ....60 lbs.
[22.68 kg]
Fig. 12-Ciutch Lever Movement Force
Litho in U.S.A.
HYDRAULIC SYSTEMS
SPECIFICATIONS
Hydraulic System Operating temperature ......................... 150° to 180°F

[65.6° to 82.2°C]
rv'lain Hydraulic Pumps Minimum output (15 gpm) ............ 14.0 gpm [53.0 IJ
at 2250 psi [158.2 kg/cm2 ]
at 2500 rpm.
(23 gpm) .................... 22.6 gpm [85.5 I]
at 2250 psi [158.2 kg/cm2 ]
at 2500 rpm.
(28 gpm) ..................... 28 gpm [106.0 I]

at 2250 psi [158.2 kg/cm 2 ]
at 2500 rpm.
2
Relief Valve Pressure Settings Loader - System relief... .... 2250 psi [158.2 kg/cm ]
2
Boom raise .......... 2500 psi [175.8 kg/cm ]
Bucket roll-back .. 2500 psi [175.8 kg/em~
Bucket dump ........ 1000 psi [70.3 kg/em~
Bulldozer - System relief... 1750 psi [ 123.0 kg/ cm 2]

Selector valve (with backhoe) ...................... 2000 psi
[140.6 kg/cm2 ]
2
Backhoe - Crowd relief ..... 2375 psi [167.0 kg/cm ]
2
Swing relief ...... 1625 psi [ 114.2 kg/ cm ]
Boom relief (lower) ..................... 3500 psi
[246.1 kg/cm 2 ]
Boom raise ..................................................... 2375 psi
[167.0 kg/cm 2 ]
Multipurpose bucket clam relief .................... 2500 psi
[175.8 kg/cm 2]
Breakaway Couplers Force to uncouple coupler .............................. 30 lbs.
[ 13.6 kg] at 0 psi [0 kg/ em~
Max. breakaway angle ............................. 30 degrees
Pressure drop through coupler ........................ 22 psi
[1.5 kg/cm 2 ] at 6 gpm L22.7 I]
at 150°F [65.6°C]
Reservoir Pressure cap setting .............................. 12 to 15 psi
2
[0.8 to 1.0 kg/cm ]
Vacuum valve setting in pressure cap .............. 6 psi
2
[0.4 Rg/cm ]
Litho in U.S.A.
HYDRAULIC SYSTEMS
SPECIFICATIONS-Contiued
H-L-R Transmission Hydraulic oil pressures at 150° to 180°F [65.6° to

82.2°CJ.
Lubrication oil to clutches .................. 58 to 72 psi

[ 4.1 to 5.6 kg/em~
Engaging oil to clutches ................ 170 to 180 psi

[11.9 to 12.6 kg/cm 2 ]
Pressure regulating valve ............... 170 to 180 psi

2
[11.9 to 12.6 kg/cm ]
Oil cooler bypass valve .................... 80 to 100 psi

[5.6 to 7.0 kg/cm 2] above lube pressure
Clutch lubricating bypass

valve ..................................................... 58 to 72 psi
[ 4.1 to 5.6 kg/cm 2 ]
Shifting time - high to low .................. 1 sec. max.
Shifting time - high to reverse .................. 1.5 sec.
Winch System Pump output ....................................... 1.0 to 1.4 gpm

2
[3.8 to 5.3 I] at 650 psi [ 45.7 kg/cm ]
Relief valve ....................................... 950 to 1050 psi

[66.8 to 73.8 kg/cm 2 ] at 1900 engine rpm
Relief valve ............................................. 800 psi min.

[56.2 kg/cm 2 ] at 800 engine rpm.
SPECIAL TOOLS
Convenience Tools
Tool No. Use
Driver (not illustrated) 630-11 * To press oil seal in winch input
shaft quill.
Driver (not illustrated) 630-17* To press bearing cone on winch

main drive shaft.
Driver (not illustrated) 630-13* To press bushings in winch fairlead

rollers.
*Order from: Service Tools Inc.

1901 Indiana Ave.
Chicago, Ill. 60616
Litho in U.S.A.
TM-1102 (Nov-73) Specifications and Special Tools 35- 13
1 - Track sag ................................... 7/ 8 to 1-1 / 8 in.

[22.23 to 28.58 mm]
Fig. 13- Track Sag
- Front Idler Alignment... ........................... centered

between track links.
Fig. 14-Front Idler Alignment
Litho in U.S.A.
35-14 Specifications and Special Tools TM- 1102 (Nov-73)
- Loader boom side adjustment... ..t.. up to 1/2 in.
[1 2.7 mm]
Fig. 15-Boom Side Adjustment
1 - Angle of 6405 and 64 10 Bulldozer

blades ............... .... maximum of 25" right or left.
2 - Maximum tilt:
6405 Bulldozer - 14 in. [355.6 mm)
6410 Bulldozer - 11 in. [279.4 mm)
6415 Bulldozer - 11 .5 in. [292.1 mm)
T32141N
Fig. 16-Bu/ldozer Adjustments
- Distance between
lumber fork tines ............................... 70 to 15 in.
[1,778 to 381 mm]
Fig. 17-Lumber Fork
Litho in U.S.A.
Crawler - JD450-C
TM-11 02 (Nov-73) Index 1
INDEX
A Oil flow ...................................... 50-20-1 - 50-20-6

Accumulator. .................................................... 50-20-9 Operation ................................... 50-20-1 - 50-20-6
After-sale inspection ................. 10-10-23 - 10-10-50 Removal ....................................................... 50-20-7
Air cleaner ....................................................... 20-35-1 Repair .......................................................... 50-20-7
Air intake system .......................... 20-35-1 - 20-35-7 Connecting rods .......................... 20-1 0-7 - 20-1 0-11
Air restriction indicator ................................... 20-35-2 Cooling system ............................. 20-20-1 - 20-20-4
Alternator ..................................... 30-1 0-1 - 30-1 0-1 0 Crankshaft.. ............................... 20-1 0-12 - 20-1 0-14
Assembly ................................... 30-1 0-8 - 30-1 0-9 Cylinder block ............................. 20-1 0-7 - 20-1 0-11
Components ................................................. 30-10-3 Cylinder head ................................ 20-10-2 - 20-10-6
Disassembly ............................... 30-10-2 - 30-10-6 Cylinder liners ............................. 20-1 0-8 - 20-1 0-1 0
Installation .................................................. 30-1 0-1 0 Cylinder liners, deglazing ............................... 20-10-9
Removal ....................................................... 30-1 0-2 Cylinders, hydraulic .................... 50-50-1 - 50-50-19
Tests ......................... 30-1 0-6 - 30-1 0-8, 30-1 0-1 0
Ammeter ........................................ 30-20-1 - 30-20-2 D
Deglazing cylinder liners ................................ 20-10-9
8 Delivery service ............................................ 10-1 0-23
Backhoe ......................................... 60-40-1 - 60-40-7 Diagnosis and testing ....................................... 70-5-2
Installation .................................................... 60-40-7 Dozer ............................................. 60-30-1 - 60-30-4
Removal ....................................................... 60-40-1 Components ............................... 60-30-2 - 60-30-3
Repair ........................................ 60-40-2 - 60-40-7 Installation .................................................... 60-30-4
9250 ....................................... 60-40-4 - 60-40-6 Removal ....................................................... 60-30-2
9300 ....................................... 60-40-2 - 60-40-4 Repair ........................................ 60-30-2 - 60-30-4
Backhoe control valve .................. 50-40-1 - 50-40-5 Dozer adjustments .......................................... 70-30-5
Backhoe cylinders ....................... 50-50-7 - 50-50-17 Dozer control valves .................... 50-35-1 - 50-35-5
Balancer shafts ............................................. 20-1 0-15 Auxiliary valve ............................................. 50-35-4
Basic engine ............................... 20-10-1 - 20-10-19 Components ................................................. 50-35-3
Batteries ............................................ 30-5-2 - 30-5-6 Installation .................................................... 50-35-5
Charging ........................................................ 30-5-5 Oil flow ...................................... 50-35-1 - 50-35-2
Installation ...................................................... 30-5-6 Removal ....................................................... 50-35-3
Precautions .................................................... 30-5-2 Repair .......................................................... 50-35-3
Removal ......................................................... 30-5-3 Valve linkage ............................................... 50-35-5
Testing ........................................... 30-5-3 - 30-5-5
Bearings, main .......................... 20-10-12 - 20-10-14 E
Break-in, engine ........................................... 20-40-11 Electrical system testing ............ 70-15-1 - 70-15-21
Breakaway coupler, hydraulic ........................ 50-55-8 Block diagram ............................................. 70-15-8
Bucket, loader ............................... 60-25-3 - 60-25-5 Malfunctions ............................... 70-15-6 - 70-15-7
Operational theory ..................... 70-15-1 - 70-15-3
c Precautions ................................ 70-15-4 - 70-15-5
Camshaft ......................................................... 20-1 0-6 Schematic diagram ..................................... 70-15-9
Charging system ......................... 30-10-1 - 30-1 0-1 0 Tests ...................................... 70-15-12- 70-15-21
Cigar lighter .................................................... 30-20-2 Visual inspection .... .".................................... 70-15-5
Circuit breaker ................................................ 30-20-2 Wiring routes ......................... 70-15-1 0 - 70-15-11
Clutch assembly ............................... 40-5-2 - 40-5-7 Engine break-in ............................................ 20-40-11
Components ................................................... 40-5-3 Engine components .................... 20-10-1 - 20-10-19
Installation ...................................................... 40-5-7 Balancer shafts ......................................... 20-1 0-15
Linkage .......................................... 40-5-6 - 40-5-7 Camshaft... ................................. 20-1 0-6 - 20-1 0-7
Removal ......................................................... 40-5-3 Connecting rods ...................... 20-1 0-7 - 20-1 0-11
Repair ............................................ 40-5-3 - 40-5-7 Crankshaft... ........................... 20-10-12 - 20-1 0-14
Clutch control valve ...................... 50-20-1 - 50-20-9 Cylinder block .......................... 20-10-7 - 20-10-11
Accumulator ................................................. 50-20-9 Cylinder head ............................ 20-1 0-2 - 20-1 0-6
Components ................................................. 50-20-8 Cylinder liners ......................... 20-10-8 - 20-10-10
Installation .................................................... 50-20-9 Flywheel. ................................ 20-1 0-12 - 20-1 0-14
Litho in U.S.A.
Crawler - JD450-C
2 Index TM-11 02 (Nov-73)
Gear train .............................. 20-10-16 - 20-10-19 H

Main bearings ........................ 20-10-12 - 20-10-14 Hour meter ...................................................... 30-20-2
Oil pan ....................................................... 20-10-11 Hydraulic backhoe control valve . 50-40-1 - 50-40-5
Piston rings ............................................... 20-1 0-1 0 Hydraulic breakaway coupler ......................... 50-55-8
Pistons ..................................... 20-1 0-7 - 20-1 0-11 Hydraulic cylinders ...................... 50-50-1 - 50-50-19
Rocker arm assembly ............... 20-1 0-4 - 20-1 0-5 Backhoe cylinders ................... 50-50-7 - 50-50-17
Valves ........................................ 20-10-2 - 20-10-6 Clam cylinder ........................ 50-50-18 - 50-50-19
Engine cooling system ................. 20-20-1 - 20-20-4 Dozer cylinders ......................... 50-50-3 - 50-50-5
Engine fuel system ....................... 20-25-1 - 20-25-7 Grapple cylinder .......................................... 50-50-3
Engine lubrication system ........ 20-15-1 - 20-15-3 Loader boom cylinder ................................. 50-50-1
Engine oil filter ............................................ 20-15-3 Loader bucket cylinder ............................... 50-50-2
Engine oil pressure adjustment.. ............... 70-10-9 Log and lumber clamp cylinders ............... 50-50-2
Engine oil pressure gauge ............................ 30-20-1 Ripper cylinder ............................................ 50-50-6
Engine oil pump ........................... 20-15-1 - 20-15-3 Hydraulic dozer control valves .... 50-35-1 - 50-35-5
Engine removal and installation ...................... 20-5-3 Hydraulic filters ............................................... 50-55-1
Engine system testing ................ 70-10-1 - 70-10-14 Hydraulic flow divider ................... 50-55-5 - 50-55-6
Operational theory ..................... 70-10-1 - 70-10-2 Hydraulic loader control valve ..... 50-30-1 - 50-30-7
Malfunctions ............................... 70-1 0-3 - 70-1 0-5 Hydraulic pump ............................. 50-10-1 - 50-10-3
Tests and adjustments ........... 70-10-8 - 70-10-14 Hydraulic pump, winch ................. 50-15-1 - 50-15-2
Visual inspection ....................... 70-10-6 - 70-10-7 Hydraulic reservoir .......................................... 50-55-1
Engine water temperature gauge .................. 30-20-1 Hydraulic selector valve ............... 50-55-4 - 50-55-5
Hydraulic system testing ............ 70-25-1 - 70-25-17
F Block diagram ............................................. 70-25-6
Fan belt adjustment ..................................... 70-10-10 Malfunctions ............................. 70-25-8 - 70-25-10
Fairlead, winch .............................. 60-20-1 - 60-20-2 Operational theory ....................................... 70-25-7
Flow divider ................................... 50-55-5 - 50-55-6 System diagrams ....................... 70-25-1 - 70-25-5
Filter, engine oil. ............................................. 20-15-3 Tests ...................................... 70-25-11 - 70-25-17
Filter, fuel ........................................................ 20-25-2 Visual inspection ....................................... 70-25-11
Filter, return line ............................................. 50-55-1
Filter, transmission case oil ........................... 50-55-2
Final drive assembly .................... 40-20-1 - 40-20-6 Injection nozzles, fuel. .................. 20-25-6 - 20-25-7
Components ............................... 40-20-1 - 40-20-3 Injection pump, fuel
Installation .................................................... 40-20-6 (Model JDB) .............................. 20-25-3 - 20-25-5
Removal ..................................... 40-20-2 - 40-20-3 Inspection, after-sale ................ 10-10-23- 10-10-50
Repair ........................................ 40-20-3 - 40-20-5 Instrument panel ............................................. 30-20-3
Flywheel .................................... 20-10-12 - 20-10-14
Fuel filter ......................................................... 20-25-2 K
Fuel injection nozzles ................... 20-25-6 - 20-25-7 Key switch ....................................................... 30-20-2
Fuel injection pump ...................... 20-25-3 - 20-25-5
Adjustment ................................................. 70-10-11 L
Bleeding ....................................................... 20-25-5
Loader ........................................... 60-25-1 - 60-25-6
Installation .................................................... 20-25-4
Boom ............................................................ 60-25-5
Malfunctions ............................... 20-25-3 - 20-25-4
Buckets ...................................... 60-25-3 - 60-25-5
Removal ..................................... 20-25-4 - 20-25-5
Bucket teeth ................................................ 60-25-3
Repair .......................................................... 20-25-4
Frame ........................................................... 60-25-6
Timing ........................................ 20-25-4 - 20-25-5
Installation .................................................... 60-25-6
Fuel system .................................. 20-25-1 - 20-25-7
Linkage ........................................................ 60-25-5
Fuel tank ....................................... 20-25-1 - 20-25-2
Removal ....................................................... 60-25-2
Fuel transfer pump ....................... 20-25-2 - 20-25-3
Repair ........................................ 60-25-3 - 60-25-6
Loader adjustment ........................ 70-30-4 - 70-30-5
G Loader control valve ..................... 50-30-1 - 50-30-7
Gauges and switches ................... 30-20-1 - 30-20-3 Circuit relief valve ....................................... 50-30-4
Gear train, engine .................... 20-10-16 - 20-10-19 Control valve components .......................... 50-30-5
Gear train, timing ..................... 20-10-16 - 20-10-19 Linkage ........................................................ 50-30-7
General after-sale inspection ... 10-10-23 - 10-10-50 Oil flow ...................................... 50-30-1 - 50-30-2
General predelivery service ....... 10-10-1 - 10-10-22 Removal ....................................................... 50-30-4
Litho in U.S.A.
Crawler - JD450-C
TM-1102 (Nov-73) Index 3
Repair .......................................................... 50-30-4 Pulpwood loader ........................... 60-35-1 - 60-35-3

Return-to-dig mechanism ......... 50-30-3 - 50-30-6 Pump, engine oil .......................... 20-15-1 - 20-15-3
System relief valve ..................................... 50-30-4 Pump, fuel injection ...................... 20-25-3 - 20-25-5
Lubricants ........................................................ 10-15-2 Pump, fuel transfer ....................... 20-25-2 - 20-25-3
Lubrication chart ............................................. 10-15-1 Pump, hydraulic ............................ 50-10-1 - 50-10-3
Lubrication system ........................ 20-15-1 - 20-15-3 Pump, transmission .......................... 50-5-3 - 50-5-5
Lumber fork adjustment ................................. 70-30-6 Pump, water .................................. 20-20-1 - 20-20-4
Lumber fork and pulpwood loader .. 60-35-1 - 60-35-3
R
M Radiator ........................................................... 20-20-1
Main bearings ........................... 20-10-12- 20-10-14 Reservoir, hydraulic ........................................ 50-55-1
Malfunctions: Return line filter .............................................. 50-55-1
Breakaway couplers .................................... 70-25-9 Rings, piston ................................................. 20-10-10
Clutch assembly .......................................... 70-20-4 Rods, connecting ........................ 20-10-7 - 20-10-11
Clutch control valve .................................... 70-25-9
Electrical system ....................... 70-15-6 - 70-15-7 s
Engine ........................................ 70-1 0-3 - 70-1 0-5 Safety precautions .................................................. 3-8
Hydraulic pump ........................................... 70-25-8 Service, delivery ........................................... 10-1 0-23
Hydraulic system ....................... 70-25-8 - 70-25-9 Service, predelivery .................... 10-10-1 - 10-10-22
Steering-brake system ................................ 70-20-5 Special tools:
Track system ............................................... 70-30-1 Air intake system .................. 20-40-23 - 20-40-24
Transmission ................................................ 70-20-5 Batteries ..................................... 30-25-1 - 30-25-3
Winch ........................ 70-25-9 - 70-25-10, 70-30-2 Charging system ....................... 30-25-3 - 30-25-5
Miscellaneous components Clutch assembly .......................................... 40-30-3
testing ........................................ 70-30-1 - 70-30-6 Cooling system .......................................... 20-40-20
Adjustments ............................... 70-30-3 - 70-30-6 Electrical system testing ............................. 70-35-8
Malfunctions ............................... 70-30-1 - 70-30-2 Engine, basic ......................... 20-40-12 - 20-40-16
Multipurpose bucket clam relief Engine removal ........................................... 20-40-2
valve ........................................... 50-55-6 - 50-55-7 Engine testing ........................... 70-35-3 - 70-35-5
Fuel System .............................................. 20-40-21
N Lubrication system .................................... 20-40-18
Nozzles, fuel injection .................. 20-25-6 - 20-25-7 Starting motor ............................ 30-25-8 - 30-25-9
Track carrier 3.ssembly ............. 60-45-5 - 60-45-6
0 Tracks .......................................................... 60-45-2
Oil cooler ......................................................... 20-15-3 Winch ......................................................... 60-45-1 0
Oil filter, engine .............................................. 20-15-3 Specifications:
Oil pan .......................................................... 20-1 0-11 Backhoe control valve .............. 50-60-7 - 50-60-8
Oil pressure adjustment, engine ................... 70-10-9 Batteries ....................................................... 30-25-1
Oil pressure regulating valve ......................... 20-15-2 Charging system ....................... 30-25-2 - 30-25-3
Oil pump, engine .......................... 20-15-1 - 20-15-3 Clutch assembly ........................ 40-30-1 - 40-30-3
Clutch control valve .................................... 50-60-4
p Cooling system .......................................... 20-40-19
Periodic service chart. .................................... 10-15-1 Dozer control valve ..................................... 50-60-7
Piston rings ................................................... 20-10-10 Electrical system testing ........... 70-35-6 - 70-35-7
Pistons ......................................... 20-1 0-7 - 20-1 0-11 Engine, basic ........................... 20-40-3 - 20-40-10
Power train testing ....................... 70-20-1 - 70-20-7 Engine break-in ......................................... 20-40-11
Malfunctions ............................... 70-20-4 ., 70-20-5 Engine removal ........................................... 20-40-1
Operational theory ..................... 70-20-1 - 70-20-3 Engine testing ........................... 70-35-1 - 70-35-2
Tests and adjustments ............. 70-20-5 - 70-20-7 Final drive assembly ................................. 40-30-10
Pre-cleaner ...................................................... 20-35-1 Fuel system ............................................... 20-40-20
Predelivery service ..................... 10-1 0-1 - 10-1 0-22 Gauges and switches ................................. 30-25-9
PTO and winch drive ................... 40-25-1 - 40-25-3 General:
Components ................................................. 40-25-2 Brakes ........................................................ 10-5-1
Installation .................................................... 40-25-3 Capacities ................................................... 10-5-3
Removal ....................................................... 40-25-1 Engine ........................................................ 10-5-1
Repair ........................................ 40-25-2 - 40-25-3 Horsepower ................................................ 10-5-1
Litho in U.S.A.
Crawler - JD450-C
4 Index TM-1102 (Nov-73)
Hydraulic system ....................................... 10-5-2 Front idlers ................................ 60-10-5 - 60-1 0-6
Loader ........................................................ 10-5-2 Idler recoil spring ...................... 60-1 0-7 - 60-1 0-8
Special equipment ..................................... 10-5-3 Installation .................................................. 60-10-12
Standard equipment .................................. 10-5-3 Removal ....................................................... 60-1 0-2
Steering ...................................................... 10-5-1 Repair ...................................... 60-10-2 - 60-10-11
Track and track frame .............................. 10-5-2 Track adjusting assembly ......... 60-10-8 - 60-10-9
Transmission .............................................. 10-5-1 Track carrier assembly ........... 60-1 0-9 - 60-1 0-11
Hydraulic components ........... 50-60-15 - 50-60-16 Track carrier roller .................... 60-1 0-4 - 60-1 0-5
Hydraulic cylinders ...................................... 50-60-9 Track rollers .............................. 60-10-3 - 60-10-4
Hydraulic pump ......................... 50-60-2 - 50-60-3 Track system .................................... 60-5-2 - 60-5-8
Hydraulic system testing ...... 70-35-11 - 70-35-13 Components ................................................... 60-5-3
Loader boom valve ..................................... 50-60-6 Installation ...................................................... 60-5-8
Loader bucket valve ................................... 50-60-6 Operation ....................................... 60-5-4 - 60-5-7
Lubrication system ................ 20-40-17 - 20-40-18 Removal ......................................................... 60-5-3
Lumber fork and pulpwood loader .......... 60-45-11 Repair ............................................ 60-5-3 - 60-5-7
Miscellaneous components Track press ................................................... 60-5-4
adjustment... ....................... 70-35-13 - 70-35-14 Transmission (H-L-R) ................. 40-10-1 - 40-10-29
Power train testing .................. 70-35-9 - 70-35-1 0 Adjustment, lever ...................................... 40-1 0-29
Starting motor ............................ 30-25-6 - 30-25-8 Case and components .............................. .40-1 0-1
Steering-brake assembly ............................ 40-30-8 Clutch components ..................................... 40-1 0-8
Steering valve ............................................. 50-60-5 Drive shaft and counters haft 40-1 0-13 - 40-1 0-17
Track carrier assembly ............. 60-45-3 - 60-45-5 Gear shift and H-L-R levers'
Tracks ........................................ 60-45-1 - 60-45-2 quadrant ................................................. 40-1 0-27
Transmission .............................. 40-30-4 - 40-30-8 Installation .................................................. 40-10-26
Transmission pump ..................................... 50-60-1 Linkage ...................................................... 40-1 0-28
Winch ....................................... 60-45-7 - 60-45-10 Removal ....................................................... 40-1 0-2
Winch hydraulic pump ................................ 50-60-3 Repair ...................................... 40-10-3 - 40-10-26
Speed control linkage .............. 70-1 0-12 - 70-1 0-13 Transmission case oil filter ............................ 50-55-2
Adjustments ............................................... 70-1 0-13 Transmission oil cooler .................................. 50-55-2
Components ............................................... 70-1 0-12 Transmission oil temperature gauge ............. 30-20-1
Repair ........................................................ 70-10-12 Transmission pump .......................... 50-5-3 - 50-5-5
Starting motor ............................... 30-15-1 - 30-15-9 Turbocharger ................................. 20-35-2 - 20-35-7
Components ................................................. 30-15-4 Components ................................................. 20-35-3
Installation .................................................... 30-15-9 Installation .................................................... 20-35-7
Removal ....................................................... 30-15-2 Removal ....................................................... 20-35-2
Repair ........................................ 30-15-3 - 30-15-8 Repair ........................................ 20-35-4 - 20-35-7
Tests .......................................... 30-15-2 - 30-15-3 Tests .......................................... 20-35-2 - 20-35-4
Start safety switch .......................................... 30-20-2
Start switch ..................................................... 30-20-2 v
Selector valve ............................... 50-55-4 - 50-55-5 Valve, backhoe control. ................ 50-40-1 - 50-40-5
Steering-brake assembly .............. 40-15-1 - 40-15-7 Valve, clutch control. .................... 50-20-1 - 50-20-9
Adjustment ................................................... 40-15-7 Valve guides ................................................... 20-10-3
Components ................................................. 40-15-1 Valve, hydraulic loader
Installation .................................................... 40-15-7 control ........................................ 50-30-1 - 50-30-7
Removal ....................................................... 40-15-2 Valve, hydraulic multipurpose
Repair ........................................ 40-15-3 - 40-15-6 bucket clam relief ..................... 50-55-6 - 50-55-7
Steering valve ............................... 50-25-1 - 50-25-2 Valve, hydraulic selector .............. 50-55-4 - 50-55-5
Valve lift check ............................................... 20-10-2
T Valve, oil pressure regulating ........................ 20-15-2
Temporary storage ......................................... 10-10-1 Valve seats ..................................................... 20-1 0-3
Thermostat ...................................................... 20-20-4 Valve springs .................................................. 20-10-4
Timing gear train ...................... 20-10-17 - 20-10-19 Valve tappet clearance adjustment ............... 20-10-6
Track adjustments ........................ 70-30-3 - 70-30-4 Valve, winch control ..................... 50-45-1 - 50-45-3
Track carrier assembly ............... 60-1 0-1 - 60-1 0-12 Valves, dozer control ................... 50-35-1 - 50-35-5
Components ................................................. 60-1 0-1 Valves, engine .............................. 20-10-2 - 20-10-6
Litho in U.S.A.
Crawler - JD450-C
TM-11 02 (Nov-73) Index 5
w Winch drive ................................... 40-25-1 - 40-25-3

Water pump .................................. 20-20-1 - 20-20-4 Winch fairlead assembly .............. 60-20-1 - 60-20-2
Winch control valve ...................... 50-45-1 - 50-45-3 Winch system:
Adjustment ................................................... 50-45-3 Adjustment ............................... 60-15-6 - 60-15-1 0
Components ................................................. 50-45-3 Cable attachment.. ................ 60-15-1 0 - 60-15-11
Installation .................................................... 50-45-3 Repair ........................................ 60-15-2 - 60-15-9
Oil flow ...................................... 50-45-1 - 50-45-2 Removal ....................................................... 60-15-1
Removal ....................................................... 50-45-2 Wiring harnesses ...................... 70-15-1 0 - 70-15-11
Repair .......................................................... 50-45-3
Litho in U.S.A.

John Deere 450C Crawler Service Manual 1973

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John Deere 450C Crawler Service Manual 1973

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John Deere

Litho in U.S.A. (T) New

The specifications and design information con-

MAINTENANCE WITHOUT ACCIDENT

A This safety alert symbol identifies important

MAINTENANCE WITHOUT ACCIDENT

Avoid working on equipment with the engine run-

Flame Is Not a Flashlight!

<'::: ~ ;::* ;·, '*

MAINTENANCE WITHOUT ACCIDENT

Avoid working directly under raised and blocked SERVICING PRECAUTIONS

Lower mounted equipment and tools to the ground

Engine coolant gets hot! Don't remove the radiator

Exhaust gases are dangerous! Periodically check

Don't forget a hydraulic system may be pressur-

Wear safety glasses when drilling, grinding, or

MAINTENANCE WITHOUT ACCIDENT

Keep ALL equipment free of dirt and oil. This at-

Before removing any housing covers, stop engine.

MAINTENANCE WITHOUT ACCIDENT

PRECAUTIONS DURING When changing cutting edges on blade-

Before repairing the electrical system, or perform-

MAINTENANCE WITHOUT ACCIDENT

KNOW EQUIPMENT IS READY!

Be sure to clean any oil, grease or mud accumula-

In freezing weather beware of snow or ice deposits

Remove loose bolts, tools, or other objects from

Illustrations and copy reproduced in part by per-

Horsepower Cooling ....................... Pressurized w/thermostat and

LOADER HYDRAULIC SYSTEM: SAE Heaped

CAPACITIES u.s. Litres SPECIAL EQUIPMENT:

Cooling system ...................... . 4 gal. 15.1 Tachometer

4. Check crankcase oil level. Oil should be at top

5. Relieve hydraulic pressure by stopping engine,

1- Restrlctlon Indicator 3-filter Element

Fig. 1-Air Cleaner

Check air filter restriction indicator, if equipped. If

2. Fuel Filter 4. Fuel Tank

Fig. 2-Fuel Filter

IMPORTANT: Do not pry on the rear half of the

Belt tension lbs {kg] tension

8. Check Air Intake Hoses

7. Alternator Belt Tension

Fig. 8-Hydraulic System Oil Level Window and Latch

Fig. 7-Adjusting Alternator Belt Tension

To add oil, turn latch and lift reservoir cover. Turn

NOTE: The hydraulic pump on crawlers not

IMPORTANT: Do not operate crawler without

Fig. 9-Pre-Cieaner Attachment

Check the pre-cleaner and empty it if the accumu-

NOTE: Under extremely dusty conditions, it will be

Pre-cleaner cleaned out Yes No Fig. 11-Winch Oil Level

13. Fuel Tank Sump 15. Steering Reservoir Oil Level

Fig. 12-Fuel Tank Sump

1- 0il Level Plug 2-Drain Plug

Fig. 13-Final Drive

The oil supply in the final drives should be main-

17. Check Engine Speed Controls

1- Hand Throttle Lever &-Adjustable Yoke a- Adjustable Yoke

Fig. 16-Speed Control Unkage

Engine speeds checked

18. Check Transmission Shifting 19. Gauge Operation

Fig. 18-Ammeter Fig. 19-Engine Coolant

If the indicator hand of the engine coolant temper-