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524K Loader Repair

TECHNICAL MANUAL 524K Loader Repair TM10687 14OCT08 (ENGLISH)

For complete service information also see: 524K Loader Test Manual . . . . . . . . . . . . . . TM10686 524K Loader Operator’s Manual . . . . . . . . . . OMT231637 PowerTech 4.5 L and 6.8 L Diesel Engines—Base Engine . . . . . . . . . . . . . . . . . CTM104 PowerTech E 4.5 & 6.8L Diesel Engines—Level 16 Electronic Fuel System with Denso HPCR . . . . . . . . . . . . . . . . . . . . . CTM502 TeamMate IV 1200 and 1400 Series Inboard Planetary Axles . . . . . . . . . . . . . . . . CTM442 120 Series Hydraulic Cylinders . . . . . . . . . . TM-H120A 125 Series Hydraulic Cylinders . . . . . . . . . . TM-H125A Super Caddy Oil Cleanup Procedure . . . . . . CTM310 JDLink / ZXLink Machine Monitoring System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CTM10006 Specifications Manual . . . . . . . . . . . . . . . . . . SP458

Worldwide Construction And Forestry Division LITHO in U.S.A.

Introduction Foreword This manual is written for an experienced technician. Essential tools required in performing certain service work are identified in this manual and are recommended for use. Live with safety: Read the safety messages in the introduction of this manual and the cautions presented throughout the text of the manual. This is the safety-alert symbol. When you see this symbol on the machine or in this manual, be alert to the potential for personal injury. Technical manuals are divided in two parts: repair and operation and tests. Repair sections tell how to repair the components. Operation and tests sections help you identify the majority of routine failures quickly.

Information is organized in groups for the various components requiring service instruction. At the beginning of each group are summary listings of all applicable essential tools, service equipment and tools, other materials needed to do the job, service parts kits, specifications, wear tolerances, and torque values. Technical Manuals are concise guides for specific machines. They are on-the-job guides containing only the vital information needed for diagnosis, analysis, testing, and repair. Fundamental service information is available from other sources covering basic theory of operation, fundamentals of troubleshooting, general maintenance, and basic type of failures and their causes.

DX,TMIFC –19–29SEP98–1/1

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Introduction

Technical Information Feedback Form We need your help to continually improve our technical publications. Please copy this page and FAX or mail your comments, ideas and improvements. SEND TO:

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FAX NUMBER:

563-589-5800

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Company Name: Technician Name: Address: Phone: Fax No.: Dealer Acct. No.: THANK YOU!

TX,II,FAX –19–10JUL01–1/1

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Introduction

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SECTION 17—Frame or Supporting Structure Group 1740—Frame Installation Group 1746—Frame Bottom Guards Group 1749—Chassis Weights

SECTION 00—General Information Group 0001—Safety Information SECTION 01—Wheels Group 0110—Powered Wheels and Fasteners

SECTION 18—Operator’s Station Group 1800—Removal and Installation Group 1810—Operator Enclosure Group 1821—Seat and Seat Belt Group 1830—Heating and Air Conditioning

SECTION 02—Axles and Suspension Systems Group 0200—Removal and Installation Group 0225—Axle Shafts and U-Joints Group 0250—Axle Shaft, Bearings, Reduction Gears Group 0260—Hydraulic System

SECTION 19—Sheet Metal and Styling Group 1910—Hood or Engine Enclosure

SECTION 31—Loader Group 3102—Bucket Group 3140—Frames Group 3160—Hydraulic System

SECTION 03—Transmission Group 0300—Removal and Installation Group 0350—Gears, Shafts, Bearings and Power Shift Clutch Group 0360—Hydraulic System

SECTION 99—Dealer Fabricated Tools Group 9900—Dealer Fabricated Tools

SECTION 04—Engine Group 0400—Removal and Installation

SECTION 05—Engine Auxiliary Systems Group 0505—Cold Weather Starting Aids Group 0510—Cooling System Group 0520—Intake System Group 0530—External Exhaust System Group 0560—External Fuel Supply Systems

SECTION 07—Dampener Drive Group 0752—Elements

SECTION 09—Steering System Group 0960—Hydraulic System 09

SECTION 10—Service Brakes Group 1011—Active Elements Group 1060—Hydraulic System SECTION 11—Park Brake Group 1111—Active Elements Group 1160—Hydraulic System

All information, illustrations and specifications in this manual are based on the latest information available at the time of publication. The right is reserved to make changes at any time without notice.

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Section 00

General Information Contents Page

Group 0001—Safety Information Recognize Safety Information . . . . . . . . . . . .00-0001-1 Follow Safety Instructions . . . . . . . . . . . . . . .00-0001-1 Operate Only If Qualified. . . . . . . . . . . . . . . .00-0001-2 Wear Protective Equipment . . . . . . . . . . . . . .00-0001-2 Avoid Unauthorized Machine Modifications . . . . . . . . . . . . . . . . . . . . . . .00-0001-2 Add Cab Guarding For Special Uses . . . . . .00-0001-3 Inspect Machine . . . . . . . . . . . . . . . . . . . . . .00-0001-3 Stay Clear of Moving Parts . . . . . . . . . . . . . .00-0001-3 Avoid High-Pressure Fluids . . . . . . . . . . . . . .00-0001-4 Avoid High-Pressure Oils . . . . . . . . . . . . . . .00-0001-4 Beware of Exhaust Fumes . . . . . . . . . . . . . .00-0001-5 Prevent Fires. . . . . . . . . . . . . . . . . . . . . . . . .00-0001-5 Clean Trash from Machine . . . . . . . . . . . . . .00-0001-6 Prevent Battery Explosions . . . . . . . . . . . . . .00-0001-6 Handle Chemical Products Safely . . . . . . . . .00-0001-6 Dispose of Waste Properly . . . . . . . . . . . . . .00-0001-7 Prepare for Emergencies. . . . . . . . . . . . . . . .00-0001-7 Use Steps and Handholds Correctly . . . . . . .00-0001-7 Start Only From Operator’s Seat . . . . . . . . . .00-0001-8 Use and Maintain Seat Belt. . . . . . . . . . . . . .00-0001-8 Prevent Unintended Machine Movement . . . .00-0001-9 Avoid Work Site Hazards . . . . . . . . . . . . . .00-0001-10 Use Special Care When Operating Loader . . . . . . . . . . . . . . . . . . . . . . . . . . .00-0001-11 Keep Riders Off Machine . . . . . . . . . . . . . .00-0001-11 Avoid Backover Accidents . . . . . . . . . . . . . .00-0001-12 Avoid Machine Tip Over . . . . . . . . . . . . . . .00-0001-13 Operating on Slopes . . . . . . . . . . . . . . . . . .00-0001-13 Operating or Traveling On Public Roads . . .00-0001-14 Inspect and Maintain ROPS . . . . . . . . . . . .00-0001-14 Add and Operate Attachments Safely . . . . .00-0001-14 Park And Prepare For Service Safely . . . . .00-0001-15 Service Cooling System Safely . . . . . . . . . .00-0001-15 Service Tires Safely . . . . . . . . . . . . . . . . . .00-0001-16 Remove Paint Before Welding or Heating . . . . . . . . . . . . . . . . . . . . . . . . . .00-0001-17 Make Welding Repairs Safely . . . . . . . . . . .00-0001-18 Drive Metal Pins Safely . . . . . . . . . . . . . . . .00-0001-18

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Group 0001

Safety Information 00 0001 1

Follow the precautions and safe operating practices highlighted by this symbol.

T133555

This is the safety alert symbol. When you see this symbol on your machine or in this manual, be alert for the potential of personal injury.

–UN–28AUG00

Recognize Safety Information

T133588

On your machine, DANGER signs are red in color, WARNING signs are orange, and CAUTION signs are yellow. DANGER and WARNING signs are located near specific hazards. General precautions are on CAUTION labels.

–19–28AUG00

A signal word — DANGER, WARNING, or CAUTION — is used with the safety alert symbol. DANGER identifies the most serious hazards.

TX03679,00016CC –19–01OCT07–1/1

T133556

Read the safety messages in this manual and on the machine. Follow these warnings and instructions carefully. Review them frequently. Keep safety signs in good condition. Replace missing or damaged safety signs. Replacement safety signs are available from your authorized John Deere dealer.

–UN–24AUG00

Follow Safety Instructions

Be sure all operators of this machine understand every safety message. Replace operator’s manual and safety labels immediately if missing or damaged.

TX03679,00016F9 –19–18OCT07–1/1

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Safety Information

Operate Only If Qualified Do not operate this machine unless you have read the operator’s manual carefully and you have been qualified by supervised training and instruction.

machine functions with the machine in an open area before starting to work. Know and observe all safety rules that may apply to your work situation and your work site.

Familiarize yourself with the job site and your surroundings before operating. Try all controls and

TX03679,00016FA –19–01OCT07–1/1

Wear Protective Equipment Guard against injury from flying pieces of metal or debris; wear goggles or safety glasses.

–UN–23AUG88

Wear close fitting clothing and safety equipment appropriate to the job. Prolonged exposure to loud noise can cause impairment or loss of hearing. Wear suitable hearing protection such as earmuffs or earplugs to protect against objectionable or uncomfortable loud noises.

TS206

00 0001 2

TX03679,00016D0 –19–01OCT07–1/1

Avoid Unauthorized Machine Modifications John Deere recommends using only genuine John Deere replacement parts to ensure machine performance. Never substitute genuine John Deere parts with alternate parts not intended for the application as these can create hazardous situations or hazardous performance. Non-John Deere Parts, or any damage or failures resulting from their use are not covered by any John Deere warranty. Modifications of this machine, or addition of unapproved products or attachments, may affect

machine stability or reliability, and may create a hazard for the operator or others near the machine. The installer of any modification which may affect the electronic controls of this machine is responsible for establishing that the modification does not adversely affect the machine or its performance. Always contact an authorized John Deere dealer before making machine modifications that change the intended use, weight or balance of the machine, or that alter machine controls, performance or reliability.

AM40430,00000A9 –19–14JAN08–1/1

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Safety Information 00 0001 3

Use load-clamping grapples to keep bulky loads from falling and add special screens or guarding when objects may be directed toward the cab. Contact your authorized John Deere dealer for information on devices intended to protect the operator from falling or flying objects in special work situations.

T141893

Special work situations or machine attachments may create an environment with falling or flying objects. Loading logs, using fork attachments, or operating in waste management applications requires special work tools. Added cab guarding to protect the operator may also be required.

–UN–04MAY01

Add Cab Guarding For Special Uses

TX03679,00017C6 –19–18OCT07–1/1

Inspect Machine

T6607AQ

Keep all guards and shields in good condition and properly installed. Fix damage and replace worn or broken parts immediately. Pay special attention to hydraulic hoses and electrical wiring.

–UN–18OCT88

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

TX03679,0001734 –19–01OCT07–1/1

Stop engine before examining, adjusting or maintaining any part of machine with moving parts. Keep guards and shields in place. Replace any guard or shield that has been removed for access as soon as service or repair is complete.

T133592

Entanglements in moving parts can cause serious injury.

–UN–12SEP01

Stay Clear of Moving Parts

TX03679,00016D2 –19–01OCT07–1/1

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Avoid High-Pressure Fluids

Search for leaks with a piece of cardboard. Protect hands and body from high pressure fluids.

X9811

Avoid the hazard by relieving pressure before disconnecting hydraulic or other lines. Tighten all connections before applying pressure.

–UN–23AUG88

Escaping fluid under pressure can penetrate the skin causing serious injury.

DX,FLUID –19–03MAR93–1/1

Avoid High-Pressure Oils

T133509

If hydraulic oil penetrates your skin, see a doctor immediately. Injected oil must be removed surgically within hours or gangrene may result. Contact a knowledgeable medical source or the Deere & Company Medical Department in Moline, Illinois, U.S.A.

–UN–20SEP00

Never search for leaks with your hands. Protect hands. Use a piece of cardboard to find location of escaping oil. Stop engine and relieve pressure before disconnecting lines or working on hydraulic system.

–UN–17MAR06

This machine uses a high-pressure hydraulic system. Escaping oil under pressure can penetrate the skin causing serious injury.

T133840

00 0001 4

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If you must operate in an enclosed space, provide adequate ventilation. Use an exhaust pipe extension to remove the exhaust fumes or open doors and windows to bring outside air into the area.

T133546

Prevent asphyxiation. Engine exhaust fumes can cause sickness or death.

–UN–24AUG00

Beware of Exhaust Fumes

TX03679,00016D4 –19–03JAN07–1/1

T133552 T133554

Keep A Fire Extinguisher Available: Always keep a multipurpose fire extinguisher on or near the machine. Know how to use extinguisher properly.

–UN–07SEP00

Maintain Hoses and Wiring: Replace hydraulic hoses immediately if they begin to leak, and clean up any oil spills. Examine electrical wiring and connectors frequently for damage.

T133553

Clean Machine Regularly: Keep trash, debris, grease and oil from accumulating in engine compartment, around fuel lines, hydraulic lines, exhaust components, and electrical wiring. Never store oily rags or flammable materials inside a machine compartment.

–UN–07SEP00

Handle Fuel Safely: Store flammable fluids away from fire hazards. Never refuel machine while smoking or when near sparks or flame.

–UN–14SEP00

Prevent Fires

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Clean Trash from Machine

Temperature in engine compartment may go up immediately after engine is stopped. BE ON GUARD FOR FIRES DURING THIS PERIOD.

T6669AG

Clean any oil spills or fuel spills on machine surfaces.

–UN–18OCT88

Keep engine compartment, radiator, batteries, hydraulic lines, exhaust components, fuel tank, and operator’s station clean and free of debris.

Open access door(s) to cool the engine faster, and clean engine compartment.

OUT4001,00000E3 –19–14APR08–1/1

Prevent Battery Explosions

Never check battery charge by placing a metal object across the posts. Use a voltmeter or hydrometer.

TS204

Do not charge a frozen battery; it may explode. Warm battery to 16°C (60°F).

–UN–23AUG88

Battery gas can explode. Keep sparks, lighted matches, and open flame away from the top of battery.

TX03679,000174A –19–03JAN07–1/1

Exposure to hazardous chemicals can cause serious injury. Under certain conditions, lubricants, coolants, paints and adhesives used with this machine may be hazardous. If uncertain about safe handling or use of these chemical products, contact your authorized dealer for a Material Safety Data Sheet (MSDS) or go to internet website http://www.jdmsds.com. The MSDS describes physical and health hazards, safe use procedures, and emergency response techniques for chemical substances. Follow MSDS recommendations to handle chemical products safely.

–UN–25AUG00

Handle Chemical Products Safely

T133580

00 0001 6

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Never pour waste onto the ground, down a drain, or into any water source.

T133567

Improper disposal of waste can threaten the environment. Fuel, oils, coolants, filters and batteries used with this machine may be harmful if not disposed of properly.

–UN–25AUG00

Dispose of Waste Properly

Air conditioning refrigerants can damage the atmosphere. Government regulations may require using a certified service center to recover and recycle used refrigerants. If uncertain about the safe disposal of waste, contact your local environmental or recycling center or your dealer for more information.

TX03679,0001733 –19–28NOV06–1/1

Prepare for Emergencies Be prepared if an emergency occurs or a fire starts.

TS291

Keep emergency numbers for doctors, ambulance service, hospital, and fire department near your telephone.

–UN–23AUG88

Keep a first aid kit and fire extinguisher handy.

TX03679,000174B –19–31JAN07–1/1

Use extra care when mud, snow, or moisture present slippery conditions. Keep steps clean and free of grease or oil. Never jump when exiting machine. Never mount or dismount a moving machine.

T133468

Prevent falls by facing the machine when getting on and off. Maintain 3-point contact with steps and handrails. Never use machine controls as handholds.

–UN–30AUG00

Use Steps and Handholds Correctly

TX03679,00016F2 –19–15MAR07–1/1

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Safety Information

Never attempt to start engine from the ground. Do not attempt to start engine by shorting across the starter solenoid terminals.

T133715

Avoid unexpected machine movement. Start engine only while sitting in operator’s seat. Ensure all controls and working tools are in proper position for a parked machine.

–UN–07SEP00

Start Only From Operator’s Seat

TX03679,0001799 –19–03JAN07–1/1

Use seat belt when operating machine. Remember to fasten seat belt when loading and unloading from trucks and during other uses. Examine seat belt frequently. Be sure webbing is not cut or torn. Replace seat belt immediately if any part is damaged or does not function properly.

–19–14SEP00

Use and Maintain Seat Belt

T133716

00 0001 8

The complete seat belt assembly should be replaced every 3 years, regardless of appearance.

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Safety Information 00 0001 9

Prevent Unintended Machine Movement Lower all equipment to the ground during work interruptions. Place transmission control in neutral, press park brake switch (1) to engage park brake, press pilot enable/boom down switch (2) to disable the hydraulics, and stop engine before allowing anyone to approach the machine. Follow these same precautions before standing up, leaving the operator’s seat, or exiting the machine.

TX1041772A

–UN–02MAY08

1—Park Brake Switch 2—Pilot Enable/Boom Down Switch

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Safety Information

Keep bystanders clear at all times. Keep bystanders away from raised booms, attachments, and unsupported loads. Avoid swinging or raising booms, attachments, or loads over or near personnel. Use barricades or a signal person to keep vehicles and pedestrians away. Use a signal person if moving machine in congested areas or where visibility is restricted. Always keep signal person in view. Coordinate hand signals before starting machine. Operate only on solid footing with strength sufficient to support machine. Be especially alert working near embankments or excavations. Avoid working under over-hanging embankments or stockpiles that could collapse under or on machine.

T141894 –UN–24APR01

Avoid boom or attachment contact with overhead obstacles or overhead electrical lines. Never move machine closer than 3 m (10 ft) plus twice the line insulator length to overhead wires.

T141670

Prepare work site properly. Avoid operating near structures or objects that could fall onto the machine. Clear away debris that could move unexpectedly if run over.

–UN–04MAY01

Avoid contact with gas lines, buried cables and water lines. Call utility line location services to identify all underground utilities before starting work.

–UN–15JUN01

Avoid Work Site Hazards

T141672

00 0001 10

Reduce machine speed when operating with tool on or near ground when obstacles may be hidden (e.g., during snow removal or clearing mud, dirt, etc.). At high speeds hitting obstacles (rocks, uneven concrete or manholes) can cause a sudden stop. Always wear your seatbelt.

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Safety Information 00 0001 11

Ensure that objects in the bucket are secure. Do not attempt to lift or carry objects that are too big or too long to fit inside the bucket unless secured with an adequate chain or other device. Keep bystanders away from raised loads. Be careful when lifting objects. Never attempt to lift objects too heavy for your machine. Assure machine stability and hydraulic capability with a test lift before attempting other maneuvers. Use an adequate chain or sling and proper rigging techniques to attach and stabilize loads. Never lift an object above or near another person.

T141957 –UN–07MAY01

Operate carefully with raised loads. Raising the load reduces machine stability, especially on side slopes or an unstable surface. Drive and turn slowly with a raised load.

T141902

Never use the loader to lift people. Do not allow anyone to ride in the bucket or use the bucket as a work platform.

–UN–15MAY01

Use Special Care When Operating Loader

TX03768,0000B70 –19–14MAY01–1/1

Keep Riders Off Machine

Riders may obstruct operator’s view or impair his ability to operate machine safely.

T141671

Riders are subject to injury. They may fall from machine, be caught between machine parts, or be struck by foreign objects.

–UN–04MAY01

Only allow operator on machine.

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Safety Information

Before moving machine, be sure that all persons are clear of machine path. Turn around and look directly for best visibility. Use mirrors to assist in checking all around machine. Keep windows and mirrors clean, adjusted, and in good repair. Be certain reverse warning alarm is working properly.

–UN–04MAY01

Avoid Backover Accidents

T141673

00 0001 12

Use a signal person when backing if view is obstructed or when in close quarters. Keep signal person in view at all times. Use prearranged hand signals to communicate. Do not rely on the rear camera and rear object detection systems to determine if personnel are behind the machine. The system has limitations due to maintenance practices, environmental conditions, and operating range.

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Be careful on slopes. Avoid sharp turns. Balance loads so weight is evenly distributed and load is stable. Carry tools and loads close to the ground to aid visibility and lower center of gravity. Use extra care on soft, rocky or frozen ground. Know the capacity of the machine. Do not overload. Be careful with heavy loads. Using oversize buckets or lifting heavy objects reduces machine stability.

T133716 T141672

Ensure solid footing. Use extra care in soft ground conditions that may not uniformly support the wheels, especially when raising the boom. Do not operate close to banks or open excavations that may cave in and cause machine to tip or fall.

–UN–04MAY01

Load and unload from trucks or trailers carefully. Be sure truck is wide enough and on a firm level surface. Use loading ramps and attach them properly to truck bed.

T141676

Do not jump if the machine tips. You will be unlikely to jump clear and the machine may crush you.

–UN–04MAY01

Use seat belt at all times.

–19–14SEP00

Avoid Machine Tip Over

TX03679,000179D –19–02MAY01–1/1

Select low gear speed before starting down slope. The grade of the slope will be limited by ground condition and load being handled. Use service brakes to control speed. Sudden brake application with a loaded bucket on downhill side could cause machine to tip forward.

T141681

Avoid side slope travel whenever possible. Drive up steep slope in forward and down in reverse.

–UN–30APR01

Operating on Slopes

TX03679,000179E –19–14MAY01–1/1

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Safety Information

Operating or Traveling On Public Roads

–UN–22MAY01

Machines that work near vehicle traffic or travel slower than normal highway speeds must have proper lighting and markings to assure they are visible to other drivers. Install additional lights, beacons, slow moving vehicle (SMV) emblems, or other devices and use as required to make the machine visible and identify it as a work machine. Check state and local regulations to assure compliance. Keep these devices clean and in working condition.

T141891

00 0001 14

TX03679,00017C8 –19–02MAR07–1/1

Inspect and Maintain ROPS To maintain the ROPS:

A damaged roll-over protective structure (ROPS) should be replaced, not reused. The protection offered by ROPS will be impaired if ROPS is subjected to structural damage, is involved in an overturn incident, or is in any way altered by welding, bending, drilling, or cutting.

• Replace missing hardware using correct grade hardware. • Check hardware torque. • Check isolation mounts for damage, looseness or wear; replace them if necessary. • Check ROPS for cracks or physical damage.

If ROPS was loosened or removed for any reason, inspect it carefully before operating the machine again.

TX03679,000179F –19–07SEP06–1/1

Add and Operate Attachments Safely Always verify compatibility of attachments by contacting your authorized dealer. Adding unapproved attachments may affect machine stability or reliability, and may create a hazard for others near the machine. Ensure that a qualified person is involved in attachment installation. Add guards to machine if operator protection is required or recommended. Verify

that all connections are secure and attachment responds properly to controls. Carefully read attachment manual and follow all instructions and warnings. In an area free of bystanders and obstructions, carefully operate attachment to learn its characteristics and range of motion.

TX03679,00016F0 –19–24JAN07–1/1

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Safety Information 00 0001 15

Park And Prepare For Service Safely

T133332

• Park machine on a level surface and lower equipment to the ground. • Engage park brake. • Stop engine. • Install frame locking bar. • Attach a “Do Not Operate” tag in an obvious place in the operator’s station.

–19–14DEC01

Warn others of service work. Always park and prepare your machine for service or repair properly.

Understand service procedures before beginning repairs. Keep service area clean and dry. Use two people whenever the engine must be running for service work.

TS229

• Do not support machine with boom, bucket, or other hydraulically actuated equipment. • Do not support machine with cinder blocks or wooden pieces that can crumble or crush. • Do not support machine with a single jack or other devices that could slip out of place.

–UN–23AUG88

Securely support machine or attachment before working under it.

DP99999,0000391 –19–06MAR08–1/1

Service Cooling System Safely

TS281

Shut off engine. Only remove surge tank filler cap when cool enough to touch with bare hands. Slowly loosen cap to relieve pressure before removing completely.

–UN–23AUG88

Explosive release of fluids from pressurized cooling system can cause serious burns.

DP99999,0000331 –19–09OCT07–1/1

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Safety Information

Service Tires Safely Explosive separation of a tire and rim parts can cause serious injury or death. Do not attempt to mount a tire unless you have the proper equipment and experience to perform the job. Always maintain the correct tire pressure. Do not inflate the tires above the recommended pressure. Never weld or heat a wheel and tire assembly. The heat can cause an increase in air pressure resulting in a tire explosion. Welding can structurally weaken or deform the wheel.

Check wheels for low pressure, cuts, bubbles, damaged rims or missing lug bolts and nuts.

–UN–23AUG88

When inflating tires, use a clip-on chuck and extension hose long enough to allow you to stand to one side and NOT in front of or over the tire assembly. Use a safety cage if available.

TS211

00 0001 16

DX,RIM –19–24AUG90–1/1

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Safety Information 00 0001 17

Remove Paint Before Welding or Heating Avoid potentially toxic fumes and dust.

• Remove paint a minimum of 100 mm (4 in.) from area to be affected by heating. If paint cannot be removed, wear an approved respirator before heating or welding. • If you sand or grind paint, avoid breathing the dust. Wear an approved respirator. • If you use solvent or paint stripper, remove stripper with soap and water before welding. Remove solvent or paint stripper containers and other flammable material from area. Allow fumes to disperse at least 15 minutes before welding or heating.

TS220

Remove paint before heating:

–UN–23AUG88

Hazardous fumes can be generated when paint is heated by welding, soldering, or using a torch.

Do not use a chlorinated solvent in areas where welding will take place. Do all work in an area that is well ventilated to carry toxic fumes and dust away. Dispose of paint and solvent properly.

DX,PAINT –19–24JUL02–1/1

TM10687 (14OCT08)

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Safety Information

Avoid welding or heating near pressurized fluid lines. Flammable spray may result and cause severe burns if pressurized lines fail as a result of heating. Do not let heat go beyond work area to nearby pressurized lines.

T133547

IMPORTANT: Disable electrical power before welding. Turn off main battery switch or disconnect positive battery cable. Separate harness connectors to engine and vehicle microprocessors.

–UN–31AUG00

Make Welding Repairs Safely

Remove paint properly. Do not inhale paint dust or fumes. Use a qualified welding technician for structural repairs. Make sure there is good ventilation. Wear eye protection and protective equipment when welding.

TX03679,00016D5 –19–25APR08–1/1

Always wear protective goggles or safety glasses and other protective equipment before striking hardened parts. Hammering hardened metal parts such as pins and bucket teeth may dislodge chips at high velocity. Use a soft hammer or a brass bar between hammer and object to prevent chipping.

–UN–14SEP00

Drive Metal Pins Safely

T133738

00 0001 18

TX03679,0001745 –19–03JAN07–1/1

TM10687 (14OCT08)

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Section 01

Wheels Contents

Page

Group 0110—Powered Wheels and Fasteners Wheel Remove and Install . . . . . . . . . . . . . .01-0110-1 Tire Remove and Install . . . . . . . . . . . . . . . .01-0110-2

TM10687 (14OCT08)

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Contents

TM10687 (14OCT08)

01-2

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Group 0110

Powered Wheels and Fasteners Wheel Remove and Install CAUTION: Prevent crushing injury from heavy component. Use appropriate lifting device when lifting component.

01 0110 1

1. Raise machine and place 10-ton shop stand under axle. 2. Place wheel lift under wheel. Fasten safety chain around upper part of tire.

AA95137,0001B87 –19–04SEP08–1/2

3. Remove cap screws (1) to remove wheel.

Specification Wheel Retainer Cap Screws—Dry Torque .......................................................................................... 624 N•m 460 lb-ft

TX1043030A

1—Cap Screw (14 used)

–UN–29MAY08

4. Clean mounting surface on wheel and axle flange. Install wheel. Install cap screws. Tighten cap screws to specification.

AA95137,0001B87 –19–04SEP08–2/2

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01-0110-1

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Powered Wheels and Fasteners

Tire Remove and Install

Always maintain the correct tire pressure. Do not inflate the tires above the recommended pressure. Never weld or heat a wheel and tire assembly, as heating can increase air pressure and result in tire explosion. Welding can also structurally weaken or deform the wheel.

–UN–12APR90 TS952

Explosive Single Piece Rim and Tire

For initial inflation, always use a clip-on chuck and extension hose long enough to allow you to stand to one side and NOT in front of, or over, the tire assembly. Inflate in a safety cage if available. Use safety chains, cables, or equivalent restraining devices during inflation. CAUTION: Stand clear when using a cable or chain sling. These devices can snap and lash out, causing serious injury or death. Check tire and wheel assemblies for low pressure, cuts, bubbles, damaged rim components, or missing lug bolts and nuts.

Wheels may contain multi-piece rim components. Inspect all rim components and replace those that are cracked, worn, damaged, or severely rusted. Use only rim components designed to work with one another. Do not combine rim components from different rim types or rim manufacturers. Incorrectly assembled or mismatched rim components can fly apart with explosive force.

–UN–23AUG88

Check that the tire size exactly matches the rim size. Improperly-sized tires may not perform as intended.

TS211

01 0110 2

CAUTION: Tire repair should only be performed by a qualified tire repair service. Do not attempt to mount or demount a tire unless you have the proper equipment and experience to perform the job safely. Failure to follow proper procedures when mounting or demounting a tire from a wheel or rim can result in explosive separation of a tire and rim parts, causing serious injury or death

Explosive Multi-Piece Rim and Tire

TX18203,00000C6 –19–16SEP08–1/1

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01-0110-2

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Section 02

Axles and Suspension Systems Contents Page

Group 0200—Removal and Installation TeamMate IV Axles . . . . . . . . . . . . . . . . . .02-0200-1 Front Axle and Differential Remove and Install. . . . . . . . . . . . . . . . . . . . . . . . . . . . .02-0200-2 Rear Axle and Differential Remove and Install. . . . . . . . . . . . . . . . . . . . . . . . . . . . .02-0200-6 Axle Oscillating Supports Disassemble and Assemble. . . . . . . . . . . . . . . . . . . . . . . . .02-0200-11

Group 0225—Axle Shafts and U-Joints Universal Joint and Drive Shaft Remove and Install . . . . . . . . . . . . . . . . . . . . . . . . .02-0225-2

Group 0250—Axle Shaft, Bearings, Reduction Gears TeamMate IV Axles . . . . . . . . . . . . . . . . . .02-0250-1

Group 0260—Hydraulic System Differential Lock Solenoid Valve Remove and Install . . . . . . . . . . . . . . . . . . . . . . . . .02-0260-1 Axle Circulation System Remove and Install—If Equipped . . . . . . . . . . . . . . . . . .02-0260-2

TM10687 (14OCT08)

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Contents

TM10687 (14OCT08)

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Group 0200

Removal and Installation TeamMate IV Axles For additional information on TeamMate IV axles and components, see TeamMate IV 1200 - 1400 Series Inboard Planetary Axles. (CTM442.)

TeamMate is a trademark of Deere & Company

TM10687 (14OCT08)

MH66O88,000071B –19–25FEB08–1/1

02-0200-1

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02 0200 1

Removal and Installation

Front Axle and Differential Remove and Install

–UN–23AUG88

CAUTION: Escaping fluid under pressure can penetrate the skin, causing serious injury.

Search for leaks with a piece of cardboard. Protect hands and body from high-pressure fluids.

–UN–04APR06

TX1005979A

02 0200 2

X9811

Avoid the hazard by relieving pressure before disconnecting hydraulic or other lines. Tighten all connections before applying pressure.

2. Raise boom and install boom lock. See Boom Lock. (Operator’s Manual.)

Frame Articulation Lock Bar and Floor Stands 1—Frame Articulation Lock Bar 2—12-1/2-Ton Floor Stand

CAUTION: Prevent possible injury from unexpected machine movement. Install frame articulation lock bar before working in frame hinge area. 3. Install frame articulation lock bar (1). 4. Perform Hydraulic System Pressure and Accumulators Discharge. (Group 9025-25.) 5. Drain differential oil into an appropriate container for storage or disposal. See Drain and Refill Front and Rear Axle Oil. (Operator’s Manual.)

Continued on next page

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02-0200-2

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Removal and Installation

CAUTION: Prevent crushing injury from heavy component. Use appropriate lifting device when lifting component. Specification Standard Cab Machine with Multi-Purpose Bucket—Weight (approximate).............................................................................. 12 686 kg 27 968 lb

6. Raise front of machine. Install 12-1/2 ton floor stands (2) under loader frame.

02 0200 3

CAUTION: Prevent crushing injury from heavy component. Use appropriate lifting device when lifting component. 7. Remove wheels. See Wheel Remove and Install. (Group 0110.) IMPORTANT: Avoid machine damage. Do not reuse drive shaft universal joint cap screws. 8. Remove and discard universal joint cap screws. Remove drive shaft. See Universal Joint and Drive Shaft Remove and Install. (Group 0225.)

AA95137,0001B51 –19–19AUG08–2/5

NOTE: For assembly purposes, identify all lines before removing.

6 9. Disconnect lines from ports (3—6). Close all openings using caps and plugs.

TX1028396

–UN–05SEP07

3—Grease Port 4—Differential Lock Port 5—Brake Port 6—Breather Port

Front Axle and Differential Ports

Continued on next page

TM10687 (14OCT08)

02-0200-3

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Removal and Installation

CAUTION: Prevent crushing injury from heavy component. Use appropriate lifting device when lifting component. 10. Install JT01642A Low-Lift Jack (7) under axle and differential. –UN–06SEP07 TX1029035A

02 0200 4

Specification Front Axle and Differential— Weight (approximate) ...................................................................... 953 kg 2100 lb

11. Remove nuts (8), washers, and cap screws. Lower axle and differential. Low-Lift Jack and Axle

12. Lower axle and differential assembly.

7—Low-Lift Jack 8—Nut (12 used)

13. Repair or replace axle or differential. See TeamMate IV 1200 - 1400 Series Inboard Planetary Axles. (CTM442.) 14. Clean mating surfaces on axle housing and loader frame. CAUTION: Prevent crushing injury from heavy component. Use appropriate lifting device when lifting component. 15. Install axle and differential to loader frame. 16. Install cap screws, washers, and nuts. Tighten to specification. Specification Nut—Torque ................................................................................. 675 N•m 498 lb-ft

Continued on next page

TM10687 (14OCT08)

02-0200-4

AA95137,0001B51 –19–19AUG08–4/5

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Removal and Installation 17. Connect lines to ports (3—6). IMPORTANT: Avoid machine damage. Do not reuse drive shaft universal joint cap screws.

4 3

19. Install wheels. See Wheel Remove and Install. (Group 0110.) Specification Wheel Retainer Cap Screw— Torque .......................................................................................... 678 N•m 500 lb-ft

TX1028396

Specification Drive Shaft Universal Joint Cap Screw—Torque ............................................................................... 78 N•m 58 lb-ft

–UN–05SEP07

18. Connect drive shaft. See Universal Joint and Drive Shaft Remove and Install. (Group 0225.) Install new drive shaft universal joint cap screws and tighten to specification.

3—Grease Port 4—Differential Lock Port 5—Brake Port 6—Breather Port

20. Remove floor stands. 21. Fill differential with oil. See Drain and Refill Front and Rear Axle Oil. (Operator’s Manual.) Check differential oil level with machine on level ground. 22. Bleed brakes. See Service Brake Bleeding Procedure. (Group 9020-20.)

AA95137,0001B51 –19–19AUG08–5/5

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02-0200-5

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02 0200 5

Removal and Installation

Rear Axle and Differential Remove and Install CAUTION: Escaping fluid under pressure can penetrate the skin causing serious injury.

Search for leaks with a piece of cardboard. Protect hands and body from high-pressure fluids.

X9811

02 0200 6

–UN–23AUG88

Avoid the hazard by relieving pressure before disconnecting hydraulic or other lines. Tighten all connections before applying pressure.

Escaping Fluid Under Pressure

Continued on next page

TM10687 (14OCT08)

02-0200-6

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Removal and Installation

CAUTION: Prevent crushing injury from heavy component. Use appropriate lifting device when lifting component.

–UN–04APR06

5. Raise rear of machine using floor jack. Install 12-1/2 ton floor stands under frame on each side and under rear corners of frame.

TX1005981A

Specification Standard Cab Machine with Multi-Purpose Bucket—Weight (approximate).............................................................................. 12 686 kg 27 968 lb

6. Remove wheels. See Wheel Remove and Install. (Group 0110.)

Floor Stand Under Frame

7. Remove and discard universal joint cap screws. Disconnect drive shaft from axle. See Universal Joint and Drive Shaft Remove and Install. (Group 0225.)

TX1005982A

–UN–04APR06

1—Floor Stand (4 used)

Positioning Floor Stands

Continued on next page

TM10687 (14OCT08)

02-0200-7

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02 0200 7

Removal and Installation NOTE: For assembly purposes, identify all lines before removing. 8. Disconnect lines from ports (2—5).

CAUTION: Prevent crushing injury from heavy component. Use appropriate lifting device when lifting component. 9. Install JT01642A Low-Lift Jack under axle assembly.

Specification

–UN–27AUG07

Axle and Differential with Oscillating Supports—Weight (approximate)................................................................................... 953 kg 2100 lb

10. Remove axle and differential mounting cap screws (6 and 7) from oscillating supports.

TX1028540

02 0200 8

6 5

Rear Axle and Differential Ports

11. Lower supports, axle and differential assembly. 2—Service Brake Port 3—Differential Lock Port 4—Lubrication Port 5—Breather Port 6—Cap Screw (6 used) 7—Cap Screw (4 used)

Continued on next page

TM10687 (14OCT08)

02-0200-8

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Removal and Installation

27 28

02 0200 9

18 –UN–18OCT07

TX1030742

10 9

TX1030742 Oscillating Supports 8—Pivot Cover 9—Thrust Bearing 10—Retaining Ring 11—Thrust Plate 12—O-Ring 13—Thrust Bearing

14—Bushing 15—Seal 16—Rear Oscillating Support 17—Pivot Cover Cap Screw (6 used) 18—Thrust Plate Cap Screw (4 used)

19—Washer (4 used) 20—Cap Screw (6 used) 21—Washer (12 used) 22—Nut (6 used) 23—Seal (2 used)

24—Rear Axle Support 25—Bushing 26—Washer (4 used) 27—Cap Screw (4 used) 28—Bushing (4 used)

12. Remove rear axle support (24) from differential assembly.

16. Tighten thrust plate cap screws (18) and pivot cover cap screws (17) to specification.

13. Remove rear oscillating support (16) from differential assembly.

Specification Oscillating Support Thrust Plate Cap Screw—Torque .............................................................. 350 N•m 255 lb-ft Oscillating Support Pivot Cover Cap Screw—Torque .............................................................. 140 N•m 105 lb-ft

14. Repair or replace axle. See TeamMate IV 1200 1400 Series Inboard Planetary Axles. (CTM442.) NOTE: DO NOT apply grease to rear axle support or rear oscillating support bushings. These joints are designed to run dry. Greasing these bushings will reduce the life of the oscillating joints.

17. Clean mating surfaces on oscillating supports and loader frame. 18. Install axle and differential with oscillating supports.

15. Install rear axle support and rear oscillating support.

Continued on next page

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Removal and Installation Specification Axle and Differential with Oscillating Supports—Weight (approximate) ............................................................................ 953 kg 2100 lb

02 0200 10

Specification Drive Shaft Universal Joint Cap Screw—Torque ........................................................................ 78 N•m 58 lb-ft

19. Install and tighten axle and differential mounting cap screws to specification.

22. Install wheels. See Wheel Remove and Install. (Group 0110.) Tighten wheel retaining cap screws to specification.

Specification Axle and Differential Mounting Cap Screw—Torque .............................................................. 675 N•m 500 lb-ft

Specification Wheel Retaining Cap Screw— Torque.................................................................................... 675 N•m 500 lb-ft

20. Connect lines to differential.

23. Remove floor stands.

IMPORTANT: Do not reuse drive shaft universal joint cap screws. Install new cap screws to avoid machine damage.

24. Fill differential with oil. See Drain and Refill Front and Rear Axle Oil. (Operator’s Manual.) Check differential oil level with machine on level ground.

21. Connect drive shaft. See Universal Joint and Drive Shaft Remove and Install. (Group 0225.) Install new drive shaft universal joint cap screws and tighten to specification.

25. Bleed brakes. See Service Brake Bleeding Procedure. (Group 9020-20)

AA95137,0001B52 –19–19AUG08–5/5

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Removal and Installation

Axle Oscillating Supports Disassemble and Assemble

4 10 9

02 0200 11

13 14

12 16

17 18

11 4

–UN–16OCT07

2 7

TX1030662

TX1030662 Oscillating Supports 1—Nut (6 used) 2—Washer (16 used) 3—Rear Oscillating Support 4—Lip Seal (2 used) 5—Bushing (4 used)

6—Cap Screw (6 used) 7—Seal 8—Bushing 9—Rear Axle Support 10—Bushing

11—Cap Screw (4 used) 12—Thrust Bearing (2 used) 13—Thrust Plate 14—Washer (4 used) 15—Cap Screw (4 used)

NOTE: The axle oscillation support assembly does not contain any shims for setting end play. If excessive end play occurs due to wear, thrust bearings should be replaced. End play can be checked with dial indicator measuring between front support and the differential housing. Also check thrust plate (between both thrust bearings) for wear on the front side. The disk should not have more than a 0.254 mm (0.01 in.) wear step on the face that contacts the front thrust bearings. If out of specification, replace thrust plate and thrust bearings.

16—Retaining Ring 17—Pivot Cover 18—Cap Screw (6 used) 19—O-Ring

1. Remove rear axle and differential assembly. See Rear Axle and Differential Remove and Install. (Group 0200.) 2. Remove rear axle support (9). 3. Remove cap screws (15 and 18) from pivot cover (17) and thrust plate (13) in rear oscillating support (3). 4. Remove rear oscillating support (3). 5. Repair or replace parts as necessary.

Specification Axle-to-Oscillation Support— End Play (maximum) ........................................................... 0.762 mm 0.03 in.

6. Inspect bushings (8 and 10) and thrust bearings (12) for wear.

Continued on next page

TM10687 (14OCT08)

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Removal and Installation NOTE: DO NOT apply grease to rear axle support or rear oscillating support bushings. These joints are designed to run dry. Greasing these bushings will reduce the life of the oscillating joints. 7. Press bushings into front and rear supports, being careful not to damage the bushings.

Specification Thrust Plate-to-Axle Cap Screw—Torque ...................................................................... 350 N•m 255 lb-ft Pivot Cover-to-Rear Oscillation Support—Torque ................................................................... 140 N•m 105 lb-ft

10. Install rear axle and differential assembly. See Rear Axle and Differential Remove and Install. (Group 0200.)

8. Install front and rear oscillating supports to the 02 differential. 0200 12

specification.

9. Tighten thrust plate-to-axle cap screws and pivot cover-to-rear oscillation support cap screws to

MH66O88,000071A –19–13AUG08–2/2

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Group 0225

Axle Shafts and U-Joints

02 0225 1

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02-0225-1

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Axle Shafts and U-Joints

Universal Joint and Drive Shaft Remove and Install

3 1

2 9 6 02 0225 2

3 2

2 2

9 3

6 9

3 2

2 3

9 3 2

8 2

TX1029271

–UN–11SEP07

Universal Joint and Drive Shaft Remove and Install Continued on next page

TM10687 (14OCT08)

02-0225-2

SW03989,000041E –19–25FEB08–1/2

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Axle Shafts and U-Joints 1—Cap Screw 2—Cap Screw 3—Strap

4—Engine-to-Transmission Drive Shaft 5—Transmission-to-Rear Axle Drive Shaft

6—Dust Cap 7—Transmission-to-Park Brake Drive Shaft

8—Park Brake-to- Front Axle 9—Universal Joint

IMPORTANT: Avoid machine damage. Do not reuse drive shaft universal joint cap screws.

CAUTION: Prevent possible injury from unexpected machine movement. Place blocks front and rear of tires to prevent machine from rolling.

4. Install new drive shaft universal joint cap screws.

Specification Drive Shaft Universal Joint Cap Screw—Torque ........................................................................ 78 N•m 58 lb-ft Engine Drive Shaft Universal-to-Transmission Cap Screw—Torque ........................................................................ 45 N•m 32 lb-ft Engine Drive Shaft-to-Engine Cap Screw—Torque .............................................................. 140 N•m 105 lb-ft

3. Inspect and replace parts as necessary.

SW03989,000041E –19–25FEB08–2/2

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02-0225-3

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02 0225 3

Axle Shafts and U-Joints

02 0225 4

TM10687 (14OCT08)

02-0225-4

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Group 0250

Axle Shaft, Bearings, Reduction Gears TeamMate IV Axles For additional information on TeamMate IV axles and components, see TeamMate IV 1200 - 1400 Series Inboard Planetary Axles. (CTM442.)

TeamMate is a trademark of Deere & Company

TM10687 (14OCT08)

SW03989,000041F –19–25FEB08–1/1

02-0250-1

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02 0250 1

Axle Shaft, Bearings, Reduction Gears

02 0250 2

TM10687 (14OCT08)

02-0250-2

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Group 0260

Hydraulic System Differential Lock Solenoid Valve Remove and Install See Hydraulic Pump Manifold Disassemble and Assemble. (Group 3160.)

SW03989,0000420 –19–19AUG08–1/1

TM10687 (14OCT08)

02-0260-1

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02 0260 1

Hydraulic System

Axle Circulation System Remove and Install—If Equipped

32 12 10

34 29

02 0260 2

2 1 22 21

27 2

25 24

3 1

17 15 19

36 16

11 4

9 7 10

2 1

6 22 2

14 5 3

1 15

TX1021481

–UN–11APR07

TX1021481 Axle Circulation System Continued on next page

TM10687 (14OCT08)

02-0260-2

MH66O88,0000711 –19–07AUG08–1/2

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Hydraulic System 1—O-Ring (4 used) 2—Elbow Fitting (4 used) 3—O-Ring (4 used) 4—Hydraulic Hose 5—Hydraulic Hose 6—O-Ring (4 used) 7—O-Ring (2 used) 8—Bracket (2 used) 9—Cap Screw (4 used)

10—Washer (4 used) 11—Washer (2 used) 12—Nut (2 used) 13—Hydraulic Hose 14—Hydraulic Hose 15—Filter (2 used) 16—Elbow Fitting (2 used) 17—O-Ring (2 used) 18—O-Ring

19—O-Ring 20—Hydraulic Hose 21—Hydraulic Hose 22—Tee Fitting (2 used) 23—Hydraulic Hose 24—Hydraulic Hose 25—Elbow Fitting (2 used) 26—O-Ring (4 used) 27—O-Ring (2 used)

28—Pump 29—Cap Screw (2 used) 30—Cover 31—Gasket 32—O-Ring (2 used) 33—Elbow Fitting (2 used) 34—Hydraulic Hose 35—Hydraulic Hose 36—Hydraulic Hose

Axle Circulating Pump Section Cap Screws—Torque ....................................................... 14—18 N•m 10—13 lb-ft

When repairing pumps tighten pump section cap screws to following specification. Specification Fan Pump Section Cap Screws—Torque ............................................................... 51—58 N•m 38—43 lb-ft

For more information on axle circulation system, see Power Train Component Location. (Group 9020-15.)

MH66O88,0000711 –19–07AUG08–2/2

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02-0260-3

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02 0260 3

Hydraulic System

02 0260 4

TM10687 (14OCT08)

02-0260-4

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PN=54

Section 03

Transmission Contents Page

Group 0300—Removal and Installation Transmission Remove and Install . . . . . . . . .03-0300-1 Group 0350—Gears, Shafts, Bearings and Power Shift Clutch Torque Converter and Housing Remove . . . .03-0350-1 Torque Converter and Housing Install . . . . . .03-0350-6 Clutches and Input and Output Shafts Remove . . . . . . . . . . . . . . . . . . . . . . . . . .03-0350-10 Clutches and Input and Output Shafts Install. . . . . . . . . . . . . . . . . . . . . . . . . . . .03-0350-19 Clutch Pack KV and KR Disassemble . . . .03-0350-33 Clutch Pack KV and KR Assemble. . . . . . .03-0350-37 Clutch Pack K1, K2, and K3 Disassemble . . . . . . . . . . . . . . . . . . . . . .03-0350-46 Clutch Pack K1, K2, and K3 Assemble . . . .03-0350-49 Clutch Pack K4 Disassemble . . . . . . . . . . .03-0350-61 Clutch Pack K4 Assemble . . . . . . . . . . . . . .03-0350-62 Input Shaft Disassemble . . . . . . . . . . . . . .03-0350-69 Input Shaft Assemble . . . . . . . . . . . . . . . . .03-0350-70 Axle Disconnect Remove and Install . . . . . .03-0350-74 Axle Disconnect Disassemble and Assemble. . . . . . . . . . . . . . . . . . . . . . . . .03-0350-76

Group 0360—Hydraulic System Transmission Pump Remove and Install . . . .03-0360-1 Converter Minimum Pressure Regulator Valve Remove and Install . . . . . . . . . . . . .03-0360-5 Transmission Hydraulic Control Valve Remove and Install . . . . . . . . . . . . . . . . . .03-0360-6 Transmission Hydraulic Control Valve Cross Section View . . . . . . . . . . . . . . . . . . . . . .03-0360-10 Transmission Hydraulic Control Valve Disassemble and Assemble. . . . . . . . . . .03-0360-11 Torque Converter Relief Valve Remove, Disassemble, and Install . . . . . . . . . . . . .03-0360-23 Transmission Internal Oil Pipes and Tubes Remove and install . . . . . . . . . . . . . . . . .03-0360-25 Axle Disconnect Solenoid Valve Remove and Install . . . . . . . . . . . . . . . . . . . . . . . .03-0360-29

TM10687 (14OCT08)

03-1

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PN=1

Contents

TM10687 (14OCT08)

03-2

524K Loader 101408

PN=2

Group 0300

Removal and Installation Transmission Remove and Install

X9811

–UN–23AUG88

CAUTION: Escaping fluid under pressure can penetrate the skin, causing serious injury. Avoid the hazard by relieving pressure before disconnecting hydraulic or other lines. Tighten all connections before applying pressure. Search for leaks with a piece of cardboard. Protect hands and body from high-pressure fluids. If an accident occurs, see a doctor immediately. Any fluid injected into the skin must be surgically removed within a few hours or gangrene may result. Doctors unfamiliar with this type of injury should reference a knowledgeable medical source. Such information is available from Deere & Company Medical Department in Moline, Illinois, U.S.A.

03 0300 1

1. Park and prepare machine for service.See Park and Prepare for Service Safely. (Group 0001.) 2. Perform Hydraulic System Pressure and Accumulators Discharge. (Group 9025-25.) 3. Remove cab. See Cab Remove and Install. (Group 1800.) 4. Drain hydraulic oil reservoir or apply vacuum. If draining reservoir, see Drain and Refill Hydraulic System Oil. (Operator’s Manual.)

Continued on next page

TM10687 (14OCT08)

03-0300-1

MH66O88,000071F –19–19AUG08–1/3

524K Loader 101408

PN=57

Removal and Installation 5. Disconnect all transmission drive shaft U-joints (1—4). See Universal Joint and Drive Shaft Remove and Install. (Group 0225.)

TX1028579

7. Drain transmission oil into an appropriate container for storage or disposal. See Drain and Refill Transmission Oil and Replace Filter. (Operator’s Manual.)

Transmission 1—Drive Shaft U-Joint 2—Drive Shaft U-Joint 3—Drive Shaft U-Joint 4—Hydraulic Pump

8. Remove transmission oil fill tube. 03 0300 2

–UN–29AUG07

6. Remove all hoses and electrical harnesses at hydraulic pump and transmission. For hose routing, see Hydraulic System Component Location (Group 9025-15.) and see Power Train Component Location. (Group 9020-15.)

CAUTION: Prevent crushing injury from heavy component. Use appropriate lifting device when lifting component. 9. Install appropriate lifting device to transmission lifting brackets and support transmission. Specification Transmission with Hydraulic Pump Attached—Weight (approximate)................................................................................... 431 kg 950 lb

10. Remove transmission isolator cap screws. 11. Remove transmission front mounts from transmission. 12. Remove transmission and place in D01003AA Repair Stand using JDG1129A Transmission Mounting Brackets. Repair or replace as necessary. 13. Install transmission in machine. Tighten cap screws to specification. Specification Isolator Cap Screw—Torque ........................................................ 475 N•m 350 lb-ft Mounting Bracket-to-Transmission Cap Screw (Front)—Torque ......................................................... 435 N•m 320 lb-ft Mounting Bracket-to-Transmission Cap Screw (Rear)—Torque.......................................................... 350 N•m 255 lb-ft

Continued on next page

TM10687 (14OCT08)

03-0300-2

MH66O88,000071F –19–19AUG08–2/3

524K Loader 101408

PN=58

Removal and Installation 14. Connect all hydraulic lines and electrical harnesses to transmission and hydraulic pump. IMPORTANT: Avoid machine damage. Do not reuse drive shaft universal joint cap screws. 15. Install transmission drive shafts using new cap screws and tighten to specification. Specification Transmission-to-Rear Axle Drive Shaft U-Joint—Torque .................................................................... 78 N•m 58 lb-ft Engine-to-Transmission Drive Shaft U-Joint—Torque .................................................................... 41 N•m 30 lb-ft

03 0300 3

16. Install cab. See Cab Remove and Install. (Group 1800.) 17. Fill transmission and remove vacuum or fill hydraulic reservoir to specification. See Drain and Refill Hydraulic System Oil and see Drain and Refill Transmission Oil and Replace Filter. (Operator’s Manual.)

MH66O88,000071F –19–19AUG08–3/3

TM10687 (14OCT08)

03-0300-3

524K Loader 101408

PN=59

Removal and Installation

03 0300 4

TM10687 (14OCT08)

03-0300-4

524K Loader 101408

PN=60

Group 0350

Gears, Shafts, Bearings and Power Shift Clutch Torque Converter and Housing Remove 1. Remove transmission. See Transmission Remove and Install. (Group 0350.) SW03989,0000422 –19–25FEB08–1/11

CAUTION: Prevent possible injury from crushing. Heavy component, use appropriate lifting device.

–UN–19DEC97

Specification Transmission—Weight (approximate)................................................................................... 504 kg 1110 lb

T112589

NOTE: Earlier JDG1129 Transmission Mounting Brackets require that the right side bracket be revised. Note bracket sketch showing revised mounting hole (A). Revise hole by elongating the existing hole as required.

Bracket Sketch Showing Revised Mounting Hole (A)

–UN–16APR07

2. Install transmission in repair stand using JDG1129 Transmission Mounting Brackets (1).

TX1022077A

A—Mounting Hole 1—JDG1129 Transmission Mounting Bracket (2 used)

JDG1129 Transmission Mounting Brackets SW03989,0000422 –19–25FEB08–2/11

3. Remove lock plate and cap screws from input flange washer.

T108721

–UN–17APR97

4. Remove washer and input flange from the shaft.

Lock Plate and Cap Screws

Continued on next page

TM10687 (14OCT08)

03-0350-1

SW03989,0000422 –19–25FEB08–3/11

524K Loader 101408

PN=61

03 0350 1

Gears, Shafts, Bearings and Power Shift Clutch 5. Remove cap screws from torque converter housing.

T108722

–UN–17APR97

NOTE: Identify location of cover and housing for proper alignment during assembly.

Housing Cap Screws Removal

03 0350 2 SW03989,0000422 –19–25FEB08–4/11

CAUTION: Prevent possible injury from crushing. Heavy component, use appropriate lifting device.

T108723

–UN–17APR97

6. Remove torque converter and cover from gearbox, using appropriate lifting device and an M20 or M12 eyebolt.

Cover-Converter Separation

Continued on next page

TM10687 (14OCT08)

03-0350-2

SW03989,0000422 –19–25FEB08–5/11

524K Loader 101408

PN=62

Gears, Shafts, Bearings and Power Shift Clutch

T108724

–UN–17APR97

7. Press input shaft and torque converter out of housing.

Input Shaft Press

03 0350 3 SW03989,0000422 –19–25FEB08–6/11

T108717

–UN–17APR97

8. Remove snap ring and bearing from housing.

Bearing Removal

Continued on next page

TM10687 (14OCT08)

03-0350-3

SW03989,0000422 –19–25FEB08–7/11

524K Loader 101408

PN=63

Gears, Shafts, Bearings and Power Shift Clutch

T112416

–UN–05DEC97

9. Remove drive plate from torque converter.

Drive Plate-to-Converter Cap Screw

03 0350 4 SW03989,0000422 –19–25FEB08–8/11

T112415

–UN–05DEC97

10. Remove cap screws, separating the input shaft and drive plate.

Input Shaft-to-Drive Plate Cap Screws

Continued on next page

TM10687 (14OCT08)

03-0350-4

SW03989,0000422 –19–25FEB08–9/11

524K Loader 101408

PN=64

Gears, Shafts, Bearings and Power Shift Clutch

T108720

–UN–17APR97

11. Remove speed sensor from torque converter housing.

Speed Sensor Removal

03 0350 5 SW03989,0000422 –19–25FEB08–10/11

12. Remove cap screws, separating the torque converter lower housing from the transmission case.

T108729

–UN–17APR97

13. Repair or replace parts as necessary.

Converter Lower Housing Removal

SW03989,0000422 –19–25FEB08–11/11

TM10687 (14OCT08)

03-0350-5

524K Loader 101408

PN=65

Gears, Shafts, Bearings and Power Shift Clutch

Torque Converter and Housing Install 1. Install torque converter housing to the transmission case using cap screws. Tighten to specification.

T109095

–UN–15APR97

Specification Converter Housing Cap Screw— Torque ............................................................................................ 68 N•m 50 lb-ft

Torque Converter Cap Screw Install

03 0350 6 MH66O88,0000722 –19–18FEB08–1/8

2. Assemble the input shaft to drive plate. Tighten to specification.

T112415

–UN–05DEC97

Specification Input Shaft-to-Drive Plate Cap Screw—Torque ............................................................................. 115 N•m 85 lb-ft

Input Shaft-to-Converter Hex Head Screws

Continued on next page

TM10687 (14OCT08)

03-0350-6

MH66O88,0000722 –19–18FEB08–2/8

524K Loader 101408

PN=66

Gears, Shafts, Bearings and Power Shift Clutch 3. Install input shaft drive plate assembly to torque converter. Apply PM38654 High Strength Thread Lock and Sealer to cap screws. Install washer and cap screws. Tighten to specification.

T112416

–UN–05DEC97

Specification Input Shaft Drive Plate-to-Torque Converter Cap Screw—Torque .................................................... 115 N•m 85 lb-ft

Drive Plate-to-Converter Cap Screw

03 0350 7 MH66O88,0000722 –19–18FEB08–3/8

4. Install torque converter into housing until contact is made.

T112417

–UN–05DEC97

NOTE: Speed pickup disk in the converter must be centered to the bore of the speed sensor (arrow).This ensures that the converter is seated properly.

T109098

–UN–30APR97

Converter Installation

Centered Speed Pickup Disk Continued on next page

TM10687 (14OCT08)

03-0350-7

MH66O88,0000722 –19–18FEB08–4/8

524K Loader 101408

PN=67

Gears, Shafts, Bearings and Power Shift Clutch

T109099

–UN–15APR97

5. Insert bearing until contact is obtained in bore and install snap ring.

MH66O88,0000722 –19–18FEB08–5/8

NOTE: Alignment of both housings needs to be the same as in the disassembly process. 6. Assemble housing. –UN–15APR97

CAUTION: Prevent possible injury from heated components. Use proper safety equipment while handling heated components. 7. Heat yoke shaft splines evenly to specifications before installing. Use temperature measuring stick or infrared meter to verify temperature.

T109100

03 0350 8

Input Flange Installation

Specification Input Yoke Preheat— Temperature ............................................................................ 80—120° C 175—250° F

Install input yoke and washer. Draw cover down evenly against shoulder with cap screws. Specification Input Yoke Cap Screw—Torque .................................................... 34 N•m 25 lb-ft

Continued on next page

TM10687 (14OCT08)

03-0350-8

MH66O88,0000722 –19–18FEB08–6/8

524K Loader 101408

PN=68

Gears, Shafts, Bearings and Power Shift Clutch 8. Install cover with cap screws and nuts on the torque converter housing. Tighten to specification.

T109101

–UN–15APR97

Specification Torque Converter Top Cover Cap Screw—Torque ............................................................................... 46 N•m 34 lb-ft

Torque Converter Top Cover Installation

03 0350 9 MH66O88,0000722 –19–18FEB08–7/8

9. Install input and output flange to drive plate. Install cap screw and tighten to specification.

–UN–02MAY97

Specification Output Yoke Cap Screws— Torque ............................................................................................ 34 N•m 25 lb-ft

A—Deep Well Socket (2 used)

T109147B

Install lock plate using hammer and two deep well sockets (A) taped together with a hex nut between them for proper spacing. Output Flange Shown

MH66O88,0000722 –19–18FEB08–8/8

TM10687 (14OCT08)

03-0350-9

524K Loader 101408

PN=69

Gears, Shafts, Bearings and Power Shift Clutch

Clutches and Input and Output Shafts Remove

–UN–18APR97

1. Remove front and rear output flange from output shafts.

T108778

2. Remove output shaft seals from housing bores.

Remove Output Flange from Shaft

03 0350 10 MH66O88,0000723 –19–10OCT08–1/19

3. Remove torque converter input speed sensor, internal clutch speed sensor, and torque converter output speed sensor.

TX1021874A

–UN–12APR07

1—Sensor (3 used)

Sensor Location

Continued on next page

TM10687 (14OCT08)

03-0350-10

MH66O88,0000723 –19–10OCT08–2/19

524K Loader 101408

PN=70

Gears, Shafts, Bearings and Power Shift Clutch 4. Remove cap screws (2) from transmission cover

–UN–09OCT08

5. Drive both dowel pins (3) down far enough to clear cover for removal.

TX1049934

2—Cap Screw 3—Dowel Pin (2 used)

Cap Screws and Dowel Pins

03 0350 11 MH66O88,0000723 –19–10OCT08–3/19

CAUTION: Prevent possible injury from crushing. Heavy component; use appropriate lifting device.

T108774

–UN–18APR97

6. Using an appropriate lifting device, separate housing cover carefully from gear case housing and remove.

Housing Cover/Gear Case Separation

Continued on next page

TM10687 (14OCT08)

03-0350-11

MH66O88,0000723 –19–10OCT08–4/19

524K Loader 101408

PN=71

Gears, Shafts, Bearings and Power Shift Clutch 7. The figure on the right shows the proper position of the single clutches as well as of the input shaft (5) and output shaft (4).

TX1028676A

–UN–31AUG07

4—Output Shaft (AB) 5—Input Shaft (AN) 6—First Speed Clutch (K1) 7—Second Speed Clutch (K2) 8—Third Speed Clutch (K3) 9—Forth Speed Forward Clutch (K4) 10—Reverse Clutch (KR) 11—Forward Clutch (KV) Single Clutch Proper Positions

03 0350 12 MH66O88,0000723 –19–10OCT08–5/19

NOTE: When removing clutches, remove output shaft first.

T108776

–UN–18APR97

8. Loosen socket head cap screws from covers and remove output shaft with covers.

Clutch Removal

Continued on next page

TM10687 (14OCT08)

03-0350-12

MH66O88,0000723 –19–10OCT08–6/19

524K Loader 101408

PN=72

Gears, Shafts, Bearings and Power Shift Clutch

–UN–09OCT08

IMPORTANT: Remove sealing rings from clutch pack shafts (cover side only) before installing cover. Sealing rings may be damaged while removing and installing clutch packs.

TX1049936

IMPORTANT: Clutches KV, KR, and input shaft (13) are only held in by gear mesh. NOTE: Four Flat Washers and M10 nuts are substituted for special handles shown in graphic. Special Handles Shown

9. Install cover on transmission until it contacts the mounting surface so clutch packs can be removed from housing for repair or inspection.

12—Special Handle (4 used) 13—Clutch KR, Clutch KV, and Input Shaft

03 0350 13 MH66O88,0000723 –19–10OCT08–7/19

NOTE: Transmission cover is used to properly remove packs from transmission housing.

TX1049941A

–UN–09OCT08

10. Install four flat washers and four nuts (14) on end of clutch packs. This will hold clutch packs in place while mounting cover in rollover repair stand. This method must be used to remove clutch packs from transmission housing. 14—Flat Washers and M10 Nuts Flat Washers and M10 Nuts (4 used)

Continued on next page

TM10687 (14OCT08)

03-0350-13

MH66O88,0000723 –19–10OCT08–8/19

524K Loader 101408

PN=73

Gears, Shafts, Bearings and Power Shift Clutch

CAUTION: Prevent possible injury from crushing. Heavy component; use appropriate lifting device.

TX1049937

–UN–09OCT08

11. Remove housing cover along with all clutch packs from gear case housing using an appropriate lifting device.

Housing Cover/Gear Case Housing Separation

03 0350 14 MH66O88,0000723 –19–10OCT08–9/19

TX1028696A

–UN–29AUG07

12. Remove transmission housing from repair stand. Install transmission cover with clutch packs into repair stand using JDG1129A Mounting Brackets. Fasten transmission cover to mounting brackets using cap screws, washers, and nuts as shown.

Mounting Bracket Positions

MH66O88,0000723 –19–10OCT08–10/19

13. Rotate the repair stand so clutch packs are facing up. This will allow them to be removed from the cover.

TX1049945A

–UN–09OCT08

14. Remove washers and nuts retaining clutch packs.

Continued on next page

TM10687 (14OCT08)

03-0350-14

MH66O88,0000723 –19–10OCT08–11/19

524K Loader 101408

PN=74

Gears, Shafts, Bearings and Power Shift Clutch 15. Clutch pack layout viewed from torque converter side of transmission.

TX1028698A

–UN–29AUG07

6—First Speed Clutch (K1) 7—Second Speed Clutch (K2) 8—Third Speed Clutch (K3) 9—Forth Speed Forward Clutch (K4) 10—Reverse Clutch (KR) 11—Forward Clutch (KV)

View from Torque Converter Side

03 0350 15 MH66O88,0000723 –19–10OCT08–12/19

CAUTION: Use special care while removing clutch packs from cover due to closeness of packs and spline engagement to each other.

T108789

–UN–18APR97

16. Remove second speed clutch (K2).

Remove Second Speed Clutch (K2)

Continued on next page

TM10687 (14OCT08)

03-0350-15

MH66O88,0000723 –19–10OCT08–13/19

524K Loader 101408

PN=75

Gears, Shafts, Bearings and Power Shift Clutch

T108782

–UN–18APR97

17. Remove first speed clutch (K1) while lifting forth speed forward clutch (K4) to the side for clearance.

Remove First Speed Clutch (K1)

03 0350 16 MH66O88,0000723 –19–10OCT08–14/19

T108783

–UN–18APR97

18. Remove third speed clutch (K3).

Remove Third Speed Clutch (K3)

Continued on next page

TM10687 (14OCT08)

03-0350-16

MH66O88,0000723 –19–10OCT08–15/19

524K Loader 101408

PN=76

Gears, Shafts, Bearings and Power Shift Clutch

T108784

–UN–18APR97

19. Remove forth speed forward clutch (K4) while lifting input shaft slightly.

Remove Forth Speed Forward Clutch (K4)

03 0350 17 MH66O88,0000723 –19–10OCT08–16/19

NOTE: Clutches KV and KR can be serviced.

T108785

–UN–18APR97

20. Remove forward (KV) and reverse (KR) clutches together with input shaft from the housing cover. To disassemble forward and reverse clutches, see Clutch Pack KV and KR Disassemble. (Group 0350.)

Separate Forward (KV) and Reverse (KR) Clutches

Continued on next page

TM10687 (14OCT08)

03-0350-17

MH66O88,0000723 –19–10OCT08–17/19

524K Loader 101408

PN=77

Gears, Shafts, Bearings and Power Shift Clutch

T108790

–UN–18APR97

21. Remove bearing outer race and pull output shaft from housing bore.

Remove Output Shaft

03 0350 18 MH66O88,0000723 –19–10OCT08–18/19

22. Remove snap ring (16) and bearing (15) from shaft.

TX1049946A

–UN–09OCT08

15—Bearing 16—Snap Ring

Snap Ring

MH66O88,0000723 –19–10OCT08–19/19

TM10687 (14OCT08)

03-0350-18

524K Loader 101408

PN=78

Gears, Shafts, Bearings and Power Shift Clutch

Clutches and Input and Output Shafts Install IMPORTANT: High tolerance bearings are used in all clutch pack applications. Use only John Deere sourced bearings when replacing.

–UN–29AUG07

NOTE: If bearings are reused, they must be assembled in the same bores from which they were removed.

TX1028716A

1. Insert all bearing outer races into the housing cover until contact with bottom of bore is obtained. 1—Output Shaft (AB) 2—Input Shaft (AN) 3—First Speed Clutch (K1) 4—Second Speed Clutch (K2) 5—Third Speed Clutch (K3) 6—Forth Speed Forward Clutch (K4) 7—Reverse Clutch (KR) 8—Forward Clutch (KV)

Bearing Outer Race Installation

03 0350 19

AA95137,0001B50 –19–10OCT08–1/28

2. Install reverse clutch (2), input shaft (7), and forward clutch (8) into housing cover.

TX1028717A

–UN–30AUG07

2—Input Shaft (AN) 7—Reverse Clutch (KR) 8—Forward Clutch (KV)

KR, KV, and Input Shaft Installation

Continued on next page

TM10687 (14OCT08)

03-0350-19

AA95137,0001B50 –19–10OCT08–2/28

524K Loader 101408

PN=79

Gears, Shafts, Bearings and Power Shift Clutch

TX1029592A

–UN–20SEP07

3. Install forth speed forward clutch.

Clutch K4 Installation

03 0350 20 AA95137,0001B50 –19–10OCT08–3/28

T109007

–UN–09MAY97

4. Install third speed clutch.

Clutch K3 Installation

Continued on next page

TM10687 (14OCT08)

03-0350-20

AA95137,0001B50 –19–10OCT08–4/28

524K Loader 101408

PN=80

Gears, Shafts, Bearings and Power Shift Clutch

T112554B

–UN–17DEC97

5. Install second speed clutch.

Clutch K2 Installation

03 0350 21 AA95137,0001B50 –19–10OCT08–5/28

T112553B

–UN–17DEC97

6. Install first speed clutch.

Clutch K1 Installation

Continued on next page

TM10687 (14OCT08)

03-0350-21

AA95137,0001B50 –19–10OCT08–6/28

524K Loader 101408

PN=81

Gears, Shafts, Bearings and Power Shift Clutch 7. The figure on the right shows the proper installation position of the single clutches in the housing cover.

TX1028761A

–UN–31AUG07

3—First Speed Clutch (K1) 4—Second Speed Clutch (K2) 5—Third Speed Clutch (K3) 6—Forth Speed Forward Clutch (K4) 7—Reverse Clutch (KR) 8—Forward Clutch (KV)

Proper Installation Positions

03 0350 22 AA95137,0001B50 –19–10OCT08–7/28

TX1049945A

–UN–09OCT08

8. Retain clutches K1, K2, K3, and K4 clutches using four M10 nuts and flat washers.

Clutch Retaining

Continued on next page

TM10687 (14OCT08)

03-0350-22

AA95137,0001B50 –19–10OCT08–8/28

524K Loader 101408

PN=82

Gears, Shafts, Bearings and Power Shift Clutch

T109012

–UN–29APR97

9. Install sealing rings (7 used) on clutch pack shafts. Grease sealing rings and align.

Sealing Ring Installation

03 0350 23 AA95137,0001B50 –19–10OCT08–9/28

IMPORTANT: Clutches KV, KR, and input shaft (13) are only held in by gear mesh.

–UN–09OCT08

10. Turn housing cover 180° and install eyebolts.

TX1049937

11. Remove transmission cover with clutch packs from repair stand. Install transmission housing into repair stand.

Eyebolts Mounted

Continued on next page

TM10687 (14OCT08)

03-0350-23

AA95137,0001B50 –19–10OCT08–10/28

524K Loader 101408

PN=83

Gears, Shafts, Bearings and Power Shift Clutch NOTE: Note the engagement of the oil pipes with the bores in the housing cover.

–UN–09OCT08

12. Install alignment studs in the housing. Install cover with clutch packs carefully onto housing. Make sure all components are properly seated.

TX1049936

13. Remove nuts and flat washers from clutch packs. 12—Special Handle (4 used) 13—Clutch KR, Clutch KV, and Input Shaft Cover Installation

03 0350 24 AA95137,0001B50 –19–10OCT08–11/28

T109016

–UN–09MAY97

14. Remove housing cover from gear case housing.

Housing Cover Removal

Continued on next page

TM10687 (14OCT08)

03-0350-24

AA95137,0001B50 –19–10OCT08–12/28

524K Loader 101408

PN=84

Gears, Shafts, Bearings and Power Shift Clutch

T109066

–UN–15APR97

15. Assemble oil cover onto shaft and press both bearing inner races against shoulder until contact is obtained.

Oil Cover over Shaft

03 0350 25 AA95137,0001B50 –19–10OCT08–13/28

T109068

–UN–29APR97

16. Install bearing outer race into the housing bore until contact is obtained.

Bearing Outer Race Installation

Continued on next page

TM10687 (14OCT08)

03-0350-25

AA95137,0001B50 –19–10OCT08–14/28

524K Loader 101408

PN=85

Gears, Shafts, Bearings and Power Shift Clutch

T109069

–UN–15APR97

17. Position inner oil cover.

Inner Oil Cover Position

03 0350 26 AA95137,0001B50 –19–10OCT08–15/28

T109070

–UN–15APR97

18. Install output shaft with cover in housing.

Output Shaft Installation

Continued on next page

TM10687 (14OCT08)

03-0350-26

AA95137,0001B50 –19–10OCT08–16/28

524K Loader 101408

PN=86

Gears, Shafts, Bearings and Power Shift Clutch 19. Apply PM37418 Loctite Medium-Strength Thread Lock and Sealer to socket head cap screws. Install socket head cap screws and tighten to specification to fasten both covers.

T109071

–UN–15APR97

Specification Output Shaft Socket Head Cap Screw—Torque ............................................................................... 23 N•m 17 lb-ft

Socket Head Cap Screw Installation

03 0350 27 AA95137,0001B50 –19–10OCT08–17/28

T109072

–UN–29APR97

20. Install sealing rings (6 used) into the recesses of the clutch shafts. Grease sealing rings and align.

Sealing Rings Installation

Continued on next page

TM10687 (14OCT08)

03-0350-27

AA95137,0001B50 –19–10OCT08–18/28

524K Loader 101408

PN=87

Gears, Shafts, Bearings and Power Shift Clutch NOTE: Note the engagement of the oil pipe with the bores in the housing cover.

T109075

–UN–29APR97

21. Lubricate and install both O-rings into the groove of the oil pipes.

O-Ring Installation

03 0350 28 AA95137,0001B50 –19–10OCT08–19/28

CAUTION: Prevent possible injury from crushing. Heavy component; use appropriate lifting device.

T109076

–UN–15APR97

22. Apply PM38657 High Flex Form-in-Place Gasket to mounting face of cover. Install housing cover carefully against gear case housing until contact is obtained.

Housing Cover Installation

Continued on next page

TM10687 (14OCT08)

03-0350-28

AA95137,0001B50 –19–10OCT08–20/28

524K Loader 101408

PN=88

Gears, Shafts, Bearings and Power Shift Clutch 23. Install dowel pins (2).

TX1049939

–UN–09OCT08

14—Dowel Pin (2 used)

Dowel Pin Installation

03 0350 29 AA95137,0001B50 –19–10OCT08–21/28

NOTE: Locate hanger in same position as it was removed from.

–UN–15APR97

24. Install housing cover cap screws and tighten to specification.

T109078

Specification Housing Cover Cap Screw— Torque ............................................................................................ 46 N•m 34 lb-ft

Torque Cap Screw

Continued on next page

TM10687 (14OCT08)

03-0350-29

AA95137,0001B50 –19–10OCT08–22/28

524K Loader 101408

PN=89

Gears, Shafts, Bearings and Power Shift Clutch NOTE: Grease sealing lip of shaft seal.

T109079

–UN–15APR97

25. Using JDG10837 Output Shaft Seal Installer, install shaft seal with the lip facing inward.

Shaft Seal Installation

03 0350 30 AA95137,0001B50 –19–10OCT08–23/28

26. Apply PM38657 High Flex Form-in-Place Gasket to contact area of washer.

–UN–15APR97

CAUTION: Prevent possible injury from heated components. Use proper safety equipment while handling heated components.

T109080

27. Heat yoke shaft splines evenly to specifications before installing. Use temperature measuring stick or infrared meter to verify temperature. Specification Output Flange—Preheat Temperature ................................................................................ 66—93°C 150—200°F

Flange Installation

Continued on next page

TM10687 (14OCT08)

03-0350-30

AA95137,0001B50 –19–10OCT08–24/28

524K Loader 101408

PN=90

Gears, Shafts, Bearings and Power Shift Clutch 28. Install locking plate using two 5/8 in. deep well sockets (A). Install flange in same manner on opposite side.

T109147B

–UN–02MAY97

A—Deep Well Socket (2 used)

Locking Plate Installation

03 0350 31 AA95137,0001B50 –19–10OCT08–25/28

29. If removed, install flat gasket and cover. Install cover cap screws and tighten to specification.

T109094

–UN–15APR97

Specification Flat Gasket and Cover Cap Screw—Torque ............................................................................... 23 N•m 17 lb-ft

Cover Installation

Continued on next page

TM10687 (14OCT08)

03-0350-31

AA95137,0001B50 –19–10OCT08–26/28

524K Loader 101408

PN=91

Gears, Shafts, Bearings and Power Shift Clutch 30. Install oil level tube and tighten cap screw to specification.

–UN–15APR97

Specification Oil Level Tube Cap Screw— Torque ............................................................................................ 23 N•m 17 lb-ft.

Oil Level Tube Installation

AA95137,0001B50 –19–10OCT08–27/28

32. Install drain plug and tighten to specification.

–UN–15APR97

Specification Oil Drain Plug—Torque .................................................................. 80 N•m 59 lb-ft

T109120

03 0350 32

Specification Torque Converter Input Speed Sensor—Torque ............................................................................. 30 N•m 22 lb-ft Internal Clutch Speed Sensor— Torque ............................................................................................ 30 N•m 22 lb-ft Torque Converter Output Speed Sensor—Torque ............................................................................. 30 N•m 22 lb-ft

T109117

31. Install torque converter input speed sensor, internal clutch speed sensor, and torque converter output speed sensor. Tighten sensors to specification.

Oil Drain Plug Installation

AA95137,0001B50 –19–10OCT08–28/28

TM10687 (14OCT08)

03-0350-32

524K Loader 101408

PN=92

Gears, Shafts, Bearings and Power Shift Clutch

Clutch Pack KV and KR Disassemble 1. Remove sealing ring (1).

TX1028771A

–UN–31AUG07

1—Sealing Ring

Sealing Ring

03 0350 33 MH66O88,00006EB –19–15AUG08–1/10

T108793

–UN–18APR97

2. Remove tapered roller bearing from shaft using JDG1134 Bearing Puller and JDG1035 Bearing Puller Mandrel. Remove opposite tapered roller bearing.

Tapered Roller Bearing

Continued on next page

TM10687 (14OCT08)

03-0350-33

MH66O88,00006EB –19–15AUG08–2/10

524K Loader 101408

PN=93

Gears, Shafts, Bearings and Power Shift Clutch

T108794

–UN–18APR97

3. Using a soft faced mallet, separate plate carrier from shaft.

Plate Carrier and Shaft

03 0350 34 MH66O88,00006EB –19–15AUG08–3/10

T108795

–UN–18APR97

4. Remove clutch pack.

Clutch Plates

Continued on next page

TM10687 (14OCT08)

03-0350-34

MH66O88,00006EB –19–15AUG08–4/10

524K Loader 101408

PN=94

Gears, Shafts, Bearings and Power Shift Clutch 5. Preload compression spring with JDG10911 Assembly Fixture (Inner Installer and Pressure Piece) and a press. Remove L-Ring.

T108761

–UN–17APR97

6. Remove piston from carrier.

Preload Compression Spring

03 0350 35 MH66O88,00006EB –19–15AUG08–5/10

T108758

–UN–29APR97

7. Remove O-rings from piston.

Piston O-Rings

Continued on next page

TM10687 (14OCT08)

03-0350-35

MH66O88,00006EB –19–15AUG08–6/10

524K Loader 101408

PN=95

Gears, Shafts, Bearings and Power Shift Clutch

T108759

–UN–17APR97

8. Remove inner snap ring.

Inner Snap Ring.

03 0350 36 MH66O88,00006EB –19–15AUG08–7/10

T108752

–UN–17APR97

9. Remove idler gear from shaft using a press.

Idler Gear

Continued on next page

TM10687 (14OCT08)

03-0350-36

MH66O88,00006EB –19–15AUG08–8/10

524K Loader 101408

PN=96

Gears, Shafts, Bearings and Power Shift Clutch

T108753

–UN–17APR97

10. Remove released needle bearing.

Needle Bearing

03 0350 37 MH66O88,00006EB –19–15AUG08–9/10

11. Remove snap ring and bearing.

T108754

–UN–17APR97

12. Repair or replace parts as necessary.

MH66O88,00006EB –19–15AUG08–10/10

Clutch Pack KV and KR Assemble

–UN–30AUG07

IMPORTANT: Check function of the drain valve and drain ball (1). Ball must move freely. If ball does not move freely, check for contamination or replace.

TX1028798A

NOTE: Clutches KV and KR are assembled in the same manner. Clutch KV is shown. 1. Apply oil to new O-rings (1) and install to piston ID and OD.

Drain Ball O-Rings

1—Drain Ball 2—O-Ring (2 used)

Continued on next page

TM10687 (14OCT08)

03-0350-37

MH66O88,00006EC –19–14AUG08–1/18

524K Loader 101408

PN=97

Gears, Shafts, Bearings and Power Shift Clutch NOTE: For proper installation of piston, install same way as removed.

T108662

–UN–10APR97

2. Install piston until it bottoms in plate carrier.

Assemble Piston

03 0350 38 MH66O88,00006EC –19–14AUG08–2/18

T108663

–UN–10APR97

3. Install spring and guides.

Install Spring and Guides

Continued on next page

TM10687 (14OCT08)

03-0350-38

MH66O88,00006EC –19–14AUG08–3/18

524K Loader 101408

PN=98

Gears, Shafts, Bearings and Power Shift Clutch NOTE: Always install new L-ring during assembly of clutch pack.

T108664

–UN–10APR97

4. Compress the spring using JDG10911 Assembly Fixture (Inner Installer and Pressure Piece), JDG10910 Assembly Aid, and a press. Install new L-ring into plate carrier groove.

Install New L-ring.

03 0350 39 MH66O88,00006EC –19–14AUG08–4/18

–UN–30AUG07

IMPORTANT: Install one-sided friction disk (5) with the fiber side always facing toward other disk or plate. Smooth side should be against piston or end shim, depending on which end of stack it is used on.

TX1028824

NOTE: Plate and disk position is the same for clutches KV and KR. For proper adjustment of plate clearance, install disk and plates temporarily without being oiled.

Clutch Packs KV and KR

5. Install a one-sided fiber disk (5) into the plate carrier (3) with the fiber side facing out or away from piston (4). Install a two-sided fiber disk (7) into the plate carrier and alternate with a plate (6), until all ten plates and nine disks are installed in carrier.

3—Plate Carrier 4—Piston 5—One-Sided Fiber Disk (Friction) (2 used) 6—Plate (Separator) (10 used) 7—Two-Sided Fiber Disk (Friction) (9 used) 8—End Shim 9—L-Ring 10—Idler

6. Install the remaining one-sided fiber disk into carrier with the fiber side facing in or away from the end shim.

Continued on next page

TM10687 (14OCT08)

03-0350-39

MH66O88,00006EC –19–14AUG08–5/18

524K Loader 101408

PN=99

Gears, Shafts, Bearings and Power Shift Clutch

T108666

–UN–10APR97

7. Install end shim and L-ring.

End Shim and L-Ring

03 0350 40 MH66O88,00006EC –19–14AUG08–6/18

–UN–10APR97

NOTE: For the adjustment of plate clearance there are snap rings of different thicknesses available that can be used if proper clearance cannot be obtained. To ensure proper measuring result, install plates temporarily without oil.

T108667

8. Press down on end shim and measure the dimension from the end face/plate carrier to the end shim with depth gauge. Record dimension as No. 1.

Adjust Plate Clearance

Continued on next page

TM10687 (14OCT08)

03-0350-40

MH66O88,00006EC –19–14AUG08–7/18

524K Loader 101408

PN=100

Gears, Shafts, Bearings and Power Shift Clutch 9. Press end shim against L-Ring (upward) until contact is made and measure with gauge. Record dimension as No. 2. Example for Clutch Pack Clearance Check

Dimension No. 2

4.75 mm (0.187 in.)

Difference = Plate Clearance

2.5 mm (0.098 in.)

Specification = Pack Clearance

2.5—2.7 mm (0.098—0.106 in.)

–UN–10APR97

7.24 mm (0.285 in.)

T108668

Dimension No. 1

10. If a clutch pack clearance is not in specification, correct by using the proper corresponding snap ring from service parts to increase or decrease clearance. Snap rings come in various sizes.

Press End Shim Against L-Ring

03 0350 41

Specification KV and KR Clutch Pack Plate— Clearance .............................................................................. 2.5—2.7 mm 0.098—0.106 in.

11. After proper clearance is obtained, remove disks and plates from assembly. Add oil to plates and disks, and reassemble clutch pack assembly.

MH66O88,00006EC –19–14AUG08–8/18

T108669

–UN–10APR97

12. Install idler gear until all inner plates are engaged. This step makes later assembling of the idler gear easier. Remove idler gear from clutch pack assembly.

Install Idler Gear

Continued on next page

TM10687 (14OCT08)

03-0350-41

MH66O88,00006EC –19–14AUG08–9/18

524K Loader 101408

PN=101

Gears, Shafts, Bearings and Power Shift Clutch 13. Apply PM37418 Loctite Medium-Strength Thread Lock and Sealer to stud. Install stud on end of shaft if removed. Tighten to specification.

T108670

–UN–10APR97

Specification Shaft Stud—Torque ........................................................................ 17 N•m 150 lb-in.

Install Stud on End of Shaft

03 0350 42 MH66O88,00006EC –19–14AUG08–10/18

T108671

–UN–10APR97

14. Insert ball bearing until seated and install snap ring.

Ball Bearing

Continued on next page

TM10687 (14OCT08)

03-0350-42

MH66O88,00006EC –19–14AUG08–11/18

524K Loader 101408

PN=102

Gears, Shafts, Bearings and Power Shift Clutch

T108672

–UN–10APR97

15. Install needle bearing.

Install Needle Bearing

03 0350 43 MH66O88,00006EC –19–14AUG08–12/18

NOTE: Push against cone of bearing.

–UN–10APR97

On clutch KR, there is no recess in the shaft. Installation of snap ring will be in contact of bearing cone.

T108673

16. Press idler gear against shoulder.

Press Idler Gear Against Shoulder

Continued on next page

TM10687 (14OCT08)

03-0350-43

MH66O88,00006EC –19–14AUG08–13/18

524K Loader 101408

PN=103

Gears, Shafts, Bearings and Power Shift Clutch

T108674

–UN–10APR97

17. Retain idler gear by means of snap ring.

Retain Idler Gear

03 0350 44 MH66O88,00006EC –19–14AUG08–14/18

T108675

–UN–10APR97

18. Assemble pre-assembled plate carrier until all plates are engaged.

Assemble Plate Carrier

Continued on next page

TM10687 (14OCT08)

03-0350-44

MH66O88,00006EC –19–14AUG08–15/18

524K Loader 101408

PN=104

Gears, Shafts, Bearings and Power Shift Clutch

T108676

–UN–10APR97

19. Ensure carrier face is flush with shaft spline.

Carrier Face Flush With Shaft Spline

03 0350 45 MH66O88,00006EC –19–14AUG08–16/18

T108677

–UN–10APR97

20. Press tapered roller bearing against shoulder. Installation of opposite tapered roller bearing will be the same.

MH66O88,00006EC –19–14AUG08–17/18

NOTE: Make sure clutch pack components are correctly installed, apply compressed air as shown and listen for movement of the clutch pack. The clutch pack will move freely when installed correctly.

T108678

–UN–10APR97

21. Check function of clutch by means of compressed air.

Check Clutch Function

MH66O88,00006EC –19–14AUG08–18/18

TM10687 (14OCT08)

03-0350-45

524K Loader 101408

PN=105

Gears, Shafts, Bearings and Power Shift Clutch

Clutch Pack K1, K2, and K3 Disassemble

–UN–29APR97

NOTE: The following art shows the disassembly of clutch K3. K1 and K2 are identical in disassembly methods.

T108755

1. Remove rectangular sealing ring from shaft.

MH66O88,000097F –19–15AUG08–1/9

2. Pull tapered roller bearing from the shaft using mandrel and puller as shown below.

Bearing Puller Mandrel No.

JDG1041

JDG1034

JDG1197

JDG1035

JDG1197

JDG1035

JDG1197

JDG1034

JDG1041

JDG1034

T108764

Bearing Puller No.

–UN–17APR97

Tool Usage Chart Clutch Shaft

MH66O88,000097F –19–15AUG08–2/9

–UN–17APR97

3. Remove snap ring, disk, needle bearing, and washer.

T108765

03 0350 46

Continued on next page

TM10687 (14OCT08)

03-0350-46

MH66O88,000097F –19–15AUG08–3/9

524K Loader 101408

PN=106

Gears, Shafts, Bearings and Power Shift Clutch

T108766

–UN–17APR97

4. Remove idler gear.

MH66O88,000097F –19–15AUG08–4/9

5. Remove both needle bearings as well as axial bearing.

T108767

–UN–17APR97

03 0350 47

MH66O88,000097F –19–15AUG08–5/9

T108760

–UN–17APR97

6. Remove snap ring and remove plates and disks.

MH66O88,000097F –19–15AUG08–6/9

7. Preload compression spring using JDG10911 Assembly Fixture (Inner Installer and Pressure Piece) in a press.

–UN–17APR97

NOTE: Discard L-ring and install a new one when assembling clutch pack.

T108761

8. Remove L-ring and discard. Remove components.

Continued on next page

TM10687 (14OCT08)

03-0350-47

MH66O88,000097F –19–15AUG08–7/9

524K Loader 101408

PN=107

Gears, Shafts, Bearings and Power Shift Clutch

CAUTION: Prevent possible injury from flying debris. Clear area of bystanders. Wear personal protection equipment including eye protection.

T108762

–UN–17APR97

9. Press piston out of the plate carrier, using compressed air.

Press Piston Out

03 0350 48 MH66O88,000097F –19–15AUG08–8/9

T108763

–UN–17APR97

10. Pry plate carrier from the shaft.

Pry Plate Carrier From Shaft

MH66O88,000097F –19–15AUG08–9/9

TM10687 (14OCT08)

03-0350-48

524K Loader 101408

PN=108

Gears, Shafts, Bearings and Power Shift Clutch

Clutch Pack K1, K2, and K3 Assemble

–UN–10APR97

NOTE: Clutches K1, K2 and K3 are assembled in a similar manner. The following assembly story art shows clutch K3. 1. Apply PM37477 Thread Lock and Sealer (medium strength) to stud.

T108679

2. Install stud on end of shaft. Tighten stud to specification. Stud-to-Shaft Installation

Specification Shaft Stud—Torque .......................................................................... 17 Nm 150 lb-in.

03 0350 49 MH66O88,0000980 –19–20AUG08–1/23

T108680

–UN–10APR97

3. Assemble plate carrier until bottomed.

Plate Carrier Assembly

Continued on next page

TM10687 (14OCT08)

03-0350-49

MH66O88,0000980 –19–20AUG08–2/23

524K Loader 101408

PN=109

Gears, Shafts, Bearings and Power Shift Clutch

–UN–29APR97

IMPORTANT: Check function of the drain valve. Check function of drain ball. Ball must move freely. If ball does not move freely, check for contamination or replace.

T108981

4. Install new O-rings (arrows) into the ID and OD of the piston. Apply a light coat of oil to O-rings.

O-Ring Installation

03 0350 50 MH66O88,0000980 –19–20AUG08–3/23

T108734

–UN–10APR97

5. Install piston in carrier until seated.

Proper Piston Installation

Continued on next page

TM10687 (14OCT08)

03-0350-50

MH66O88,0000980 –19–20AUG08–4/23

524K Loader 101408

PN=110

Gears, Shafts, Bearings and Power Shift Clutch

T108735

–UN–10APR97

6. Install compression spring and two spring guides into plate carrier.

Spring Type Shown May Vary

03 0350 51 MH66O88,0000980 –19–20AUG08–5/23

NOTE: Always install new L-ring during assembly of clutch pack.

T108736

–UN–10APR97

7. Use JDG10911 Assembly Fixture (Inner Installer and Pressure Piece), JDG10910 Assemble Aid, and a press to install new L-ring into plate carrier groove for clutch K1, K2, and K3.

Install L-Ring

Continued on next page

TM10687 (14OCT08)

03-0350-51

MH66O88,0000980 –19–20AUG08–6/23

524K Loader 101408

PN=111

Gears, Shafts, Bearings and Power Shift Clutch

T112161

–UN–20NOV97

03 0350 52

Clutch Pack K1 1—Plate Carrier 2—Piston

3—Disk (Friction) (One Side Fiber Coated)

IMPORTANT: Install one-sided friction disk (3) with the fiber side always facing toward plate. Smooth side should be against piston.

4—Plate (Separator) (9 used) 5—Disk (Friction) (9 used)

6—Snap Ring 7—End Shim

8. Install one-sided fiber disk into carrier with the fiber side facing out or away from piston.

NOTE: For proper adjustment of plate clearance, install disk and plates temporarily without being oiled.

Continued on next page

TM10687 (14OCT08)

03-0350-52

MH66O88,0000980 –19–20AUG08–7/23

524K Loader 101408

PN=112

Gears, Shafts, Bearings and Power Shift Clutch 9. Install plate and then disk, alternately, until seven plates and seven disks are installed in carrier.

T108737

–UN–10APR97

10. Install two plates, then two disks.

Plates and Disks Installation

03 0350 53 MH66O88,0000980 –19–20AUG08–8/23

T108738

–UN–10APR97

11. Install end shim and snap ring.

End Shim and Snap Ring Installation

Continued on next page

TM10687 (14OCT08)

03-0350-53

MH66O88,0000980 –19–20AUG08–9/23

524K Loader 101408

PN=113

Gears, Shafts, Bearings and Power Shift Clutch

–UN–10APR97

NOTE: For the adjustment of the plate clearance there are snap rings of different thicknesses available that can be used if proper clearance cannot be obtained. To ensure proper measuring result, install plates temporarily without oil. 12. Adjust plate clearance to specification.

T108739

Specification K1 Clutch Pack Plate—Clearance .......... 2.4—2.6 mm (0.094—0.102 in.)

a. Press end shim and measure the dimension from the end face/plate carrier to the end shim with depth gauge. Record dimension (No. 1).

End Shim Press

03 0350 54 MH66O88,0000980 –19–20AUG08–10/23

b. Press end shim against snap ring (upward) until contact and measure with gauge. Record dimension (No. 2). Example for Clutch Pack Clearance Check

Dimension No. 2

6.00 mm (0.236 in.)

Difference = Plate Clearance

2.50 mm (0.079 in.)

Specification = Pack Clearance

2.4—2.6 mm (0.094—0.102 in.)

–UN–09MAY97

8.50 mm (0.335 in.)

T108740

Dimension No. 1

c. If a clutch pack clearance is not to specification, correct by using the proper corresponding snap ring from service parts to increase or decrease clearance. Snap rings come in various sizes.

Clutch Pack Clearance Check

d. After proper clearance is obtained, remove disks and plates from assembly. 13. Add oil to plates and disks. 14. Reassemble clutch pack assembly.

Continued on next page

TM10687 (14OCT08)

03-0350-54

MH66O88,0000980 –19–20AUG08–11/23

524K Loader 101408

PN=114

Gears, Shafts, Bearings and Power Shift Clutch

T112160

–UN–20NOV97

03 0350 55

Clutch Packs K2 and K3 1—Plate Carrier 2—Piston

3—Disk (Friction) (One Side Fiber Coated)

4—Plate (Separator) (7 used) 5—Disk (Friction) (7 used)

For proper adjustment of plate clearance, install disk and plates temporarily without being oiled.

IMPORTANT: Install one sided friction disk (3) with the fiber side always facing toward plate. Smooth side should be against piston. NOTE: Plate and disk position is the same for clutches K2 and K3.

15. Install one-sided fiber disk into carrier with the fiber side facing out or away from piston.

Continued on next page

TM10687 (14OCT08)

6—Snap Ring 7—End Shim

03-0350-55

MH66O88,0000980 –19–20AUG08–12/23

524K Loader 101408

PN=115

Gears, Shafts, Bearings and Power Shift Clutch 16. Install plate and then disk, alternately, until five plates and five disks are installed in carrier.

T108737

–UN–10APR97

17. Install two plates, then two disks.

Plates and Disks Installation

03 0350 56 MH66O88,0000980 –19–20AUG08–13/23

T108738

–UN–10APR97

18. Install end shim and snap ring.

End Shim and Snap Ring Installation

Continued on next page

TM10687 (14OCT08)

03-0350-56

MH66O88,0000980 –19–20AUG08–14/23

524K Loader 101408

PN=116

Gears, Shafts, Bearings and Power Shift Clutch

–UN–10APR97

T108739

Specification K2 and K3 Clutch Pack Plate— Clearance ................................................ 1.8—2.0 mm (0.071—0.079 in.)

a. Press end shim and measure the dimension from the end face/plate carrier to the end shim with depth gauge. Record dimension (No. 1).

End Shim Press

03 0350 57 MH66O88,0000980 –19–20AUG08–15/23

b. Press end shim against snap ring (upward) until contact and measure with gauge. Record dimension (No. 2). Example for Clutch Pack Clearance Check

Dimension No. 2

6.00 mm (0.236 in.)

Difference = Plate Clearance

2.0 mm (0.079 in.)

Specification = Pack Clearance

1.8—2.0 mm (0.071—0.079 in.)

–UN–09MAY97

8.00 mm (0.315 in.)

T108740

Dimension No. 1

c. If a clutch pack clearance is not to specification, correct by using the proper corresponding snap ring from service parts to increase or decrease clearance. Snap rings come in various sizes.

Clutch Pack Clearance Check

d. After proper clearance is obtained, remove disks and plates from assembly. 20. Add oil to plates and disks. 21. Reassemble clutch pack assembly.

Continued on next page

TM10687 (14OCT08)

03-0350-57

MH66O88,0000980 –19–20AUG08–16/23

524K Loader 101408

PN=117

Gears, Shafts, Bearings and Power Shift Clutch 22. Assemble thrust disk (1), thrust bearing (2), and thrust washer (3).

T108741

–UN–09MAY97

1—Thrust Disk 2—Thrust Bearing 3—Thrust Washer

Thrust Disk, Bearing, and Washer

03 0350 58 MH66O88,0000980 –19–20AUG08–17/23

T108742

–UN–09MAY97

23. Install both needle bearings.

Needle Bearings Installation

Continued on next page

TM10687 (14OCT08)

03-0350-58

MH66O88,0000980 –19–20AUG08–18/23

524K Loader 101408

PN=118

Gears, Shafts, Bearings and Power Shift Clutch

T108743

–UN–09MAY97

24. Install idler gear until all inner plates are engaged with splines.

Idler Gear Installation

03 0350 59 MH66O88,0000980 –19–20AUG08–19/23

25. Install thrust washer (3), thrust bearing (2), and thrust disk (1).

–UN–09MAY97

NOTE: Install disk (1) with chamfer facing the thrust bearing. 26. To ensure proper assembly, top surface of thrust disk must be flush with shaft step.

T108744

1—Thrust Disk 2—Thrust Bearing 3—Thrust Washer

Continued on next page

TM10687 (14OCT08)

03-0350-59

MH66O88,0000980 –19–20AUG08–20/23

524K Loader 101408

PN=119

Gears, Shafts, Bearings and Power Shift Clutch 27. Install snap ring (4). 4

–UN–27MAY08

4—Snap Ring

TX1042857

03 0350 60

MH66O88,0000980 –19–20AUG08–21/23

T108746

–UN–09MAY97

28. Press tapered roller bearing against shoulder.

Tapered Roller Bearing Press

Continued on next page

TM10687 (14OCT08)

03-0350-60

MH66O88,0000980 –19–20AUG08–22/23

524K Loader 101408

PN=120

Gears, Shafts, Bearings and Power Shift Clutch

CAUTION: Prevent possible injury from flying debris. Clear area of bystanders, and wear personal protection equipment including eye protection.

T108747

–UN–09MAY97

NOTE: Make sure clutch pack components are correctly installed, apply compressed air as shown, and listen for movement of the clutch pack. The clutch pack will move freely when installed correctly. 29. Check function of clutch by means of compressed air. Function Check With Compressed Air

03 0350 61 MH66O88,0000980 –19–20AUG08–23/23

Clutch Pack K4 Disassemble 1. Remove sealing ring.

–UN–17APR97

2. Pull tapered roller bearing from the shaft with JDG1035 Bearing Puller Mandrel and JDG1134 and JDG1197 Bearing Pullers.

T108768

3. Remove opposite tapered roller bearing accordingly.

MH66O88,0000981 –19–15AUG08–1/4

T108769

–UN–17APR97

4. Remove snap ring and plate carrier from shaft.

Continued on next page

TM10687 (14OCT08)

03-0350-61

MH66O88,0000981 –19–15AUG08–2/4

524K Loader 101408

PN=121

Gears, Shafts, Bearings and Power Shift Clutch

T108770

–UN–18APR97

5. Remove snap ring and remove plates and disks.

MH66O88,0000981 –19–15AUG08–3/4

NOTE: Remove and discard L-ring. Replace with new during assembly.

–UN–14APR97

6. Use JDG10911 Assembly Fixture (Inner Installer and Pressure Piece) and a press to preload compression spring.

T108983

7. Remove L-ring and components. Remove piston.

MH66O88,0000981 –19–15AUG08–4/4

Clutch Pack K4 Assemble NOTE: Gear is a very tight press fit. Shaft or gear may be damaged if pressed apart. –UN–14APR97

1. Cool shaft to specification. Heat gear to specification and install it until bottomed. Specification K4 Clutch Pack Shaft— Temperature ....................................................................... Cools at -80°C -112°F K4 Clutch Pack Gear— Temperature ...................................................................... Heats at 120°C 248°F

T108748

03 0350 62

Continued on next page

TM10687 (14OCT08)

03-0350-62

MH66O88,0000982 –19–15AUG08–1/20

524K Loader 101408

PN=122

Gears, Shafts, Bearings and Power Shift Clutch

T108749

–UN–14APR97

2. Install snap ring to retain gear.

Snap Ring Installation

03 0350 63 MH66O88,0000982 –19–15AUG08–2/20

3. Apply PM37477 Thread Lock and Sealer (medium strength) to stud.

–UN–29APR97

4. Install shaft stud to end of shaft. Tighten to specification.

T108750

Specification Shaft Stud—Torque .......................................................................... 17 Nm 150 lb-in.

MH66O88,0000982 –19–15AUG08–3/20

–UN–29APR97

IMPORTANT: Check function of the drain valve. Check function of drain ball. Ball must move freely. If ball does not move freely, check for contamination or replace.

T108981

5. Install new O-rings into the ID and OD of the piston as shown. Lightly oil O-rings before installing piston.

Continued on next page

TM10687 (14OCT08)

03-0350-63

MH66O88,0000982 –19–15AUG08–4/20

524K Loader 101408

PN=123

Gears, Shafts, Bearings and Power Shift Clutch

T108982

–UN–14APR97

6. Assemble piston until contact is made with bottom of disk carrier.

MH66O88,0000982 –19–15AUG08–5/20

NOTE: Always install new L-ring during assembly of clutch pack.

–UN–14APR97

7. Install compression spring and spring guides into disk carrier. 8. Use JDG10911 Assembly Fixture (Inner Installer and Pressure Piece) and JDG10910 Assembly Aid in a press to preload compression spring. Install new L-ring into disk carrier groove.

T108983

03 0350 64

Continued on next page

TM10687 (14OCT08)

03-0350-64

MH66O88,0000982 –19–15AUG08–6/20

524K Loader 101408

PN=124

Gears, Shafts, Bearings and Power Shift Clutch

T112159

–UN–20NOV97

03 0350 65

Clutch Packs K4 1—Plate Carrier 2—Piston

3—Disk (Friction) (One Side Fiber Coated)

IMPORTANT: Install one sided friction disk (3) with fiber side always facing toward the plate. Smooth side should be against piston.

4—Plate (Separator) (5 used) 5—Disk (Friction) (5 used)

6—Snap Ring 7—End Shim

9. Install one sided fiber disk into carrier with the fiber side facing out or away from piston.

NOTE: For proper adjustment of plate clearance, install disk and plates temporarily without being oiled.

MH66O88,0000982 –19–15AUG08–7/20

T108984

–UN–14APR97

10. Install plate and then disk alternately until five plates and five disks are installed in carrier.

Continued on next page

TM10687 (14OCT08)

03-0350-65

MH66O88,0000982 –19–15AUG08–8/20

524K Loader 101408

PN=125

Gears, Shafts, Bearings and Power Shift Clutch

–UN–09MAY97

NOTE: For the adjustment of plate clearance, there are snap rings of different thicknesses available that can be used if proper clearance is unable to be obtained. To ensure proper measuring result, install plates temporarily without oil.

T108985

11. Install end shim and snap ring.

MH66O88,0000982 –19–15AUG08–9/20

12. Adjust plate clearance to specification. Specification K4 Clutch Pack Plate—Clearance ........................................ 1.2—1.4 mm 0.047—0.055 in.

T108986

–UN–14APR97

a. Press end shim and measure the dimension from the end face/plate carrier to the end shim with a depth gauge. Record dimension (No. 1).

MH66O88,0000982 –19–15AUG08–10/20

b. Press end shim against snap ring (upward) until contact and measure with gauge. Record dimension (No. 2). Example for Clutch Pack Clearance Check 7.20 mm (0.283 in.)

Dimension No. 2

6.00 mm (0.236 in.)

Difference = Plate Clearance

1.2 mm (0.047 in.)

Specification = Pack Clearance

1.2—1.4 mm (0.047—0.055 in.)

–UN–14APR97

Dimension No. 1

T108987

03 0350 66

c. If clutch pack clearance is not in specification, correct by using the proper corresponding snap ring from service parts to increase or decrease clearance. After proper clearance is obtained, remove disk and plates from assembly. 13. Add oil to plates and disks. 14. Assemble clutch pack assembly.

Continued on next page

TM10687 (14OCT08)

03-0350-66

MH66O88,0000982 –19–15AUG08–11/20

524K Loader 101408

PN=126

Gears, Shafts, Bearings and Power Shift Clutch 15. Install idler gear until inner plates are meshed with splines.

T108988

–UN–14APR97

16. Remove idler gear.

MH66O88,0000982 –19–15AUG08–12/20

17. Install thrust washers and bearing.

T108989

–UN–14APR97

03 0350 67

MH66O88,0000982 –19–15AUG08–13/20

T108990

–UN–14APR97

18. Install two needle bearings.

MH66O88,0000982 –19–15AUG08–14/20

T108991

–UN–14APR97

19. Assemble idler gear.

Continued on next page

TM10687 (14OCT08)

03-0350-67

MH66O88,0000982 –19–15AUG08–15/20

524K Loader 101408

PN=127

Gears, Shafts, Bearings and Power Shift Clutch NOTE: Install thrust disk (1) with chamfer facing thrust washer. 20. Install thrust washer (3), bearing (2), and disk (1).

T108992

–UN–29APR97

1—Disc 2—Bearing 3—Thrust Washer

MH66O88,0000982 –19–15AUG08–16/20

T108993

–UN–14APR97

21. Assemble K4 carrier assembly onto shaft until seated and all plates are engaged.

MH66O88,0000982 –19–15AUG08–17/20

T108994

–UN–14APR97

22. Install snap ring to retain plate.

MH66O88,0000982 –19–15AUG08–18/20

–UN–14APR97

23. Press tapered roller bearing against shoulder. Install opposite tapered roller bearing.

T108995

03 0350 68

Continued on next page

TM10687 (14OCT08)

03-0350-68

MH66O88,0000982 –19–15AUG08–19/20

524K Loader 101408

PN=128

Gears, Shafts, Bearings and Power Shift Clutch

–UN–14APR97

CAUTION: Prevent possible injury from flying debris. Reduce compressed air pressure to less than 210 kPa (2 bar) (30 psi) when using for cleaning purposes. Clear area of bystanders, guard against flying chips, and wear personal protection equipment including eye protection.

T108996

NOTE: Make sure clutch pack components are correctly installed, apply compressed air as shown, and listen for movement of the clutch pack. The clutch pack will move freely when installed correctly. 24. Check function of clutch by means of compressed air.

03 0350 69 MH66O88,0000982 –19–15AUG08–20/20

Input Shaft Disassemble NOTE: The turbine shaft is axially fixed by means of a snap ring. The snap ring will be destroyed when pressing the turbine shaft out of the input shaft. 1. If necessary, press the turbine shaft out of the input shaft.

MH66O88,0000727 –19–18FEB08–1/3

2. Remove rectangular ring (1).

–UN–27MAR07

3. Remove the tapered roller bearings (2) using JDG1035 Mandrel and JDG1134 Bearing Puller.

TX1021155A

1—Rectangular Ring 2—Tapered Roller Bearing (2 used)

Remove Tapered Roller Bearings

Continued on next page

TM10687 (14OCT08)

03-0350-69

MH66O88,0000727 –19–18FEB08–2/3

524K Loader 101408

PN=129

Gears, Shafts, Bearings and Power Shift Clutch 4. Remove snap ring (3). Using a press, remove input shaft gear (4) from input shaft (5) .

–UN–28MAR07

5. Repair or replace parts as necessary.

TX1021169A

3—Snap Ring 4—Input Shaft Gear 5—Input Shaft

Shaft-to-Gear Assembly

03 0350 70 MH66O88,0000727 –19–18FEB08–3/3

Input Shaft Assemble CAUTION: Prevent possible burn injury. Hot equipment and fluids can cause burns to unprotected skin. Wear gloves and protective clothes when working with hot equipment and fluids. 1. Cool the input shaft to about -80°C (-112°F). Heat the input gear to about 120°C (250°F) and assemble gear to shaft until seated. 2. Install snap ring to retain input shaft gear.

Continued on next page

TM10687 (14OCT08)

03-0350-70

MH66O88,0000728 –19–18FEB08–1/7

524K Loader 101408

PN=130

Gears, Shafts, Bearings and Power Shift Clutch 3. Install snap ring (6) into recess on turbine shaft (7).

TX1021177A

–UN–28MAR07

6—Snap Ring 7—Snap Ring Recess

Snap Ring Installation

03 0350 71 MH66O88,0000728 –19–18FEB08–2/7

4. Install turbine shaft (9) into input shaft. Make sure snap ring “snaps” into groove of input shaft.

TX1021178A

–UN–28MAR07

8—Turbine Shaft 9—Snap Ring Recess

Turbine Shaft Installation

Continued on next page

TM10687 (14OCT08)

03-0350-71

MH66O88,0000728 –19–18FEB08–3/7

524K Loader 101408

PN=131

Gears, Shafts, Bearings and Power Shift Clutch NOTE: Tapered roller bearings must contact shoulder on input shaft.

T109001

–UN–09MAY97

5. Press both bearing inner races against shoulder of input shaft.

Press On Bearings

03 0350 72 MH66O88,0000728 –19–18FEB08–4/7

TX1021179A

–UN–28MAR07

6. Install ball bearing and sealing ring to turbine shaft.

Install Bearing

Continued on next page

TM10687 (14OCT08)

03-0350-72

MH66O88,0000728 –19–18FEB08–5/7

524K Loader 101408

PN=132

Gears, Shafts, Bearings and Power Shift Clutch

T109003

–UN–09MAY97

7. Install output shaft into housing bore until seated.

Install Output Shaft

03 0350 73 MH66O88,0000728 –19–18FEB08–6/7

NOTE: If bearings are reused, they must be installed in the same bores they were removed from.

T108657

–UN–10APR97

8. Install bearings.

Transmission Bearing Bores

MH66O88,0000728 –19–18FEB08–7/7

TM10687 (14OCT08)

03-0350-73

524K Loader 101408

PN=133

Gears, Shafts, Bearings and Power Shift Clutch

Axle Disconnect Remove and Install 1. Park and prepare machine for service. See Park and Prepare for Service Safely. (Group 0001.) 2. Remove transmission to rear axle drive shaft. See Universal Joint and Drive Shaft Remove and Install. (Group 0225.) 3. Drain transmission oil into an appropriate container for storage or disposal. See Drain and Refill Transmission Oil and Replace Filter. (Operator’s Manual.)

03 0350 74 MH66088,000099E –19–06OCT08–1/5

4. Remove axle disconnect hydraulic hose (1) from axle disconnect housing. 5. Remove socket head cap screws (2) and remove axle disconnect (3) from transmission. 1—Axle Disconnect Hydraulic Hose 2—Socket Head Cap Screw (9 used) 3—Axle Disconnect

–UN–19AUG08

TX1047393

1 Axle Disconnect Removal

Continued on next page

TM10687 (14OCT08)

03-0350-74

MH66088,000099E –19–06OCT08–2/5

524K Loader 101408

PN=134

Gears, Shafts, Bearings and Power Shift Clutch 6. Remove cap screws (4) and washer (5). Remove engagement flange (6) from transmission shaft.

–UN–08SEP08

7. Repair or replace parts as necessary.

TX1047563A

4—Cap Screw (2 used) 5—Washer 6—Engagement Flange

Engagement Flange Removal

03 0350 75 MH66088,000099E –19–06OCT08–3/5

8. Install shield (7), if removed, with flat side facing transmission, using JDG10946 Shield Driver.

–UN–02OCT08

CAUTION: Prevent possible injury from heated components. Use proper safety equipment while handling heated components.

TX1049629

9. Heat engagement flange to specification before installing. Use temperature measuring stick or infrared meter to verify temperature. Install washer and cap screws and tighten to specification. Specification Engagement Flange—Preheat Temperature ....................................................................................... 80°C 176°F Cap Screw—Torque ....................................................................... 34 N•m 24 lb-ft

Shield Installation

TX1049628

–UN–02OCT08

7—Shield 8—JDG10946 Shield Driver

JDG10946 Shield Driver

Continued on next page

TM10687 (14OCT08)

03-0350-75

MH66088,000099E –19–06OCT08–4/5

524K Loader 101408

PN=135

Gears, Shafts, Bearings and Power Shift Clutch 10. Apply high-temperature grease to O-ring groove (9) before installing O-ring.

TX1047571A

–UN–03OCT08

NOTE: Using two M12 x 1.75 cap screws, cut cap screw length to 150 mm by removing head end of cap screws. Cap screws will be used as alignment pins and will help in supporting axle disconnect during installation. 11. Make alignment pins from two M12 x 1.75 cap screws. Cut cap screw length to 150 mm by removing head end of cap screws. Thread the pins into opposing axle disconnect mounting holes in transmission. 03 0350 76

O-Ring Groove 9—O-Ring Groove

12. Install axle disconnect to transmission and tighten socket head cap screws to specification. Remove alignment pins and install remaining socket head cap screws to specification. Specification Socket Head Cap Screw—Torque ................................................. 79 N•m 58 lb-ft

13. Install axle disconnect hydraulic hose. 14. Install transmission to rear axle drive shaft. See Universal Joint and Drive Shaft Remove and Install. (Group 0225.) 15. Refill transmission with oil. See Drain and Refill Transmission Oil and Replace Filter. (Operator’s Manual.)

MH66088,000099E –19–06OCT08–5/5

Axle Disconnect Disassemble and Assemble 1. Remove axle disconnect from transmission. See Axle Disconnect Remove and Install. (Group 0350.) Continued on next page

TM10687 (14OCT08)

03-0350-76

MH66088,000099F –19–06OCT08–1/19

524K Loader 101408

PN=136

Gears, Shafts, Bearings and Power Shift Clutch 2. Remove cap screws (1), washer (2), and O-ring (3). Remove output flange.

TX1047526A

–UN–20AUG08

1—Cap Screw (2 used) 2—Washer 3—O-Ring

Output Flange Removal

03 0350 77 MH66088,000099F –19–06OCT08–2/19

3. Remove output flange seal and discard.

TX1047527A

–UN–20AUG08

4—Output Flange Seal

Output Flange Seal Removal

Continued on next page

TM10687 (14OCT08)

03-0350-77

MH66088,000099F –19–06OCT08–3/19

524K Loader 101408

PN=137

Gears, Shafts, Bearings and Power Shift Clutch 4. Remove output shaft (5) from axle disconnect housing (6) using a press.

TX1047528A

–UN–20AUG08

5—Output Shaft 6—Axle Disconnect Housing

Output Shaft Removal

03 0350 78 MH66088,000099F –19–06OCT08–4/19

5. Remove seal rings (7) from output shaft.

TX1047530A

–UN–20AUG08

7—Seal Ring (2 used)

Seal Ring Removal

Continued on next page

TM10687 (14OCT08)

03-0350-78

MH66088,000099F –19–06OCT08–5/19

524K Loader 101408

PN=138

Gears, Shafts, Bearings and Power Shift Clutch 6. Remove snap ring (8), retainer (9), compression spring (10), and engagement sleeve (11) using a press.

TX1047531A

–UN–20AUG08

8—Snap Ring 9—Retainer 10—Compression Spring 11—Engagement Sleeve

Engagement Sleeve Removal

03 0350 79 MH66088,000099F –19–06OCT08–6/19

7. Remove O-rings (12) from output shaft an discard.

TX1047532A

–UN–20AUG08

12—O-Ring (2 used)

O-Ring Removal

Continued on next page

TM10687 (14OCT08)

03-0350-79

MH66088,000099F –19–06OCT08–7/19

524K Loader 101408

PN=139

Gears, Shafts, Bearings and Power Shift Clutch 8. Inspect bushing (13) for wear or damage; replace if necessary.

–UN–20AUG08

9. Remove orifice (14).

TX1047533A

13—Bushing 14—Orifice

Bushing Inspection

03 0350 80 MH66088,000099F –19–06OCT08–8/19

10. Remove snap ring (15) and remove bearing (16).

TX1047534A

–UN–20AUG08

15—Snap Ring 16—Bearing

Bearing Removal

Continued on next page

TM10687 (14OCT08)

03-0350-80

MH66088,000099F –19–06OCT08–9/19

524K Loader 101408

PN=140

Gears, Shafts, Bearings and Power Shift Clutch 11. Remove screw plugs (17).

–UN–20AUG08

12. Remove socket head cap screw (18), retainer (19), and solenoid valve (20). 13. Repair or replace parts as necessary.

TX1047535A

17—Screw Plug (2 used) 18—Socket Head Cap Screw 19—Retainer 20—Solenoid Valve Solenoid Valve Removal

03 0350 81 MH66088,000099F –19–06OCT08–10/19

14. Install output shaft bearing (16) to housing until seated. Install snap ring (15).

TX1047534A

–UN–20AUG08

15—Snap Ring 16—Output Shaft Bearing

Output Shaft Bearing Installation

Continued on next page

TM10687 (14OCT08)

03-0350-81

MH66088,000099F –19–06OCT08–11/19

524K Loader 101408

PN=141

Gears, Shafts, Bearings and Power Shift Clutch 15. Install orifice (14) and tighten to specification.

–UN–20AUG08

Specification Orifice—Torque .............................................................................. 15 N•m 133 lb-in.

16. Install bushing (13) if removed.

TX1047533A

13—Bushing 14 —Orifice

Bushing and Orifice Installation

03 0350 82 MH66088,000099F –19–06OCT08–12/19

17. Install new O-rings (12) to output shaft and apply light coat of oil to O-rings.

TX1047532A

–UN–20AUG08

12—O-Ring (2 used)

O-Ring Installation

Continued on next page

TM10687 (14OCT08)

03-0350-82

MH66088,000099F –19–06OCT08–13/19

524K Loader 101408

PN=142

Gears, Shafts, Bearings and Power Shift Clutch 18. Install engagement sleeve (11), compression spring (10), retainer (9), and snap ring (8) using a press.

TX1047531A

–UN–20AUG08

8—Snap Ring 9—Retainer 10—Compression Spring 11—Engagement Sleeve

Engagement Sleeve Installation

03 0350 83 MH66088,000099F –19–06OCT08–14/19

IMPORTANT: Seal ring ends MUST be interlocked and aligned vertically to avoid damage to seal rings and/or output shaft bearing.

–UN–20AUG08

19. Install seal rings (7) to output shaft. Make sure both ends of seal rings are interlocked. Apply a light coat of grease to seal rings and rotate seal rings until both ends are aligned vertically.

TX1047530A

7—Seal Ring (2 used)

Seal Ring Installation

Continued on next page

TM10687 (14OCT08)

03-0350-83

MH66088,000099F –19–06OCT08–15/19

524K Loader 101408

PN=143

Gears, Shafts, Bearings and Power Shift Clutch

–UN–21AUG08

CAUTION: Prevent possible injury from heated components. Use proper safety equipment while handling heated components.

TX1047584A

20. Heat output shaft bearing to specification before installing output shaft assembly. Use temperature measuring stick or infrared meter to verify temperature. Specification Output Shaft Bearing—Preheat Temperature ..................................................................................... 120°C 248°F

5—Output Shaft Assembly 6—Axle Disconnect Housing

Install output shaft assembly (5) to axle disconnect housing (6) until seated.

MH66088,000099F –19–06OCT08–16/19

–UN–20AUG08

21. Apply L64500 Flange Sealant to outside diameter of new output flange seal. Using JDG10848 Driver Tool, Shaft Seal-Axle Disconnect, install seal with lip facing inward. CAUTION: Prevent possible injury from heated components. Use proper safety equipment while handling heated components.

TX1047527A

03 0350 84

Output Shaft Assembly Installation

22. Heat output flange to specifications before installing. Use temperature measuring stick or infrared meter to verify temperature.

Output Flange Seal Installation 4—Output Flange Seal

Specification Output Flange—Preheat Temperature ....................................................................................... 80°C 176°F

Continued on next page

TM10687 (14OCT08)

03-0350-84

MH66088,000099F –19–06OCT08–17/19

524K Loader 101408

PN=144

Gears, Shafts, Bearings and Power Shift Clutch When output flange has cooled, install O-ring (3), washer (2), and output flange retaining cap screws (1), and tighten to specification.

TX1047526A

–UN–20AUG08

Specification Output Flange Retaining Cap Screw—Torque ............................................................................... 34 N•m 25 lb-ft

1—Cap Screw (2 used) 2—Washer 3—O-Ring Output Flange Installation

03 0350 85 MH66088,000099F –19–06OCT08–18/19

–UN–20AUG08

23. Install new O-ring to solenoid valve and lightly oil O-ring. Install solenoid valve (20) to axle disconnect housing. Install retainer (19) and socket head cap screw (18), but do not tighten at this time. 24. Position solenoid valve as shown. Tighten socket head cap screw to specification.

25. Install screw plugs (17) with new O-rings and tighten to specification. Specification Screw Plug—Torque ...................................................................... 10 N•m 89 lb-in

TX1047557A

Specification Socket Head Cap Screw—Torque ................................................ 9.5 N•m 84 lb-in Solenoid Valve Installation 17—Screw Plug (2 used) 18—Socket Head Cap Screw 19—Retainer 20—Solenoid Valve

26. Install axle disconnect to transmission. See Axle Disconnect Remove and Install. (Group 0350.)

MH66088,000099F –19–06OCT08–19/19

TM10687 (14OCT08)

03-0350-85

524K Loader 101408

PN=145

Gears, Shafts, Bearings and Power Shift Clutch

03 0350 86

TM10687 (14OCT08)

03-0350-86

524K Loader 101408

PN=146

Group 0360

Hydraulic System Transmission Pump Remove and Install

T108730

–UN–17APR97

1. Remove socket head cap screws.

MH66O88,00008AE –19–19AUG08–1/14

2. Install puller on the recess below the splines of the stator shaft. Pull pump assembly (7) out of the housing bore.

T108731

–UN–17APR97

03 0360 1

Continued on next page

TM10687 (14OCT08)

03-0360-1

MH66O88,00008AE –19–19AUG08–2/14

524K Loader 101408

PN=147

Hydraulic System

TX1029405

–UN–17SEP07

03 0360 2

1—O-Ring 2—Snap Ring 3—Seal

4—Shim 5—Needle Bearing

6—Ring 7—Pump Assembly

IMPORTANT: Avoid transmission damage. If signs of wear are noticed within the pump housing or the cam disk, the complete pump must be replaced.

8—O-Ring (10 used) 9—Cap Screw (10 used)

3. Remove transmission pump from stator.

MH66O88,00008AE –19–19AUG08–3/14

T108732

–UN–17APR97

4. Remove cam plate from pump. Observe drive gear spline location and two small dowel pins.

Continued on next page

TM10687 (14OCT08)

03-0360-2

MH66O88,00008AE –19–19AUG08–4/14

524K Loader 101408

PN=148

Hydraulic System 5. Loosen cap screws and remove oil feed housing. 6. Remove flat gasket.

–UN–17APR97

7. Inspect and replace parts as required.

T108725

8. Install cam disk and retain it by means of grooved pins (2 used).

MH66O88,00008AE –19–19AUG08–5/14

9. Install alignment studs (1) and install flat gasket. 03 0360 3

TX1028774A

–UN–29AUG07

1—Alignment Stud (2 used)

MH66O88,00008AE –19–19AUG08–6/14

NOTE: Install cap screws until contact is obtained. Do not tighten. 10. Install oil feed housing, washers and cap screws.

T109086

–UN–15APR97

11. Leave loose at this time. This allows for oil pump alignment later in assembly.

MH66O88,00008AE –19–19AUG08–7/14

NOTE: Observe overlapping of the bores.

T109087

–UN–15APR97

12. Install alignment studs and stator shaft until it is bottomed in housing.

Continued on next page

TM10687 (14OCT08)

03-0360-3

MH66O88,00008AE –19–19AUG08–8/14

524K Loader 101408

PN=149

Hydraulic System 13. Using JDG10840 Transmission Seal Installer (2), install transmission pump seal (3).

2 2—JDG10840 Transmission Seal Installer 3—Transmission Pump Seal

TX1047325

–UN–10SEP08

MH66O88,00008AE –19–19AUG08–9/14

14. Lubricate and install O-ring (4).

TX1047323A

–UN–19AUG08

4—O-Ring

MH66O88,00008AE –19–19AUG08–10/14

–UN–15APR97

IMPORTANT: Avoid transmission pump failure. Do not tighten assembly screws, they are used to hold pump together for installation and are not to be torqued or removed.

T109089

15. Install transmission pump.

MH66O88,00008AE –19–19AUG08–11/14

NOTE: Apply multipurpose grease to O-rings.

–UN–19AUG08

16. Install socket head screws with new O-rings (5). 5—O-Ring

TX1047324A

03 0360 4

Continued on next page

TM10687 (14OCT08)

03-0360-4

MH66O88,00008AE –19–19AUG08–12/14

524K Loader 101408

PN=150

Hydraulic System 17. Install transmission pump and socket head cap screws.

T109091

–UN–15APR97

Specification Socket Head Cap Screw—Torque ................................................. 46 N•m 34 lb-ft

MH66O88,00008AE –19–19AUG08–13/14

NOTE: Note locations of hanger strap from original location.

03 0360 5

18. Tighten cap screws to specification.

T109092

–UN–15APR97

Specification Pump Cap Screw—Torque ............................................................ 25 N•m 221 lb-in.

MH66O88,00008AE –19–19AUG08–14/14

Converter Minimum Pressure Regulator Valve Remove and Install 1. Remove transmission pump. See Transmission Pump Remove and Install. (Group 0360.)

MH66O88,00008AF –19–27NOV07–1/3

T108726

–UN–17APR97

2. Remove converter minimum pressure regulator valve from housing bore.

Continued on next page

TM10687 (14OCT08)

03-0360-5

MH66O88,00008AF –19–27NOV07–2/3

524K Loader 101408

PN=151

Hydraulic System NOTE: Pressure must be relieved on roll pin (4) before removing.

–UN–29APR97

3. Preload the compression spring (2), and remove roll pin (4) from the pressure regulator valve. 4. Inspect and replace parts as required.

T109082

5. Install pre-assembled converter minimum pressure regulator valve into housing bore. 1—Piston 2—Compression Spring 3—Valve Insert 4—Roll Pin

03 0360 6 MH66O88,00008AF –19–27NOV07–3/3

TX1048258

–UN–09SEP08

Transmission Hydraulic Control Valve Remove and Install

Transmission Hydraulic Control Valve Assembly 1—Stud (14 used) 2—Gasket 3—Manifold Plate

4—Nut (14 used) 5—Plate 6—Cap Screw (23 used)

7—Plug 8—O-Ring (8 used) 9—Cap Screw (36 used)

Continued on next page

TM10687 (14OCT08)

03-0360-6

10—Spring 11—Valve Spool 12—Pressure Switch

TW73308,000037C –19–10OCT08–1/6

524K Loader 101408

PN=152

Hydraulic System 1. Replace two cap screws (6) with alignment studs. 2. Remove the remaining cap screws (6) and remove control valve from manifold plate (3). 3. Remove plate (5).

TX1048486A

–UN–10SEP08

6—Cap Screw (23 used)

TW73308,000037C –19–10OCT08–2/6

4. Remove manifold plate (3) and gasket (2) from the transmission housing. 5. Inspect and repair parts as necessary. See Transmission Hydraulic Control Valve Disassemble and Assemble. (Group 0360.)

TX1029379A

–UN–13SEP07

2—Gasket 3—Manifold Plate

Continued on next page

TM10687 (14OCT08)

03-0360-7

TW73308,000037C –19–10OCT08–3/6

524K Loader 101408

PN=153

03 0360 7

Hydraulic System 6. Clean mating surfaces on transmission and manifold plate (3).

TX1029382A

–UN–17SEP07

3—Manifold Plate

03 0360 8 TW73308,000037C –19–10OCT08–4/6

7. Install gasket (2) and manifold plate (3) to the transmission housing.

–UN–15APR97

8. Install cap screws (9) and nuts (4). Tighten to specification.

T109107

Specification Cap Screw—Torque ....................................................................... 23 N•m 204 lb-in Nut—Torque ................................................................................... 23 N•m 204 lb-in

9. Install alignment studs to the manifold plate. 10. Install plate (5) to the manifold plate.

Continued on next page

TM10687 (14OCT08)

03-0360-8

TW73308,000037C –19–10OCT08–5/6

524K Loader 101408

PN=154

Hydraulic System 11. Install the transmission control valve with cap screws (6). Tighten to specification. Specification Cap Screw—Torque ...................................................................... 9.5 N•m 84 lb-in.

TX1048486A

–UN–10SEP08

6—Cap Screw (23 used)

TW73308,000037C –19–10OCT08–6/6

TM10687 (14OCT08)

03-0360-9

524K Loader 101408

PN=155

03 0360 9

Hydraulic System

Transmission Hydraulic Control Valve Cross Section View 3

03 0360 10

–UN–08SEP08

TX1048260

TX1048260 Transmission Control Valve—Cross Section 1—Solenoid Valve— Proportional (6 used) 2—Pressure Regulating Valve—Piston

3—Pressure Reducing Valve— Piston

4—Connector—Wiring Harness 5—Cover (2 used)

6—Valve Block—Control Valve 7—Housing (2 used)

TW73308,0000380 –19–09SEP08–1/1

TM10687 (14OCT08)

03-0360-10

524K Loader 101408

PN=156

Hydraulic System

Transmission Hydraulic Control Valve Disassemble and Assemble

TX1048466

–UN–09SEP08

03 0360 11

1—Cap Screw (64 used) 2—Cover 3—Clamp (clip) 4—Wiring Harness 5—Gasket 6—Solenoid Valve— Proportional (6 used) 7—O-Ring (6 used) 8—Cap Screw (6 used)

9—Plate (6 used) 10—Housing 11—Gasket 12—Spring 13—Piston (system pressure reducing valve) 14—Piston (pressure control valve) (6 used) 15—Spring (6 used)

16—Orifice (6 used) 17—Valve Block (control) 18—Spring 19—Piston (system pressure regulating valve) 20—Spring (6 used) 21—Piston (dampening valve) (6 used)

Continued on next page

TM10687 (14OCT08)

03-0360-11

22—Gasket 23—Housing 24—Gasket 25—Cover 26—Plate (center) 27—Screen (6 used) 28—Cap Screw (18 used) 29—Plate

TW73308,000037D –19–12SEP08–1/24

524K Loader 101408

PN=157

Hydraulic System 1. Remove cap screws (1), cover (25), and gasket (24). 2. Disconnect connectors from solenoid valves (6).

T108686

–UN–16APR97

3. Remove cap screws (8), retaining plates (9), and solenoid valves (6).

Control Valve

T108687

–UN–16APR97

03 0360 12

Solenoid Valves Pulled Out TW73308,000037D –19–12SEP08–2/24

4. Remove cap screws (1), housing (23), and gasket (22). 5. Remove three pressure control valve pistons (14) and compression springs (15). –UN–12JAN01

6. Remove three dampening valve pistons (21) and compression springs (20).

T135928

7. Remove system pressure regulating valve piston (19) and compression spring (18).

Remove Housing and Valves

Continued on next page

TM10687 (14OCT08)

03-0360-12

TW73308,000037D –19–12SEP08–3/24

524K Loader 101408

PN=158

Hydraulic System

T108689

–UN–16APR97

8. Remove clamp (clip) (3) from wire harness connector.

Clamp Removal from Wire Harness Connector

03 0360 13 TW73308,000037D –19–12SEP08–4/24

9. Remove cap screws (1), cover (2), and gasket (5). 10. Disconnect wire harness from solenoid valves (6).

T108682

–UN–16APR97

11. Remove cap screws (8), retaining plates (9), and solenoid valves (6).

Cover and Solenoid Valve Removal

Continued on next page

TM10687 (14OCT08)

03-0360-13

TW73308,000037D –19–12SEP08–5/24

524K Loader 101408

PN=159

Hydraulic System 12. Remove cap screws (1), housing (10), and gasket (11).

–UN–16APR97

13. Remove three pressure control valve pistons (14) and compression springs (15). 14. Remove three dampening valve pistons (21) and compression springs (20).

T108683

15. Remove compression spring (12) and system pressure reducing valve piston (13). Housing and Valves Removed

16. Inspect all components for damage and replace if necessary. 17. Before installation, check free travel of moving parts within housing. 18. Oil components before assembly.

TW73308,000037D –19–12SEP08–6/24

19. Insert orifices (16) (if removed) until contact is obtained.

–UN–10SEP08

20. Install screens (27) if removed. 16—Orifices (6 used)

TX1048500A

03 0360 14

Valve Block

Continued on next page

TM10687 (14OCT08)

03-0360-14

TW73308,000037D –19–12SEP08–7/24

524K Loader 101408

PN=160

Hydraulic System 21. Install three compression springs (15) and pressure control valve pistons (14).

–UN–16APR97

22. Install three compression springs (20) and dampening valve pistons (21).

T108683

23. Install system pressure reducing valve piston (13) and compression spring (12).

Valve Installation in Control Valve Block

03 0360 15 TW73308,000037D –19–12SEP08–8/24

NOTE: To aid assembly of solenoid housing, push pistons into bore and retain by using a 5 mm pin or cap screw.

T108694

–UN–16APR97

24. Install two alignment studs into valve block. Install gasket (11).

Piston Installation

Continued on next page

TM10687 (14OCT08)

03-0360-15

TW73308,000037D –19–12SEP08–9/24

524K Loader 101408

PN=161

Hydraulic System

T108695

–UN–16APR97

25. Install housing (10) while routing wiring harness (4) into position.

Wiring Harness Routing for Housing Installation

03 0360 16 TW73308,000037D –19–12SEP08–10/24

26. Fasten housing (10) with cap screws (1) and remove alignment studs. Tighten to specification. Remove assembly aid pins or cap screws.

T108696

–UN–16APR97

Specification Housing-to-Valve Block Cap Screw—Torque ................................................................................. 5 N•m 44 lb-in.

Torque Housing

Continued on next page

TM10687 (14OCT08)

03-0360-16

TW73308,000037D –19–12SEP08–11/24

524K Loader 101408

PN=162

Hydraulic System NOTE: Install retaining plate with the claw facing the housing bottom.

–UN–16APR97

27. Install three solenoid valves (6) with O-rings (7). Fasten with retaining plate (9) and cap screws (8). Tighten to specification.

T108697

Specification Retaining Plate Cap Screw— Torque .............................................................................................. 5 N•m 44 lb-in.

Solenoid Valves Installation

T108698

–UN–16APR97

03 0360 17

Solenoid Valves Torque TW73308,000037D –19–12SEP08–12/24

T108691

–UN–16APR97

28. Connect wire harness to solenoid valves.

Wiring Harness and Connectors Installation

Continued on next page

TM10687 (14OCT08)

03-0360-17

TW73308,000037D –19–12SEP08–13/24

524K Loader 101408

PN=163

Hydraulic System 29. Install two alignment studs into housing. Install gasket (5)

–UN–16APR97

Install cover (2), cap screws (1), and remove alignment studs. Tighten to specification.

T108692

Specification Solenoid Cover-to-Housing Cap Screw—Torque ................................................................................. 5 N•m 44 lb-in.

Solenoid Cover Installation

03 0360 18 TW73308,000037D –19–12SEP08–14/24

30. Install wiring harness connector (4) with clamp (3) to cover (2).

T108693

–UN–16APR97

NOTE: Ensure that the clamp snaps in.

Wiring Harness Connector Installation

Continued on next page

TM10687 (14OCT08)

03-0360-18

TW73308,000037D –19–12SEP08–15/24

524K Loader 101408

PN=164

Hydraulic System 31. Install three compression springs (15) and pressure control valve pistons (14).

–UN–12JAN01

32. Install three compression springs (20) and dampening valve pistons (21).

T135928

33. Install compression spring (18) and system pressure regulating valve (19).

Valves Installed into Control Valve Block

03 0360 19 TW73308,000037D –19–12SEP08–16/24

NOTE: To aid assembly of solenoid housing, push pistons into bore and retain by using a 5 mm pin or cap screw.

T108703

–UN–16APR97

34. Install pistons of the pressure control valves (14) into position.

Piston Installation

Continued on next page

TM10687 (14OCT08)

03-0360-19

TW73308,000037D –19–12SEP08–17/24

524K Loader 101408

PN=165

Hydraulic System 35. Install two alignment studs into valve block. Install gasket (22).

T108704

–UN–16APR97

Install housing (23) while routing wiring harness (4) into position.

Alignment Studs Placement

03 0360 20 TW73308,000037D –19–12SEP08–18/24

36. Install cap screws and remove alignment studs. Tighten to specification. Remove assembly aid pins or cap screws.

T108705

–UN–16APR97

Specification Housing-to-Valve Block Cap Screw—Torque ................................................................................. 5 N•m 44 lb-in.

Torque Housing

Continued on next page

TM10687 (14OCT08)

03-0360-20

TW73308,000037D –19–12SEP08–19/24

524K Loader 101408

PN=166

Hydraulic System NOTE: Install retaining plate with the claw facing the housing bottom.

–UN–16APR97

37. Install three solenoid valves (6) with O-rings (7). Fasten with retaining plate (9) and cap screw (8). Tighten to specification.

T108698

Specification Retaining Plate Cap Screw— Torque .............................................................................................. 5 N•m 44 lb-in.

Solenoid Valves Tightening

03 0360 21 TW73308,000037D –19–12SEP08–20/24

38. Connect wiring harness to solenoid valves.

–UN–10SEP08

39. Install two alignment studs in housing. Install gasket (24). Install cover (25), and cap screws (1) and remove alignment studs. Tighten to specification.

TX1048501A

Specification Solenoid Cover-to-Housing Cap Screw—Torque ................................................................................. 5 N•m 44 lb-in. Solenoid Cover Installation

Continued on next page

TM10687 (14OCT08)

03-0360-21

TW73308,000037D –19–12SEP08–21/24

524K Loader 101408

PN=167

Hydraulic System 40. Install diagnostic plugs with O-rings in ports, if removed during disassembly. Tighten to specification.

T108700

–UN–16APR97

Specification Diagnostic Port Plug—Torque .......................................................... 6 N•m 55 lb-in.

Diagnostic Plugs Installation

03 0360 22 TW73308,000037D –19–12SEP08–22/24

T108701

–UN–16APR97

41. Install two alignment studs and plate (26).

Alignment Studs Placement

Continued on next page

TM10687 (14OCT08)

03-0360-22

TW73308,000037D –19–12SEP08–23/24

524K Loader 101408

PN=168

Hydraulic System NOTE: Tighten inboard cap screws first and continue toward the outside.

–UN–17APR97

42. Install plate (29) to valve block with cap screws (28) and remove alignment studs. Tighten to specification.

T108708

Specification Plate-to-Valve Block Cap Screw—Torque ............................................................................ 10.5 N•m 93 lb-in.

Plate-to-Valve Block

03 0360 23 TW73308,000037D –19–12SEP08–24/24

Torque Converter Relief Valve Remove, Disassemble, and Install 1. Remove transmission hydraulic control valve. See Transmission Hydraulic Control Valve Remove and Install. (Group 0360.)

TW73308,0000381 –19–10SEP08–1/4

T108715

–UN–17APR97

2. Remove torque converter relief valve out of housing bore.

Removing Torque Converter Relief Valve

Continued on next page

TM10687 (14OCT08)

03-0360-23

TW73308,0000381 –19–10SEP08–2/4

524K Loader 101408

PN=169

Hydraulic System 3. Remove preload compression spring (3) carefully, remove roll pin (6) as required to inspect and replace parts as needed. –UN–10SEP08

4. Assemble torque converter relief valve.

TX1048502A

1—Plate 2—Ball 3—Compression Spring 4—Valve Insert 5—Valve Sleeve 6—Roll Pin Torque Converter Relief Valve Components

03 0360 24 TW73308,0000381 –19–10SEP08–3/4

5. Install torque converter relief valve into housing bore until it bottoms.

T109105

–UN–15APR97

6. Install transmission hydraulic control valve. See Transmission Hydraulic Control Valve Remove and Install. (Group 0360.)

Insert Converter Relief Valve

TW73308,0000381 –19–10SEP08–4/4

TM10687 (14OCT08)

03-0360-24

524K Loader 101408

PN=170

Hydraulic System

Transmission Internal Oil Pipes and Tubes Remove and Install

TX1048261

–UN–08SEP08

03 0360 25

1—Pipe (use JDG1139 Swaging Tool for installing) 2—O-Ring (6 used) 3—Pressure Pipe (use JDG1132 Swaging Tool for installing)

4—Cap Screw (3 used) 5—Pressure Pipe (use JDG1132 Swaging Tool for installing) 6—Tube (use JDG1133 Swaging Tool for installing)

7—Tube (use JDG1133 Swaging Tool for installing) 8—Pipe (2 used) 9—Cap Screw (2 used)

Continued on next page

TM10687 (14OCT08)

03-0360-25

10—Suction Tube (use JDG1131 Swaging Tool for installing)

TW73308,000037B –19–11SEP08–1/5

524K Loader 101408

PN=171

Hydraulic System Transmission Housing Front Half

TX1048471A

–UN–10SEP08

NOTE: The internal transmission oil tube forming tools are now classified as recommended tools. DTAC will no longer be the source for these tools for transmission repair. These tools can be ordered online through ServiceGard on the DealerNet or by calling 1-888-563-3373. 1. All oil pipes and tubes can be removed by using a small pry bar inside the housing. Swaging Tools 11—JDG1132 Swaging Tool 12—JDG1131 Swaging Tool 13—JDG1133 Swaging Tool 14—JDG1139 Swaging Tool

03 0360 26

Continued on next page

TM10687 (14OCT08)

03-0360-26

TW73308,000037B –19–11SEP08–2/5

524K Loader 101408

PN=172

Hydraulic System

–UN–10APR97

2. Install pressure pipes (3 and 5) using JDG1194 Locating Bar tool as shown in photo to properly position pipe before swaging pipe into housing bores. This will ensure the pipes line up with transmission cover during assembly.

T108655

1—Pipe 3—Pressure Pipe 5—Pressure Pipe 10—Suction Tube

JDG1194 Locating Bar Shown to Locate Two Pressure Pipes

TX1048468A

–UN–10SEP08

03 0360 27

Transmission Housing (front half) Continued on next page

TM10687 (14OCT08)

03-0360-27

TW73308,000037B –19–11SEP08–3/5

524K Loader 101408

PN=173

Hydraulic System NOTE: Pipe must be positioned slightly below housing surface on opposite side.

–UN–10NOV97

3. Locate pipe slightly below housing surface on opposite side. 4. Insert JDG1131 Swaging Tool (16) into pipe end in bore until seated against tools edge (15).

T112164B

5. Slide rolling pin (17) down until seated. Start turning pin with wrench. Pressure will slowly increase. Turn approximately 10 to 12 full turns. JDG1131 Swaging Tool Shown Installing Suction Tube

6. Install hardware as required on suction tube (10) and two pressure pipes (3 and 5).

–UN–10SEP08

Specification Tube Mounting Hardware— Torque ............................................................................................ 23 N•m 17 lb-ft

15—Tool Edge 16—JDG1131 Swaging Tool (used for Suction Tube) 17—Rolling Pin

TX1048469A

03 0360 28

JDG1131 Swaging Tool Shown

Continued on next page

TM10687 (14OCT08)

03-0360-28

TW73308,000037B –19–11SEP08–4/5

524K Loader 101408

PN=174

Hydraulic System Transmission Housing Rear Half

–UN–10SEP08

1. All tubes can be removed by using a small pry bar inside the cover.

TX1048467A

IMPORTANT: Oil tubes must be positioned slightly below housing surface on opposite side. 2. Install two oil tubes (6 and 7) in transmission cover using JDG1133 Swaging Tool (16). Transmission Housing (rear half)

3. Insert swaging tool into oil tube end in bore until seated against tool edge (15). 4. Slide rolling pin (17) down until seated. Start turning pin with wrench. Pressure will slowly increase. Turn approximately 10 to 12 full turns.

–UN–10SEP08

03 0360 29

TX1048469A

15—Tool Edge 16—JDG1131 Swaging Tool (used for Suction Tube) 17—Rolling Pin

JDG1131 Swaging Tool Shown TW73308,000037B –19–11SEP08–5/5

Axle Disconnect Solenoid Valve Remove and Install 1. Turn battery disconnect switch to the OFF position. Continued on next page

TM10687 (14OCT08)

03-0360-29

AA95137,0001B8B –19–05SEP08–1/2

524K Loader 101408

PN=175

Hydraulic System NOTE: For location of axle disconnect solenoid, see Transmission Harness (W10) Component Location. (Group 9015-10.) 2. Disconnect electrical connector (1) from axle disconnect solenoid (5).

4. Remove cap screw (4) and solenoid retainer (2).

2 1 5

3 4

–UN–05SEP08

3. Tag and disconnect hydraulic line (3). Close all openings using caps and plugs.

03 0360 30

TX1048382

NOTE: Axle disconnect solenoid internal parts cannot be replaced separately. Replace solenoid and valve together. 5. Remove axle disconnect solenoid (5). NOTE: Axle disconnect solenoid must be installed at the correct angle to ensure axle disconnect will function. 6. Install axle disconnect solenoid. See Axle Disconnect Disassemble and Assemble. (Group 0350.)

Axle Disconnect Solenoid Remove and Install 1—Electrical Connector 2—Solenoid Retainer 3—Hydraulic Line 4—Cap Screw 5—Axle Disconnect Solenoid

7. Connect hydraulic line (3). 8. Connect electrical connector (1) to solenoid (5). 9. Turn battery disconnect switch to the ON position.

AA95137,0001B8B –19–05SEP08–2/2

TM10687 (14OCT08)

03-0360-30

524K Loader 101408

PN=176

Section 04

Engine Contents Page

Group 0400—Removal and Installation PowerTech E 6.8 L John Deere Engine . . .04-0400-1 Engine Remove and Install . . . . . . . . . . . . .04-0400-2 Serpentine Belt Remove and Install . . . . . .04-0400-10 Crankshaft Dampener Remove and Install. . . . . . . . . . . . . . . . . . . . . . . . . . . .04-0400-11

TM10687 (14OCT08)

04-1

524K Loader 101408

PN=1

Contents

TM10687 (14OCT08)

04-2

524K Loader 101408

PN=2

Group 0400

Removal and Installation PowerTech E 6.8 L John Deere Engine

PowerTech is a trademark of Deere & Company PowerTech E is a trademark of Deere & Company

M44215

• PowerTech 4.5 L and 6.8 L Diesel Engines—Base Engine. (CTM104.) • PowerTech E 4.5 L and 6.8 L Diesel Engines—Level 16 Electronic Fuel System with Denso HPCR. (CTM502.)

–UN–07SEP88

For additional information on John Deere PowerTech and PowerTech E engines and components, see the following component technical manuals:

CS33148,0002A6C –19–08SEP08–1/1

04 0400 1

TM10687 (14OCT08)

04-0400-1

524K Loader 101408

PN=179

Removal and Installation

Engine Remove and Install 1. Lower boom and bucket to ground. Stop engine.

–UN–23AUG88

2. Turn battery disconnect switch to the OFF position.

TS281

CAUTION: Prevent possible injury from explosive release of fluids from pressurized cooling system. Shut off engine. Only remove filler cap when cool enough to touch with bare hands. Slowly loosen cap to first stop to relieve pressure before removing completely.

Explosive Release of Fluids

3. Attach hose to radiator drain valve. Drain engine coolant. 4. Remove cooling package doors. See Radiator Remove and Install (Group 0510.)

04 0400 2

5. Remove hood with air cleaner and exhaust stack. See Hood Remove and Install. (Group 1910.) 6. Remove cold weather starting aid. See Start Aid Nozzle Remove and Install. (Group 0505.) 7. Remove intercooler tubes. See Intercooler Remove and Install. (Group 0510.) Close all openings using caps and plugs. 8. Remove cooling system surge tank with hoses. 9. Remove radiator hoses.

Continued on next page

TM10687 (14OCT08)

04-0400-2

MM16633,0002506 –19–11SEP08–1/10

524K Loader 101408

PN=180

Removal and Installation

CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device. –UN–30OCT03

10. Support hood support (1) with appropriate lifting device and remove cap screws (2).

T195758A

Specification Hood Support—Weight (approximate)..................................................................................... 82 kg 180 lb

11. Remove hood support using appropriate lifting device.

Hood Support

12. Remove engine serpentine belt. See Serpentine Belt Remove and Install. (Group 0510.) 1—Hood Support 2—Hood Support Cap Screw (4 used) 3—Left Rear Engine Mount Cap Screw 4—Lower Radiator Hose 5—Hydraulic Hose

04 0400 3

Continued on next page

TM10687 (14OCT08)

04-0400-3

MM16633,0002506 –19–11SEP08–2/10

524K Loader 101408

PN=181

Removal and Installation NOTE: It is not necessary to disconnect hydraulic hoses from pump when removing fan pump. 13. Remove hydraulic fan pump cap screws (7) and fan pump (6) from engine and use tie band to fasten aside. –UN–26MAR07

14. Remove crankcase drain hose from bottom left side of crankcase and use tie band to fasten aside.

TX1021039A

15. Remove heater hoses (8) from left side of engine. 16. Remove fuel hose from primary fuel filter. 17. Remove U-bolt and clamp for muffler.

Hydraulic Fan Pump

18. Remove muffler. See Muffler Remove and Install. (Group 0530.) Close all openings using caps and plugs. 19. Remove muffler bracket cap screws and remove bracket. –UN–26MAR07

20. Disconnect wiring harness and clamps from all engine locations. 21. Disconnect alternator harness.

TX1021040A

04 0400 4

6—Hydraulic Fan Pump 7—Hydraulic Fan Pump Cap Screw (2 used) 8—Heater Hose (2 used) 9—Turbocharger Oil Feed Line

Heater Hose

Continued on next page

TM10687 (14OCT08)

04-0400-4

MM16633,0002506 –19–11SEP08–3/10

524K Loader 101408

PN=182

Removal and Installation 22. Remove positive battery cables (10) and wires E01 WHT (11) from starter. 23. Remove ground wire (12) from starter.

–UN–26MAR07

NOTE: It is not necessary to disconnect air conditioning hoses from compressor or receiver-dryer when removing compressor.

TX1021043A

24. Remove air conditioning compressor. Use tie band to secure compressor aside. 25. Remove fuel return hose from fuel rail on right side of engine. Close all openings using caps and plugs. Starter 10—Positive Battery Cables 11—Wires E01 WHT 12—Ground Wire

04 0400 5

MM16633,0002506 –19–11SEP08–4/10

NOTE: Rotate the engine so the drive shaft U-joint bolts are accessible.

–UN–12MAR07

26. Remove four cap screws (14) from the engine-to-torque converter drive shaft (15) U-joints at the torque converter housing (13).

TX1020406A

13—Torque Convertor Housing 14—U-Joint Retaining Cap Screw (4 used) 15—Drive Shaft

Drive Shaft Cap Screws

Continued on next page

TM10687 (14OCT08)

04-0400-5

MM16633,0002506 –19–11SEP08–5/10

524K Loader 101408

PN=183

Removal and Installation 27. Install JD 244-1 Lifting Eye and JD 244-2 Lifting Eye to engine. 28. Attach JDG23 Lifting Sling to lifting eyes.

TX1021042A

–UN–26MAR07

16—Lifting Eye Locations 17—Load Positioning Sling

Lifting Eyes and Load Positioning Sling

Continued on next page

MM16633,0002506 –19–11SEP08–6/10

04 0400 6

TM10687 (14OCT08)

04-0400-6

524K Loader 101408

PN=184

Removal and Installation

22 31 33

20 21

28 33

04 0400 7

18 26

19 –UN–12MAR07

TX1020423

Engine Mounting Brackets 18—M16 Nut (2 used) 19—M20 Nut (2 used) 20—M12 x 35 Cap Screw (6 used) 21—M20 x 120 Cap Screw (2 used)

22—M16 x 110 Cap Screw (2 used) 23—Washer (2 used) 24—Washer (2 used) 25—Washer (2 used) 26—Washer (2 used)

27—Left Rear Isolator Support 28—Right Rear Isolator Support 29—Left Front Isolator Support

CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device. 29. Remove rear engine isolator support cap screw.

30—Right Front Isolator Support 31—Front Isolator (2 used) 32—Rear Isolator (2 used) 33—Washer (2 used)

CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device. 31. Lift engine from mounts and carefully remove through right side of the machine.

30. Remove front engine isolator support cap screw.

Continued on next page

TM10687 (14OCT08)

04-0400-7

MM16633,0002506 –19–11SEP08–7/10

524K Loader 101408

PN=185

Removal and Installation Specification Engine—Weight (approximate) ................................................. 660 kg 1450 lb

32. Repair or replace parts as necessary. See the following component technical manuals: • PowerTech 4.5 L and 6.8 L Diesel Engines— Base Engine. (CTM104.) • PowerTech E  4.5 & 6.8 L Diesel Engines— Level 16 Electronic Fuel System with Denso HPCR. (CTM502.) 33. Inspect engine mounting parts. Replace as needed.

Specification Rear Mounting Cap Screw— Torque........................................................................... 348—522 N•m 256—384 lb-ft Front Mounting Cap Screw— Torque........................................................................... 256—284 N•m 188—282 lb-ft

36. Install four new engine-to-transmission drive shaft U-joint cap screws. Tighten to specification. Specification Drive Shaft U-Joint Cap Screw—Torque ........................................................................ 41 N•m 30 lb-ft

37. Connect engine wiring harness to engine at all locations.

CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device.

38. Connect positive battery cables and wires E01 WHT to starter. Connect ground wire to starter. 39. Connect fuel hose to primary fuel filter.

04 0400 8

34. Install engine into machine. 35. Install front and rear engine mounting cap screw. Tighten cap screws to specification.

Continued on next page

TM10687 (14OCT08)

04-0400-8

MM16633,0002506 –19–11SEP08–8/10

524K Loader 101408

PN=186

Removal and Installation 40. Connect heater hoses (8) to left side of engine. 41. Connect crankcase drain hose at bottom left side of crankcase. 42. Install fan hydraulic pump (6) with cap screws (7). –UN–26MAR07

43. Install fuel return line. 44. Install air conditioner compressor bracket.

TX1021040A

45. Install air conditioner compressor. 46. Install engine serpentine belt. Heater Hose

CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device. 47. Lift hood support in place with appropriate lifting device and install cap screws.

04 0400 9 –UN–26MAR07

Specification Hood Support—Weight (approximate)..................................................................................... 82 Kg 180 lb

TX1021039A

48. Install radiator hoses. 49. Install cooling system surge tank with hoses to hood support. Hydraulic Fan Pump

50. Unplug openings and install intercooler hoses. 6—Hydraulic Fan Pump 7—Hydraulic Fan Pump Mounting Cap Screw (2 used) 8—Heater Hose (2 used) 9—Turbocharger Oil Feed Line

51. Connect cold weather starting aid. 52. Install muffler mounting bracket and muffler. 53. Install hood with air cleaner and exhaust stack. 54. Install hood cap screws. 55. Install intake hose to turbocharger. 56. Fill radiator with coolant. Specification Engine Coolant—Capacity (approximate).................................................................................... 22.5 L 5.9 gal

Continued on next page

TM10687 (14OCT08)

04-0400-9

MM16633,0002506 –19–11SEP08–9/10

524K Loader 101408

PN=187

Removal and Installation 57. Turn battery disconnect switch to the ON position.

MM16633,0002506 –19–11SEP08–10/10

Serpentine Belt Remove and Install 1. Open left access door. 2. Check serpentine belt (7) regularly for cracks, frayed edges, and wear at bottom of grooves.

TX1022002A

–UN–16APR07

IMPORTANT: If belt is stretched to the point that the belt tension adjuster assembly (3) is against its stop, serpentine belt must be replaced. 3. Replace serpentine belt (7) if worn. 04 0400 10

4. Remove inspection panel between engine and cooling package for more access.

1—Crankshaft 2—Water Pump 3—Tension Adjuster Assembly 4—Alternator 5—Idler 6—Air Conditioning Compressor 7—Serpentine Belt

Continued on next page

TM10687 (14OCT08)

04-0400-10

MM16633,0002504 –19–30MAY08–1/2

524K Loader 101408

PN=188

Removal and Installation 5. Hold tension adjuster assembly away from serpentine belt.

6. Remove serpentine belt. 7. Install new serpentine belt and release tension adjuster.

TX1021995

–UN–02MAY07

2 1—Crankshaft 2—Water Pump 3—Tension Adjuster Assembly 4—Alternator 5—Idler 6—Air Conditioning Compressor

1 Diagram With Air Conditioning

5 04 0400 11

TX1022016

–UN–17APR07

Diagram Without Air Conditioning

MM16633,0002504 –19–30MAY08–2/2

Crankshaft Dampener Remove and Install 1. Lower boom and bucket to ground. Stop engine. 2. Turn battery disconnect switch to the OFF position.

Continued on next page

TM10687 (14OCT08)

04-0400-11

MM16633,0002505 –19–30MAY08–1/2

524K Loader 101408

PN=189

Removal and Installation 3. Remove cooling package access door (1). 4. Remove inspection panel (2). 5. Remove lower inspection panel (3).

–UN–26MAR07

6. Remove serpentine belt. See Serpentine Belt Remove and Install. (Group 0400.)

TX1021089A

7. Remove radiator. See Radiator Remove and Install. (Group 1510.) 8. Remove engine torsional damper. See Remove Pulley or Vibration Damper and Pulley. (CTM104.) 9. Install engine torsional damper. See Install Pulley or Vibration Damper and Pulley. (CTM104.)

Access Door

10. Install radiator. See Radiator Remove and Install. (Group 1510.)

–UN–26MAR07

11. Install inspection panels between the engine and radiator. 12. Install cooling package access door. 13. Install serpentine belt. See Serpentine Belt Remove and Install. (Group 0400.)

TX1021088A

04 0400 12

IMPORTANT: Avoid machine damage, never attempt to start machine without coolant. Covers

14. Fill radiator with coolant. Specification Engine Coolant—Capacity (approximate).................................................................................... 22.5 L 5.9 gal

1—Cooling Package Access Door 2—Inspection Panel 3—Lower Inspection Panel

15. Turn battery disconnect switch to the ON position.

MM16633,0002505 –19–30MAY08–2/2

TM10687 (14OCT08)

04-0400-12

524K Loader 101408

PN=190

Section 05

Engine Auxiliary Systems Contents Page

Group 0505—Cold Weather Starting Aids Start Aid Nozzle Remove and Install . . . . . . .05-0505-1 Start Aid Solenoid Remove and Install . . . . .05-0505-2 Engine Coolant Heater Remove and Install. . . . . . . . . . . . . . . . . . . . . . . . . . . . .05-0505-3 Group 0510—Cooling System Intercooler Remove and Install . . . . . . . . . . .05-0510-1 Radiator Remove and Install . . . . . . . . . . . . .05-0510-2 Hydraulic Oil Cooler Remove and Install . . . .05-0510-5 Transmission Oil Cooler Remove and Install. . . . . . . . . . . . . . . . . . . . . . . . . . . . .05-0510-7 Axle Oil Coolers Disassemble and Assemble—If Equipped . . . . . . . . . . . . . . .05-0510-8 Cooling Package Plenum Remove and Install. . . . . . . . . . . . . . . . . . . . . . . . . . . . .05-0510-9

Group 0520—Intake System Air Cleaner Remove and Install. . . . . . . . . . .05-0520-1 Precleaner Remove and Install—If Equipped . . . . . . . . . . . . . . . . . . . . . . . . . .05-0520-3

Group 0530—External Exhaust System Muffler Remove and Install . . . . . . . . . . . . . .05-0530-1

Group 0560—External Fuel Supply Systems Fuel Tank Remove and Install. . . . . . . . . . . .05-0560-1 Primary Fuel Filter (Water Separator) Remove and Install . . . . . . . . . . . . . . . . . .05-0560-5

TM10687 (14OCT08)

05-1

524K Loader 101408

PN=1

Contents

TM10687 (14OCT08)

05-2

524K Loader 101408

PN=2

Group 0505

Cold Weather Starting Aids Start Aid Nozzle Remove and Install 1. Open left engine access door. 2. Disconnect start aid tube (2) from start aid nozzle (1).

–UN–27MAR07

3. Loosen start aid nozzle jam nut (4) from start aid nozzle (1). 4. Remove start aid nozzle (1) from air inlet.

NOTE: Red paint dot indexing mark (3) on nozzle indicates direction of nozzle opening.

TX1021161A

5. Clean or replace as necessary. Inspect start aid nozzle O-ring (5) and replace if necessary. Start Aid Nozzle Location

6. Apply PM37421 High Strength Thread Lock and Sealer to nozzle before installing into air inlet with red paint dot indexing mark (3) pointing upward and tighten jam nut. –UN–10NOV03

7. Connect start aid tube (2) to start aid nozzle (1).

T196125

8. Close left engine access door. 1—Start Aid Nozzle 2—Start Aid Tube 3—Red Paint Dot Indexing Mark 4—Start Aid Nozzle Jam Nut 5—Start Aid Nozzle O-Ring

Start Aid Nozzle

MM16633,0002507 –19–22AUG08–1/1

TM10687 (14OCT08)

05-0505-1

524K Loader 101408

PN=193

05 0505 1

Cold Weather Starting Aids

Start Aid Solenoid Remove and Install 1. Open left cooling package access door. Remove start aid components (1—6). IMPORTANT: When operating machine without start aid container installed, protect components from possible damage. Install start aid dust cap (6) in solenoid. 2. Install start aid components. Remove safety cap from new container (4). Turn container clockwise in start aid solenoid (2) to install. 3. Tighten mounting clamp (5). Close cooling package door.

T196126A

–UN–10NOV03

1—Electrical Connector 2—Start Aid Solenoid 3—Start Aid Mounting Bracket 4—Start Fluid Container 5—Start Fluid Container Mounting Clamp 6—Cold Weather Start Aid Solenoid Dust Cap

Cold Weather Start Aid

05 0505 2

MM16633,0002508 –19–22AUG08–1/1

TM10687 (14OCT08)

05-0505-2

524K Loader 101408

PN=194

Cold Weather Starting Aids

Engine Coolant Heater Remove and Install

–UN–01NOV88

CAUTION: Prevent injury from pressurized coolant. Explosive release of fluids from cooling system can cause serious burns.

T6642EK

Shut off engine. Remove filler cap when cool to touch. Slowly loosen filler cap to relieve the pressure, then remove. 1. Drain cooling system into appropriate container for storage or disposal. See Drain Cooling System. (Operator’s Manual.)

Coolant May Be Hot

2. Remove power cord (1). Loosen nut (2) and remove heater element (6) from block.

6 CAUTION: Prevent injury, keep electrical connectors clean to prevent arcing. Only plug coolant heater into electrical power if heater element is immersed in coolant. Sheath could burst and result in personal injury.

Use a heavy-duty grounded cord to connect coolant heater to electrical power.

–UN–09JAN08

3. Disassemble parts (3—6).

TX1028458

NOTE: The heater element (7) cannot be repaired. Replace if defective. 4. Inspect and replace parts as necessary. 5. Assemble parts (3—6). Install heater into cylinder block with element pointing to the rear of engine.

1—Power Cord 2—Nut 3—Adapter 4—O-Ring 5—Gasket 6—Heater Element

6. Turn element clockwise and then counterclockwise until element contacts casting. Move element midway between contact points. 7. Hold assembly, using a wrench. Tighten nut (2) to specification. Specification Engine Coolant Heater Nut— Torque ............................................................................................ 34 N•m 25 lb-ft

Continued on next page

TM10687 (14OCT08)

05-0505-3

MH66O88,0000709 –19–11AUG08–1/2

524K Loader 101408

PN=195

05 0505 3

Cold Weather Starting Aids 8. Install power cord (1). 9. Fill cooling system. See Fill and Deaerate Cooling System. (Operator’s Manual.) MH66O88,0000709 –19–11AUG08–2/2

05 0505 4

TM10687 (14OCT08)

05-0505-4

524K Loader 101408

PN=196

Group 0510

Cooling System Intercooler Remove and Install 1. Park machine, shut off engine, and lower attachment to the ground. 2. Remove intercooler access door.

WS68074,0001BFB –19–22AUG08–1/2

CAUTION: Prevent burning injury from hot intercooler. Allow intercooler and its components to cool before removing. 3. Remove handrail (2). 4. Remove upper intercooler tube (3) from intake manifold and intercooler (1).

–UN–11AUG08

5. Remove lower intercooler tube (4) from turbocharger and intercooler (1). Close all openings using caps and plugs. 6. Remove intercooler (1).

TX1046760A

7. Install intercooler. 8. Install lower intercooler tube to turbocharger and intercooler. 9. Install upper intercooler tube to intake manifold and intercooler. 10. Install handrail.

1—Intercooler 2—Handrail 3—Upper Intercooler Tube 4—Lower Intercooler Tube

WS68074,0001BFB –19–22AUG08–2/2

TM10687 (14OCT08)

05-0510-1

524K Loader 101408

PN=197

05 0510 1

Cooling System

Radiator Remove and Install 1. Park machine and lower bucket to ground. Allow engine to cool. 2. Turn battery disconnect switch to the OFF position.

WS68074,0001BFC –19–22AUG08–1/5

CAUTION: Prevent crushing injury from heavy component. Use appropriate lifting device when lifting component. 3. Remove cooling package access doors (1).

TX1021341A

–UN–12APR07

1—Cooling Package Access Door (3 used)

05 0510 2

Continued on next page

TM10687 (14OCT08)

05-0510-2

WS68074,0001BFC –19–22AUG08–2/5

524K Loader 101408

PN=198

Cooling System

CAUTION: Prevent injury from pressurized coolant. Explosive release of fluids from cooling system can cause serious burns.

–UN–23AUG88

Shut off engine. Remove filler cap when cool to touch. Slowly loosen filler cap to relieve the pressure, then remove.

TS281

4. Remove access panel (2), drain engine coolant, and dispose of waste properly. See Drain Cooling System. (Operator’s Manual.) Specification Engine Coolant—Capacity (approximate)....................................................................................... 30 L 8 gal.

TX1028509A

–UN–28AUG07

TX1028508A

–UN–28AUG07

2—Access Panel 3—Radiator Drain

Continued on next page

TM10687 (14OCT08)

05-0510-3

WS68074,0001BFC –19–22AUG08–3/5

524K Loader 101408

PN=199

05 0510 3

Cooling System 5. Remove coolant surge tank (4) and hoses. 6. Disconnect upper and lower radiator hoses from radiator.

–UN–28AUG07

CAUTION: Prevent crushing injury from heavy component. Use appropriate lifting device when lifting component.

TX1028515A

7. Remove cap screws from the cooling package frame and remove radiator. Specification Radiator—Weight (approximate) ....................................................... 34 kg 75 lb.

4—Surge Tank

8. Repair or replace as necessary. 9. Install radiator into cooling package plenum. 10. Install cap screws. Close radiator drain valve (if open). 11. Connect upper and lower radiator hoses. 12. Install surge tank and hoses. 05 0510 4

WS68074,0001BFC –19–22AUG08–4/5

13. Install cooling package access doors (1). IMPORTANT: Avoid machine damage. Do not use cooling system sealing additives or antifreeze that contains sealing additives. –UN–12APR07

Do not mix ethylene glycol and propylene glycol base coolants.

TX1021341A

14. Fill cooling system. See Fill and Deaerate Cooling System. (Operator’s Manual.) 15. Turn battery disconnect switch to the ON position. 1—Cooling Package Access Door (3 used)

WS68074,0001BFC –19–22AUG08–5/5

TM10687 (14OCT08)

05-0510-4

524K Loader 101408

PN=200

Cooling System

Hydraulic Oil Cooler Remove and Install CAUTION: Escaping fluid under pressure can penetrate the skin causing serious injury. –UN–23AUG88

Avoid the hazard by relieving pressure before disconnecting hydraulic or other lines. Tighten all connections before applying pressure.

X9811

Search for leaks with a piece of cardboard. Protect hands and body from high-pressure fluids.

Escaping Fluid Under Pressure

05 0510 5

Continued on next page

TM10687 (14OCT08)

05-0510-5

SW03989,0000459 –19–07AUG08–1/2

524K Loader 101408

PN=201

Cooling System 2. Remove access panels (1). 3. Remove radiator. See Radiator Remove and Install. (Group 0510.) 4. Remove intercooler tubes (2). 5. Apply vacuum to hydraulic oil reservoir. NOTE: For assembly purposes, tag hydraulic lines before disconnecting.

7. Remove hydraulic oil cooler (3).

TX1046230

–UN–29JUL08

6. Tag and disconnect hydraulic lines at the hydraulic oil cooler. Close all openings using caps and plugs.

8. Repair or replace as necessary. 9. Install hydraulic oil cooler. Hydraulic Oil Cooler Removal

10. Connect hydraulic lines.

1—Access Panel (3 used) 2—Intercooler Tube (2 used) 3—Hydraulic Oil Cooler

11. Release vacuum from hydraulic oil reservoir. 12. Install intercooler tubes. 05 0510 6

13. Install radiator. See Radiator Remove and Install. (Group 0510.) 14. Install access panels. 15. Check all fluid levels. See Check Hydraulic Oil Level. (Operator’s Manual.)

SW03989,0000459 –19–07AUG08–2/2

TM10687 (14OCT08)

05-0510-6

524K Loader 101408

PN=202

Cooling System

Transmission Oil Cooler Remove and Install

1. Remove cooling package access doors and hand rails (1). NOTE: For assembly purposes, identify transmission oil cooler lines before disconnecting.

2. Identify and disconnect transmission oil cooler lines at the transmission oil cooler (2). Close all openings using caps and plugs. –UN–28AUG07

3. Remove transmission oil cooler cap screws. 4. Remove transmission oil cooler (2).

TX1028584

5. Repair or replace as necessary. 6. Install transmission oil cooler. 7. Install transmission oil cooler cap screws. 8. Connect transmission oil cooler lines to transmission oil cooler.

1—Hand Rails 2—Transmission Oil Cooler

9. Install cooling package access doors and hand rails. 05 0510 7

10. Check transmission oil level. See Check Transmission Oil Level. (Operator’s Manual.)

MM61211,0001C52 –19–06AUG08–1/1

TM10687 (14OCT08)

05-0510-7

524K Loader 101408

PN=203

Cooling System

Axle Oil Coolers Disassemble and Assemble—If Equipped

14 11

4 –UN–19MAR07

TX1020660

TX1020660 05 0510 8

Axle Oil Cooler—Exploded View 1—Front Axle Test Port 2—Tee Fitting (2 used) 3—Hydraulic Hose 4—Hydraulic Hose

5—Cap Screw (4 used) 6—Washer (4 used) 7—Top Bracket 8—Cooler

9—Hydraulic Hose 10—Hydraulic Hose 11—Rear Axle Test Port

NOTE: For removal and installation of axle coolers, See Cooling Package Plenum Remove and Install. (Group 0510.)

12— Lower Bracket 13—O-Ring (2 used) 14—O-Ring (2 used)

2. Repair or replace parts as necessary. 3. Assemble parts (1—14) as shown.

1. Disassemble parts (1—14) as shown.

MM16633,0002501 –19–11AUG08–1/1

TM10687 (14OCT08)

05-0510-8

524K Loader 101408

PN=204

Cooling System

Cooling Package Plenum Remove and Install

X9811

–UN–23AUG88

CAUTION: Escaping fluid under pressure can penetrate the skin causing serious injury. Avoid the hazard by relieving pressure before disconnecting hydraulic or other lines. Tighten all connections before applying pressure. Search for leaks with a piece of cardboard. Protect hands and body from high-pressure fluids. If an accident occurs, see a doctor immediately. Any fluid injected into the skin must be surgically removed within a few hours or gangrene may result. Doctors unfamiliar with this type of injury should reference a knowledgeable medical source. Such information is available from Deere & Company Medical Department in Moline, Illinois, U.S.A. 1. Park machine and lower attachment to ground. Allow engine to cool. 2. Turn battery disconnect switch to the OFF position. CAUTION: Prevent injury from pressurized coolant. Explosive release of fluids from cooling system can cause serious burns.

05 0510 9

Shut off engine. Remove filler cap when cool to touch. Slowly loosen filler cap to relieve the pressure, then remove. 3. Release any pressure from radiator surge tank.

Continued on next page

TM10687 (14OCT08)

05-0510-9

SW03989,000045A –19–11AUG08–1/5

524K Loader 101408

PN=205

Cooling System

CAUTION: Prevent crushing injury from heavy component. Use appropriate lifting device when lifting component. 4. Remove cooling package access doors (1). Specification Access Door—Weight (approximate)..................................................................................... 31 kg 68 lb

–UN–20MAR08

5. Remove inspection panels between engine and radiator.

TX1037488

6. Disconnect wire harness (2) to the cooling package plenum. 7. Remove rear cover plate (3). NOTE: For assembly purposes, identify all lines before removing. 1—Cooling Package Access Door (3 used) 2—Wire Harness 3—Rear Cover Plate 4—Intercooler Tube (2 used)

8. Discharge refrigerant from the air conditioning system. See R134a System Evacuate. (Group 1830.)

05 0510 10

9. Disconnect air conditioning lines at condenser. Close all openings with caps and plugs. 10. Remove intercooler tubes (4). 11. Drain engine coolant. See Drain Cooling System. (Operator’s Manual.) 12. Remove upper and lower radiator hoses. 13. Apply vacuum to hydraulic reservoir. NOTE: For assembly purposes, identify all lines before removing. 14. Disconnect hydraulic lines from fan and fan control valve. Close all openings with caps and plugs. 15. Remove upper and lower hydraulic oil cooler lines.

Continued on next page

TM10687 (14OCT08)

05-0510-10

SW03989,000045A –19–11AUG08–2/5

524K Loader 101408

PN=206

Cooling System 16. Install JT01748 Lifting Brackets (5) into hood support holes.

CAUTION: Prevent crushing injury from heavy component. Use appropriate lifting device when lifting component. 17. Support cooling package plenum (6) with appropriate lifting device.

–UN–29AUG07

Specification Cooling Package Plenum Assembly—Weight (approximate) ................................................... 305 kg 669 lb

TX1028640

18. Remove cooling package plenum retaining cap screws. NOTE: Guide cooling package hydraulic lines through the grommet when removing plenum package. 19. Remove cooling package plenum.

5—Lifting Bracket (2 used) 6—Cooling System Plenum

TX1028619

–UN–29AUG07

05 0510 11

Continued on next page

TM10687 (14OCT08)

05-0510-11

SW03989,000045A –19–11AUG08–3/5

524K Loader 101408

PN=207

Cooling System 20. Repair or replace parts as necessary. CAUTION: Prevent crushing injury from heavy component. Use appropriate lifting device when lifting component. 21. Use appropriate lifting device and lift cooling package plenum into place. Guide the cooling package hydraulic lines through the rubber grommet of cooling package plenum.

–UN–29AUG07

22. Install cap screws, securing the cooling package plenum to the machine frame. 23. Remove JT01748 Lifting Brackets.

TX1028641

24. Connect hydraulic lines to the fan and fan control valve. 25. Install intercooler tube from engine to intercooler. 6—Cooling System Plenum 7—Transmission Cooler 8—Radiator 9—Hydraulic Oil Cooler 10—Intercooler

26. Install upper and lower radiator hoses to radiator. 27. Connect transmission cooler lines to transmission oil cooler. 05 0510 12

28. Connect hydraulic cooler lines to hydraulic oil cooler. 29. Remove vacuum from hydraulic reservoir. 30. Connect wire harness cooling package plenum. 31. Install inspection panels between engine and radiator. NOTE: When reconnecting system using R134a refrigerant, be sure to apply a thin coat of PAG (Polyakyleneglycol refrigerant oil) to the fittings and O-rings. 32. Install air conditioning lines at condenser using new o-rings. 33. Fill cooling system. See Fill and Deaerate Cooling System. (Operator’s Manual.) 34. Check and fill fluids. See Check Hydraulic Oil Level and see Check Transmission Oil Level. (Operator’s Manual.)

Continued on next page

TM10687 (14OCT08)

05-0510-12

SW03989,000045A –19–11AUG08–4/5

524K Loader 101408

PN=208

Cooling System 35. Charge air conditioning system. See R134a System Charge. (Group 1830.) 36. Install cooling package access doors. 37. Turn battery disconnect switch to the ON position.

SW03989,000045A –19–11AUG08–5/5

05 0510 13

TM10687 (14OCT08)

05-0510-13

524K Loader 101408

PN=209

Cooling System

05 0510 14

TM10687 (14OCT08)

05-0510-14

524K Loader 101408

PN=210

Group 0520

Intake System Air Cleaner Remove and Install

TX1040331

–UN–14APR08

05 0520 1

1—Lock Nut (4 used) 2—Cap Screw (4 used) 3—Washer (4 used) 4—Hose Clamp 5—Band Clamp (2 used)

6—Primary Filter Element 7—Secondary Filter Element 8—Housing 9—Dust Valve 10—Housing Cover

11—Hose Clamp 12—Tie Band 13— Hose Clamp 14—Air Filter Restriction Switch

15—Air Intake Hose 16—Turbocharger Hose 17—Elbow Fitting

1. Turn battery disconnect switch to the OFF position.

Continued on next page

TM10687 (14OCT08)

05-0520-1

TW73308,000022C –19–07AUG08–1/2

524K Loader 101408

PN=211

Intake System 2. Disconnect wiring harness connector from air filter restriction switch (14).

7. Install housing cover. 8. Install housing assembly.

3. Loosen hose clamp (11) on turbocharger hose (16) and separate turbocharger hose from housing (8). 4. Remove cap screws (2), lock nuts (1), and washers (3) from band clamps (5).

9. Connect turbocharger hose to housing and tighten hose clamp. 10. Connect wiring harness connector to air filter restriction switch.

5. Remove housing assembly. 11. Turn battery disconnect switch to the ON position. 6. Remove housing cover (10) and inspect for wear or damage. See Inspect Air Cleaner Elements. (Group 0520.)

TW73308,000022C –19–07AUG08–2/2

05 0520 2

TM10687 (14OCT08)

05-0520-2

524K Loader 101408

PN=212

Intake System

Precleaner Remove and Install—If Equipped

TX1040336

–UN–14APR08

05 0520 3

1—Precleaner 2—Clamp

3—Inlet Tube

4—Cap Screw (4 used)

5—Mounting Plate

1. Turn battery disconnect switch to the OFF position.

4. Remove inlet tube (3) with precleaner (1) attached.

2. Remove cap screws (4).

5. Repair or replace parts as necessary.

3. Remove mounting plate (5). Continued on next page

TM10687 (14OCT08)

05-0520-3

TW73308,000022D –19–11AUG08–1/2

524K Loader 101408

PN=213

Intake System 6. Slide mounting plate over inlet of air cleaner, flat side up.

8. Attach inlet tube using mounting plate and cap screws.

7. Install inlet tube with precleaner.

9. Turn battery disconnect switch to the ON position. TW73308,000022D –19–11AUG08–2/2

05 0520 4

TM10687 (14OCT08)

05-0520-4

524K Loader 101408

PN=214

Group 0530

External Exhaust System Muffler Remove and Install 1

CAUTION: Prevent injury from hot muffler. Allow muffler and its components to cool before removing.

1. Turn battery disconnect switch to the OFF position. 3

2. Remove hood. See Hood Remove and Install. (Group 1910.)

–UN–08AUG08

3. Remove muffler to turbocharger clamp (3). 4. Remove U-bolt (1) and lock nuts (4).

TX1046661

5. Remove muffler (2). 4

6. Inspect and replace parts if necessary. 7. Install muffler (2), U-bolt (1), and lock nuts (4). Do not tighten lock nuts at this time. 8. Install muffler-to-turbocharger clamp (3) and tighten.

1—U-Bolt 2—Muffler 3—Muffler-to-Turbocharger Clamp 4—Lock Nut (2 used)

9. Tighten lock nuts to specification. Specification Lock Nut—Torque .......................................................................... 34 N•m 25 lb-ft

05 0530 1

10. Install hood. See Hood Remove and Install. (Group 1910.) 11. Turn battery disconnect switch to the ON position.

TW73308,0000237 –19–22AUG08–1/1

TM10687 (14OCT08)

05-0530-1

524K Loader 101408

PN=215

External Exhaust System

05 0530 2

TM10687 (14OCT08)

05-0530-2

524K Loader 101408

PN=216

Group 0560

External Fuel Supply Systems Fuel Tank Remove and Install 1. Turn battery disconnect switch to the OFF position. 2. Remove counterweights. See Counterweights Remove and Install. (Group 1749.)

Continued on next page

MH66O88,00008EA –19–22AUG08–1/4

05 0560 1

TM10687 (14OCT08)

05-0560-1

524K Loader 101408

PN=217

External Fuel Supply Systems

2 3

1 7

5 6 4

6 8

20 9

10 10

12 13

15 16 17

TX1046662

Continued on next page

TM10687 (14OCT08)

–UN–08AUG08

TX1046662

05 0560 2

05-0560-2

MH66O88,00008EA –19–22AUG08–2/4

524K Loader 101408

PN=218

External Fuel Supply Systems 1—O-Ring 2—Cap Screw (6 used) 3—Washer (6 used) 4—Gasket 5—Breather 6—Clamp

7—Fuel Return Hose 8—Breather Tube 9—Fitting 10—Clamp (2 used) 11—Fuel Return Hose (in tank) 12—Filler Cap

3. Identify and disconnect hose (7) and breather tube (8) from tank. 4. Identify and disconnect fuel line (22) from primary fuel filter.

13—Gasket 14—Funnel 15—O-Ring 16—Chain Link 17—Fuel Tank

18—Check Valve 19—Fuel Return Hose (in tank) 20—Fitting 21—In-Line Fuel Filter 22—Fuel Supply Line

5. Drain or pump fuel into an appropriate container for reuse. See Drain and Refill Capacities. (Operator’s Manual) 6. Disconnect wiring harness from fuel sender.

NOTE: Remove fuel to reduce weight of fuel tank.

Continued on next page

MH66O88,00008EA –19–22AUG08–3/4

05 0560 3

TM10687 (14OCT08)

05-0560-3

524K Loader 101408

PN=219

External Fuel Supply Systems

–UN–08AUG08

CAUTION: Prevent crushing injury from heavy component. Use appropriate lifting device when lifting component. 7. Position appropriate lifting device (24) beneath fuel tank guard (23).

Specification Empty Fuel Tank with Guard— Weight (approximate) ...................................................................... 306 kg 675 lb Full Fuel Tank with Guard— Weight (approximate) ...................................................................... 666 kg 1465 lb

TX1046663A

8. Remove mounting cap screws to fuel tank guard and lower guard with fuel tank to ground.

23—Fuel Tank Guard 24—Lifting Device

9. Remove retaining straps to fuel tank and separate fuel tank from guard. 10. Replace parts as necessary. 11. Install fuel tank to guard. Install retaining straps to fuel tank.

05 0560 4

CAUTION: Prevent crushing injury from heavy component. Use appropriate lifting device when lifting component. 12. Raise guard and fuel tank into place. Install mounting cap screws and tighten to specification. Specification Mounting Cap Screw—Torque ..................................................... 318 N•m 235 lb-ft

13. Connect wiring harness to fuel sender. 14. Install breather tube (8). 15. Connect hoses (7 and 11) to fuel tank. 16. Install counterweights. See Counterweights Remove and Install. (Group 1749.) 17. Turn battery disconnect switch to the ON position.

MH66O88,00008EA –19–22AUG08–4/4

TM10687 (14OCT08)

05-0560-4

524K Loader 101408

PN=220

External Fuel Supply Systems

Primary Fuel Filter (Water Separator) Remove and Install 1. Open left-side engine access door to access primary fuel filter (6).

–UN–26MAR07

2. Place container under drain valve (5) and drain primary filter. NOTE: Lift retaining ring as it is rotated.

1—Bleed Screw (primary filter) 2—Bleed Screw (final filter) 3—Final Fuel Filter 4—Drain Valve (final filter) 5—Drain Valve (primary filter) 6—Primary Fuel Filter (water separator)

TX1021050A

3. Rotate retaining ring counterclockwise 1/4 turn around primary filter element. Fuel Filter Location

MH66O88,000071C –19–15JAN08–1/2

4. Remove fuel inlet fitting (7) and fuel drain plug (9). 5. Flush any debris from filter base (8). –UN–01OCT07

6. Install fuel inlet drain plug and fuel inlet fitting. 7. Install filter element to fuel filter base.

TX1030045A

8. Close left-side engine access door. 9. Dispose of waste properly. Fuel Filter Base Identification

7—Fuel Inlet Fitting 8—Filter Base 9—Fuel Drain Plug

MH66O88,000071C –19–15JAN08–2/2

TM10687 (14OCT08)

05-0560-5

524K Loader 101408

PN=221

05 0560 5

External Fuel Supply Systems

05 0560 6

TM10687 (14OCT08)

05-0560-6

524K Loader 101408

PN=222

Section 07

Dampener Drive Contents Page

Group 0752—Elements Output Dampener Remove and Install. . . . . .07-0752-1

TM10687 (14OCT08)

07-1

524K Loader 101408

PN=1

Contents

TM10687 (14OCT08)

07-2

524K Loader 101408

PN=2

Group 0752

Elements Output Dampener Remove and Install

–UN–10SEP07

1. Remove engine. See Engine Remove and Install. (Group 0400.) 2. Remove covers (1) and output dampener (2).

TX1029203

3. Inspect and replace as necessary. 4. Install output dampener. Tighten cap crews to specification. Specification Dampener-to-Flywheel Cap Screw—Torque ............................................................................... 68 N•m 50 lb-ft

Output Dampener 1—Cover (2 used) 2—Output Dampener

5. Install covers. Tighten securely. 6. Install engine. See Engine Remove and Install. (Group 0400.)

MH66O88,0000703 –19–27NOV07–1/1

07 0752 1

TM10687 (14OCT08)

07-0752-1

524K Loader 101408

PN=225

Elements

07 0752 2

TM10687 (14OCT08)

07-0752-2

524K Loader 101408

PN=226

Section 09

Steering System Contents Page

Group 0960—Hydraulic System NeverGrease Pin Joints . . . . . . . . . . . . . . .09-0960-1 Orbital Steering Valve Remove and Install. . . . . . . . . . . . . . . . . . . . . . . . . . . . .09-0960-4 Steering Column Remove and Install . . . . . .09-0960-7 Steering Column Disassemble and Assemble. . . . . . . . . . . . . . . . . . . . . . . . . .09-0960-8 Steering Cylinders Remove and Install . . . . .09-0960-9 Steering Cylinder Bushings Remove and Install. . . . . . . . . . . . . . . . . . . . . . . . . . . .09-0960-12 Secondary Steering Pump Remove and Install—If Equipped . . . . . . . . . . . . . . . . .09-0960-13 Secondary Steering Valve Remove and Install—If Equipped . . . . . . . . . . . . . . . . .09-0960-16 Loader Start-Up Procedure (Steering Cylinder) . . . . . . . . . . . . . . . . . . . . . . . . .09-0960-18

TM10687 (14OCT08)

09-1

524K Loader 101408

PN=1

Contents

TM10687 (14OCT08)

09-2

524K Loader 101408

PN=2

Group 0960

Hydraulic System NeverGrease Pin Joints NOTE: Machines equipped with NeverGrease Pin Joints do not require lubrication. Machines with this option still require some service maintenance points for grease in specified areas. These are listed on the periodic maintenance chart on the machine and in the operator’s manual listed under service intervals. IMPORTANT: Replacement of NeverGrease pin joints require special methods for replacement of bushings and shims. If not followed the service life may be decreased. NeverGrease pin joints consist of two types. They are a bushing (sliding element) type or a bearing (rolling element or roller bearing) type. The application determines what type is used. Both types require the same replacement methods. Throughout this information the term “bushing” will be used to simplify procedures, with the exception when a special instruction is needed for a certain type bushing such as “bearing type” it will be called out specifically. Cleanliness Cleanliness is very critical. The bushing must be kept clean at all times. Nothing should come in contract with the bushing surfaces which can contaminate or

damage the surfaces. If replacing with new service bushing keep in clean shipping containers until installation. No lubrication should be used on any surfaces of the bore, pin or bushing itself when installing. No lubrication should be used on any components of joint including pin when servicing. This may decrease life of joint. Removal and Replacement of Pins IMPORTANT: Removal and reinstallation of any pin requires extra cleanliness attention to the area supported by the pin. Any debris inside of the joint will severely affect the life of the joint. Prior to pin removal, all material must be completely removed from both ends of the pin and from the area surrounding the structures connected by the pin by means of a thorough power wash. Prior to pin reinstallation, any remaining material on the pin or surrounding structure must be removed. The NeverGrease bushing must also be inspected and any material must be removed through the use of compressed air or a clean dry rag only. Any debris inside of the joint will severely affect the life of the joint.

09 0960 1 NeverGrease is a trademark of Deere & Company

TM10687 (14OCT08)

Continued on next page

09-0960-1

TX04577,0000150 –19–10JAN08–1/3

524K Loader 101408

PN=229

Hydraulic System Removal and Replacement of Bushings

1 2

IMPORTANT: Only use a hydraulic puller for removal and installing bushing . Never use slide hammer or impact type puller.

–UN–03APR07

TX1020245

Shimming is required where specified. Some joints are more critical and will be specified when required. Alignment in the joint is important to prevent premature wear. Installing Bushing

1. Remove the old bushing from bore with Hydraulic Puller Set D01047AA or Hydraulic Press D01013AA for larger bushings.

3. Check to make sure bore, bushing is perfectly clean and dry. Do not apply an lubrication to any components in joint.

–UN–03APR07

2. Clean up bores thoroughly.

TX1020247

4. Measure bore I.D. for size to determine what disk (3) size will be required for installation of bushing. It must pass through the bore I.D. for proper centering in frame bore with a hydraulic puller.

7 Bushing Type Joint

IMPORTANT: No lubrication should be used on any components of joint including pin. This may decrease life of joint.

TX1020248

IMPORTANT: Must have the bushing aligned square to the bore while installing. This will 09 keep from having misalignment in bore 0960 and damage to bushing. 2

–UN–03APR07

5. Assemble Hydraulic Puller Set D01047AA and rod (4) through center of bushing and bore and attach proper size disk (3). Support tooling to not come in contact with bushing surfaces.

Bushing Type Joint with External Split Seal (optional type seals shown)

6. Make sure the bushing (2) is square to the bore. With hydraulic puller install bushing into bore or frame. Keep perfectly square and aligned to bore while installing. Center bushing in bore by pulling slightly past face of boss. Check each side to make sure bushing is centered in bore.

1—Boss 2—Bushing 3—Disk 4—Hydraulic Puller Rod 5—Shim (as required) 6—Frame 7—Clearance 8—Split Seal (as required) 9—Pin 10—Internal Bushing Seal

Continued on next page

TM10687 (14OCT08)

09-0960-2

TX04577,0000150 –19–10JAN08–2/3

524K Loader 101408

PN=230

Hydraulic System 7. Make sure pin (9) and bore are clean. 8. Align frame with bore. 9. Using different size shims (5) from service, place shims at frame and boss joint for setting up proper clearance. Center boss in frame (6) by shimming evenly. Add shims as required to reduce clearance but not bind joint. Bearing type joints (roller bearing type) require a specified clearance (7), see specification. Use a smaller size shim as gauge to check final clearance between boss and frame joint when required on specified tolerances. Specification Bearing Type Joint (roller bearing)—Clearance (maximum total of both sides) ............................................................................. 1 mm .040 in

IMPORTANT: No lubrication should be used on any parts of joint including pin. This may decrease life of joint. 10. Check for alignment, cleanliness of joint and install clean pin. No interference should be felt while installing pin when proper alignment is established. If restriction or interference is noted make sure of proper alignment in joint. Also, when using the bushing type which has internal edge lip seals (10) make sure they are in the retracted position to allow for smooth pin installation. Note art work item (10). 11. Install external split seals (8) if required. Split seals that have a larger lip are installed with large O.D. lip away form bushing center. Seal must be placed tight against boss face.

09 0960 3

Split seals with O-ring configuration are placed tight against the boss face. Tighten banding screw.

TX04577,0000150 –19–10JAN08–3/3

TM10687 (14OCT08)

09-0960-3

524K Loader 101408

PN=231

Hydraulic System

Orbital Steering Valve Remove and Install CAUTION: Prevent possible injury from unexpected machine movement. Install articulation lock bar before working in frame hinge area. 1. Install frame articulation lock bar. Stop engine.

MH66O88,000070A –19–13AUG08–1/5

CAUTION: Escaping fluid under pressure can penetrate the skin causing serious injury.

–UN–23AUG88

Avoid the hazard by relieving pressure before disconnecting hydraulic or other lines. Tighten all connections before applying pressure.

X9811

3. Turn battery disconnect switch to the OFF position. 4. Drain hydraulic reservoir or apply vacuum. If draining the hydraulic reservoir. See Drain and Refill Hydraulic System Oil. (Operator’s Manual.)

Continued on next page

TM10687 (14OCT08)

09-0960-4

MH66O88,000070A –19–13AUG08–2/5

524K Loader 101408

PN=232

Hydraulic System 5. Remove front cab panel (1). 6. Remove cover from steering column.

TX1022021A

–UN–17APR07

1—Front Cab Panel

Front Cab Panel

MH66O88,000070A –19–13AUG08–3/5

NOTE: For assembly purposes, identify hydraulic steering lines and fittings before disconnecting.

–UN–31AUG07

7. Disconnect hydraulic steering lines (2). Close all openings using caps and plugs.

TX1028843A

2—Hydraulic Steering Line (5 used)

Hydraulic Steering Lines

09 0960 5 Continued on next page

TM10687 (14OCT08)

09-0960-5

MH66O88,000070A –19–13AUG08–4/5

524K Loader 101408

PN=233

Hydraulic System NOTE: Avoid dropping the orbital steering valve. Support the orbital steering valve before removing.

–UN–31AUG07

8. Support orbital steering valve and remove socket head cap screws (3) and washers (4). 9. Remove orbital steering valve.

TX1028845A

10. Repair or replace parts as necessary. 11. Install orbital steering valve. a. Install socket head cap screws and washers evenly, until finger tight.

Socket Head Cap Screws 3—Socket Head Cap Screw (4 used) 4—Washer (4 used)

b. Rotate orbital steering shaft two revolutions in both clockwise and counterclockwise directions. c. Tighten socket head cap screws to specification in a criss-cross pattern. Specification Orbital Steering Valve Socket Head Cap Screws—Torque ........................................................... 28 N•m 21 lb-ft

d. Rotate orbital steering shaft two revolutions in both clockwise and counterclockwise directions. 12. Connect hydraulic steering lines. 13. Remove vacuum or fill hydraulic reservoir. See Drain and Refill Hydraulic System Oil. (Operator’s Manual.) 14. Install cover to steering column. 09 0960 6

15. Install front cab panel. 16. Turn battery disconnect switch to the ON position. 17. Remove frame articulation lock bar.

MH66O88,000070A –19–13AUG08–5/5

TM10687 (14OCT08)

09-0960-6

524K Loader 101408

PN=234

Hydraulic System

–UN–04SEP07

Steering Column Remove and Install

TX1028869

TX1028869 Steering Column (Shown With Steering Column Covers Removed.) 1—Cap Screw (4 used)

2—Electrical Connector

1. Install frame articulation lock bar. Stop engine.

9. Install steering column.

2. Turn battery disconnect switch to the OFF position.

10. Install cap screws and tighten securely.

3. Remove steering column covers.

11. Connect electrical connector to front console harness.

4. Disconnect orbital steering valve from steering column. See Orbital Steering Valve Remove and Install. (Group 0960.)

12. Connect orbital steering valve to steering column. See Orbital Steering Valve Remove and Install. (Group 0960.)

5. Disconnect electrical connector (2) from front console harness.

13. Install steering column covers.

6. Remove cap screws (1).

14. Turn battery disconnect switch to the ON position.

7. Remove steering column and repair or replace parts as needed.

15. Remove frame articulation lock bar.

8. Apply PM37566 Silver-Grade Anti-Seize lubricant or equivalent to steering column tilt pivots.

MH66O88,000070B –19–07AUG08–1/1

TM10687 (14OCT08)

09-0960-7

524K Loader 101408

PN=235

09 0960 7

Hydraulic System

Steering Column Disassemble and Assemble 6

2 3

4 5

7 9

11 12

–UN–05SEP07

TX1028969

TX1028969 Steering Column Components 1—Cover 2—Spring Cover 3—Spring 4—Nut 5—Lock Washer

09 0960 8

6—Knob 7—Steering Wheel 8—Steering Shaft 9—Brush Set 10—Dowel Pin (2 used)

11—Spring 12—U-Joint 13—Lower Steering Shaft 14—Orbital Steering Valve Mounting Plate

15—Base Assembly 16—Column Tilt Pedal 17—Seal

1. Disassemble steering column.

4. Assemble orbital steering column.

2. Repair or replace parts as necessary.

Specification Steering Wheel-to-Steering Column Nut—Torque ............................................................... 68 N•m 50 lb-ft

3. Apply PM37566 Silver-Grade Anti-Seize lubricant or equivalent to steering column tilt pivot points and threads on steering shaft.

MH66O88,000070C –19–07AUG08–1/1

TM10687 (14OCT08)

09-0960-8

524K Loader 101408

PN=236

Hydraulic System

Steering Cylinders Remove and Install CAUTION: Escaping fluid under pressure can penetrate the skin causing serious injury. –UN–23AUG88

Avoid the hazard by relieving pressure before disconnecting hydraulic or other lines. Tighten all connections before applying pressure.

X9811

Search for leaks with a piece of cardboard. Protect hands and body from high-pressure fluids. If an accident occurs, see a doctor immediately. Any fluid injected into the skin must be surgically removed within a few hours or gangrene may result. Doctors unfamiliar with this type of injury should reference a knowledgeable medical source. Such information is available from Deere & Company Medical Department in Moline, Illinois, U.S.A. CAUTION: Prevent possible injury from unexpected machine movement. Install articulation lock bar before working in frame hinge area. 1. Install frame articulation lock bar. Stop engine. 2. Perform Hydraulic System Pressure and Accumulators Discharge. (Group 9025-25.) 3. Turn battery disconnect switch to the OFF position. 4. Drain hydraulic reservoir or apply vacuum. If draining the hydraulic reservoir. See Drain and Refill Hydraulic System Oil. (Operator’s Manual.)

09 0960 9

Continued on next page

TM10687 (14OCT08)

09-0960-9

SW03989,00004B3 –19–20AUG08–1/3

524K Loader 101408

PN=237

Hydraulic System NOTE: For assembly purposes, identify each hydraulic line and fitting before disconnecting. 5. Disconnect hydraulic lines from cylinder. Close all openings with caps or plugs.

TX1022056A

–UN–16APR07

IMPORTANT: NeverGrease Pin Joints have servicing requirements to follow to maintain a long life. Shimming is required in some applications. Some joints are more critical and will be specified when required. Alignment in the joint is critical to prevent premature wear. Cleanliness is also necessary for all joint components. Clean and burr free pins must be used when replacing. See NeverGrease Pin Joints. (Group 3140.)

Steering Cylinder 1—Steering Cylinder 2—Head End Pin 3—Rod End Pin

6. Remove pins from rod end (3) and head end (2) of cylinder. CAUTION: Prevent possible injury from crushing. Heavy component; use appropriate lifting device. 7. Remove cylinder from machine. Specification Steering Cylinder—Weight (approximate)..................................................................................... 50 kg 100 lb

8. Repair or replace parts as necessary. See Disassemble Cylinder. (TM-H120A.) See Assemble Cylinder. (TM-H120A.) 9. Install cylinder head end first in frame. Use shims equally on both sides of the head end to center 09 cylinder in frame. Install shims as required to remove 0960 gap but not bind cylinder. 10 10. Install clean pin with NO lubrication. No lubrication should be used on any of the joint components. For more information see NeverGrease Pin Joints. (Group 3140.)

NeverGrease is a trademark of Deere & Company

TM10687 (14OCT08)

Continued on next page

09-0960-10

SW03989,00004B3 –19–20AUG08–2/3

524K Loader 101408

PN=238

Hydraulic System 11. Install rod end of cylinder. Fill gap on both sides of rod end as required to remove gap but not bind cylinder. 12. Install clean pin with NO lubrication. No lubrication should be used on any of the joint components. IMPORTANT: Pre-fill cylinders prior to connecting hydraulic lines. 13. Connect lines. 14. Check hydraulic oil level or fill if system was drained. See Check Hydraulic Oil Level or see Drain and Refill Hydraulic System Oil 15. Turn battery disconnect switch to the ON position. IMPORTANT: When a machine is started for the first time after cylinder rebuild or oil is drained from cylinder, the loader start-up procedure must be performed to prevent oil from “dieseling” inside the cylinder. 16. Remove frame articulation lock bar and perform loader start-up procedure for steering cylinders. Perform Loader Start-Up Procedure (Steering Cylinder). (Group 0960.)

SW03989,00004B3 –19–20AUG08–3/3

09 0960 11

TM10687 (14OCT08)

09-0960-11

524K Loader 101408

PN=239

Hydraulic System

Steering Cylinder Bushings Remove and Install IMPORTANT: Only use a hydraulic puller for removal and installing NeverGrease Pin Joint type bushings. Never use slide hammer or impact type puller. Shimming is required where specified. Some joints are more critical and will be specified when required. Alignment in the joint is important to prevent premature wear. Remove and install bushings in steering cylinder using Hydraulic Puller Set D01047AA. See NeverGrease Pin Joints. (Group 3140.)

NeverGrease is a trademark of Deere & Company

SW03989,00004B4 –19–19MAR08–1/1

09 0960 12

TM10687 (14OCT08)

09-0960-12

524K Loader 101408

PN=240

Hydraulic System

Secondary Steering Pump Remove and Install—If Equipped

3 2

TX1035011

–UN–16JAN08

TX1035011 Secondary Steering Pump 1—Hydraulic Lines

2—Cap Screw (4 used)

3—Wiring Harness

CAUTION: Prevent possible injury from unexpected machine movement. Install articulation lock bar before working in frame hinge area.

4—Secondary Steering Pump

1. Install articulation lock bar. Stop engine.

09 0960 13 Continued on next page

TM10687 (14OCT08)

09-0960-13

MH66O88,00008F5 –19–23SEP08–1/3

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PN=241

Hydraulic System

CAUTION: Escaping fluid under pressure can penetrate the skin causing serious injury.

–UN–23AUG88

Avoid the hazard by relieving pressure before disconnecting hydraulic or other lines. Tighten all connections before applying pressure.

X9811

Search for leaks with a piece of cardboard. Protect hands and body from high-pressure fluids. If an accident occurs, see a doctor immediately. Any fluid injected into the skin must be surgically removed within a few hours or gangrene may result. Doctors unfamiliar with this type of injury should reference a knowledgeable medical source. Such information is available from Deere & Company Medical Department in Moline, Illinois, U.S.A. 2. Perform Hydraulic System Pressure and Accumulators Discharge. (Group 9025-25.) 3. Turn battery disconnect switch to the OFF position. 4. Drain hydraulic reservoir or apply vacuum. If draining the hydraulic reservoir, See Drain and Refill Capacities. (Operator’s Manual.) NOTE: For assembly purposes, identify hydraulic lines and fittings before disconnecting. 5. Disconnect hydraulic lines (1) from secondary steering pump (4). Close all openings using caps and plugs. NOTE: For assembly purposes, identify all wiring harness connections before disconnecting. 09 0960 14

6. Disconnect wiring harness (3). 7. Remove pump retaining cap screws (2). 8. Repair or replace parts as necessary. 9. Install pump and pump retaining cap screws and tighten securely.

Continued on next page

TM10687 (14OCT08)

09-0960-14

MH66O88,00008F5 –19–23SEP08–2/3

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PN=242

Hydraulic System 10. Install wiring harness. 11. Connect hydraulic lines. 12. Remove vacuum and check hydraulic oil level. Fill hydraulic oil reservoir if drained.See Drain and Refill Capacities. (Operator’s Manual.) 13. Turn battery disconnect switch to the ON position. 14. Remove frame articulation lock bar.

MH66O88,00008F5 –19–23SEP08–3/3

09 0960 15

TM10687 (14OCT08)

09-0960-15

524K Loader 101408

PN=243

Hydraulic System

Secondary Steering Valve Remove and Install—If Equipped

TX1035012

–UN–16JAN08

TX1035012 Secondary Steering Valve 1—Hydraulic Lines (4 used)

2—Cap Screw (4 used)

CAUTION: Prevent possible injury from unexpected machine movement. Install articulation lock bar before working in frame hinge area.

3—Secondary Steering Valve

1. Install frame articulation lock bar. Stop engine.

09 0960 16 Continued on next page

TM10687 (14OCT08)

09-0960-16

MH66O88,00008F6 –19–11AUG08–1/3

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PN=244

Hydraulic System

CAUTION: Escaping fluid under pressure can penetrate the skin causing serious injury.

–UN–23AUG88

Avoid the hazard by relieving pressure before disconnecting hydraulic or other lines. Tighten all connections before applying pressure.

X9811

Search for leaks with a piece of cardboard. Protect hands and body from high-pressure fluids. If an accident occurs, see a doctor immediately. Any fluid injected into the skin must be surgically removed within a few hours or gangrene may result. Doctors unfamiliar with this type of injury should reference a knowledgeable medical source. Such information is available from Deere & Company Medical Department in Moline, Illinois, U.S.A. 2. Perform Hydraulic System Pressure and Accumulators Discharge. (Group 9025-25.) 3. Turn battery disconnect switch to the OFF position. 4. Drain hydraulic reservoir or apply vacuum. If draining the hydraulic reservoir, see Drain and Refill Hydraulic System Oil. (Operator’s Manual.) 5. Disconnect hydraulic lines (1) from secondary steering valve (3). Close all openings using caps and plugs. 6. Remove secondary steering valve retaining cap screws (2) to remove valve. 7. Repair or replace parts as necessary. 8. Install secondary steering valve and tighten retaining cap screws securely.

09 0960 17

9. Connect hydraulic lines to secondary steering valve. 10. Remove vacuum or fill hydraulic reservoir. See Check Hydraulic Oil Level or see Drain and Refill Hydraulic System Oil. (Operator’s Manual.) 11. Turn battery disconnect switch to the ON position.

Continued on next page

TM10687 (14OCT08)

09-0960-17

MH66O88,00008F6 –19–11AUG08–2/3

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PN=245

Hydraulic System 12. Remove frame articulation lock bar.

MH66O88,00008F6 –19–11AUG08–3/3

Loader Start-Up Procedure (Steering Cylinder) IMPORTANT: Avoid possible machine damage, perform procedure with engine at low idle (no acceleration). 1. Slowly articulate the loader 3/4 turn to the right and then 3/4 turn to the left. Do not make contact at loader frame stops. 2. Repeat previous step four times. 3. Articulate the loader fully to the right and then fully to the left. Repeat four times.

SW03989,00004B5 –19–19MAR08–1/1

09 0960 18

TM10687 (14OCT08)

09-0960-18

524K Loader 101408

PN=246

Section 10

Service Brakes Contents Page

Group 1011—Active Elements Service Brake Assembly Remove and Install. . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-1011-1 Service Brake Pedal and Linkage Disassemble and Assemble. . . . . . . . . . . .10-1011-2 Group 1060—Hydraulic System Service Brake Valve Remove and Install. . . .10-1060-1 Service Brake Accumulator Remove and Install. . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-1060-2

TM10687 (14OCT08)

10-1

524K Loader 101408

PN=1

Contents

TM10687 (14OCT08)

10-2

524K Loader 101408

PN=2

Group 1011

Active Elements

TX1028832

–UN–01OCT07

Service Brake Assembly Remove and Install

Service Brakes 1—Backing Plate 2—Dowel Pin (2 used)

3—Brake Disk 4—Piston

5—OD Seal Ring

6—ID Seal Ring

10 1011 1

For information on brake assembly, see Disassemble and Assemble Brakes. (CTM442.)

SW03989,00004B8 –19–19MAR08–1/1

TM10687 (14OCT08)

10-1011-1

524K Loader 101408

PN=249

Active Elements

Service Brake Pedal and Linkage Disassemble and Assemble

1 23

20 19

17 11

–UN–14OCT08

TX1049990

TX1049990 Service Brake Pedal and Linkage

10 1011 2

1—Cap Screw (6 used) 2—washer (2 used) 3—Cap Screw (2 used) 4—Shaft 5—Right Pedal 6—O-Ring

7—Check Valve (2 used) 8—O-Ring 9—Boot 10—Seal 11—Brake Valve 12—O-Ring

13—O-Ring 14—O-Ring 15—Pressure Switch 16—Tee Fitting 17—O-Ring 18—Adapter Fitting

19—O-Ring 20—Elbow Fitting 21—Nut (6 used) 22—Gasket (2 used) 23—Left Pedal

Inspect serve brake pedal and linkage. Replace as necessary.

TW73308,00003AC –19–13OCT08–1/1

TM10687 (14OCT08)

10-1011-2

524K Loader 101408

PN=250

Group 1060

Hydraulic System Service Brake Valve Remove and Install CAUTION: Escaping fluid under pressure can penetrate the skin causing serious injury. –UN–23AUG88

Avoid the hazard by relieving pressure before disconnecting hydraulic or other lines. Tighten all connections before applying pressure.

X9811

Search for leaks with a piece of cardboard. Protect hands and body from high-pressure fluids. If an accident occurs, see a doctor immediately. Any fluid injected into the skin must be surgically removed within a few hours or gangrene may result. Doctors unfamiliar with this type of injury should reference a knowledgeable medical source. Such information is available from Deere & Company Medical Department in Moline, Illinois, U.S.A. CAUTION: Prevent possible injury from unexpected machine movement. Install articulation lock bar before working in frame hinge area. 1. Install frame articulation lock bar. 2. Stop engine and relieve hydraulic pressure. Perform Hydraulic System Pressure and Accumulators Discharge. (Group 9025-25.) 3. Remove front and left-side trim panels. 4. Apply vacuum or drain hydraulic reservoir. If draining hydraulic reservoir, see Drain and refill Capacities. (Operator’s Manual.)

10 1060 1

Continued on next page

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10-1060-1

SW03989,00004B6 –19–29MAY08–1/2

524K Loader 101408

PN=251

Hydraulic System 5. Identify and disconnect hydraulic lines. Close all openings with caps and plugs. 3

6. Disconnect service brake pressure sensor (2). 7. Support the service brake valve and remove two socket head cap screws under the service brake pedal (3). 8. Remove service brake valve (1).

10. Install service brake valve and socket head cap screws. 11. Connect hydraulic lines to the service brake valve.

12. Connect service brake pressure sensor. 13. Remove vacuum or fill hydraulic reservoir. If filling hydraulic reservoir, see Drain and refill Capacities. (Operator’s Manual.)

TX1028841

–UN–31AUG07

9. Repair or replace parts as necessary.

1—Service Brake Valve 2—Service Brake Pressure Sensor 3—Service Brake Pedal

14. Remove frame articulation lock bar.

SW03989,00004B6 –19–29MAY08–2/2

Service Brake Accumulator Remove and Install

10 1060 2

CAUTION: Prevent possible injury from unexpected machine movement. Install frame articulation lock bar before working in frame hinge area. 1. Install frame articulation lock bar.

Continued on next page

TM10687 (14OCT08)

10-1060-2

SW03989,00004B7 –19–15AUG08–1/3

524K Loader 101408

PN=252

Hydraulic System

CAUTION: Escaping fluid under pressure can penetrate the skin causing serious injury.

–UN–23AUG88

Avoid the hazard by relieving pressure before disconnecting hydraulic or other lines. Tighten all connections before applying pressure.

X9811

Continued on next page

SW03989,00004B7 –19–15AUG08–2/3

10 1060 3

TM10687 (14OCT08)

10-1060-3

524K Loader 101408

PN=253

Hydraulic System 5. Tag and disconnect hydraulic lines from service brake accumulators (1). Close all openings using caps and plugs. 1 6. Disconnect electrical connectors from accumulators. 7. Remove brackets (2). 8. Remove service brake accumulators.

–UN–31AUG07

NOTE: Service brake accumulators are not serviceable. New accumulators are precharged. 9. Replace as necessary.

TX1028839

10. Install service brake accumulators and brackets. 11. Connect electrical connectors. 12. Connect hydraulic lines.

Service Brake Accumulators

13. Remove vacuum or fill hydraulic reservoir. If filling hydraulic reservoir, see Drain and Refill Capacities. (Operator’s Manual.)

1—Service Brake Accumulator (2 used) 2—Bracket (2 used)

14. Remove frame articulation lock bar.

SW03989,00004B7 –19–15AUG08–3/3

10 1060 4

TM10687 (14OCT08)

10-1060-4

524K Loader 101408

PN=254

Section 11

Park Brake Contents Page

Group 1111—Active Elements Park Brake Remove and Install . . . . . . . . . . .11-1111-1 Park Brake Disassemble and Assemble . . . .11-1111-4 Group 1160—Hydraulic System Park Brake Release Solenoid Valve Remove and Install . . . . . . . . . . . . . . . . . . . . . . . . .11-1160-1

TM10687 (14OCT08)

11-1

524K Loader 101408

PN=1

Contents

TM10687 (14OCT08)

11-2

524K Loader 101408

PN=2

Group 1111

Active Elements Park Brake Remove and Install CAUTION: Escaping fluid under pressure can penetrate the skin causing serious injury. –UN–23AUG88

Avoid the hazard by relieving pressure before disconnecting hydraulic or other lines. Tighten all connections before applying pressure.

X9811

Search for leaks with a piece of cardboard. Protect hands and body from high-pressure fluids.

Escaping Fluid Under Pressure

If an accident occurs, see a doctor immediately. Any fluid injected into the skin must be surgically removed within a few hours or gangrene may result. Doctors unfamiliar with this type of injury should reference a knowledgeable medical source. Such information is available from Deere & Company Medical Department in Moline, Illinois, U.S.A. CAUTION: Prevent possible injury from unexpected machine movement. Never rely on loader attachment to keep machine from moving. Machine can unexpectedly roll, resulting in death or serious injury. Always block wheels to hold machine when working on park brake. 1. Park machine on level surface and install blocks at front and rear tires. CAUTION: Prevent possible injury from unexpected machine movement. Install frame articulation lock bar before working in frame hinge area. 2. Install frame articulation lock bar.

Continued on next page

SW03989,0000393 –19–02SEP08–1/4

11 1111 1

TM10687 (14OCT08)

11-1111-1

524K Loader 101408

PN=257

Active Elements 3. Disconnect hydraulic park brake line (3). 6

4. Disconnect breather hose (5). 5. Remove front drive shaft (1) and articulation drive shaft (4). Discard universal joint cap screws. See Universal Joint and Drive Shaft Remove and Install. (Group 0225.)

4 2

CAUTION: Prevent possible injury from heavy component. Use appropriate lifting device when lifting component.

–UN–28FEB08

6. Remove park brake mounting cap screws (7).

TX1037491

7. Remove park brake assembly (2). Specification Park Brake Assembly—Weight (approximate)..................................................................................... 43 kg 95 lb

Park Brake 1—Front Drive Shaft 2—Park Brake Assembly 3—Hydraulic Park Brake Line 4—Articulation Drive Shaft 5—Breather Hose 6—Hydraulic Pump Manifold 7—Park Brake Mounting Cap Screw (4 used)

8. Repair or replace parts as necessary. See Park Brake Disassemble and Assemble. (Group 1111.) 9. Install park brake assembly (2). Tighten park brake mounting cap screws (7) to specification. Specification Park Brake Mounting Cap Screw—Torque ............................................................................. 319 N•m 235 lb-ft

10. Apply PM37566 Silver-Grade Anti-Seize lubricant or equivalent on park brake shaft. 11. Install universal yoke on park brake shaft. 12. Install front drive shaft (1) and articulation drive shaft (4). Ensure proper orientation, see Universal Joint and Drive Shaft Remove and Install. (Group 0225.) IMPORTANT: Avoid machine damage. Do not reuse drive shaft universal joint cap screws. 13. Install new drive shaft universal joint cap screws and tighten to specification.

11 1111 2

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11-1111-2

SW03989,0000393 –19–02SEP08–2/4

524K Loader 101408

PN=258

Active Elements Specification Universal Joint Cap Screw— Torque ............................................................................................ 78 N•m 58 lb-ft

14. Install breather hose (5). 15. Install hydraulic park brake line (3).

SW03989,0000393 –19–02SEP08–3/4

IMPORTANT: Avoid machine damage. Do not overfill park brake. Fill only to port. 11

16. Check and add park brake oil at fill level plug (8) as necessary. See Transmission, Park Brake, and Axle Oil. (Operator’s Manual.)

17. Add grease to grease fittings at each end of park brake assembly until grease purges out between the outer seals and yokes. 8—Fill Level Plug 9—Drain Plug 10—Shaft 11—Grease Fitting (2 used)

TX1028891

–UN–13FEB08

Specification Park Brake Oil—Capacity .............................................................. 300 mL 10 oz

SW03989,0000393 –19–02SEP08–4/4

11 1111 3

TM10687 (14OCT08)

11-1111-3

524K Loader 101408

PN=259

Active Elements

Park Brake Disassemble and Assemble 27

17 28

26 24

31 30

18 16

15 14

8 4

21 10

27 3

TX1028900 Continued on next page

TM10687 (14OCT08)

11-1111-4

TX1028900

11 1111 4

–UN–13FEB08

SW03989,0000394 –19–18AUG08–1/6

524K Loader 101408

PN=260

Active Elements 1—Drive Shaft Nut 2—Washer 3—Cotter Pin 4—O-Ring (6 used) 5—Yoke 6—Outer Seal 7—Cap Screw (6 used) 8—Housing Cover 9—Fitting

10—Dowel Pin (2 used) 11—Spacer 12—Inner Seal 13—Snap Ring 14—Bearing Cone Assembly 15—O-Ring 16—Shims 17—O-Ring 18—Piston

NOTE: Yoke (33) is on the splined end of drive shaft (25).

19—O-Ring 20—Separator Plate (7 used) 21—Friction Disk (7 used) 22—Backing Plate 23—Spring (36 used) 24—Spring Retainer 25—Drive Shaft 26—Bearing Cone Assembly

4. Remove spacer (11) and snap ring (13) through the bore of housing cover (8) off of drive shaft (25).

1. Remove yoke (33) from drive shaft (25).

CAUTION: Prevent possible injury from flying objects. Cover plate under spring pressure. Remove cap screws evenly to avoid possible injury.

2. Remove cotter pin (3), drive shaft nut (1), washer (2), and yoke (5). 3. Remove seal retainer snap rings (27) and outer seals (6 and 32) from both ends of park brake assembly.

27—Seal Retainer Snap Ring (2 used) 28—Inner Seal 29—Plug and O-Ring 30—Plug and O-Ring 31—Housing 32—Outer Seal 33—Yoke

5. Remove cap screws (7) evenly.

Continued on next page

SW03989,0000394 –19–18AUG08–2/6

11 1111 5

TM10687 (14OCT08)

11-1111-5

524K Loader 101408

PN=261

Active Elements NOTE: Remove housing cover and piston as one assembly.

6. Remove housing cover (8) from housing (31).

7. Separate piston (18) with O-rings (15 and 19) and shims (16) from housing cover (8).

25 9. Remove drive shaft (25), friction disks (21), separator plates (20), bearing cone assemblies (14 and 26) from housing (31).

10. Remove bearing cone assembly (14), separator plates (20), and friction disks (21) from drive shaft (25).

TX1029130

8. Remove inner seal (12) from bore of housing cover (8).

–UN–10SEP07

14—Bearing Cone Assembly 15—O-Ring 18—Piston 20—Separator Plate (7 used) 21—Friction Disk (7 used) 25—Drive Shaft 26—Bearing Cone Assembly

11. Remove bearing cone assembly (26) from drive shaft (25). NOTE: Bearing cups will be in the housing cover and housing. 12. Remove bearing cups from housing cover (8) and housing (31).

Continued on next page

SW03989,0000394 –19–18AUG08–3/6

11 1111 6

TM10687 (14OCT08)

11-1111-6

524K Loader 101408

PN=262

Active Elements 13. Remove backing plate (22) from housing (31).

22 14. Remove springs (23) and spring retainer (24). 15. Remove dowel pins (10) and inner seal (28) from housing (31).

17. Install new bearing cups in housing cover (8) and housing (31).

17 31

18. Install a new inner seal (28), outer seal (32) into housing (31). 19. Lubricate O-ring (17) and install on housing (31).

TX1029137

–UN–10SEP07

16. Inspect and replace parts as necessary.

10—Dowel Pin (2 used) 17—O-Ring 22—Backing Plate 23—Spring (36 used) 24—Spring Retainer 31—Housing

20. Install spring retainer (24), springs (23), and backing plate (22) into housing (31). NOTE: Make sure long splined end of drive shaft is installed into housing first. 21. Install bearing cone assembly (26) to the drive shaft (25) and install splined end into housing (31). 22. Apply fresh oil and install friction disks (21) and separator plates (20). Alternate disks so that a friction disk (21) is after the backing plate (22) and a separator plate (20) is last on the threaded end of the drive shaft (25). 23. Install lubricated O-rings (15 and 19) on piston (18). 24. Install piston (18) into housing (31). 25. Install bearing cone assembly (14) onto drive shaft (25). NOTE: Bearing cone and cup assemblies are a select pair to create a shaft end play of 0.127—0.305 mm (0.005—0.012 in.). The number and thicknesses of shims may vary. 26. Install shims (16) and new inner seal (12) onto housing cover (8) to obtain proper end play.

11 1111 7

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11-1111-7

SW03989,0000394 –19–18AUG08–4/6

524K Loader 101408

PN=263

Active Elements 27. Install housing cover (8) onto housing (31), making sure dowel pins (10) align. 28. Install cap screws (7) with O-rings (4) to housing cover (8) and tighten evenly to specification. Specification Cap Screw with O-Ring—Torque ................................................. 122 N•m 90 lb-ft

29. Install snap ring (13) onto drive shaft (25) through bore of housing cover (8). 30. Place spacer (11) through bore of housing cover (8) onto drive shaft (25). 31. Install outer seal (6) and seal retainer snap ring (27) into the bore of housing cover (8). 32. Apply PM37566 Silver-Grade Anti-Seize lubricant or equivalent to drive shaft splines. 33. Install yoke (5), washer (2), and drive shaft nut (1). Tighten drive shaft nut to specification. Specification Drive Shaft Nut—Torque .............................................................. 407 N•m 300 lb-ft

34. Turn drive shaft nut (1) counterclockwise until cotter pin (3) can be installed. Spread cotter pin ends to lock in place. IMPORTANT: Prevent park brake from overheating. Do not overfill park brake. Fill only to bottom of fill plug opening. Specification Park Brake Oil—Capacity (approximate).................................................................................. 300 mL 10 oz

35. Fill park brake with oil at plug and O-ring (29). Allow oil to drain to bottom of plug opening before installing plug and O-ring (29) to prevent overfilling. See Transmission, Park Brake, and Axle Oil. (Operator’s Manual.)

11 1111 8

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11-1111-8

SW03989,0000394 –19–18AUG08–5/6

524K Loader 101408

PN=264

Active Elements IMPORTANT: Ensure proper alignment and orientation of the yoke (33) when installed onto the drive shaft and park brake.

T112153

37. Add grease at the grease fittings on each end of park brake assembly housing flanges until grease purges out between the outer seals (6 and 32) and yokes (5 and 33). See Park Brake Remove and Install. (Group 1111.)

–UN–06NOV97

36. Install yoke (33) onto drive shaft (25). See Universal Joint and Drive Shaft Remove and Install. (Group 0225.)

Yoke Alignment

38. Bench test the park brake. 39. Install D01018AA Hydraulic Hand Pump to the park brake. 40. Slowly increase pressure until the shaft rotates freely and compare to specification. Specification Park Brake Release—Pressure ........................................ 896—1068 kPa 8.9—10.6 bar 130—155 psi

41. Increase pressure to specification. Specification Park Brake Increase—Pressure .................................................. 3450 kPa 34.5 bar 500 psi

42. Slowly release brake pressure until free rotation of the shaft stops and compare to specification. Brake engagement pressure range must not be more than the brake release pressure. Specification Park Brake—Pressure Change ..................................................... 210 kPa 2.1 bar 30 psi

11 1111 9

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TM10687 (14OCT08)

11-1111-9

524K Loader 101408

PN=265

Active Elements

11 1111 10

TM10687 (14OCT08)

11-1111-10

524K Loader 101408

PN=266

Group 1160

Hydraulic System Park Brake Release Solenoid Valve Remove and Install See Hydraulic Pump Manifold Disassemble and Assemble. (Group 3160.)

MH66O88,0000713 –19–21AUG08–1/1

11 1160 1

TM10687 (14OCT08)

11-1160-1

524K Loader 101408

PN=267

Hydraulic System

11 1160 2

TM10687 (14OCT08)

11-1160-2

524K Loader 101408

PN=268

Section 17

Frame or Supporting Structure Contents Page

Group 1740—Frame Installation Welding Major Structure . . . . . . . . . . . . . . . .17-1740-1 Engine and Loader Frame Separate . . . . . . .17-1740-3 Upper Pivot Bearing and Seals Remove and Install . . . . . . . . . . . . . . . . . . . . . . . . .17-1740-7 Lower Pivot Bearing and Seals Remove and Install . . . . . . . . . . . . . . . . . . . . . . . . .17-1740-9 Group 1746—Frame Bottom Guards Front Axle Guard Remove and Install . . . . . .17-1746-1 Transmission Bottom Guard Remove and Install. . . . . . . . . . . . . . . . . . . . . . . . . . . . .17-1746-2

Group 1749—Chassis Weights Counterweights Remove and Install . . . . . . .17-1749-1 Rear Counterweight Remove and Install . . . .17-1749-3

TM10687 (14OCT08)

17-1

524K Loader 101408

PN=1

Contents

TM10687 (14OCT08)

17-2

524K Loader 101408

PN=2

Group 1740

Frame Installation Welding Major Structure 17 1740 1

–UN–23AUG88

CAUTION: Avoid potentially toxic fumes and dust. Hazardous fumes can be generated when paint is heated by welding, soldering, or using a torch. Do all work outside or in a well ventilated area. Dispose of paint and solvent properly.

TS220

If you sand or grind paint, avoid breathing the dust. Wear an approved respirator. If you use solvent or paint stripper, remove stripper with soap and water before welding. Remove solvent or paint stripper containers and other flammable material from area. Allow fumes to disperse at least 15 minutes before welding or heating. IMPORTANT: Have only a qualified welder do this job. Connect welder ground clamp close to each weld area so electrical current does not pass through any bearings. Remove or protect all parts that can be damaged by heat or weld splatter. 1. Disconnect both negative and positive cables from batteries. 2. Disconnect the following controllers. For controller location, see Load Center Harness (W3) Component Location. (Group 9015-10.) • Advance Display Unit (ADU). See Advanced Display Unit (ADU) Remove and Install. (Group 9015-20.) • Sealed Switch module (SSM). See Sealed Switch Module (SSM) Remove and Install. (Group 9015-20.) • Flex Load Controller (FLC). See Flex Load Controller (FLC) Remove and Install. (Group 9015-20.) • Engine Control Unit (ECU). See Engine Control Unit (ECU) Remove and Install. (Group 9015-20.) • Transmission Control Unit (TCU). See Transmission Control Unit (TCU) Remove and Install. (Group 9015-20.) 3. Remove paint before welding. Use one of the following weld processes:

Continued on next page

TM10687 (14OCT08)

17-1740-1

MH66O88,0000935 –19–29FEB08–1/2

524K Loader 101408

PN=271

Frame Installation • AWS-E-7018 covered electrode with shielded metal arc welding (SMAW) process. 17 • AWS-ER-70S-3f wire electrode with gas metal arc 1740 welding (GMAW) process. 2 • AWS-E70T-1 or E71T-1 wire electrode with flux core arc welding (FCAW) process. Specification Weld Metal—Tensile Strength................................................... 482.6 mPa 70,000 psi Yield Strength ............................................................................ 413.7 mPa 60,000 psi Elongation ............................................................................................ 22%

Preheat area to be repaired to allow better weld penetration. To repair weld metal failure, remove failed weld metal using arc or grinding equipment. Thoroughly clean area to be welded. Preheat structural assemblies to a minimum of 38°C (100°F). Preheat structural ground engaging tools (cutting edges, skid shoes, and teeth shanks) to 177°C (350°F). Specification Structural Assemblies—Preheat Temperature ....................................................................................... 38°C 100°F Ground Engaging Tools—Preheat Temperature ..................................................................................... 177°C 350°F

To repair base metal failure remove enough material to allow weld to penetrate to the bottom of crack. Preheat structural ground engaging tools (cutting edges, skid shoes, and teeth shanks) to 177°C (350°F).

MH66O88,0000935 –19–29FEB08–2/2

TM10687 (14OCT08)

17-1740-2

524K Loader 101408

PN=272

Frame Installation

Engine and Loader Frame Separate 17 1740 3

CAUTION: Escaping fluid under pressure can penetrate the skin causing serious injury. –UN–23AUG88

Avoid the hazard by relieving pressure before disconnecting hydraulic or other lines. Tighten all connections before applying pressure.

X9811

Search for leaks with a piece of cardboard. Protect hands and body from high-pressure fluids.

Escaping Fluid Under Pressure

If an accident occurs, see a doctor immediately. Any fluid injected into the skin must be surgically removed within a few hours or gangrene may result. Doctors unfamiliar with this type of injury should reference a knowledgeable medical source. Such information is available from Deere & Company Medical Department in Moline, Illinois, U.S.A. 1. Park machine on smooth level surface and align frames. Stop engine. CAUTION: Prevent possible injury from crushing. Use appropriate lifting device. NOTE: Service jack wheels must roll freely and straight ahead when loader frame is moved forward. 3. Place a 10-ton service jack under center of bucket. 4. Attach an appropriate lifting device to the front loader frame. CAUTION: Prevent possible injury from unexpected machine movement. Place supports under the front and rear of engine frame section of the machine. 5. Install 20-ton floor stands under the front and rear of engine frame.

Continued on next page

TM10687 (14OCT08)

17-1740-3

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524K Loader 101408

PN=273

Frame Installation

17 1740 4

CAUTION: Escaping fluid under pressure can penetrate the skin causing serious injury. Avoid the hazard by relieving pressure before disconnecting hydraulic or other lines. Tighten all connections before applying pressure. 6. Perform Hydraulic System Pressure and Accumulators Discharge. (Group 9025-25.) 7. Identify and disconnect electrical harnesses connecting the loader frames. 8. Apply vacuum to hydraulic oil reservoir. 9. Identify and disconnect hydraulic lines routed from front loader frame to engine frame. Close all openings with caps and plugs. For hose routing, see Hydraulic System Component Location. (Group 9025-15.) 10. Disconnect U-joints on transmission to park brake drive shaft and park brake to front axle drive shaft.

Continued on next page

TM10687 (14OCT08)

17-1740-4

SW03989,0000426 –19–13AUG08–2/4

524K Loader 101408

PN=274

Frame Installation

17 1740 5

–UN–05SEP07

3 6

TX1028964

TX1028964 Center Articulating Point 1—Upper Pivot Pin 2—Steering Cylinder Pin (2 used)

3—Lower Pivot Pin 4—Cap Screw

5—Bushing 6—Engine Frame

7—Cap Screw (6 used)

15. Remove upper pivot pin (1). See Upper Pivot Bearing and Seals Remove and Install. (Group 1740.)

11. Remove steering cylinder pins (2). 12. Remove cap screw (4). 13. Remove cap screws (7) holding bushing (5) to the frame. 14. Remove lower pivot pin (3). See Lower Pivot Bearing and Seals Remove and Install. (Group 1740.)

Continued on next page

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524K Loader 101408

PN=275

Frame Installation 16. Slowly roll front loader frame, service jack, and overhead hoist forward and away from engine frame 17 (6). 17. Inspect and replace parts as necessary. 18. Attach front loader frame to engine frame. Install upper pivot pin (1). 19. Install bushing (5) and lower pivot pin (3). 20. Connect all hydraulic hoses. See Hydraulic System Component Location. (Group 9025-15.) 21. Connect all electrical harnesses. See Loader Frame Harness (W2) Component Location. (Group 9015-10.)

–UN–24OCT88

IMPORTANT: Avoid machine damage. Do not reuse drive shaft U-joint cap screws. 22. Connect drive shafts U-joints. Tighten U-joint cap screws to specification. Specification Drive Shafts U-Joint Cap Screws—Torque ............................................................................. 78 N•m 58 lb-ft

T77721

1740 6

Front Loader Frame

23. Connect steering cylinders. Install maximum number of washers between loader frame and steering cylinder rod end. Install equal number above and below rod end. 24. Remove vacuum to hydraulic oil reservoir. 25. Perform Service Brake Bleeding Procedure. (Group 9020.)

SW03989,0000426 –19–13AUG08–4/4

TM10687 (14OCT08)

17-1740-6

524K Loader 101408

PN=276

Frame Installation

Upper Pivot Bearing and Seals Remove and Install

TX1028986

–UN–05SEP07

17 1740 7

1—Pivot Pin 2—Engine Frame 3—Seal

4—Cover Plate 5—Shim (as needed) 6—Loader Frame

7—Bearing 8—Seal Spacer 9—Seal

1. Remove upper and lower pivot pins (1) and separate frames. See Engine and Loader Frame Separate. (Group 1740.)

10—Cap Screw (6 used) 11—Pin Cap Screw 12—Grease Fitting

5. Apply TY6341 Multi-Purpose SD Polyurea Grease to the bearing (7).

2. Remove cap screws (10), cover plate (4), and seal (3).

6. Press seal (9) into seal spacer (8) with lip facing out. The seal must seat against seal spacer shoulder.

NOTE: Lower seal cannot be pushed through spacer. Remove seal spacer to remove seal.

7. Install seal spacer (8) in bottom of loader frame bore.

3. Using D01047AA 17-1/2-Ton Puller Set and JT01933 Driver Set, remove the bearing (7), seal spacer (8), and seal (9) from loader frame bore.

8. Use D01072AA Bushing, Bearing and Seal Driver Set to press bearing (7) into frame bore.

4. Inspect and replace parts as necessary.

9. Install seal (3) into cover with lip facing out. Press seal to cover plate (4) shoulder.

Continued on next page

TM10687 (14OCT08)

17-1740-7

SW03989,0000427 –19–25FEB08–1/2

524K Loader 101408

PN=277

Frame Installation 10. Hold cover in place and measure gap between cover plate and loader frame. Take a 17 measurement in three places. Cover must contact 1740 top of bearing. Calculate the average of these 8 three measurements to determine the correct shim pack required. 11. Install shims to obtain the specified preload of bearings. Specification Upper Pivot Bearing—Preload ................................... 0.03—0.13 mm 0.001—0.005 in.

12. Apply grease to the top of bearing. Fill cavity above bearing to machined surface to prevent moisture from entering bearing through shims. 13. Tighten cap screws (10) to specification. Rotate bearing after tightening. Specification Upper Pivot Bearing Cover Cap Screw—Torque ...................................................................... 128 N•m 95 lb-ft

SW03989,0000427 –19–25FEB08–2/2

TM10687 (14OCT08)

17-1740-8

524K Loader 101408

PN=278

Frame Installation

Lower Pivot Bearing and Seals Remove and Install 14

17 1740 9

8 –UN–11SEP07

TX1028998 1—Pin Retaining Cap Screw 2—Cap Screw (6 used) 3—Plate 4—Engine Frame

5—Spacer (engine frame) 6—Spacer (loader frame) 7—Cover Seal 8—Cap Screw (6 used)

TX1028998

1 9—Cover Plate 10—Shim (as needed) 11—Loader Frame 12—Bearing

13—Seal Spacer 14—Seal 15—Lower Pivot Pin

1. Remove pin retaining cap screw (1) and lower pivot pin (15), and separate machine frames. See Engine and Loader Frame Separate. (Group 1740.)

4. Press out spacer (5) from engine frame bore.

2. Remove cap screws (8), cover plate (9), spacer (6), cover seal (7), and shims (10).

6. Install spacer (5) into engine frame bore flush with bottom of frame.

5. Inspect and replace parts as necessary.

NOTE: Spacer seal cannot be pushed through spacer. Remove seal and spacer to remove seal. 3. Using D01047AA 17-1/2 Ton Puller Set and JT01933 Driver Set, remove the bearing (12), seal spacer (13), and seal (14) from loader frame bore.

Continued on next page

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17-1740-9

SW03989,0000428 –19–19AUG08–1/3

524K Loader 101408

PN=279

Frame Installation

17 1740 10

–UN–19AUG08

TX1028999

6 8

TX1028999 6—Spacer (loader frame) 7—Cover Seal 8—Cap Screw (6 used)

9—Cover Plate 10—Shim (as needed) 11—Loader Frame

12—Bearing 13—Seal Spacer

14—Seal 15—Lower Pivot Pin

7. Apply TY6341 Multi-Purpose SD Polyurea Grease to the bearing (12).

13. Install shims (10) to obtain the specified preload of bearings.

8. Press seal (14) into seal spacer (13), with lips facing out. Seal must seat against the seal spacer shoulder.

Specification Lower Pivot Bearing—Shim Pack Thickness........................................................... 0.03—0.13 mm 0.001—0.005 in.

9. Install seal spacer and seal to bottom of loader frame bore. 10. Press bearing (12) into loader frame bore. 11. Install seal into cover plate (9) with lips facing out. Press seal to cover shoulder. 12. Hold cover plate (9) in place and measure gap between cover and frame. Take a measurement in three places. Cover plate (9) must contact top of bearing. Calculate the average of the three measurements to determine the shim pack required.

14. Apply grease to the top of bearing. Fill cavity above bearing to machined surface to prevent moisture from entering bearing through shims. 15. Tighten lower pivot cap screws (8) to specification. Rotate bearing after tightening. Specification Lower Pivot Bearing Cap Screw—Torque ...................................................................... 128 N•m 95 lb-ft

16. Install spacer (6) into cover plate (9).

Continued on next page

TM10687 (14OCT08)

17-1740-10

SW03989,0000428 –19–19AUG08–2/3

524K Loader 101408

PN=280

Frame Installation 17. Move frames together and install lower pivot pin (15) and plate (3). Install pin retaining cap screw (1) and cap screws (2) finger tight before tightening. 18. Tighten pin retaining cap screw (1) to specification. Steel dowels or cap screws may be inserted into holes in top of pivot pin and a bar inserted between them to prevent pin from turning

during tightening of cap screw. Tighten cap screws (2) and plate (3) to specification. Specification Cap Screw—Torque .............................................................. 128 N•m 95 lb-ft Pin Retaining Cap Screw— Torque.................................................................................. 2129 N•m 1570 lb-ft

SW03989,0000428 –19–19AUG08–3/3

TM10687 (14OCT08)

17-1740-11

524K Loader 101408

PN=281

17 1740 11

Frame Installation

17 1740 12

TM10687 (14OCT08)

17-1740-12

524K Loader 101408

PN=282

Group 1746

Frame Bottom Guards Front Axle Guard Remove and Install 17 1746 1

CAUTION: Prevent possible injury from crushing. Heavy component, use appropriate lifting device. Approximate weight of front axle guard is 32 kg (72 lb). Weight may increase due to build up of mud and debris. 1. Remove caps screws and use appropriate lifting device to lower front axle guard. Specification Front Axle Guard—Weight (approximate)..................................................................................... 32 kg 72 lb

2. Repair or replace as necessary.

MH66O88,00006FE –19–18FEB08–1/2

T108117

–UN–12MAR97

3. Install front axle guard and tighten cap screws securely.

Front Axle Guard

MH66O88,00006FE –19–18FEB08–2/2

TM10687 (14OCT08)

17-1746-1

524K Loader 101408

PN=283

Frame Bottom Guards

Transmission Bottom Guard Remove and Install

Approximate weight of transmission bottom guard is 62 kg (137 lb.). Weight may increase due to buildup of mud and debris.

–UN–12MAR97

CAUTION: Prevent possible injury from heavy component. Use appropriate lifting device.

T108118

17 1746 2

Specification Transmission Bottom Guard— Weight (approximate) ........................................................................ 62 kg 137 lb.

1. Remove cap screws and use appropriate lifting device to lower transmission bottom guard. 2. Disconnect ground speed radar electrical connector (if equipped). 3. Repair or replace transmission bottom guard as necessary. 4. Connect ground speed radar electrical connector (if equipped). 5. Install transmission bottom guard and tighten cap screws securely.

MH66O88,00006FF –19–20AUG08–1/1

TM10687 (14OCT08)

17-1746-2

524K Loader 101408

PN=284

Group 1749

Chassis Weights Counterweights Remove and Install 17 1749 1 –UN–07OCT08

NOTE: The right side removal procedure is shown; left side removal procedure is the same. 1. Park machine on level surface and lower bucket to ground.

TX1049773

2. Remove engine access door. 3. Remove fuel filler access door. Counterweights

4. Remove tapped hole plugs (1) and install JT01748 Lifting Brackets.

1—Tapped Hole Plug (2 used) 2—Counterweight Cap Screw (3 used) 3—Counterweight

CAUTION: Prevent possible crushing injury. Use appropriate lifting device when lifting component. Specification Counterweight—Weight (approximate)................................................................................... 377 kg 830 lb.

5. Attach appropriate lifting device to lifting brackets and support the counterweight (3). 6. Remove counterweight cap screws (2). CAUTION: Loader is unbalanced without counterweight. If travel of loader is necessary without counterweight, make sure the bucket is as close to the ground as possible. Never load the bucket when counterweights are removed. 7. Carefully remove counterweight (3) past fuel filler neck and away from machine. IMPORTANT: Do not allow outer counterweight to come in contact with fuel filler neck. 8. Install counterweight. Install counterweight cap screws and tighten to specification.

Continued on next page

TM10687 (14OCT08)

17-1749-1

PM10405,0000302 –19–07OCT08–1/2

524K Loader 101408

PN=285

Chassis Weights

17 1749 2

Specification Counterweight Cap Screw— Torque ........................................................................................ 1071 N•m 790 lb-ft

9. Remove lifting brackets and install tapped hole plugs. 10. Install fuel filler access door. 11. Install engine access door.

PM10405,0000302 –19–07OCT08–2/2

TM10687 (14OCT08)

17-1749-2

524K Loader 101408

PN=286

Chassis Weights

Rear Counterweight Remove and Install 17 1749 3 –UN–09APR07

1. Park machine on level surface and lower bucket to the ground. 2. Shut off engine.

CAUTION: Prevent possible injury from unexpected movement when removing counterweights. Keep bystanders clear of machine. Keep hands, feet, and clothing away from moving parts.

TX1021706A

3. Install appropriate eyebolt to rear counterweight.

Rear Counterweight 1—Cap Screw

Loader is unbalanced without counterweights. Do not attempt to move machine without counterweights. Never load the bucket when counterweights are removed. Prevent possible injury from crushing. Heavy component; use appropriate lifting device. NOTE: Before removing counterweight, relieve pressure on cap screws by lifting counterweight slightly. 4. Attach appropriate lifting device to counterweight. Remove cap screws (1). 5. Remove rear counterweight. Specification Rear Counterweight—Weight (approximate)................................................................................... 129 kg 285 lb

6. Install rear counterweight using appropriate lifting device. 7. Install cap screws and tighten to specification. Specification Rear Counterweight Cap Screw— Torque .......................................................................................... 623 N•m 460 lb-ft

MH66O88,0000701 –19–07OCT08–1/1

TM10687 (14OCT08)

17-1749-3

524K Loader 101408

PN=287

Chassis Weights

17 1749 4

TM10687 (14OCT08)

17-1749-4

524K Loader 101408

PN=288

Section 18

Operator’s Station Contents Page

Page

Group 1800—Removal and Installation Cab Remove and Install . . . . . . . . . . . . . . . .18-1800-1

Air Conditioning High-Low Pressure Switch Remove and Install. . . . . . . . . . . .18-1830-24 Fresh Air Filter Remove and Install . . . . . . .18-1830-25 Recirculating Air Filter Remove and Install. . . . . . . . . . . . . . . . . . . . . . . . . . . .18-1830-26 Compressor Remove and Install . . . . . . . . .18-1830-27 Compressor Clutch—R134a Disassemble and Assemble . . . . . . . . . . . . . . . . . . . . .18-1830-28 Clutch Hub Clearance—R134a Check. . . . .18-1830-29

Group 1810—Operator Enclosure Windowpanes Remove and Install . . . . . . . .18-1810-1 Cab Door Hold-Open Release Adjust . . . . . .18-1810-1 Front and Rear Windshield Wiper Motor Remove and Install . . . . . . . . . . . . . . . . . .18-1810-2

Group 1821—Seat and Seat Belt Seat Remove and Install . . . . . . . . . . . . . . . .18-1821-1 Seat Belt Remove and Install . . . . . . . . . . . .18-1821-2

Group 1830—Heating and Air Conditioning Proper Refrigerant Handling . . . . . . . . . . . . .18-1830-1 R134a Refrigerant Cautions . . . . . . . . . . . . .18-1830-1 R134a Compressor Oil Charge Check . . . . .18-1830-2 R134a Compressor Oil Removal . . . . . . . . . .18-1830-2 R134a Component Oil Charge . . . . . . . . . . .18-1830-3 Refrigerant Leak Testing . . . . . . . . . . . . . . . .18-1830-4 Refrigerant Hoses and Tubing Inspection . . .18-1830-4 R134a Refrigerant Recovery/Recycling and Charging Station Installation Procedure . . . . . . . . . . . . . . . . . . . . . . . . .18-1830-5 R134a System Recover . . . . . . . . . . . . . . . .18-1830-6 R134a System Evacuate . . . . . . . . . . . . . . . .18-1830-7 R134a System Charge . . . . . . . . . . . . . . . . .18-1830-9 Air Conditioner System Cleaning Procedures . . . . . . . . . . . . . . . . . . . . . . .18-1830-10 Air Conditioner System Purge . . . . . . . . . . .18-1830-11 Air Conditioner System Flush . . . . . . . . . . .18-1830-12 Air Conditioning Module With Heater/Evaporator Coil. . . . . . . . . . . . . . .18-1830-14 Heater/Evaporator Coil Remove and Install. . . . . . . . . . . . . . . . . . . . . . . . . . . .18-1830-15 Expansion Valve Remove and Install . . . . .18-1830-16 Freeze Control Switch Remove and Install. . . . . . . . . . . . . . . . . . . . . . . . . . . .18-1830-17 Freeze Control Switch Bench Test . . . . . . .18-1830-18 Heater Control Valve Remove and Install. . . . . . . . . . . . . . . . . . . . . . . . . . . .18-1830-19 Heater Control Valve Leak Check . . . . . . . .18-1830-20 Blower Motor Assembly Remove and Install. . . . . . . . . . . . . . . . . . . . . . . . . . . .18-1830-21 Receiver-Dryer Remove and Install . . . . . . .18-1830-22 Condenser Remove and Install . . . . . . . . . .18-1830-23

TM10687 (14OCT08)

18-1

524K Loader 101408

PN=1

Contents

TM10687 (14OCT08)

18-2

524K Loader 101408

PN=2

Group 1800

Removal and Installation Cab Remove and Install CAUTION: Escaping fluid under pressure can penetrate the skin causing serious injury. –UN–23AUG88

Avoid the hazard by relieving pressure before disconnecting hydraulic or other lines. Tighten all connections before applying pressure.

X9811

Search for leaks with a piece of cardboard. Protect hands and body from high-pressure fluids. If an accident occurs, see a doctor immediately. Any fluid injected into the skin must be surgically removed within a few hours or gangrene may result. Doctors unfamiliar with this type of injury should reference a knowledgeable medical source. Such information is available from Deere & Company Medical Department in Moline, Illinois, U.S.A. 1. Perform Hydraulic System Pressure and Accumulators Discharge. (Group 9025-25.) CAUTION: Prevent possible injury from unexpected machine movement. Install frame articulation lock bar before working in frame hinge area. 2. Install frame articulation lock bar. 3. Turn battery disconnect switch to the OFF position or disconnect battery ground cable. 4. Evacuate and recover refrigerant from air conditioning system. See R134a System Evacuate. (Group 1830.) 5. Remove platform from right side of machine. 6. Remove platform with steps from left side of machine. 7. Remove cab shields. 8. Drain hydraulic reservoir or apply vacuum. If draining reservoir, see Drain and Refill Hydraulic System Oil. (Operator’s Manual.)

Continued on next page

TM10687 (14OCT08)

18-1800-1

MH66O88,0000714 –19–11AUG08–1/9

524K Loader 101408

PN=291

18 1800 1

Removal and Installation 9. Remove right and left heater/defroster ducts (1). 1—Heater/Defroster Duct

TX1028989A

–UN–05SEP07

18 1800 2

Heater/Defroster Duct

MH66O88,0000714 –19–11AUG08–2/9

10. Identify and remove steering valve hydraulic lines (2) from steering valve (3). Close all openings using caps and plugs. NOTE: Brake valve-to-brake accumulator hydraulic lines may stay connected for cab remove procedure. –UN–05SEP07

11. Identify and remove hydraulic lines from brake valve. Close all openings using caps and plugs.

TX1028990A

12. Drain radiator. See Drain Cooling System. (Operator’s Manual.) 13. Open electrical access door on right side of machine. Steering Valve 2—Steering Valve Hydraulic Lines 3—Steering Valve Continued on next page

TM10687 (14OCT08)

18-1800-2

MH66O88,0000714 –19–11AUG08–3/9

524K Loader 101408

PN=292

Removal and Installation 14. Disconnect pilot control hydraulic fittings (4) from right side of cab. Close all openings using caps and plugs. 15. Disconnect cab harness electrical connectors (5) from right side of cab.

–UN–05SEP07

16. Disconnect cab-to-frame ground strap from right side of cab.

TX1028997A

4—Pilot Control Hydraulic Fittings (8 used) 5—Cab Harness Electrical Connectors (4 used)

Pilot Control Hydraulic Fittings and Cab Harness Connectors

MH66O88,0000714 –19–11AUG08–4/9

17. Identify and disconnect wires (6—8) in starter-to-cab wiring harness from starter.

TX1029003A

–UN–05SEP07

6—Red Wire on Starter Solenoid 7—White Wire on Starter Solenoid (2 used) 8—Black Wire on Starter Motor Body (3 used)

Starter Harness

Continued on next page

TM10687 (14OCT08)

18-1800-3

MH66O88,0000714 –19–11AUG08–5/9

524K Loader 101408

PN=293

18 1800 3

Removal and Installation 18. Disconnect brake accumulator-to-hydraulic pump manifold hydraulic line (9) from tee fitting at accumulator on left side of machine. Close all openings using caps and plugs.

20. Remove wiring harness (11) from underside of cab on left side of machine

TX1029006A

21. Disconnect heater hoses (12) from underside of cab. Close all openings using caps and plugs. 22. Disconnect windshield washer fluid hose from left front of cab.

Air Conditioning Lines 9—Brake Accumulator-to-Hydraulic Pump Manifold Hydraulic Line 10—Air Conditioning Line (2 used) 11—Wiring harness 12—Heater Hose (2 used)

23. Disconnect rear window washer fluid hose at left rear of cab.

MH66O88,0000714 –19–11AUG08–6/9

–UN–05SEP07

CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device. Specification Cab—Weight (approximate) ............................................................ 771 kg 1700 lb

24. Attach appropriate lifting device to lifting brackets (13) on cab roof.

TX1029012A

18 1800 4

–UN–05SEP07

19. Disconnect air conditioning lines (10). Close all openings using caps and plugs.

25. Remove mounting hardware from bottom front and rear of cab.

Cab Remove 13—Lifting Bracket (4 used)

26. Remove cab.

Continued on next page

TM10687 (14OCT08)

18-1800-4

MH66O88,0000714 –19–11AUG08–7/9

524K Loader 101408

PN=294

Removal and Installation 27. Inspect cab mounting hardware. Replace as needed. 28. Install cab. 29. Install cab mounting hardware and tighten to specifications. Specification Cab Mounting Hardware—Torque ............................................. 1150 N•m 850 lb-ft

18 1800 5

30. Connect front and rear window washer fluid hoses. 31. Connect heater hoses to underside of cab. –UN–30MAR07

32. Install wiring harness to underside of cab on left side of machine.

TX1021306

33. Connect air conditioner lines at right side of machine. 34. Connect hydraulic pump manifold hydraulic line to brake accumulator. Cab Mounts and Hardware

35. Connect wires from starter wiring harness to starter. 1—Nut (2 used) 2—Washer (6 used) 3—Washer (4 used) 4—Rubber Mount (4 used) 5—Cap Screw (M24 x 150) (2 used) 6—Cap Screw (M24 x 120) (2 used)

36. Connect cab-to-frame ground strap at right side of cab. 37. Connect electrical connectors at right side of cab. 38. Connect pilot control hydraulic fittings at right side of cab. 39. Close electrical access door. 40. Install steering and brake valve lines. 41. Remove vacuum and check hydraulic oil level. Fill hydraulic reservoir if drained. See Check Hydraulic Oil Level or see Drain and Refill Hydraulic System Oil. (Operator’s Manual.) 42. Install heater/defroster ducts. 43. Install cab shields. 44. Install platform with steps onto left side of machine. 45. Install platform onto right side of machine.

Continued on next page

TM10687 (14OCT08)

18-1800-5

MH66O88,0000714 –19–11AUG08–8/9

524K Loader 101408

PN=295

Removal and Installation 46. Charge air conditioning system. See R134a System Evacuate. (Group 1830.) 47. Remove frame articulation lock bar. 48. Turn battery disconnect switch to the ON position. 18 1800 6

49. Fill radiator to specification. See Fill and Deaerate Cooling System. (Operator’s Manual.)

MH66O88,0000714 –19–11AUG08–9/9

TM10687 (14OCT08)

18-1800-6

524K Loader 101408

PN=296

Group 1810

Operator Enclosure Windowpanes Remove and Install The adhesive used to hold the windowpanes in place is a urethane adhesive that is used on most automobile windshields. Urethane adhesive manufactured by Loctite Corporation or equivalent is recommended. Do not use any other type of adhesive. It is also recommended that an auto glass dealer install the windowpanes. IMPORTANT: Windowpanes must have an ultra-violet barrier around the edge of the glass since ultra-violet rays will deteriorate the adhesive. Windowpanes ordered through John Deere Parts have the ultra-violet barrier. If the windowpane is purchased through a glass dealer, the dealer must put an ultra-violet barrier on the glass. Do not apply paint to the border of the glass. If an auto glass dealer is not installing the windowpanes, use the following procedure: 1. Purchase urethane adhesive from your local auto glass dealer. 2. If window frame is removable, remove frame from cab.

3. Scrape broken glass off existing adhesive. Do not remove adhesive from window frame or cab. IMPORTANT: Adhesive will not stick to bare metal. 4. If existing adhesive is removed from frame and paint is scraped off window frame, paint window frame. Paint must be fully cured before installing windowpane.

18 1810 1

5. Trim existing adhesive so it has a smooth surface. 6. Follow the manufacturer’s instructions for using the adhesive. 7. Apply a 6 mm (1/4 in.) bead of adhesive on top of the existing adhesive. 8. Put a new windowpane into position. Use hand pressure to force windowpane down around the edges until even with metal frame. 9. If windowpane is installed directly on cab, use duct tape to hold it in place while adhesive cures. 10. Allow adhesive to cure for 24 hours before operating machine.

T52,1810,C19 –19–05JUN98–1/1

Cab Door Hold-Open Release Adjust 1. Remove door striker cover from left rear side of ROPS. 2. Adjust cable length so door release latch releases door when lever is moved 1/3 of full travel distance. 3. Apply Thread Lock and Sealer (medium strength) to cable eye retaining nut. Cable eye must remain loose.

MH66O88,000072C –19–29JUL08–1/1

TM10687 (14OCT08)

18-1810-1

524K Loader 101408

PN=297

Operator Enclosure

Front and Rear Windshield Wiper Motor Remove and Install Front Windshield Wiper Motor Remove and Install 1. Park front wiper. 18 1810 2

Continued on next page

TM10687 (14OCT08)

18-1810-2

MH66O88,000072D –19–29JUL08–1/7

524K Loader 101408

PN=298

Operator Enclosure

18 1810 3

TM10687 (14OCT08)

18-1810-3

524K Loader 101408

PN=299

Operator Enclosure

T188479

–UN–25MAR03

18 1810 4

Front Wiper Assembly

Continued on next page

TM10687 (14OCT08)

18-1810-4

MH66O88,000072D –19–29JUL08–2/7

524K Loader 101408

PN=300

Operator Enclosure 1—Wiper Motor Bracket 2—Wiper Arm Mounting Kit 3—Link 4—Pivot 5—Washer Hose Elbow Bulkhead Fitting

6—Washer Hose Coupler 7—Windshield Washer 8—Washer Hose 9—Washer Hose Clip

10—Wiper Arm 11—Wiper Motor 12—Wiper Blade 13—Pivot Retaining Nut

2. Lift wiper arm covers and remove wiper arm mounting kit (2). Remove wiper arms (10) and wiper blades (12).

14—Pivot Washer 15—Windshield Wiper Assembly 16—Washer Hose

3. Disconnect windshield washer hose (16) at coupler (6).

MH66O88,000072D –19–29JUL08–3/7

4. Remove front wiper motor mounting plate screws (18).

–UN–18DEC03

5. Remove wiper motor (11) with wiper motor mounting plate (17) and disconnect electrical harness from wiper motor. 6. Disassemble parts as shown and replace as necessary.

T196713A

7. Connect electrical harness to wiper motor. 8. Connect windshield washer hose to coupler. Front Wiper Motor and Mounting Plate

9. Install wiper motor and wiper motor mounting plate with mounting plate screws.

17—Front Wiper Motor Mounting Plate 18—Front Wiper Motor Mounting Plate Screws

10. Install wiper arms and wiper blades. Specification Wiper Arm Retaining Nut— Torque ......................................................................................... 14.9 N•m 132 lb-in.

Rear Windshield Wiper Remove and Install 1. Park rear windshield wiper. 2. Remove roof retaining cap screws and move roof forward to access wiper motor wiring harness connector. 3. Remove tie band and disconnect wiper motor harness.

Continued on next page

TM10687 (14OCT08)

18-1810-5

MH66O88,000072D –19–29JUL08–4/7

524K Loader 101408

PN=301

18 1810 5

Operator Enclosure

T193133

–UN–18NOV03

18 1810 6

Rear Windshield Wiper Motor

Continued on next page

TM10687 (14OCT08)

18-1810-6

MH66O88,000072D –19–29JUL08–5/7

524K Loader 101408

PN=302

Operator Enclosure 1—Washer Hose Clip (2 used) 2—Grommet 3—Wiper Blade 4—Wiper Arm 5—Pivot Retaining Hardware Kit

6—Washer Hose Elbow Bulkhead Fitting 7—Pivot Retaining Nut 8—Pivot Washer

9—Rear Wiper Motor 10—Rear Wiper Motor Assembly 11—Rear Wiper Assembly

12—Washer Hose Coupler 13—Washer Hose 14—Washer Arm Hose

4. Disconnect washer hose (13) at coupler (12). 18 1810 7

MH66O88,000072D –19–29JUL08–6/7

5. Remove rear wiper motor mounting plate (16). 6. Lower rear wiper motor (9), mounting plate (16), and wiper arm (4). –UN–18DEC03

7. Remove rear wiper motor from mounting plate.

T196711A

8. Disassemble parts as shown and replace as necessary. 9. Install rear wiper motor to mounting plate. 10. Install wiper motor and mounting plate with mounting hardware.

Rear Windshield Wiper 15—Rear Wiper Motor Mounting Plate Screws 16—Rear Wiper Motor Mounting Plate

11. Connect electrical harness to wiper motor. 12. Connect windshield washer hose to coupler. 13. Install roof.

MH66O88,000072D –19–29JUL08–7/7

TM10687 (14OCT08)

18-1810-7

524K Loader 101408

PN=303

Operator Enclosure

18 1810 8

TM10687 (14OCT08)

18-1810-8

524K Loader 101408

PN=304

Group 1821

Seat and Seat Belt Seat Remove and Install 1. Park machine on flat level surface. Lower all implements to ground. 2. Lift seat cushion. 3. Disconnect harness to seat cushion and seat suspension.

18 1821 1 –UN–05JAN05

4. Remove cushion.

Specification Seat Back—Weight ........................................................................... 19 kg 42 lb

6. Remove cap screws from under seat suspension.

T206685A

5. Remove cap screws (1—3) and remove seat back from machine.

Seat Back 1—Cap Screw (2 used) 2—Cap Screw (2 used) 3—Cap Screw (2 used)

CAUTION: Avoid crushing injury from heavy component. Use appropriate lifting device when removing seat suspension. 7. Use appropriate lifting device and remove seat suspension. Specification Seat Suspension—Weight................................................................. 31 kg 68 lb

8. Repair or replace parts as necessary. 9. Install seat suspension and connect harness. 10. Install seat back and cushion.

AA95137,0001B45 –19–13AUG08–1/1

TM10687 (14OCT08)

18-1821-1

524K Loader 101408

PN=305

Seat and Seat Belt

Seat Belt Remove and Install 1. Park machine on flat level surface. Lower all implements to ground.

3. Remove cap screw (4) and seat belt (3).

T216764A

4. Repair or replace parts as necessary. 5. Install seat belt and cap screw. Seat Belt Buckle Specification Seat Belt—Torque .......................................................................... 39 N•m 29 lb-ft

6. Install seat belt buckle and cap screw.

1—Cap Screw 2—Seat Belt Buckle 3—Seat Belt 4—Cap Screw

–UN–27OCT05

Specification Seat Belt Buckle—Torque .............................................................. 39 N•m 29 lb-ft

T216765A

18 1821 2

–UN–27OCT05

2. Remove cap screw (1) and seat belt buckle (2).

Seat Belt

AA95137,0001B46 –19–13AUG08–1/1

TM10687 (14OCT08)

18-1821-2

524K Loader 101408

PN=306

Group 1830

Heating and Air Conditioning Proper Refrigerant Handling The U.S. Environmental Protection Agency prohibits discharge of any refrigerant into the atmosphere, and requires that refrigerant be recovered using the approved recovery equipment. IMPORTANT: Use correct refrigerant recovery, recycling and charging stations. Do not use refrigerant, hoses, fittings, components or refrigerant oils intended for use with R12 refrigerant.

18 1830 1

Recovery, recycling and charging stations for R12 and R134a refrigerants must not be interchanged. Systems containing R12 refrigerant use a different oil than systems using R134a. Certain seals are not compatible with both types of refrigerants.

MH66O88,0000931 –19–18FEB08–1/1

R134a Refrigerant Cautions CAUTION: Do not allow liquid refrigerant to contact eyes or skin. Liquid refrigerant will freeze eyes or skin on contact. Wear goggles, gloves and protective clothing. If liquid refrigerant contacts eyes or skin, Do not rub the area. Splash large amounts of cool water on affected area. Go to a physician or hospital immediately for treatment. Do not allow refrigerant to contact open flames or very hot surfaces such as electric welding arc, electric heating element and lighted smoking materials.

develop high pressure which can burst the container. Keep refrigerant containers away from heat sources. Store refrigerant in a cool place. Do not handle damp refrigerant container with your bare hands. Skin may freeze to container. Wear gloves. If skin freezes to container, pour cool water over container to free the skin. Go to a physician or hospital immediately for treatment.

Do not heat refrigerant over 52°C (125°F) in a closed container. Heated refrigerant will

MH66O88,0000932 –19–18FEB08–1/1

TM10687 (14OCT08)

18-1830-1

524K Loader 101408

PN=307

Heating and Air Conditioning

R134a Compressor Oil Charge Check Remove compressor if R134a leakage was detected and repaired. See Compressor Remove and Install. (Group 1830.) Drain oil from the compressor and record the amount. 18 See R134a Compressor Oil Removal. (Group 1830.) 1830 2

3. Flush the complete system with TY16134 air conditioning flushing solvent. 4. If the compressor is serviceable, pour flushing solvent in the manifold ports and internally wash out the old oil.

NOTE: Drain oil and save if this is a new compressor.

5. Install a new receiver-dryer.

If the oil drained from a compressor removed from operation is very black or the amount of oil is less than 6 mL (0.2 fl oz), perform the following:

6. Install required amount of TY22025 refrigerant oil in the compressor. See R134a Component Oil Charge. (Group 1830.)

1. Remove and discard the receiver-dryer.

7. Connect all components, evacuate and charge the system. See R134a System Evacuate, and see R134a System Charge. (Group 1830.)

2. Remove, clean, but do not disassemble the valve.

MH66O88,0000913 –19–18FEB08–1/1

R134a Compressor Oil Removal 1. Remove compressor from machine. See Compressor Remove and Install. (Group 1830.) 2. Remove inlet/outlet manifold from compressor, and clutch dust cover. 3. Drain oil into graduated container while rotating compressor shaft. 4. Record measured oil and discard oil properly. 5. Install new oil. See R134a Component Oil Charge. (Group 1830.) 6. Install compressor. See Compressor Remove and Install. (Group 1830.)

MH66O88,0000914 –19–18FEB08–1/1

TM10687 (14OCT08)

18-1830-2

524K Loader 101408

PN=308

Heating and Air Conditioning

R134a Component Oil Charge CAUTION: All new compressors are charged with a mixture of nitrogen, R134a refrigerant and TY22025 (R134a) refrigerant oil. Wear safety goggles and discharge the compressor slowly to avoid possible injury. Do not leave the system or R134a compressor oil containers open. This oil easily absorbs moisture. Do not spill R134a compressor oil on acrylic or ABS plastic. This oil will deteriorate these materials rapidly. Identify R134a oil containers and measures to eliminate accidental mixing of different oils. IMPORTANT: Determine the amount of system oil charge before installing compressor on machine. 1. Compressors can be divided into the following three categories when determining the correct oil charge for the system: • New compressor from parts depot • Used compressor removed from operation • Compressor internally washed with flushing solvent 2. If the complete system, lines, and components were flushed add the correct amount of oil as described. • A new compressor from parts depot contains 210—250 mL (7.0—8.4 fl oz) of new oil. The system requires an additional 135 mL (4.58 fl oz) of new oil. • A Used compressor removed from operation, drained and flushed requires 365 mL (12.35 fl oz) of new oil.

3. If the complete system was not flushed add the correct amount of oil for the compressor plus the amount of oil for each component that was serviced. • New compressor from parts depot, drain and 18 return 45 mL (1.5 fl oz) of oil to the compressor. 1830 3 See R134a Compressor Oil Removal. (Group 1830.) • Used compressor removed from operation and oil drained. Add 45 mL (1.5 fl oz) of new oil. See R134a Compressor Oil Removal. (Group 1830.) • Used compressor removed from operation, drained and flushed. Add 60 mL (2.0 fl oz) of new oil. See R134a Compressor Oil Removal, and see Air Conditioner System Flush. (Group 1830.) NOTE: Components listed below which have been removed, drained or flushed, require the removal of the compressor to determine the correct oil charge. 4. Use the following chart as a guide for adding oil to components: Evaporator

158 mL (5.4 fl oz)

Condenser

70 mL (2.4 fl oz)

Receiver-Dryer

37 mL (1.25 fl oz)

Hoses

73 mL (2.5 fl oz)

5. If any section of hose is removed and flushed, or replaced, measure the length of hose and use the following formula to determine the correct amount of oil to be added: • Hoses = 3 mL per 30 cm (0.1 fl oz per ft). Approximate total length equals 727 cm (24 ft)

MH66O88,0000915 –19–18FEB08–1/1

TM10687 (14OCT08)

18-1830-3

524K Loader 101408

PN=309

Heating and Air Conditioning

Refrigerant Leak Testing 1. Inspect all lines, fittings and components for oily or dusty spots. When refrigerant leaks from the system, a small amount of oil is carried out with it.

3. If a leak detector is used, move the leak detector probe under the hoses and around the connections at a rate of 25 mm (1 in.) per second.

2. A soap and water solution can be sprayed on the components in the system to form bubbles at the 18 source of the leak. 1830

4. Some Freon manufacturers add dye to Freon to aid in leak detection.

MH66O88,0000916 –19–21FEB08–1/1

Refrigerant Hoses and Tubing Inspection IMPORTANT: Hose used for air conditioning systems contains special barriers in its walls to prevent migration of refrigerant gas.

material. If such contamination is present in hoses, tubing, or fittings and cannot be removed by cleaning, then replace parts. Fittings that have grease or dirt on them should be wiped clean with a cloth dampened with alcohol. Chlorinated solvents (such as trichloroethylene) are contaminants, and must not be used for cleaning.

Do not use hydraulic hoses as replacement hoses in the air conditioning system. Use ONLY certified hose meeting SAE J51b requirements. When a component is disconnected from the system, special care should be given to inspecting hoses and tubing for moisture, grease, dirt, rust, or other foreign

To assist in making leak-proof joints in R134a systems, use a small amount of clean polyakyleneglycol (PAG) refrigerant oil on all hoses and tube connections. Dip O-rings in PAG oil before assembly.

MH66O88,0000917 –19–21FEB08–1/1

TM10687 (14OCT08)

18-1830-4

524K Loader 101408

PN=310

Heating and Air Conditioning

R134a Refrigerant Recovery/Recycling and Charging Station Installation Procedure CAUTION: Do not remove high pressure relief valve (1). Air conditioning system will discharge rapidly causing possible injury. 18 1830 5

IMPORTANT: Use correct refrigerant recovery/recycling and charging stations. Do not mix refrigerant, hoses, fittings, components or refrigerant oils. 1. Close both high and low pressure valves on refrigerant recovery/recycling and charging station (4). 2. Remove cap from low pressure test port (8).

–UN–11SEP07

3. Connect low pressure blue hose (5) from refrigerant recovery/recycling and charging station (4) to low pressure test port (8) on compressor.

TX1029096

4. Connect high pressure red hose (3) to high pressure test port (2). 5. Follow the manufacturers instructions when using the refrigerant recovery/recycling and charging station. 1—High Pressure Relief Valve 2—High Pressure Test Port 3—Red Hose 4—Refrigerant Recovery/Recycling and Charging Station 5—Blue Hose 6—High Pressure Hose 7—Low Pressure Hose 8—Low Pressure Test Port

MH66O88,0000918 –19–08AUG08–1/1

TM10687 (14OCT08)

18-1830-5

524K Loader 101408

PN=311

Heating and Air Conditioning

R134a System Recover CAUTION: Do not remove high pressure relief valve (1). Air conditioning system will discharge rapidly causing possible injury. IMPORTANT: Use correct refrigerant recovery, recycling and charging stations. Do not mix refrigerant, hoses, fittings, components or refrigerant oils. 1. Run air conditioning system for three minutes to help in the recovery process.

3. With engine OFF, connect refrigerant recovery, recycling and charging station. See R134a Refrigerant Recovery/Recycling and Charging Station Installation Procedure. (Group 1830.) 4. Follow the manufacturer’s instructions when using the refrigerant recovery, recycling and charging station. 1—High Pressure Relief Valve 2—High Pressure Test Port 3—Red Hose 4—Refrigerant Recovery/Recycling and Charging Station 5—Blue Hose 6—High Pressure Hose 7—Low Pressure Hose 8—Low Pressure Test Port

–UN–11SEP07

2. Put air conditioning system in the OFF position.

TX1029096

18 1830 6

MH66O88,0000919 –19–13AUG08–1/1

TM10687 (14OCT08)

18-1830-6

524K Loader 101408

PN=312

Heating and Air Conditioning

R134a System Evacuate CAUTION: Do not remove high pressure relief valve (1). Air conditioning system will discharge rapidly causing possible injury. IMPORTANT: Use correct refrigerant recovery, recycling and charging stations. Do not mix refrigerant, hoses, fittings, components or refrigerant oils.

18 1830 7

Do not run compressor while evacuating.

–UN–11SEP07

1. Connect refrigerant recovery, recycling and charging station. See R134a Refrigerant Recovery/Recycling and Charging Station Installation Procedure. (Group 1830.) 2. Open low and high pressure valves on refrigerant recovery, recycling and charging station.

TX1029096

3. Follow the manufacturers instructions and evacuate the system. NOTE: The vacuum specifications listed are for sea level conditions. Subtract 3.4 kPa (34 mbar) (1 in. Hg) from 98 kPa (980 mbar) (29 in. Hg) for each 300 m (1000 ft) elevation above sea level.

1—High Pressure Relief Valve 2—High Pressure Test Port 3—Red Hose 4—Refrigerant Recovery/Recycling and Charging Station 5—Blue Hose 6—High Pressure Hose 7—Low Pressure Hose 8—Low Pressure Test Port

4. Evacuate system until low pressure gauge registers 98 kPa (980 mbar) (29 in. Hg) vacuum. If 98 kPa (980 mbar) (29 in. Hg) vacuum cannot be obtained in 15 minutes, test the system for leaks. See Refrigerant Leak Testing. (Group 9031-25.) Repair any leaks. 5. When vacuum is 98 kPa (980 mbar) (29 in. Hg), close low-side and high-side valves. Turn vacuum pump off. 6. If the vacuum decreases more than 3.4 kPa (34 mbar) (1 in. Hg) in 5 minutes, there is a leak in the system. 7. Repair leak. 8. Start to evacuate.

Continued on next page

TM10687 (14OCT08)

18-1830-7

MH66O88,000091A –19–13AUG08–1/2

524K Loader 101408

PN=313

Heating and Air Conditioning 9. Open low-side and high-side valves. 10. Evacuate system for 30 minutes after 98 kPa (980 mbar) (29 in. Hg) vacuum is reached. 11. Close low-side and high-side valves. Stop evacuation. 18 1830 8

12. Charge the system. See R134a System Charge. (Group 1830.)

MH66O88,000091A –19–13AUG08–2/2

TM10687 (14OCT08)

18-1830-8

524K Loader 101408

PN=314

Heating and Air Conditioning

R134a System Charge CAUTION: Do not remove high pressure relief valve (1). Air conditioning system will discharge rapidly causing possible injury. IMPORTANT: Use correct refrigerant recovery, recycling and charging stations. Do not mix refrigerant, hoses, fittings, components or refrigerant oils.

18 1830 9

1. Connect JT02045 R134a refrigerant recovery, recycling and charging station. See R134a Refrigerant Recovery/Recycling and Charging Station Installation Procedure. (Group 1830.)

–UN–11SEP07

2. Evacuate the system. See R134a System Evacuate. (Group 1830.)

3. Follow the manufacturer’s instructions and charge the system. 4. Add refrigerant until system is charged to specification. Specification Refrigerant—Capacity .................................................................... 2.16 kg 4.75 lb

TX1029096

NOTE: Before beginning to charge air conditioning system, the following conditions must exist: Engine STOPPED, the pump must be capable of pulling at least 28.6 in. Hg vacuum (sea level). Subtract 3.4 kPa (34 mbar) (1 in. Hg) from 98 kPa (980 mbar) (29 in. Hg) for each 300 m (1000 ft) elevation above sea level. 1—High Pressure Relief Valve 2—High Pressure Test Port 3—Red Hose 4—Refrigerant Recovery/Recycling and Charging Station 5—Blue Hose 6—High Pressure Hose 7—Low Pressure Hose 8—Low Pressure Test Port

5. Conduct air conditioner checks and tests. See R134a Air Conditioning System Test. (Group 9031-25.)

MH66O88,000091B –19–13AUG08–1/1

TM10687 (14OCT08)

18-1830-9

524K Loader 101408

PN=315

Heating and Air Conditioning

Air Conditioner System Cleaning Procedures

18 1830 10

Flushing: Flushing the system or component is a cleaning process using a liquid solvent to remove oil and debris. Purging is always necessary after flushing to remove solvent from the system or component.

Purging: Purging the system or a component is a cleaning process using a gas to force liquid from the system. Purging alone will not remove refrigerant oil from the system.

Following is a list of situations that require a flushing procedure be done:

Following is a list of situations that require a purging procedure be done:

• The compressor has an internal failure. • No oil remains in used compressor. • Oil drained from compressor appears or smells overheated. • System was contaminated with a mixture of refrigerant oils. • System was left open to the atmosphere long enough for dirt, moisture, or debris to enter the tubing or components. • System has an internal blockage.

• After flushing system with solvent, to prevent oil dilution • System was contaminated with nitrogen or two refrigerants. • System was left open to the atmosphere and flushing could not be performed. • Installation of new lines, condenser, or evaporator was required.

The following solvent is recommended for flushing air conditioner systems. Use only solvents with an equivalent MSDS.

Evacuating: Evacuating the system is a process to remove air and moisture from the system, creating a vacuum.

• TY16134 John Deere Air Conditioning System Flushing Solvent

MH66O88,000091C –19–18FEB08–1/1

TM10687 (14OCT08)

18-1830-10

524K Loader 101408

PN=316

Heating and Air Conditioning

Air Conditioner System Purge IMPORTANT: Air compressors used for purging systems require a water separator. Purging without a separator adds moisture, creating hydrofluoric acid when combined with refrigerant oil. Acid is corrosive to metal tubing.

18 1830 11

1. Connect dry nitrogen hose to gauge manifold center hose. 2. Connect gauge manifold suction hose to compressor suction port, and open valves. 3. Connect gauge manifold discharge hose to compressor discharge post, and open valve. Disconnect discharge hose from gauge manifold to allow purging nitrogen to atmosphere. 4. Open nitrogen tank valve and adjust regulator to 275 kPa (40 psi) (2.75 bar). Purge system for two minutes. Disconnect nitrogen supply. Specification Nitrogen Tank Valve Regulator— Pressure ........................................................................................ 275 kPa 2.75 bar 40 psi

5. Evacuate system. See R134a System Evacuate. (Group 1830.)

MH66O88,000091D –19–21FEB08–1/1

TM10687 (14OCT08)

18-1830-11

524K Loader 101408

PN=317

Heating and Air Conditioning

Air Conditioner System Flush Add flushing solvent to system with JT02075 Flusher and JT02098 Fitting Kit. NOTE: Flushing can be performed on vehicle. 18 1830 12

1. Recover refrigerant. See R134a System Recover. (Group 1830.)

b. Evaporator, including inlet and outlet hoses. (Steps 13—26) IMPORTANT: Do not attempt to flush through compressor or receiver-dryer. Flushing through expansion valve is acceptable if refrigerant oil has normal odor and appearance.

2. Remove compressor. 7. To Flush/Purge Condenser: 3. Drain oil from compressor. See R134a Compressor Oil Removal. (Group 1830.)

Connect flusher outlet hose to inlet end of compressor discharge line using JT02102 Adapter.

4. Clean compressor as follows: a. Pour 240 mL (8 fl oz) of flushing solvent into suction port and 120 mL (4 fl oz) into discharge port. Plug both ports in compressor manifold using JT02099 and JT02100 with JT03194 Caps. b. Turn compressor end for end and roll it side to side. c. Remove both plugs from manifold ports and drain solvent from compressor. d. Connect battery power to compressor clutch coil. Rotate pulley at least five revolutions to move solvent out of cylinders.

8. Attach a return hose and aerator nozzle to outlet end of receiver-dryer inlet hose using JT03197 Adapter. Put nozzle in container to collect flushing solvent. 9. Fill flusher tank with 4 L (1 gal) of solvent and fasten all connections. NOTE: Air pressure must be at least 620 kPa (6.2 bar) (90 psi) for flushing and purging. 10. Connect a supply line of moisture-free compressed air or dry nitrogen to flusher air valve.

e. Invert compressor, roll end for end, and side to side. Drain thoroughly.

11. Open air valve to force flushing solvent into condenser circuit. Flusher tank is empty when hose pulsing stops. Additional flushing cycles are required if system is heavily contaminated with burned oil or metal particles.

f. Let compressor sit inverted for three to five minutes.

NOTE: Purging the condenser circuit takes 10—12 minutes to thoroughly remove solvent.

g. Repeat previous two steps at least three times.

12. Disconnect hose from aeration nozzle to check circuit for solvent. Hold hose close to a piece of cardboard; continue purging until cardboard is dry.

5. Remove and discard receiver-dryer.

13. Go to Step 13 to flush evaporator. Go to Step 22 if evaporator does not require flushing.

6. Divide system into two circuits: a. Condenser, including inlet and outlet hoses. (Steps 6—12)

14. To Flush Evaporator:

Continued on next page

TM10687 (14OCT08)

18-1830-12

MH66O88,000091E –19–21FEB08–1/2

524K Loader 101408

PN=318

Heating and Air Conditioning If system is contaminated with burned refrigerant oil or debris, remove and bench flush evaporator. Go to Step 18 to flush evaporator through expansion valve, if oil appears normal. See Heater/Evaporator Coil Remove and Install. (Group 1830.) 15. Force flushing solvent through evaporator inlet with compressed air.

NOTE: Purging the evaporator circuit takes 12—15 minutes to thoroughly remove solvent. 22. Disconnect hose from aeration nozzle to check circuit for solvent. Hold hose close to a piece of cardboard. Continue purging until cardboard is dry. 23. Install a new receiver-dryer compatible with R134a refrigerant. Fasten connections and mounting bracket.

16. Purge system until dry. 24. Add required oil. See R134a System Charge. (Group 1830.)

17. Reinstall evaporator.

25. Install compressor. See Compressor Remove and Install. (Group 1830.)

18. Go to Step 22. 19. To Flush Evaporator Through Expansion Valve:

26. Purge system. See Air Conditioner System Purge. (Group 1830.)

Connect flusher outlet hose to connection of receiver-dryer outlet hose using JT03188 Adapter. 20. Attach a hose and aerator nozzle to compressor inlet line using JT02101 Adapter. Put nozzle in a container to collect solvent.

27. Evacuate system. See R134a System Evacuate. (Group 1830.) 28. Charge system. See R134a System Charge. (Group 1830.)

21. Repeat steps 8, 9 and 10 to flush evaporator.

MH66O88,000091E –19–21FEB08–2/2

TM10687 (14OCT08)

18-1830-13

524K Loader 101408

PN=319

18 1830 13

Heating and Air Conditioning

Air Conditioning Module With Heater/Evaporator Coil

18 1830 14

6 5 23

4 7 21

11 9

22 14

TX1029425

–UN–17SEP07

TX1029425 Air Conditioning Module with Heater/Evaporator Coil 1—Upper Case 2—Isolator 3—Freeze Control Switch 4—Clip (11 used) 5—Resistor 6—Condensation Tube 7—Condensation Fitting

8—Condensation Tee 9—Tube 10—Elbow 11—Gasket 12—Blower Isolator 13—Impeller 14—Blower Motor

15—Lower Case 16—Isolator 17—Bracket 18—Heater Hose 19—Air Conditioning Lines 20—Heater Hose 21—Heat Control Valve

22—Heater Hose 23—Pressure Switch 24—Heater Coil 25—Air Conditioning Evaporator 26—Expansion Valve

MH66O88,000091F –19–21FEB08–1/1

TM10687 (14OCT08)

18-1830-14

524K Loader 101408

PN=320

Heating and Air Conditioning

Heater/Evaporator Coil Remove and Install

18 1830 15

5 4

TX1029249

–UN–11SEP07

TX1029249 1—Heater/Evaporator Coil Upper Case

2—Clip (11 used) 3—Blower Motor

4—Resistor 5—Freeze Control Switch Probe

1. Recover refrigerant from the system. See R134a System Recover. (Group 1830.)

6—Expansion Valve

8. Remove heater/evaporator coil top cover. 9. Remove freeze control switch probe (5) from coil.

2. Remove seat cap screws and move seat forward to access air conditioning-heater components. 3. Remove console tray and fresh air filter. See Fresh Air Filter Remove and Install. (Group 1830.)

10. Disconnect air conditioning lines from expansion valve (6) and heater hoses from coil. 11. Remove heater/evaporator coil. 12. Install expansion valve on heater/evaporator coil.

4. Remove upper panel behind seat to expose heater/evaporator coil housing. 5. Remove upper two cap screws from blower motor (3).

13. Check lower housing to make sure drain tube is not plugged. 14. Install heater/evaporator coil.

6. Disconnect wire harness from freeze control switch and resistor (4). 7. Remove clips (2) attaching heater/evaporator coil top cover (1) to lower case.

15. Connect air conditioner lines and heater hoses. 16. Install freeze control switch in coil.

Continued on next page

TM10687 (14OCT08)

18-1830-15

SW03989,00004C0 –19–20MAR08–1/2

524K Loader 101408

PN=321

Heating and Air Conditioning 17. Install heater/evaporator coil top cover with clips.

individually. See Air Conditioner System Flush and see Air Conditioner System Purge. (Group 1830.)

18. Install upper panel behind seat. 19. Connect wire harness to freeze control switch and resistor. 18 20. Install cab filter and console tray. See Fresh Air Filter Remove and Install. (Group 1830.) 1830 16

21. Move seat back and tighten cap screws securely. 22. If the system is contaminated, each component in the system must be flushed and purged

23. Drain oil from compressor. See R134a Compressor Oil Removal. (Group 1830.) 24. If system was not completely flushed, see Air Conditioner System Flush. (Group 1830.) 25. Purge, evacuate, and charge the system. See Air Conditioner System Purge, see R134a System Evacuate, and see R134a System Charge. (Group 1830.)

SW03989,00004C0 –19–20MAR08–2/2

Expansion Valve Remove and Install 1. Recover refrigerant from the system. See R134a System Recover. (Group 1830.) 2. Remove rear cover behind seat.

3. Disconnect air conditioning lines (1) from expansion valve (2). 1

4. Remove expansion valve.

–UN–11SEP07

5. Install expansion valve. 6. Connect air conditioning lines to expansion valve.

8. Purge, evacuate, and charge the system. See Air Conditioner System Purge, see R134a System Evacuate, and see R134a System Charge. (Group 1830.)

TX1029255

7. Install rear cover behind seat.

1—Air Conditioning Lines 2—Expansion Valve

MH66O88,0000921 –19–13AUG08–1/1

TM10687 (14OCT08)

18-1830-16

524K Loader 101408

PN=322

Heating and Air Conditioning

Freeze Control Switch Remove and Install

3. Disconnect wire leads from freeze control switch and remove switch from cover. 4. Test freeze control switch. See Freeze Control Switch Bench Test. (Group 1830.)

TX1029277

2. Remove probe (2) of freeze control switch (1) from heater/evaporator coil.

–UN–11SEP07

1. Remove heater/evaporator coil top cover. See Heater/Evaporator Coil Remove and Install. (Group 1830.)

1—Freeze Control Switch 2—Probe

5. Attach freeze control switch to heater/evaporator coil top cover. 6. Connect wire leads to freeze control switch. 7. Insert freeze control switch probe into heater/evaporator coil. 8. Install heater/evaporator coil top cover. See Heater/Evaporator Coil Remove and Install. (Group 1830.)

MH66O88,0000922 –19–18FEB08–1/1

TM10687 (14OCT08)

18-1830-17

524K Loader 101408

PN=323

18 1830 17

Heating and Air Conditioning

Freeze Control Switch Bench Test 1. Apply 24 volts to pin A and ground pin C on the freeze control switch connector. 2. Using a voltmeter, measure voltage at pin B; make sure negative lead is grounded. Meter reading should be 24 volts. 18 1830 18

3. Place end of probe into an ice and saltwater solution. When cut-out temperature specification is reached or exceeded, meter reading should be zero. Specification Freeze Control Switch—Cut-Out Temperature ......................................................................... -1.06°—.06°C (30.1°—31.9°F)

4. Warm the water. When cut-in temperature specification is reached or exceeded, meter reading should be 24 volts. Specification Freeze Control Switch—Cut-In Temperature ....................................................................... -1.72°— -2.7°C (35.1°—36.9°F)

If switch operates within specifications, reinstall switch. If switch does not operate within specifications, replace with new switch.

MH66O88,0000923 –19–21FEB08–1/1

TM10687 (14OCT08)

18-1830-18

524K Loader 101408

PN=324

Heating and Air Conditioning

Heater Control Valve Remove and Install 1. Remove console tray. See Fresh Air Filter Remove and Install. (Group 1830.) 2. Remove rear cover behind seat. –UN–17SEP07

3. Disconnect temperature control switch cable from heater control valve.

TX1029307A

4. Remove heater control valve (1) and test. See Heater Control Valve Leak Check. (Group 1830.) 5. Inspect heater hoses and replace as required. 6. Connect the temperature control cable. Tighten all hose connections.

1—Heater Control Valve

7. Install rear cover behind seat. 8. Install console tray. 9. Add coolant to the surge tank to account for coolant in the heater circuit. Start engine and run the heating system to check for leaks.

TW73308,0000242 –19–22APR08–1/1

TM10687 (14OCT08)

18-1830-19

524K Loader 101408

PN=325

18 1830 19

Heating and Air Conditioning

Heater Control Valve Leak Check 1. Remove heater control valve. See Heater Control Valve Remove and Install. (Group 1830.) 2. Using an external water pressure source, connect a hose to the heater control valve inlet and turn the valve arm to the closed position. 18 1830 20

3. Apply water pressure. 4. Check for leakage from the heater control valve outlet. NOTE: The heater control valve is not serviceable. 5. Replace heater control valve if there is leakage. 6. Install heater control valve. See Heater Control Valve Remove and Install. (Group 1830.)

TW73308,00000F6 –19–17SEP07–1/1

TM10687 (14OCT08)

18-1830-20

524K Loader 101408

PN=326

Heating and Air Conditioning

Blower Motor Assembly Remove and Install 1. Turn battery disconnect switch to the OFF position. –UN–11SEP07

2. Remove cap screws from seat pedestal to cab floor and move pedestal and seat assembly forward.

TX1029269A

3. Remove left console tray. 4. Remove rear cover behind seat. 5. Disconnect electrical connectors (1). Blower Motor Assembly

6. Remove cap screws from blower motor assembly to housing.

1—Electrical Connector (4 used) 2—Blower Motor Assembly

7. Remove blower motor assembly (2). 8. Repair or replace parts as necessary. 9. Install blower motor assembly to housing and secure using cap screws. 10. Connect electrical connectors. 11. Install rear cover behind seat. 12. Install console tray. 13. Position pedestal and seat assembly and secure to cab floor using cap screws. 14. Turn battery disconnect switch to the ON position.

TW73308,0000241 –19–21APR08–1/1

TM10687 (14OCT08)

18-1830-21

524K Loader 101408

PN=327

18 1830 21

Heating and Air Conditioning

Receiver-Dryer Remove and Install

–UN–19SEP07

1. Evacuate and recover refrigerant from air conditioning system. See R134a System Evacuate (Group 1830.) and see R134a System Recover. (Group 1830.) 2. Disconnect lines (2 and 4) from receiver-dryer (3). 3. Loosen mounting clamps (1) on receiver-dryer.

TX1029492A

18 1830 22

4. Remove receiver-dryer. IMPORTANT: A new receiver-dryer must always be installed after purging the system. Do not use a flushed or used receiver-dryer. Contamination of system can cause component failure.

1—Mounting Clamp (2 used) 2—Line 3—Receiver-Dryer 4—Line

5. Remove plug from new receiver-dryer and add 15 mL (0.5 fl oz) of compressor oil. Install plug. 6. Install new receiver-dryer. 7. Apply compressor oil to new O-rings. Remove plugs from receiver-dryer inlet and outlet ports and immediately connect lines. 8. See R134a Component Oil Charge. (Group 1830.) 9. Tighten mounting clamps on receiver-dryer . 10. Charge air conditioning system. See R134a System Charge. (Group 1830.)

MH66O88,0000928 –19–25FEB08–1/1

TM10687 (14OCT08)

18-1830-22

524K Loader 101408

PN=328

Heating and Air Conditioning

Condenser Remove and Install

–UN–19SEP07

1. Evacuate and recover refrigerant from air conditioning system. See R134a System Evacuate (Group 1830.) and see R134a System Recover. (Group 1830.)

TX1029213A

2. Open cooling package door. Disconnect lines (1 and 3) from condenser (2). Close all openings using caps and plugs. 3. Open rear hood. 4. Remove condenser and repair or replace as necessary.

1—Line 2—Condenser 3—Line

5. Install condenser. 6. Connect lines to condenser. 7. Charge air conditioning system. See R134a System Charge. (Group 1830.)

TW73308,00000FA –19–17SEP07–1/1

TM10687 (14OCT08)

18-1830-23

524K Loader 101408

PN=329

18 1830 23

Heating and Air Conditioning

Air Conditioning High-Low Pressure Switch Remove and Install 1. Remove knob (1). 2. Remove console tray (2). –UN–25FEB08

3. Disconnect electrical connector from pressure switch (3).

TX1037230A

NOTE: A schrader valve is located in the port connection for the binary pressure switch to prevent the air conditioning from discharging when the switch is removed. Console Tray

4. Remove pressure switch. 5. Inspect and replace as necessary.

–UN–08AUG08

6. Install pressure switch. Check for leaks. See Refrigerant Leak Testing. (Group 1830.) 7. Connect electrical connector to pressure switch. 8. Install console tray and secure with knob.

TX1037345A

18 1830 24

Pressure Switch 1—Knob 2—Console Tray 3—Pressure Switch MH66O88,0000929 –19–13AUG08–1/1

TM10687 (14OCT08)

18-1830-24

524K Loader 101408

PN=330

Heating and Air Conditioning

Fresh Air Filter Remove and Install NOTE: The fresh air filter is located inside left console. 1. Remove knob (1).

–UN–25FEB08

2. Remove console tray (2). 3. Remove fresh air filter retainer (5).

CAUTION: Prevent possible injury from flying debris. Reduce compressed air to less than 210 kPa (2 bar) (30 psi) when using for cleaning purposes. Clear area of bystanders, guard against flying chips, and wear personal protection equipment, including eye protection.

TX1037230A

4. Remove fresh air filter (6).

Console Tray

–UN–25FEB08

5. Clean filter in one of these ways:

TX1037231A

• Tap filter on a flat surface with the dirty side down. • Use compressed air opposite to the normal air flow. • Wash filter in warm, soapy water. Flush filter and let it dry before using the air conditioner. 6. Install fresh air filter. Air Filters

7. Install retainer.

1—Knob 2—Console Tray 3—Recirculating Air Filter Retainer 4—Recirculating Air Filter 5—Fresh Air Filter Retainer 6—Fresh Air Filter

8. Install console tray and secure with knob.

MH66O88,000092A –19–25FEB08–1/1

TM10687 (14OCT08)

18-1830-25

524K Loader 101408

PN=331

18 1830 25

Heating and Air Conditioning

Recirculating Air Filter Remove and Install NOTE: The recirculating air filter is located inside left console. 1. Remove knob (1). –UN–25FEB08

2. Remove console tray (2). 3. Remove recirculating air filter retainer (3).

TX1037230A

4. Remove recirculating air filter (4).

Console Tray

–UN–25FEB08

5. Clean filter in one of these ways: • Tap filter on a flat surface with the dirty side facing down. • Use compressed air opposite to the normal air flow. • Wash the filter in warm, soapy water. Flush the filter and let it dry before using the air conditioner.

TX1037231A

18 1830 26

Air Filters

6. Install recirculating air filter.

1—Knob 2—Console Tray 3—Recirculating Air Filter Retainer 4—Recirculating Air Filter 5—Fresh Air Filter Retainer 6—Fresh Air Filter

7. Install retainer. 8. Install console tray and secure with knob.

MH66O88,000092B –19–21FEB08–1/1

TM10687 (14OCT08)

18-1830-26

524K Loader 101408

PN=332

Heating and Air Conditioning

Compressor Remove and Install 1. Recover refrigerant from system. See R134a System Recover. (Group 1830.) –UN–25AUG05

2. Disconnect electrical connector.

T213886A

3. Remove serpentine belt (2) from air conditioning compressor (1). See Serpentine Belt Remove and Install. (Group 0400.) 4. Remove air conditioner compressor high-pressure outlet line (4) and low-pressure inlet line (3). 5. Remove cap screws (5) and remove air conditioning compressor.

1—Air Conditioning Compressor 2—Serpentine Belt 3—Low-Pressure Inlet Line 4—High-Pressure Outlet Line 5—Cap Screw (3 used)

6. Repair or replace parts as necessary. NOTE: If compressor was replaced due to an internal failure, flush and purge each component in the air conditioning system individually. See Air Conditioner System Flush and see Air Conditioner System Purge. (Group 1830.) 7. Install compressor. 8. Install air conditioning compressor high-pressure outlet line. 9. Install air conditioning compressor low-pressure inlet line. 10. Connect electrical connector. 11. Install serpentine belt on air conditioning compressor. See Serpentine Belt Remove and Install. (Group 0510.) 12. Evacuate and charge system. See R134a System Evacuate and see R134a System Charge. (Group 1830.)

MH66O88,000092E –19–25FEB08–1/1

TM10687 (14OCT08)

18-1830-27

524K Loader 101408

PN=333

18 1830 27

Heating and Air Conditioning

Compressor Clutch—R134a Disassemble and Assemble

TX1029376

–UN–14SEP07

TX1029375

–UN–14SEP07

18 1830 28

1—JDG747 Compressor Clutch Spanner 2—Shim (as required)

3—Cap Screw 4—Clutch Hub

1. Mount compressor to holding fixture.

5—Snap Ring 6—Pulley

7—Snap Ring 8—Clutch Coil

3. Hold clutch hub using JDG747 Compressor Clutch Spanner (1) and remove cap screw (3).

2. Remove dust cover.

Continued on next page

TM10687 (14OCT08)

18-1830-28

MH66O88,000092F –19–25FEB08–1/2

524K Loader 101408

PN=334

Heating and Air Conditioning 8. Install clutch coil and new snap ring with flat side of snap ring down. Connect clutch coil lead wire.

4. Remove clutch hub (4) and shims (2). 5. Remove and discard snap ring (5). Remove pulley (6) using JDG220 Puller, JDG748 Jaws, and JDG771 Hub Protector or a soft faced mallet. 6. Disconnect clutch coil lead wire. Remove and discard snap ring (7) and remove clutch coil (8). NOTE: The pulley bearing is not serviceable. Pulley and bearing must be replaced as a unit.

9. Install pulley and new snap ring with flat side of snap ring down. Apply grease to shims and install to clutch hub. 10. Install clutch hub and cap screw. Perform Clutch Hub Clearance—R134a Check. (Group 1830.)

18 1830 29

11. Install dust cover.

7. Check pulley bearing operation. Replace pulley and bearing as required.

MH66O88,000092F –19–25FEB08–2/2

Clutch Hub Clearance—R134a Check NOTE: The clutch coil is not polarity sensitive. 1. Check pulley-to-clutch hub clearance using a dial indicator. Mount the gauge to the pulley as illustrated and connect a set of jumper wires from the compressor to a 12 V battery. 2. Rotate the pulley and check clearance in three equally spaced locations around the clutch hub. Compare readings to specification. Specification Pulley-to-Clutch Hub—Clearance...................................... 0.35—0.65 mm 0.014—0.026 in.

–UN–24JUN92

3. Add or remove shims as required. See Compressor Clutch—R134a Disassemble and Assemble. (Group 1830.) 4. After clearance is set within specification, tighten clutch shaft cap screw to specification.

RW21159

Specification Clutch Shaft Cap Screw—Torque .................................................. 14 N•m 120 lb-in. Clutch Hub Clearance Check

MH66O88,0000930 –19–25FEB08–1/1

TM10687 (14OCT08)

18-1830-29

524K Loader 101408

PN=335

Heating and Air Conditioning

18 1830 30

TM10687 (14OCT08)

18-1830-30

524K Loader 101408

PN=336

Section 19

Sheet Metal and Styling Contents Page

Group 1910—Hood or Engine Enclosure Hood Remove and Install. . . . . . . . . . . . . . .19-1910-1 Engine Side Shields Remove and Install . . .19-1910-2 19

TM10687 (14OCT08)

19-1

524K Loader 101408

PN=1

Contents

TM10687 (14OCT08)

19-2

524K Loader 101408

PN=2

Group 1910

Hood or Engine Enclosure Hood Remove and Install 1. Loosen air cleaner hose clamp at turbocharger. 2. Disconnect air filter restriction switch from harness. 3. Remove cap screws (2) and washers (3).

4. Remove hydraulic reservoir cap (4).

4 –UN–28FEB08

CAUTION: Prevent possible injury from crushing. Heavy component; use appropriate lifting device.

TX1037492

NOTE: Exhaust stack and air intake can remain attached to hood during removal and installation. 5. Attach appropriate lifting device to hood (1) and remove. Hood Assembly

Specification Hood—Weight (approximate) ............................................................ 86 kg 190 lb

6. Install hood. Install washers and cap screws. Tighten cap screws securely.

1—Hood 2—Cap Screw (8 used) 3—Washer (8 used) 4—Hydraulic Reservoir Cap

7. Install hydraulic reservoir cap. 8. Connect air filter restriction switch from harness. 9. Install air cleaner-to-turbocharger hose. Install hose clamp and tighten securely.

SW03989,0000455 –19–06OCT08–1/1

TM10687 (14OCT08)

19-1910-1

524K Loader 101408

PN=339

19 1910 1

Hood or Engine Enclosure

Engine Side Shields Remove and Install

1 19 1910 2

9 7

6 7 9

–UN–20AUG08

7 10

TX1047478

TX1047478 Engine Side Shields Remove and Install Continued on next page

TM10687 (14OCT08)

19-1910-2

MH66O88,000071E –19–20AUG08–1/2

524K Loader 101408

PN=340

Hood or Engine Enclosure 1—Hinge 2—Nut 3—Rivet 4—Door

5—Latch 6—Isolator 7—Cap Screw

8—Door 9—Plate 10—Washer

CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device.

11—Cylinder 12—Ball Stud 13—Clip

Specification Engine Side Shield—Weight (approximate) .............................................................................. 25 kg 55 lb

MH66O88,000071E –19–20AUG08–2/2

19 1910 3

TM10687 (14OCT08)

19-1910-3

524K Loader 101408

PN=341

Hood or Engine Enclosure

19 1910 4

TM10687 (14OCT08)

19-1910-4

524K Loader 101408

PN=342

Section 31

Loader Contents Page

Group 3102—Bucket Bucket Remove and Install . . . . . . . . . . . . . .31-3102-1 Welded Bucket Cutting Edges Remove and Install . . . . . . . . . . . . . . . . . . . . . . . . .31-3102-2 Bolt-On Cutting Edges Remove and Install. . . . . . . . . . . . . . . . . . . . . . . . . . . . .31-3102-3 Cracked Cutting Edge Repair . . . . . . . . . . . .31-3102-4 Group 3140—Frames Loader Bucket Tilt Linkage Remove and Install. . . . . . . . . . . . . . . . . . . . . . . . . . . . .31-3140-1 Bucket Linkage Seals and Bushings Remove and Install . . . . . . . . . . . . . . . . . . . . . . . . .31-3140-2 Loader Boom Bushings and Seals Remove and Install . . . . . . . . . . . . . . . . . . . . . . . . .31-3140-3 Boom Remove and Install . . . . . . . . . . . . . . .31-3140-4 Hi-Vis Coupler Disassemble and Assemble. . . . . . . . . . . . . . . . . . . . . . . . . .31-3140-8

Group 3160—Hydraulic System General Oil Cleanup Procedure. . . . . . . . . . .31-3160-1 Hydraulic Component Failure Cleanup Procedure . . . . . . . . . . . . . . . . . . . . . . . . .31-3160-4 Follow-Up Oil Cleanup Procedure . . . . . . . . .31-3160-7 Main Hydraulic Pump Remove and Install . . .31-3160-8 Main Hydraulic Pump Disassemble and Assemble. . . . . . . . . . . . . . . . . . . . . . . . .31-3160-12 Loader Control Valve Remove and Install. . . . . . . . . . . . . . . . . . . . . . . . . . . .31-3160-13 Loader Control Valve Disassemble and Assemble. . . . . . . . . . . . . . . . . . . . . . . . .31-3160-16 Boom Section Disassemble and Assemble. . . . . . . . . . . . . . . . . . . . . . . . .31-3160-17 Bucket Section Disassemble and Assemble. . . . . . . . . . . . . . . . . . . . . . . . .31-3160-18 Auxiliary Section Disassemble and Assemble. . . . . . . . . . . . . . . . . . . . . . . . .31-3160-19 Main Relief Valve Disassemble and Assemble. . . . . . . . . . . . . . . . . . . . . . . . .31-3160-20 Load Sense Relief Valve Disassemble and Assemble. . . . . . . . . . . . . . . . . . . . . . . . .31-3160-21 Circuit Relief With Anticavitation Valve Disassemble and Assemble. . . . . . . . . . .31-3160-22 Anticavitation Valve Disassemble and Assemble. . . . . . . . . . . . . . . . . . . . . . . . .31-3160-24 Boom Cylinder Remove and Install . . . . . . .31-3160-25 TM10687 (14OCT08)

Page

Bucket Cylinder Remove and Install . . . . . .31-3160-27 Boom and Bucket Cylinder Disassemble and Assemble. . . . . . . . . . . . . . . . . . . . . . . . .31-3160-30 Boom or Bucket Cylinder Bushings and Seals Remove and Install . . . . . . . . . . . .31-3160-31 Loader Start-Up Procedure . . . . . . . . . . . . .31-3160-32 Hydraulic Reservoir Remove and Install . . .31-3160-33 Pilot Control Valve Remove and Install . . . .31-3160-37 Pilot Control Valve Disassemble and Assemble. . . . . . . . . . . . . . . . . . . . . . . . .31-3160-40 31 Auxiliary Function Pilot Control Valve Remove and Install . . . . . . . . . . . . . . . . .31-3160-42 Auxiliary Function Pilot Control Valve Disassemble and Assemble. . . . . . . . . . .31-3160-45 Pilot Accumulator Remove and Install . . . . .31-3160-47 Hydraulic Pump Manifold Remove and Install. . . . . . . . . . . . . . . . . . . . . . . . . . . .31-3160-48 Hydraulic Pump Manifold Disassemble and Assemble. . . . . . . . . . . . . . . . . . . . . . . . .31-3160-52 Ride Control Valve Remove and Install . . . .31-3160-54 Ride Control Valve Disassemble and Assemble. . . . . . . . . . . . . . . . . . . . . . . . .31-3160-56 Pin Disconnect Valve Remove and Install. . . . . . . . . . . . . . . . . . . . . . . . . . . .31-3160-57 Pin Disconnect Valve Disassemble and Assemble. . . . . . . . . . . . . . . . . . . . . . . . .31-3160-59 Hydraulic Fan Pump and Axle Circulation Pump Remove and Install . . . . . . . . . . . .31-3160-60 Hydraulic Fan Motor Remove and Install. . .31-3160-62 Reversing Fan Valve Remove and Install. . . . . . . . . . . . . . . . . . . . . . . . . . . .31-3160-64 Reversing Fan Valve Disassemble and Assemble. . . . . . . . . . . . . . . . . . . . . . . . .31-3160-66

31-1

524K Loader 101408

PN=1

Contents

TM10687 (14OCT08)

31-2

524K Loader 101408

PN=2

Group 3102

Bucket Bucket Remove and Install 1

–UN–18OCT07

31 3102 1

TX1030754

TX1030754 Bucket 1—Shim, Bucket Link to Bucket (as needed) 2—Pin, Bucket Link to Bucket

3—Spacer (3 used) 4—Washer (3 used) 5—Cap Screw (3 used)

6—Lubrication Fitting (2 used) 7—Pin, Bucket to Boom (2 used)

CAUTION: Prevent possible injury from crushing. Heavy component; use appropriate lifting device. 1. Lower bucket to the ground. 2. Remove cap screws (5), washers (4), spacers (3), and pins (2 and 7). 3. Align boom ends with bucket. Install shims (8) between boom ends and bucket as needed to obtain maximum clearance.

4. Install an equal number of shims ± 1 on each side of boom end. 5. Install pins (7), spacers (3), washers (4), and cap screws (5). 6. Align bucket link with bucket. Install shims (1) between bucket link and bucket to obtain maximum clearance. Specification Link-to-Bucket—Clearance (maximum) .................................................................................. 2 mm 0.08 in.

Specification Boom End-to-Bucket— Clearance (maximum) ................................................................ 1 mm 0.04 in.

7. Install an equal number of shims ± 1 on each side of bucket link.

Continued on next page

TM10687 (14OCT08)

8—Shim, Bucket to Boom (as needed)

31-3102-1

MH66O88,000072E –19–30SEP08–1/2

524K Loader 101408

PN=345

Bucket 8. Install pin (2), spacers (3), washers (4), and cap screws (5).

MH66O88,000072E –19–30SEP08–2/2

Welded Bucket Cutting Edges Remove and Install 1. Perform welding in an environment with a minimum ambient temperature of 10°C (50°F).

5. Tack weld preheated plates starting at center of bucket and working toward the outside ends.

2. Clean all joints to be welded of all foreign matter such as dirt, rust, mill scale, oil, etc. with grinders and/or solvents.

6. Final weld preheated plates starting at the center of the front edge of the bucket backing plate and working toward the outside ends.

3. Use dry AWS-E7018 low hydrogen electrodes or either of the following equivalent low hydrogen wire feed electrodes: gas metal arc welding (CO2 or 31 3102 argon CO2) AWS-E70S6 or flux cored arc welding 2 AWS-E70T1. 4. Preheat parts to be welded (both tack and final welds) to minimum of 204°C (400°F). Preheat temperature must be throughout the entire thickness of the parts joined and at least 51 mm (2 in.) back from the joint. Maintain preheat throughout the entire welding operation. Tempilstiks should be used if possible.

Repeat this operation at back edge of loader blade. Tack welds may be incorporated into the final weld, providing they have been made with electrodes that meet the requirements of the final welds and no cracking has occurred in the weld metal. Tack welds not meeting these requirements must be completely removed by grinding or air arc gouging just prior to making the final weld in that area. 7. Do not remove bucket from welding environment until weld metal temperature has dropped to the ambient temperature. Do not force cooling rate of weld metal.

Specification Bucket Cutting Edge—Preheat Temperature—Minimum throughout entire thickness of parts ........................................................................................... 204°C 400°F Distance—Minimum back from joint ........................................................................................... 51 mm 2 in.

TX,31,ME120 –19–14OCT98–1/1

TM10687 (14OCT08)

31-3102-2

524K Loader 101408

PN=346

Bucket

Bolt-On Cutting Edges Remove and Install

TP48319

–UN–17APR96

31 3102 3

Bolt-On Cutting Edges 1—Nut (12 used)

2—Cutting Edge (2 used)

3—Cap Screw (12 used)

CAUTION: Prevent possible injury from crushing. Heavy component, use appropriate lifting device. 1. Remove cap screws (3) and remove cutting edges (2 and 4) from bucket using appropriate lifting device.

4—Cutting Edge (2 used)

2. Install cutting edge in position using appropriate lifting device and install new cap screws. Specification Cutting Edge-to-Bucket Cap Screw—Torque ...................................................................... 495 N•m 365 lb-ft

AA95137,0001B53 –19–20AUG08–1/1

TM10687 (14OCT08)

31-3102-3

524K Loader 101408

PN=347

Bucket

Cracked Cutting Edge Repair 1. If cutting edge has any cracks, clean the area to find end of crack. 2. Drill a small hole at end of crack to prevent spreading. 3. Grind V-grooves along crack on top and bottom of cutting edge. 4. Preheat the cracked area. Specification Cracked Cutting Edge—Preheat Temperature .......................................................................... 149°—260°C 300°—500°F

5. Fill the V-grooves with weld. Use E7018 electrodes. Extend the weld. 31 3102 4

Specification Cracked Cutting Edge— Distance—Beyond End of Crack .................................................... 13 mm 0.5 in.

TX,31,ME122 –19–23SEP98–1/1

TM10687 (14OCT08)

31-3102-4

524K Loader 101408

PN=348

Group 3140

Frames Loader Bucket Tilt Linkage Remove and Install

T108207

–19–03APR97

31 3140 1

Loader Bucket Tilt Linkage A—Bucket Cylinder B—Shim (as required) C—Bellcrank D—Shim (As Required)

E—Lubrication Fitting (3 used) F—Seal (4 used) G—Bucket Link

1. Lower bucket to the ground. CAUTION: Prevent possible injury from crushing. Heavy component, use appropriate lifting device. 2. Remove parts as necessary.

H—Pin I—Spacer (2 used) J—Washer (2 used)

K—Cap Screw (2 used) L—Pin M—Loader Boom

Specification Bucket Cylinder Rod End-to-Bellcrank—Clearance (maximum) .................................................................................. 3 mm 0.12 in.

4. Apply PM37566 Silver-Grade Anti-Seize lubricant or equivalent lubricant to bore of bellcrank pivot pin.

3. Install shims (B) and (D) to obtain maximum clearance.

SW03989,0000741 –19–05SEP08–1/1

TM10687 (14OCT08)

31-3140-1

524K Loader 101408

PN=349

Frames

Bucket Linkage Seals and Bushings Remove and Install

T108214

–19–26NOV97

31 3140 2

Bucket Linkage Seals and Bushings A—Bellcrank B—Seal (2 used)

C—Bucket Link D—Seal (4 used)

E—Bushing (2 used) F—Shim (as required)

1. Lower bucket to ground. 2. Remove and install bushings and seals in bucket link and bellcrank using disks from driver set. 3. Apply PM37566 Silver-Grade Anti-Seize lubricant or equivalent to new bushings and bushing bores.

G—Bushing

Specification Bellcrank-to-Bucket Link— Clearance (maximum) ................................................................ 3 mm 0.12 in.

7. Install shims between bellcrank and bucket to obtain maximum clearance.

4. Install bellcrank and bucket link bushings below surface.

Specification Bellcrank-to-Bucket— Clearance (maximum) ................................................................ 2 mm 0.08 in.

Specification Bucket Linkage Bushing— Distance (below surface) ......................................................... 6.4 mm 0.25 in.

8. Install shims between bellcrank and loader boom to obtain maximum clearance.

5. Install seals into bores against bushings. 6. Install shims between bellcrank and bucket link to obtain maximum clearance.

Specification Bellcrank-to-Loader Boom— Clearance (maximum) ................................................................ 3 mm 0.12 in.

SW03989,0000742 –19–05SEP08–1/1

TM10687 (14OCT08)

31-3140-2

524K Loader 101408

PN=350

Frames

Loader Boom Bushings and Seals Remove and Install

T108266

–UN–26NOV97

31 3140 3

A—Bushing (6 used)

B—Seal (12 used)

1. Lower bucket to the ground and remove bucket from boom.

C—Loader Boom

5. Remove bushings from boom using discs from driver set.

CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device. 2. Remove bucket cylinder and linkage.

6. Apply PM37566 Silver-Grade Anti-Seize lubricant or equivalent to outer surface of new bushings and bores. Center new bushings in boom bores and press seals against bushings with lips outward. 7. Install boom, cylinders, linkage and bucket.

3. Disconnect boom cylinder rod ends from boom.

8. Install shims in original locations. Install shims as needed in loader frame to boom joint.

CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device. 4. Remove boom pivot pins from machine frame and remove boom.

SW03989,0000743 –19–05SEP08–1/1

TM10687 (14OCT08)

31-3140-3

524K Loader 101408

PN=351

Frames

Boom Remove and Install 1. Lower bucket to ground. CAUTION: To prevent possible injury from unexpected machine movement, install frame locking bar before working in frame hinge area. 2. Install frame locking bar. 3. Stop engine. 4. Remove bucket. See Bucket Remove and Install. (Group 3102.) 5. Remove bucket cylinder. See Bucket Cylinder Remove and Install. (Group 3160.) 31 3140 4

6. Remove bucket linkage. See Bucket Linkage Seals and Bushings Remove and Install. (Group 3140.) CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device. 7. Connect hoist to boom using lifting straps or chains. Specification Boom—Weight—Approximate ....................................................... 1265 kg 2788 lb

Continued on next page

TM10687 (14OCT08)

31-3140-4

SW03989,0000744 –19–05SEP08–1/4

524K Loader 101408

PN=352

Frames 8. Remove cap screw and washers (2) to remove boom rod cylinder pin (1) from each side of boom.

–UN–19NOV07

9. Slowly raise boom. 10. Inspect and replace parts as necessary.

TX1032162A

11. Apply NEVER-SEEZ Anti-Seize Lubricant or equivalent on outer surface of bushings and bores. 12. Center boom in frame by adding shims to the outside of the boom boss on each side. Then fill in with shims on both inside boss-to-boom gaps to remove excess clearance but do not bind joint.

Boom-Cylinder-To-Boom Pin 1—Boom Cylinder Pin 2—Cap Screw and Washer

NEVER-SEEZ is a trademark of Emhart Chemical Group.

SW03989,0000744 –19–05SEP08–2/4

13. Install frame-to-boom pins with cap screws and washers.

–UN–19NOV07

14. Align cylinder rod eye to boom and shim as required to remove any clearances but do not bind.

TX1032163A

1—Frame-to-Boom Pin 2—Cap Screw and Washer

Loader Frame To Boom Pin

Continued on next page

TM10687 (14OCT08)

31-3140-5

SW03989,0000744 –19–05SEP08–3/4

524K Loader 101408

PN=353

31 3140 5

Frames 15. Install boom cylinder-to-boom pin (1). 16. Install cap screw and washer (2). –UN–19NOV07

17. Remove lifting straps from each side.

TX1032162A

18. Install bucket. See Bucket Remove and Install. (Group 3102.) 19. Install bucket linkage. See Bucket Linkage Seals and Bushings Remove and Install. (Group 3140.) 20. Install bucket cylinder. See Bucket Cylinder Remove and Install. (Group 3160.)

31 3140 6

Boom-Cylinder-To-Boom Pin 1—Boom Cylinder Pin 2—Cap Screw and Washer

SW03989,0000744 –19–05SEP08–4/4

TM10687 (14OCT08)

31-3140-6

524K Loader 101408

PN=354

Frames

31 3140 7

TM10687 (14OCT08)

31-3140-7

524K Loader 101408

PN=355

Frames

Hi-Vis Coupler Disassemble and Assemble

31 3140 8

8 11

8 4 3

11 15

16 5 16

TX1048435

–UN–10SEP08

TX1048435 Hi-Vis Coupler Exploded View Continued on next page

TM10687 (14OCT08)

31-3140-8

SW03989,0000746 –19–08SEP08–1/5

524K Loader 101408

PN=356

Frames 1—Cap Screw 2—Cap Screw 3—Cap Screw 4—Washer 5—Hydraulic Cylinder

6—Hi-Vis Coupler 7—Pin 8—Pin 9—Cover

10—Pin (2 used) 11—Lubrication Fitting (2 used) 12—Washers

13—Bushing (3 used) 14—Pin (2 used) 15—Washers 16—Snap Ring (2 used)

1. Remove attachment from coupler. Hydraulic attachment coupler cylinder should remain in retracted position.

SW03989,0000746 –19–08SEP08–2/5

–UN–23AUG88

X9811

Escaping Fluid Under Pressure

2. Perform Hydraulic System Pressure and Accumulators Discharge. (Group 9025-25.) CAUTION: Prevent possible injury from crushing. Heavy component, use appropriate lifting device. Specification Hi-Vis Coupler—Weight (approximate)................................................................................... 443 kg 976 lb

3. Roll coupler forward and support with wood blocks.

Continued on next page

TM10687 (14OCT08)

31-3140-9

SW03989,0000746 –19–08SEP08–3/5

524K Loader 101408

PN=357

31 3140 9

Frames

CAUTION: Prevent possible injury from sudden movement. Support bellcrank before removing any pins. 4. Support bellcrank with appropriate lifting device. 5. Disconnect hydraulic hoses (18 and 19), close all openings using caps and plugs. 6. Remove coupler-to-bucket link pin (7).

–UN–26JAN06

7. Remove coupler-to-boom pins (8). 8. Remove cover (9).

TX1002802A

9. Remove snap rings (16) and pins (10). 10. Slide pins (14) away from hydraulic cylinder (5). 31 3140 10

11. Remove hydraulic cylinder and pins.

Hi-Vis Coupler

12. To repair hydraulic cylinder, see Disassemble Cylinder. (TM-H120A.)

7—Coupler-To-Bucket Link Pin 8—Coupler-To-Boom Pin (2 used) 18—Coupler Pin Disconnect Hoses 19—4th Function Hoses (if installed)

13. Apply PM37566 Silver-Grade Anti-Seize lubricant or an equivalent to bores of coupler, bucket link, loader boom, and corresponding pivot pins. 14. Using appropriate lifting device, move coupler into position. Support with wood blocks as required. 15. Install shims (12 and 15) in original locations. Measure clearances and adjust shims as required. Specification Hi-Vis Coupler Boom End— Clearance (maximum) ....................................................................... 1 mm 0.04 in. Hi-Vis Coupler Bucket Link End— Clearance (maximum) ....................................................................... 1 mm 0.04 in.

16. Install coupler-to-boom pins (8) and coupler-to-bucket link pin (7).

Continued on next page

TM10687 (14OCT08)

31-3140-10

SW03989,0000746 –19–08SEP08–4/5

524K Loader 101408

PN=358

Frames 17. Install left and right pins (14) to openings (17) on Hi-Vis coupler as shown.

–UN–28DEC05

18. Slide snap ring (16) past grooves in left and right pins (14).

TX1001760A

19. Install hydraulic cylinder (5) into coupler with cylinder guide inserted through hole in coupler. 20. Install pin (10) through pins (14) and hydraulic cylinder (5). 21. Slide snap rings (16) to groove in pins (14) to retain pin (10). 22. Install cover (9).

Coupler Right Side 10—Pin 14—Pin 16—Snap Ring 17—Pin Opening

23. Connect hydraulic hoses. 31 3140 11

SW03989,0000746 –19–08SEP08–5/5

TM10687 (14OCT08)

31-3140-11

524K Loader 101408

PN=359

Frames

31 3140 12

TM10687 (14OCT08)

31-3140-12

524K Loader 101408

PN=360

Group 3160

Hydraulic System General Oil Cleanup Procedure SPECIFICATIONS Contaminant ISO Code Value 4 micron (c) and Larger

ISO Code 19

Contaminant ISO Code Value 6 micron (c) and Larger

ISO Code 16

Contaminant ISO Code Value 14 micron (c) and Larger

ISO Code 13

same type oil to avoid intermixing of oils. Avoid operating filter caddy in dusty or wet conditions. Oil contamination could result. Filter caddy requires a 20 amp electric circuit. Use of electrical extension cord is not recommended.

SERVICE EQUIPMENT AND TOOLS

JDG1724A Super Caddy

One Suction Hose 4.6 m (15 ft) x 25 mm (1.0 in.) I.D. 100R1 Hose with 1.0 in. M NPT Ends

One Discharge Hose 4.6 m (15 ft) x 19 mm (0.75 in.) I.D. 100R1 Hose with 0.75 in. M NPT Ends

3 Foot Suction Wand 25 mm (1.00 in.) O.D. (with angle cut tip)

3 Foot Discharge Wand 19 mm (0.75 in.) O.D.

This procedure is to be used on machines that have had hydraulic system repair without a catastrophic component failure. Filter procedure must be done prior to starting machine after a component has been repaired or replaced. The use of attachments increase the need to monitor and filter oil to a safe contamination value.

1. Filter oil at 27°C (80°F) or above for best filter caddy performance. Reduce flow rate to filter oil below 27°C (80°F). 2. Park machine on a flat level surface. 3. Clean oil fill cap and area surrounding it to prevent contamination.

IMPORTANT: Oil types and filters must not be intermixed. Use filter element in

Continued on next page

TM10687 (14OCT08)

31-3160-1

AA95137,0001B26 –19–31JUL08–1/3

524K Loader 101408

PN=361

24—Suction Wand

25—Discharge Wand

–UN–29NOV04

31—Tank Fill Cap

4. Remove and clean tank fill cap (31) and strainer (32). Store fill cap and strainer in sealed plastic bag. 31 3160 2

T204288A

T204287A

–UN–29NOV04

Hydraulic System

11. Install hydraulic oil tank fill cap and strainer. CAUTION: Avoid entanglement and possible electrocution from filter caddy power cord. Do not operate machine while filter caddy is connected to machine.

5. Cover tank oil fill tube with plastic bag or all purpose tape. 6. Use JDG1724A Super Caddy to remove oil contaminants. See Super Caddy Oil Filter General Information. (CTM310.) 7. Place caddy suction and discharge wands through cover on fill tube. Position suction wand near bottom of tank and discharge wand below oil surface. 8. Wands must maintain position in tank. 9. Filter tank oil until filter caddy shuts off and contaminant value is ISO Code 13 or lower at 14 micron (c) setting. Use CODE SCROLL to check 4 and 6 micron (c) setting. ISO codes must be within 3 of each other. Specification Contaminant ISO Code Value— 4 micron (c) and Larger .................................................. ISO Code 19 6 micron (c) and Larger .................................................. ISO Code 16 14 micron (c) and Larger ................................................ ISO Code 13

10. Install new machine system filter for cleanup procedure.

12. Make sure area is clear and large enough to operate all functions of machine. 13. Fill hydraulic oil tank to operating level. See Check Hydraulic Oil Level. (Operator’s Manual.) IMPORTANT: Do not force the hydraulic system over system relief or over the return filter by-pass. 14. Run machine at slow idle. Operate each circuit a minimum of three to five minutes in each direction to flush any remaining contaminants. 15. Repeat filter process until oil has been cycled through all functions 3—5 times and oil contaminant value is ISO Code 13 or lower at 14 micron (c) setting. Use CODE SCROLL to check 4 and 6 micron (c) setting. ISO codes must be within 3 of each other. 16. When oil reaches acceptable value of cleanliness, install new machine oil filter.

Continued on next page

TM10687 (14OCT08)

32—Strainer

31-3160-2

AA95137,0001B26 –19–31JUL08–2/3

524K Loader 101408

PN=362

Hydraulic System NOTE: Instrument cleanliness and clean work practices are critical when filtering oil or taking oil samples. Dust, wind, and moisture, as well as contaminated sample pumps, bottles and tubing can affect results. 17. Obtain oil sample for fluid analysis. Oil sample must be taken from system before oil passes through the return filter when oil is warm. 18. Fill tank to proper operating level. See Check Hydraulic Oil Level. (Operator’s Manual.)

may not be able to maintain ISO Code 19/16/13 without additional filtration equipment. Auxiliary hydraulic attachments or components can be a point of entry for contamination. Frequent attachment changes also increase the chances for contaminants to enter the hydraulic system. Use care when connecting and removing components to not introduce contamination. Quick couplers must not be connected until they have been cleaned and capped when not in use. Fluid sampling and filter changes should increase if the application requires frequent attachment changes.

19. Return machine to service. NOTE: Additional filtration equipment is recommended for machines in extreme environments. By-pass filtration systems are available. 20. Check and record oil particle counts. After a 100 hours of operation check oil particle count to confirm system is within ISO particle count specification. See Follow-Up Oil Cleanup Procedure. (Group 3160.) Some hydraulic systems

21. Every Six Months for validation purposes use sample valve on Super Caddy to check for correct instrument readings. Results from lab cannot be identical to Super Caddy particle counter readings, but a correlation must exist. If validation testing shows a discrepancy of more than one code per particle size, sample oil again. If discrepancy in instrument readings persist, the particle counter must be checked by PALL Corporation.

AA95137,0001B26 –19–31JUL08–3/3

TM10687 (14OCT08)

31-3160-3

524K Loader 101408

PN=363

31 3160 3

Hydraulic System

Hydraulic Component Failure Cleanup Procedure SPECIFICATIONS Contaminant ISO Code Value 4 micron (c) and Larger

ISO Code 19

Contaminant ISO Code Value 6 micron (c) and Larger

ISO Code 16

Contaminant ISO Code Value 14 micron (c) and Larger

ISO Code 13

SERVICE EQUIPMENT AND TOOLS

JDG1724A Super Caddy

One Suction Hose 4.6 m (15 ft) x 25 mm (1.0 in.) I.D. 100R1 Hose with 1.0 in. M NPT Ends

One Discharge Hose 4.6 m (15 ft) x 19 mm (0.75 in.) I.D. 100R1 Hose with 0.75 in. M NPT Ends

3 Foot Suction Wand 25 mm (1.00 in.) O.D. (with angle cut tip)

3 Foot Discharge Wand 19 mm (0.75 in.) O.D. 31 3160 4

JDG1770 Ultra Clean Hose Kit

This procedure is to be used on machines that have had a system catastrophic component failure. Cleanup procedure must be done prior to starting machine after a component has been repaired or replaced. The use of attachments increase the need to monitor and filter oil to a safe contamination value. IMPORTANT: Oil types and filters must not be intermixed. Use filter element in

NOTE: Instrument cleanliness and clean work practices are critical when filtering oil or taking oil samples. Dust, wind, and moisture, as well as contaminated sample pumps, bottles and tubing can effect results. 1. Filter oil at 27°C (80°F) or above for best filter caddy performance. Reduce flow rate to filter oil below 27°C (80°F). 2. Park machine on a flat level surface. 3. Clean oil fill cap and area surrounding it to prevent contamination. 4. Use JDG1724A Super Caddy to remove oil contaminants. See Super Caddy Oil Filter General Information. (CTM310.)

Continued on next page

TM10687 (14OCT08)

31-3160-4

AA95137,0001B27 –19–04AUG08–1/4

524K Loader 101408

PN=364

24—Suction Wand

25—Discharge Wand

–UN–29NOV04 T204288A

T204287A

–UN–29NOV04

Hydraulic System

31—Tank Fill Cap

5. Clean oil fill cap and area surrounding it to prevent contamination.

32—Strainer

• Loader Cylinders • Auxiliary Systems 13. Disassemble, clean, and inspect each component. Repair or replace damaged components.

6. Remove tank fill cap (31). 7. Clean and store tank fill cap in sealed plastic bag. 8. Cover tank oil fill tube with plastic bag or all purpose tape.

IMPORTANT: If system contains a large amount of debris oil cooler can not be completely cleaned of contamination and must be replaced.

9. Place both wands through cover on tank fill opening. Position suction wand near bottom of tank and discharge wand below oil surface.

14. Replace oil cooler when required.

10. Drain tank or use filter caddy to transfer hydraulic oil from tank to a clean container.

IMPORTANT: Disconnect hoses and lines from all tee fittings before cleaning. Cleaning sponge will become trapped in hose as it passes through a tee fitting.

11. Place caddy discharge wand through cover on fill tube. 12. Remove hydraulic components from machine. Clean components working with one circuit at a time. • Hydraulic Oil Tank • Hydraulic Cooler • Hydraulic Pump • Loader Control Valve • Axle Cooling Pump • Pilot Controls

15. Locate and disconnect all tee fittings. See component location to aid in cleaning procedure. See Hydraulic System Component Location (Group 9025-15) or see Power Train Component Location. (Group 9020-15.) Disconnect lines and hoses from components. Some lines and hoses may require removal to clean. Clean all hydraulic lines and hoses using JDG1770 Ultra Clean Hose Kit.

Continued on next page

TM10687 (14OCT08)

31-3160-5

AA95137,0001B27 –19–04AUG08–2/4

524K Loader 101408

PN=365

31 3160 5

Hydraulic System NOTE: Close all openings of lines and components with caps and plugs to minimize additional contamination.

ignite the oil used for assembly causing cap seal and ring damage. Start with cylinder rod retracted and the rod end filled with clean oil. Operate function to slowly extend rod. Procedure will eliminate most of the air and reduce the possibility of damage.

16. Install new machine system filter for cleanup procedure. 17. Install all serviced hydraulic components on machine. 18. Connect or install lines and hoses. 19. With all components installed fill tank to proper operating level. See Check Hydraulic Oil Level. (Operator’s Manual.) 20. Filter tank oil until filter caddy shuts off and contaminant value is ISO Code 13 or lower at 14 micron (c) setting. Use CODE SCROLL to check 4 31 and 6 micron (c) setting. ISO codes must be within 3160 6 3 of each other. Specification Contaminant ISO Code Value— 4 micron (c) and Larger .................................................. ISO Code 19 6 micron (c) and Larger .................................................. ISO Code 16 14 micron (c) and Larger ................................................ ISO Code 13

21. Disconnect oil filter caddy. CAUTION: Prevent possible personal injury from unexpected machine movement. Clear all persons from area before operating machine. 22. Make sure area is clear and large enough to operate all functions of machine. IMPORTANT: Do not force the hydraulic system over system relief or over the return filter by-pass.

23. Run machine at slow idle. Slowly operate each circuit a minimum of three minutes in each direction to move air and contaminants through machine hydraulic oil filter to tank. 24. Repeat filter process until oil has been cycled through all functions 3—5 times and oil contaminant value is ISO Code 13 or lower at 14 micron (c) setting. 25. Filter tank oil an additional 3—5 minutes on MANUAL setting to be sure oil ISO Code 13 or lower at 14 micron (c) setting is maintained. NOTE: Instrument cleanliness and clean work practices are critical when filtering oil or taking oil samples. Dust, wind, and moisture, as well as contaminated sample pumps, bottles and tubing can affect results. 26. Obtain oil sample for fluid analysis. Oil sample must be taken from system before oil passes through the return filter when oil is warm. 27. When oil reaches acceptable value of cleanliness, install new machine oil filter. 28. Fill tank to proper operating level. See Check Hydraulic Oil Level. (Operator’s Manual.) 29. Return machine to service.

Trapped air suddenly compressed in a cylinder can make enough heat to

Continued on next page

TM10687 (14OCT08)

31-3160-6

AA95137,0001B27 –19–04AUG08–3/4

524K Loader 101408

PN=366

Hydraulic System NOTE: Additional filtration equipment is recommended for machines in extreme environments. By-pass filtration systems are available. 30. Check and record oil particle counts. After a 100 hours of operation check oil particle count to confirm system is within ISO particle count specification. See Follow-Up Oil Cleanup Procedure. (Group 3160.) Some hydraulic systems may not be able to maintain ISO Code 19/16/13 without additional filtration equipment. Auxiliary hydraulic attachments or components can be a point of entry for contamination. Frequent attachment changes also increase the chances for contaminants to enter the hydraulic system. Use

care when connecting and removing components to not introduce contamination. Quick couplers must not be connected until they have been cleaned and capped when not in use. Fluid sampling and filter changes should increase if the application requires frequent attachment changes. 31. Every Six Months for validation purposes use sample valve on Super Caddy to check for correct instrument readings. Results from lab cannot be identical to Super Caddy particle counter readings, but a correlation must exist. If validation testing shows a discrepancy of more than one code per particle size, sample oil again. If discrepancy in instrument readings persist, the particle counter must be checked by PALL Corporation.

AA95137,0001B27 –19–04AUG08–4/4

Follow-Up Oil Cleanup Procedure SPECIFICATIONS

chromium, and water.

Elemental Analysis PPM (Parts Per Million) Limit Iron Quantity

15 parts per million

Copper Quantity

15 parts per million

Silicon (Silica) Quantity

10 parts per million

Chromium Quantity

8 parts per million

Water Quantity

500 parts per million

Elemental Analysis PPM (Parts Per Million) Limit—Specification Iron—Quantity ....................................................... 15 parts per million Copper—Quantity ................................................. 15 parts per million Silicon (Silica)—Quantity ...................................... 10 parts per million Chromium—Quantity .............................................. 8 parts per million Water—Quantity ................................................. 500 parts per million

Following catastrophic system failure and oil cleanup procedure, oil must be monitored closely. The following checks and tests are to help determine possible causes for contamination which could result in system failure. Systems that experience frequent contamination due to harsh conditions or frequent auxiliary component changes, additional filtering equipment is necessary. 1. Check elemental analysis for excess PPM (parts per million) for iron, copper, silicon (silica),

2. If elemental analysis is above specification, oil filtering is necessary. Every Six Months for validation purposes use sample valve on Super Caddy to check for correct instrument readings. Results from lab cannot be identical to Super Caddy particle counter readings, but a correlation must exist. If validation testing shows a discrepancy of more than one code per particle size, sample oil again. If discrepancy in instrument readings persist, the particle counter must be checked by PALL Corporation.

AA95137,0001B28 –19–05SEP08–1/1

TM10687 (14OCT08)

31-3160-7

524K Loader 101408

PN=367

31 3160 7

Hydraulic System

Main Hydraulic Pump Remove and Install

–UN–31AUG07

NOTE: Check main hydraulic pump flow before removing main hydraulic pump for repair. See Main Hydraulic Pump Flow Test. (Group 9025-25.) If main hydraulic pump does not meet test specification it must be removed. Internal components of the main hydraulic pump rotate group are not serviceable individually. Entire rotate group must be serviced as an assembly.

TX1028840A

CAUTION: Prevent possible injury from unexpected machine movement. Install frame articulation lock bar before working in frame hinge area.

Main Hydraulic Pump

1. Install frame articulation lock bar and stop engine.

1—Fitting

31 3160 8

Continued on next page

TM10687 (14OCT08)

31-3160-8

SW03989,00006D7 –19–21AUG08–1/3

524K Loader 101408

PN=368

Hydraulic System

CAUTION: Escaping fluid under pressure can penetrate the skin causing serious injury.

–UN–23AUG88

Avoid the hazard by relieving pressure before disconnecting hydraulic or other lines. Tighten all connections before applying pressure.

X9811

Escaping Fluid Under Pressure

31 3160 9

2. Perform Hydraulic System Pressure and Accumulators Discharge. (Group 9025-25.) 3. Turn battery disconnect switch to the OFF position. 4. Apply vacuum or drain hydraulic reservoir. If draining hydraulic reservoir, see Drain and Refill Hydraulic System Oil. (Operator’s Manual.) 5. Tag and disconnect hydraulic lines from main hydraulic pump. Close all openings using caps and plugs. 6. In appropriate size plug, drill and tap a M12 x 1-5/16 hole. Install plug into case drain port on hydraulic pump. See Hydraulic System Component Location. (Group 9025-15.) CAUTION: Prevent possible injury from crushing. Use appropriate lifting device. 7. Install M12 x 1-5/16 eyebolt into plug. Attach DFT1132 Hydraulic Pump Removal And Installation Tool to eyebolt and remove pump.

Continued on next page

TM10687 (14OCT08)

31-3160-9

SW03989,00006D7 –19–21AUG08–2/3

524K Loader 101408

PN=369

Hydraulic System Specification Main Hydraulic Pump—Weight (approximate)..................................................................................... 45 kg 100 lb

NOTE: Internal components of the main hydraulic pump rotating group are not serviceable individually. Entire rotating group must be serviced as an assembly. 8. Repair or replace main hydraulic pump as necessary. See Main Hydraulic Pump Disassemble and Assemble. (Group 3160.) NOTE: Apply petroleum jelly to O-rings before installation. 9. Install new O-rings.

31 3160 10

CAUTION: Prevent possible injury from crushing. Use appropriate lifting device. 10. Install main hydraulic pump using DFT1132 Hydraulic Pump Removal And Installation Tool. 11. Fill main hydraulic pump body with hydraulic oil through case drain line to ensure lubrication for start-up. 12. Connect all hydraulic lines to main hydraulic pump. For line identification see Hydraulic System Component Location. (Group 9025-15.) 13. Remove vacuum and check hydraulic fluid level. Fill hydraulic reservoir if drained. See Check Hydraulic Oil Level and see Drain and Refill Hydraulic System Oil. (Operator’s Manual.) 14. Turn battery disconnect switch to the ON position. 15. Remove frame articulation lock bar. 16. Perform Load Sense Relief Valve Pressure Test and Adjustment. (Group 9025-25.)

SW03989,00006D7 –19–21AUG08–3/3

TM10687 (14OCT08)

31-3160-10

524K Loader 101408

PN=370

Hydraulic System

31 3160 11

TM10687 (14OCT08)

31-3160-11

524K Loader 101408

PN=371

Hydraulic System

Main Hydraulic Pump Disassemble and Assemble

4 31 3160 12

7 2

8 9

TX1028953

–UN–05SEP07

TX1028953 Main Hydraulic Pump Disassemble and Assemble Continued on next page

TM10687 (14OCT08)

31-3160-12

SW03989,00006D8 –19–04AUG08–1/2

524K Loader 101408

PN=372

Hydraulic System 1—Main Hydraulic Pump 2—O-Ring 3—Pipe 4—Split Flange

5—O-Ring 6—Fitting 7—O-Ring 8—Fitting

9—O-Ring 10—Quick Coupler 11—Fitting

1. Remove main hydraulic pump. See Main Hydraulic Pump Remove and Install. (Group 3160.)

12—O-Ring 13—O-Ring 14—Cover

3. Inspect and replace parts as necessary. 4. Assemble parts as shown.

NOTE: Internal components of the main hydraulic pump rotating group are not serviceable individually. Entire rotating group must be serviced as an assembly.

5. Install main hydraulic pump. See Main Hydraulic Pump Remove and Install. (Group 3160.)

2. Disassemble parts as shown.

SW03989,00006D8 –19–04AUG08–2/2

Loader Control Valve Remove and Install 1. Remove bucket or attachment.

–UN–05SEP07

CAUTION: Prevent possible injury from unexpected machine movement. Install frame lock articulation lock bar before working in frame hinge area.

TX1028993A

2. Install frame articulation lock bar. CAUTION: Prevent serious injury or death from unexpected loader movement. Always install the loader boom service lock, or lower the front loader boom fully to the ground. Move control levers to release hydraulic pressure before working near the front of the machine.

Loader Control Valve 1—Loader Control Valve 2—Cap Screw (3 used)

3. Raise boom and install boom lock. See Boom Lock. (Operator’s Manual.)

Continued on next page

TM10687 (14OCT08)

31-3160-13

SW03989,00006D9 –19–02SEP08–1/3

524K Loader 101408

PN=373

31 3160 13

Hydraulic System

CAUTION: Escaping fluid under pressure can penetrate the skin causing serious injury.

–UN–23AUG88

Avoid the hazard by relieving pressure before disconnecting hydraulic or other lines. Tighten all connections before applying pressure.

31 3160 14

X9811

Search for leaks with a piece of cardboard. Protect hands and body from high-pressure fluids. If an accident occurs, see a doctor immediately. Any fluid injected into the skin must be surgically removed within a few hours or gangrene may result. Doctors unfamiliar with this type of injury should reference a knowledgeable medical source. Such information is available from Deere & Company Medical Department in Moline, Illinois, U.S.A. 4. Stop engine and relieve hydraulic pressure.See Hydraulic System Pressure and Accumulators Discharge. (Group 9025-25.) 5. Turn battery disconnect switch to the OFF position. 6. Apply vacuum or drain hydraulic reservoir. If draining reservoir, see Drain and Refill Hydraulic System Oil. (Operator’s Manual.) 7. Remove loader control valve access panel from front of machine. 8. Loosen hold-down clamps on bucket and boom cylinder lines. 9. Identify and disconnect all hydraulic lines from loader control valve. Close all openings using caps and plugs. 10. Tag and disconnect electrical harness from pressure sensors (if equipped). 11. Remove cap screws (2).

Continued on next page

TM10687 (14OCT08)

31-3160-14

SW03989,00006D9 –19–02SEP08–2/3

524K Loader 101408

PN=374

Hydraulic System

CAUTION: Prevent crushing injury from heavy component. Use appropriate lifting device. 12. Remove loader control valve (1) with appropriate lifting device. Specification Loader Control Valve—Weight (approximate)..................................................................................... 50 kg 110 lb

13. Inspect and repair or replace parts as necessary. See Loader Control Valve Disassemble and Assemble. (Group 3160.) 14. Install loader control valve. Connect all hydraulic lines. 15. Connect electrical harness to pressure sensors (if equipped). See Loader Frame Harness (W2) Component Location. (Group 9015-10.)

31 3160 15

16. Remove vacuum or fill hydraulic reservoir if drained. See Check Hydraulic Oil Level or see Drain and Refill Hydraulic System Oil. (Operator’s Manual.) 17. Turn battery disconnect switch to the ON position. 18. Remove boom lock and frame articulation lock bar.

SW03989,00006D9 –19–02SEP08–3/3

TM10687 (14OCT08)

31-3160-15

524K Loader 101408

PN=375

Hydraulic System

Loader Control Valve Disassemble and Assemble 1

31 3160 16

TX1029059

–UN–12SEP07

6 1

TX1029059

Loader Control Valve Disassemble and Assemble 1—Tie-Bolt (4 used) 2—Outlet Section

3—Boom Section 4—Bucket Section

5—Auxiliary Section

1. Remove tie-bolts and washers. Separate each valve section.

3. Install O-rings and seals.

2. Inspect and repair or replace parts as necessary. See Boom Section Disassemble and Assemble. (Group 3160.) See Bucket Section Disassemble and Assemble. (Group 3160.) See Auxiliary Section Disassemble and Assemble. (Group 3160.) NOTE: Apply petroleum jelly to O-rings and seals before installation.

6—Inlet Section

NOTE: Apply clean hydraulic oil to all internal parts before assembling. 4. Assemble valve sections. Tighten tie-bolt nuts to specification. Specification Tie-Bolt Nut—Torque ............................................................... 56 N•m 41 lb-ft

SW03989,000043D –19–24APR08–1/1

TM10687 (14OCT08)

31-3160-16

524K Loader 101408

PN=376

Hydraulic System

Boom Section Disassemble and Assemble

4 5

6 –UN–10SEP07

TX1029032

31 3160 17

TX1029032 Boom Section 1—Anticavitation Valve 2—Load Check Valve 3—Pressure Compensator

4—Plug 5—Cap Screw (2 used) 6—Nut

7—Shuttle Pin 8—Spool

9—Cap Screw (2 used) 10—Plug (2 used)

1. Disassemble and inspect parts for contamination, wear, or damage. Replace as necessary.

5. Install anticavitation valve and tighten to specification.

IMPORTANT: Coat all internal surfaces with clean hydraulic oil.

Specification Anticavitation Valve—Torque ............................................... 39.5 N•m 350 lb-in.

2. Assemble valve by applying clean hydraulic oil to all internal parts before assembling.

6. Install load check valve and tighten to specification.

3. Apply PM37421 Thread Lock and Sealer (High Strength) to threads of cap screws and tighten to specification. Specification Cap Screw—Torque ................................................................ 11 N•m 100 lb-in.

Specification Load Check Valve—Torque ................................................... 5.6 N•m 50 lb-in.

7. Install pressure compensator and plug. Tighten securely.

4. Apply petroleum jelly to new O-rings and backup rings before installation.

SW03989,00006DA –19–04AUG08–1/1

TM10687 (14OCT08)

31-3160-17

524K Loader 101408

PN=377

Hydraulic System

Bucket Section Disassemble and Assemble

1 9

31 3160 18

TX1029001

–UN–13SEP07

TX1029001 Bucket Section 1—Circuit Relief With Anticavitation Valve 2—Load Check Valve

3— Pressure Compensator 4—Circuit Relief With Anticavitation Valve

5—Cap Screw (4 used) 6—Shuttle Pin 7—Spool

8—Plug (2 used) 9—Pilot Orifice (2 used)

1. Disassemble and inspect parts for contamination, wear, or damage. Replace as necessary.

5. Install circuit relief with anticavitation valves and tighten to specification.

IMPORTANT: Coat all internal surfaces with clean hydraulic oil.

Specification Circuit Relief With Anticavitation Valve—Torque ...................................................................... 39.5 N•m 350 lb-in.

2. Assemble valve by applying clean hydraulic oil to all internal parts before assembling.

6. Install load check valve and tighten to specification.

3. Apply PM37421 Thread Lock and Sealer (High Strength) to threads of cap screws and tighten to specification.

Specification Load Check Valve—Torque ................................................... 5.6 N•m 50 lb-in.

Specification Cap Screw—Torque ................................................................ 11 N•m 100 lb-in.

7. Install pressure compensator and plugs. Tighten securely.

4. Apply petroleum jelly to new O-rings and backup rings before installation.

SW03989,00006DB –19–04AUG08–1/1

TM10687 (14OCT08)

31-3160-18

524K Loader 101408

PN=378

Hydraulic System

Auxiliary Section Disassemble and Assemble

4 5

TX1034675

–UN–14JAN08

TX1034675 Auxiliary Section 1—Circuit Relief With Anticavitation Valve 2—Load Check Valve

3—Pressure Compensator 4—Circuit Relief With Anticavitation Valve

5—Pilot Orifice (2 used) 6—Shuttle Pin 7—Spool

8—Cap Screw (4 used) 9—Adjuster Screw (2 used)

1. Disassemble and inspect parts for contamination, wear, or damage. Replace as necessary.

5. Install circuit relief with anticavitation valves and tighten to specification.

IMPORTANT: Coat all internal surfaces with clean hydraulic oil.

Specification Circuit Relief With Anticavitation Valve—Torque ...................................................................... 39.5 N•m 350 lb-in.

2. Assemble auxiliary section by applying clean hydraulic oil to all internal parts before assembling.

6. Install load check valve and tighten to specification.

3. Apply PM37421 Thread Lock and Sealer (High Strength) to threads of cap screws and tighten to specification.

Specification Load Check Valve—Torque ................................................... 5.6 N•m 50 lb-in.

Specification Cap Screw—Torque ................................................................ 11 N•m 100 lb-in.

7. Install pressure compensator and plugs. Tighten securely.

4. Apply petroleum jelly to new O-rings and backup rings before installation.

SW03989,00006DC –19–04AUG08–1/1

TM10687 (14OCT08)

31-3160-19

524K Loader 101408

PN=379

31 3160 19

Hydraulic System

Main Relief Valve Disassemble and Assemble NOTE: Internal components of main relief valve are not serviceable.

6 –UN–14SEP07

7 1. Inspect parts for contamination, wear, or damage. Clean or replace as necessary.

2. Apply clean hydraulic oil to internal surfaces.

Main Relief Valve

3. Apply petroleum jelly to new O-rings before installation. 4. Install main relief valve and tighten to specification.

31 3160 20

TX1029356

IMPORTANT: Coat all internal surfaces with clean hydraulic oil before assembly.

Specification Main Relief Valve—Torque ............................................................ 60 N•m 44 lb-ft

1—Valve Body 2—O-Ring 3—Floating Pilot Poppet 4—Retaining Spring Clip 5—Spring 6—Floating Poppet 7—Pin Poppet

5. Check pressure setting. See Main Relief Valve Pressure Test. (Group 9025-25.)

SW03989,0000441 –19–25APR08–1/1

TM10687 (14OCT08)

31-3160-20

524K Loader 101408

PN=380

Hydraulic System

Load Sense Relief Valve Disassemble and Assemble

1. Loosen nut (2) and remove adjusting screw (1) from body.

2. Inspect parts for wear or damage. Replace if necessary.

3. O-rings (7), backup ring (4) and spring (9) are the only repair parts available. IMPORTANT: Coat all internal surfaces with clean hydraulic oil. 4. Apply clean hydraulic oil to all internal surfaces during installation. 5. Apply petroleum jelly to new O-rings before installation. 6. Assemble load sense relief valve.

TX1029117

–UN–10SEP07

Load Sense Relief Valve 1—Adjusting Screw 2—Nut 3—Outlet 4—Backup Ring 5—Inlet 6—Inlet Screen 7—O-Ring 8—Poppet 9—Spring

31 3160 21

7. Install load sense relief valve and tighten to specification. Specification Load Sense Relief Valve—Torque .............................................. 56.4 N•m 500 lb-in.

8. Check pressure setting. See Load Sense Relief Valve Pressure Test and Adjustment. (Group 9025-25.)

SW03989,0000442 –19–24APR08–1/1

TM10687 (14OCT08)

31-3160-21

524K Loader 101408

PN=381

Hydraulic System

Circuit Relief With Anticavitation Valve Disassemble and Assemble Bucket Section

1. Inspect parts for contamination, wear, or damage. Replace as necessary.

31 3160 22

TX1037870

IMPORTANT: Coat all internal surfaces with clean hydraulic oil. 2. Apply clean hydraulic oil to all internal surfaces during installation. 3. Apply petroleum jelly to new O-rings and backup rings before installation.

–UN–03MAR08

NOTE: If circuit relief with anticavitation valve does not meet test specification, it must be removed. Inspect for contaminants, wear, or damage. Internal components of the circuit relief with anticavitation valve are not serviceable.

Bucket Section—Circuit Relief With Anticavitation Valve 1—Outlet 2—Poppet Spring 3—Pilot Poppet 4—Nut 5—Adjusting Screw 6—Circuit Relief Spring 7—Poppet 8—Poppet Pin 9—Inlet

4. Install circuit relief with anticavitation valve and tighten to specification. Specification Circuit Relief with Anticavitation Valve—Torque ............................................................................. 39.5 N•m 350 lb-in.

5. Check pressure setting. See Circuit Relief With Anticavitation Valve Pressure Test. (Group 9025-25.)

Continued on next page

TM10687 (14OCT08)

31-3160-22

AA95137,0001B4C –19–05SEP08–1/2

524K Loader 101408

PN=382

Hydraulic System Auxiliary Section

4 5 –UN–10SEP07

10 9

1. Inspect parts for contamination, wear, or damage. Replace as necessary. IMPORTANT: Coat all internal surfaces with clean hydraulic oil.

TX1029118

Auxiliary Section—Circuit Relief With Anticavitation Valve

2. Apply clean hydraulic oil to all internal surfaces during installation. 3. Apply petroleum jelly to new O-rings and backup rings before installation. 4. Install circuit relief with anticavitation valve and tighten to specification.

1—Outlet 2—Poppet Spring 3—Pilot Poppet 4—Nut 5—Adjusting Screw 6—Circuit Relief Spring 7—Poppet Ball 8—Poppet 9—Poppet Pin 10—Inlet

31 3160 23

Specification Circuit Relief with Anticavitation Valve—Torque ............................................................................. 39.5 N•m 350 lb-in.

5. Check pressure setting. See Circuit Relief With Anticavitation Valve Pressure Test. (Group 9025-25.)

AA95137,0001B4C –19–05SEP08–2/2

TM10687 (14OCT08)

31-3160-23

524K Loader 101408

PN=383

Hydraulic System

Anticavitation Valve Disassemble and Assemble

1 1. Inspect anticavitation valve for wear or damage. Replace as necessary. IMPORTANT: Coat all internal surfaces with clean hydraulic oil.

TX1037853

3. Apply petroleum jelly to backup rings and O-rings before installation.

–UN–06MAR08

2. Apply clean hydraulic oil to all internal surfaces during installation.

4. Install anticavitation valve and tighten to specification. Anticavitation Valve

31 3160 24

Specification Anticavitation Valve—Torque ........................................................ 5.6 N•m 50 lb-in.

1—Poppet 2—Spring 3—O-Ring 4—Backup Ring

SW03989,0000444 –19–24APR08–1/1

TM10687 (14OCT08)

31-3160-24

524K Loader 101408

PN=384

Hydraulic System

Boom Cylinder Remove and Install NOTE: Boom cylinder may be disassembled on the machine for seal and packing replacement. CAUTION: Prevent possible injury from unexpected machine movement. Install frame articulation lock bar before working in frame hinge area. 1. Park machine on level surface and install frame articulation lock bar.

–UN–09APR07

CAUTION: Prevent possible injury from crushing. Use appropriate lifting device and support boom cylinder before removing cylinder.

TX1021686A

2. Raise and support boom using appropriate lifting device or 10-ton shop stands. 1—Boom Cylinder Rod End Hydraulic Line 2—Boom Cylinder Head End Hydraulic Line 3—Rod End Pin 4—Head End Pin

TX1020498A

–UN–14MAR07

Boom Cylinder—Hydraulic Line Connections

Boom Cylinder—Pin Locations

Continued on next page

TM10687 (14OCT08)

31-3160-25

SW03989,00006EA –19–12SEP08–1/3

524K Loader 101408

PN=385

31 3160 25

Hydraulic System

CAUTION: Escaping fluid under pressure can penetrate the skin causing serious injury.

–UN–23AUG88

Avoid the hazard by relieving pressure before disconnecting hydraulic or other lines. Tighten all connections before applying pressure.

31 3160 26

X9811

Escaping Fluid Under Pressure

3. Stop engine and relieve hydraulic pressure. See Hydraulic System Pressure and Accumulators Discharge. (Group 9025-25.) 4. Turn battery disconnect switch to the OFF position. CAUTION: Prevent possible injury from crushing. Use appropriate lifting device. 5. Connect appropriate lifting device to boom cylinder using lifting straps. Specification Boom Cylinder—Weight (approximate)..................................................................................... 97 kg 215 lb

6. Disconnect boom cylinder hydraulic lines (1 and 2). Close all openings using caps and plugs. 7. Remove rod and head end pins (3 and 4). 8. Remove boom cylinder. 9. Repair or replace as necessary. See Disassemble Cylinder and Assemble Cylinder. (TM-H125A.)

Continued on next page

TM10687 (14OCT08)

31-3160-26

SW03989,00006EA –19–12SEP08–2/3

524K Loader 101408

PN=386

Hydraulic System 10. Install boom cylinder. 11. Install rod and head end pins. 12. Connect hydraulic lines. 13. Turn battery disconnect switch to the ON position. 14. Remove frame articulation lock bar. IMPORTANT: When machine is started for the first time after cylinder rebuild or oil is drained from cylinder, perform Loader Start-Up Procedure to prevent oil from “dieseling” inside cylinder. 15. Perform Loader Start-Up Procedure. (Group 3160.)

SW03989,00006EA –19–12SEP08–3/3

Bucket Cylinder Remove and Install NOTE: Bucket cylinder may be disassembled on the machine for seal and packing replacement. CAUTION: Prevent possible injury from unexpected machine movement. Install frame articulation lock bar before working in frame hinge area. 1. Park machine on level surface, install frame articulation lock bar, lower boom and attachment to the ground.

Continued on next page

TM10687 (14OCT08)

31-3160-27

SW03989,00006EB –19–12SEP08–1/4

524K Loader 101408

PN=387

31 3160 27

Hydraulic System

CAUTION: Escaping fluid under pressure can penetrate the skin causing serious injury.

–UN–23AUG88

Avoid the hazard by relieving pressure before disconnecting hydraulic or other lines. Tighten all connections before applying pressure.

31 3160 28

X9811

Escaping Fluid Under Pressure

2. Stop engine and relieve hydraulic pressure. See Hydraulic System Pressure and Accumulators Discharge. (Group 9025-25.) 3. Turn battery disconnect switch to the OFF position.

Continued on next page

TM10687 (14OCT08)

31-3160-28

SW03989,00006EB –19–12SEP08–2/4

524K Loader 101408

PN=388

Hydraulic System 4. Remove bucket level indicator (1) and return-to-dig switch (2).

CAUTION: Prevent possible injury from crushing. Use appropriate lifting device. 5. Connect appropriate lifting device to bucket cylinder using lifting straps. 2 Specification

–UN–15SEP08

Bucket Cylinder—Weight (approximate)..................................................................................... 97 kg 215 lb

TX1048703

6. Disconnect head and rod end hydraulic lines. Close all openings using caps and plugs. 1—Bucket Level Indicator 2—Return-to-Dig Switch Bucket Level Indicator

Continued on next page

TM10687 (14OCT08)

31-3160-29

SW03989,00006EB –19–12SEP08–3/4

524K Loader 101408

PN=389

31 3160 29

Hydraulic System 7. Remove head and rod end pins (3 and 4). 8. Remove bucket cylinder. 9. Repair or replace as necessary. See Disassemble Cylinder and see Assemble Cylinder. (TM-H125A.) 10. Install bucket cylinder.

3 4

11. Install head and rod end pins.

–UN–12SEP08

12. Connect head and rod end hydraulic lines. 13. Install bucket level indicator and return-to-dig switch.

TX1048696

14. Turn battery disconnect switch to the ON position. 15. Remove frame articulation lock bar. 31 3160 30

IMPORTANT: When machine is started for first time after bucket cylinder rebuild or oil is drained from bucket cylinder, perform Loader Start-Up Procedure to prevent oil from “dieseling” inside cylinder.

Head and Rod End Pins 3—Head End Pin 4—Rod End Pin

16. Perform Loader Start-Up Procedure. (Group 3160.)

SW03989,00006EB –19–12SEP08–4/4

Boom and Bucket Cylinder Disassemble and Assemble NOTE: 125 series cylinders are used on both boom and bucket. To repair 125 Series cylinders, see Disassemble Cylinder and see Assemble Cylinder. (TM-H125A.)

SW03989,0000447 –19–28FEB08–1/1

TM10687 (14OCT08)

31-3160-30

524K Loader 101408

PN=390

Hydraulic System

Boom or Bucket Cylinder Bushings and Seals Remove and Install 1. Remove seals (B). –UN–27OCT88

2. Remove bushings (A). 3. Install and center new bushings in bore.

5. For initial lubrication, apply NEVER-SEEZ Lubricant or an equivalent to bushings and seals.

NEVER-SEEZ is a trademark of Emhart Chemical Group.

TM10687 (14OCT08)

T6172BE

4. Install new seals. Press seals into bore tight against bushing with lip facing outward. Cylinder Bushings and Seals A—Bushings B—Seals

SW03989,0000745 –19–05SEP08–1/1

31-3160-31

524K Loader 101408

PN=391

31 3160 31

Hydraulic System

Loader Start-Up Procedure IMPORTANT: This procedure must be preformed whenever boom, or bucket cylinders are purged of oil. Failure to do so will result in internal damage to components. The following procedure is recommended to purge all air from system. 1. Pre-fill cylinder before connecting hydraulic lines. IMPORTANT: Perform procedure with engine at low idle (no acceleration). 2. Boom Cylinder: Raise boom until you are within 2—4 feet of full height. 31 3160 32

3. Slowly lower the boom until bucket is 2—4 feet from ground and stop. 4. Repeat previous steps five times. 5. Slowly raise the boom to full height. 6. Slowly lower the boom to ground. 7. Repeat previous steps three times. 8. Bucket Cylinder: Position boom at half way height and roll bucket within two feet of full roll back position. 9. Position bucket within 1 foot of full dump. 10. Repeat previous steps five times. 11. Position bucket to full rollback position. 12. Position bucket to full dump. 13. Repeat previous steps three times.

SW03989,0000448 –19–28FEB08–1/1

TM10687 (14OCT08)

31-3160-32

524K Loader 101408

PN=392

Hydraulic System

Hydraulic Reservoir Remove and Install CAUTION: Prevent possible injury from unexpected machine movement. Install frame articulation lock bar before working in frame hinge area. 1. Install frame articulation lock bar.

Continued on next page

SW03989,00006DD –19–11AUG08–1/4

31 3160 33

TM10687 (14OCT08)

31-3160-33

524K Loader 101408

PN=393

Hydraulic System

CAUTION: Escaping fluid under pressure can penetrate the skin causing serious injury.

–UN–23AUG88

Avoid the hazard by relieving pressure before disconnecting hydraulic or other lines. Tighten all connections before applying pressure.

31 3160 34

X9811

Escaping Fluid Under Pressure

2. Perform Hydraulic System Pressure and Accumulators Discharge. (Group 9025-25.) 3. Turn battery disconnect switch to the OFF position. 4. Remove hood. See Hood Remove and Install. (Group 1910.) 5. Remove engine side shields. See Engine Side Shields Remove and Install. (Group 1910.) 6. Remove cab side skirts. CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device. 7. Attach JT01748 Lifting Bracket to cab left and right side platforms and remove mounting hardware. Remove platforms. 8. Remove engine wiring harness and clamps from hydraulic reservoir.

Continued on next page

TM10687 (14OCT08)

31-3160-34

SW03989,00006DD –19–11AUG08–2/4

524K Loader 101408

PN=394

Hydraulic System

CAUTION: To avoid injury from escaping fluid under pressure, stop engine and relieve the pressure in the system before disconnecting or connecting hydraulic or other lines. Tighten all connections before applying pressure.

–UN–10SEP07

9. Open hydraulic reservoir drain valve (1) and drain hydraulic reservoir. See Drain and Refill Hydraulic System Oil. (Operator’s Manual.)

TX1029184A

10. Disconnect all lines from bottom of hydraulic reservoir (2). Close all openings using caps and plugs.

CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device.

Hydraulic Reservoir Drain Valve

NOTE: Muffler can be removed for easy access to hydraulic reservoir.

31 3160 35

6 11. Install JT01748 Lifting Brackets to hood mounting holes (6) on hydraulic reservoir. Specification Hydraulic Reservoir—Weight (approximate)................................................................................... 127 kg 280 lb

2 –UN–10SEP07

4 7

12. Remove hydraulic reservoir-to-frame cap screws (3), washers (4), and spacers (7). 4

NOTE: If hydraulic reservoir shows signs of contamination, see General Oil Cleanup Procedure. (CTM 310.)

Hydraulic Reservoir 1—Hydraulic Reservoir Drain Valve 2—Hydraulic Reservoir 3—Hydraulic Reservoir-to-Frame Cap Screw (4 used) 4—Washer (4 used) 5—Fill Tube 6—Hood Mounting Holes 7—Spacer (4 used)

13. Replace parts as necessary. 14. Install hydraulic reservoir.

Continued on next page

TM10687 (14OCT08)

TX1029180

NOTE: Tilt top of hydraulic reservoir toward rear of machine as it is lifted from machine in order to clear cab.

31-3160-35

SW03989,00006DD –19–11AUG08–3/4

524K Loader 101408

PN=395

Hydraulic System NOTE: Be sure to align spacers between inside of hydraulic reservoir and frame. 15. Install hydraulic reservoir-to-frame cap screws, washers, and spacers and tighten to specification. Specification Hydraulic Reservoir-to-Frame Cap Screw—Torque ..................................................................... 620 N•m 460 lb-ft

16. Connect all hydraulic lines to bottom of hydraulic reservoir. 17. Attach engine wiring harness and clamps to hydraulic reservoir. 18. Install muffler if removed. 31 3160 36

19. Install left and right side cab platforms and remove JT01748 Lifting Brackets. 20. Install cab side skirts. 21. Install engine side shields. 22. Install hood. 23. Close hydraulic reservoir drain valve and fill hydraulic reservoir with recommended oil. See Drain and Refill Hydraulic System Oil. (Operator’s Manual.) 24. Turn battery disconnect switch to the ON position. 25. Remove frame articulation lock bar.

SW03989,00006DD –19–11AUG08–4/4

TM10687 (14OCT08)

31-3160-36

524K Loader 101408

PN=396

Hydraulic System

Pilot Control Valve Remove and Install

X9811

–UN–23AUG88

CAUTION: Escaping fluid under pressure can penetrate the skin, causing serious injury. Avoid the hazard by relieving pressure before disconnecting hydraulic or other lines. Tighten all connections before applying high-pressure. Search for leaks with a piece of cardboard. Protect hands and body from high-pressure fluids. If an accident occurs, see a doctor immediately. Any fluid injected into the skin must be surgically removed within a few hours or gangrene may result. Doctors unfamiliar with this type of injury should reference a knowledgeable medical source. Such information is available from Deere & Company Medical Department in Moline, Illinois, U.S.A.

Escaping Fluid Under Pressure

31 3160 37

CAUTION: Prevent possible injury from unexpected machine movement. Install frame articulation lock bar before working in frame hinge area. 1. Install frame articulation lock bar. CAUTION: To avoid injury from escaping fluid under pressure, stop engine and relieve the pressure in the system before disconnecting or connecting hydraulic or other lines. Tighten all connections before applying pressure. 2. Perform Hydraulic System Pressure and Accumulators Discharge. (Group 9025-25.) 3. Turn battery disconnect switch to the OFF position. 4. Remove right armrest assembly. 5. Remove switch pad and pilot control trim panel. 6. Apply vacuum or drain hydraulic reservoir. If draining hydraulic reservoir, see Drain and Refill Hydraulic System Oil. (Operator’s Manual.)

Continued on next page

TM10687 (14OCT08)

31-3160-37

SW03989,00006DE –19–11AUG08–1/4

524K Loader 101408

PN=397

Hydraulic System 7. Open pilot control access panel on outside right of machine. 8. Disconnect all electrical connectors from pilot control valve.

Continued on next page

SW03989,00006DE –19–11AUG08–2/4

31 3160 38

TM10687 (14OCT08)

31-3160-38

524K Loader 101408

PN=398

Hydraulic System IMPORTANT: Avoid damage to wires. Do not twist control lever handle or knobs.

–UN–17APR07

NOTE: Remove control lever support to access auxiliary function pilot control valve connections.

TX1022106

The pilot control valve uses Snap-to-Connect (STC) Fittings. An STC tool is supplied with vehicle and located in operators manual packet. 9. Disconnect pilot control valve lines by performing the following:

JDG1385 Snap-to-Connect Tool

a. Clean around the STC fitting. b. Identify hydraulic lines for installation purposes. IMPORTANT: Do not pry against release sleeve (5) or damage to fitting could result.

31 3160 39

TX1022723A

–UN–25APR07

Do not force release sleeve beyond normal range of travel, otherwise release sleeve could fall off when hose is disconnected. If damage fitting is connected without the release sleeve installed, fitting will not disconnected again. Snap-to-Connect Tool/Pilot Control Valve Lines

c. Insert JDG1385 Snap-to-Connect (STC) Tool (4) between release sleeve (5) and shoulder (6) of fitting.

–UN–24NOV03

d. Gently push, do not pry, release sleeve away from shoulder to disconnect the STC fitting. e. Pull hydraulic line to disconnect.

T196380A

f. Close all openings using caps and plugs. 10. Remove pilot control valve (7). 11. Repair or replace parts as necessary.

Pilot Control Lines (Single Lever with Auxiliary Function Pilot Control Valve Shown)

12. Install pilot control valve.

4—JDG1385 Snap-to-Connect (STC) Tool 5—Release Sleeve 6—Shoulder 7—Pilot Control Valve 8—Pilot Control Valve Lines 9—Auxiliary Function Pilot Control Valve Lines

Snap-to-Connect is a registered trademark of Eaton Corporation

TM10687 (14OCT08)

Continued on next page

31-3160-39

SW03989,00006DE –19–11AUG08–3/4

524K Loader 101408

PN=399

Hydraulic System 13. Connect pilot control valve hydraulic lines. See Hydraulic System Component Location. (Group 9025-15.) 14. Connect all electrical connectors to pilot control valve. 15. Remove vacuum and check hydraulic fluid level. Fill hydraulic oil reservoir if drained. See Check Hydraulic Oil Level or see Drain and Refill Hydraulic System Oil. (Operator’s Manual.) 16. Install pilot control trim panel and switch pad. 17. Install right armrest assembly. 18. Turn battery disconnect to the ON position. 19. Operate machine and check for leaks at hydraulic line connections. 20. Close access panel. 21. Remove articulation lock bar.

SW03989,00006DE –19–11AUG08–4/4

Pilot Control Valve Disassemble and Assemble

6 1

1. Perform Pilot Control Valve Remove and Install. (Group 3160.) NOTE: Parts shown are for reference only.

2. Disassemble and assemble parts as shown. Not all the parts shown are serviceable individually. 4 1—Boom Lower Valve 2—Bucket Dump Valve 3—Boom Raise Valve 4—Pressure Oil 5—Bucket Rollback Valve 6—Return Oil (hydraulic reservoir)

3 Bottom View of Pilot Control Lever—Single Lever Shown

Continued on next page

TM10687 (14OCT08)

–UN–17APR07

TX1022237

31 3160 40

31-3160-40

SW03989,00006EC –19–05AUG08–1/2

524K Loader 101408

PN=400

Hydraulic System

TX1046548

–UN–05AUG08

31 3160 41

Pilot Control Lever—Single Lever Shown 7—Pilot Control Lever with Wiring Harness 8—Universal Joint

9—Solenoid 10—Guide 11—Push Pin

12—Pilot Control Spool Assembly

13—Boot 14—Pilot Control Valve

SW03989,00006EC –19–05AUG08–2/2

TM10687 (14OCT08)

31-3160-41

524K Loader 101408

PN=401

Hydraulic System

Auxiliary Function Pilot Control Valve Remove and Install

X9811

–UN–23AUG88

31 3160 42

If an accident occurs, see a doctor immediately. Any fluid injected into the skin must be surgically removed within a few hours or gangrene may result. Doctors unfamiliar with this type of injury should reference a knowledgeable medical source. Such information is available from Deere & Company Medical Department in Moline, Illinois, U.S.A. CAUTION: Prevent possible injury from unexpected machine movement. Install frame articulation lock bar before working in frame hinge area. 1. Install frame articulation lock bar. CAUTION: To avoid injury from escaping fluid under pressure, stop engine and relieve the pressure in the system before disconnecting or connecting hydraulic or other lines. Tighten all connections before applying pressure. 2. Perform Hydraulic System Pressure and Accumulators Discharge. (Group 9025-25.) 3. Turn battery disconnect switch to the OFF position. 4. Remove right armrest assembly. 5. Remove switch pad and pilot control trim panel. 6. Apply vacuum or drain hydraulic reservoir. If draining hydraulic reservoir, see Drain and Refill Hydraulic System Oil. (Operator’s Manual.)

Continued on next page

TM10687 (14OCT08)

31-3160-42

SW03989,00006DF –19–11AUG08–1/4

524K Loader 101408

PN=402

Hydraulic System 7. Open auxiliary function pilot control valve access panel on outside right of machine.

Continued on next page

SW03989,00006DF –19–11AUG08–2/4

31 3160 43

TM10687 (14OCT08)

31-3160-43

524K Loader 101408

PN=403

Hydraulic System 8. Disconnect all electrical connectors from auxiliary function pilot control valve (1).

–UN–17APR07

NOTE: The auxiliary function pilot control valve uses Snap-to-Connect (STC) Fittings. An STC tool is supplied with vehicle and located in Operator’s Manual Packet.

TX1022106

9. Disconnect auxiliary function pilot control valve hydraulic lines (5 and 8) by performing the following: a. Clean around the STC fittings.

JDG1385 Snap-to-Connect Tool

b. Identify hydraulic lines for installation purposes. IMPORTANT: Do not pry against release sleeve (2) or damage to Snap-to-Connect fitting could result.

TX1029503A

c. Insert JDG1385 Snap-to-Connect (STC) Tool (4) between release sleeve (5) and shoulder (6) of fitting.

–UN–17SEP07

Snap-to-Connect Tool/Auxiliary Function Pilot Control Valve

d. Gently push, do not pry, release sleeve away from shoulder to disconnect the STC fitting. e. Pull hydraulic line to disconnect. f. Close all openings using caps and plugs.

–UN–17SEP07

1—Auxiliary Function Pilot Control Valve 2—Release Sleeve 3—Shoulder 4—JDG1385 Snap-to-Connect (STC) Tool 5—Work Port A Hydraulic Line 6—Hydraulic Pressure Line 7—Hydraulic Return Line 8—Work Port B Hydraulic Line

TX1029502A

31 3160 44

Auxiliary Function Pilot Control Valve Hydraulic Lines

Snap-to-Connect is a registered trademark of Eaton Corporation

TM10687 (14OCT08)

Continued on next page

31-3160-44

SW03989,00006DF –19–11AUG08–3/4

524K Loader 101408

PN=404

Hydraulic System 10. Disconnect auxiliary function pilot control valve hydraulic lines (6 and 7). Close all openings using caps and plugs. 11. Remove auxiliary function pilot control valve (1). 12. Repair or replace parts as necessary. 13. Install auxiliary function pilot control valve. 14. Connect auxiliary function pilot control valve hydraulic lines (5—8). See Hydraulic System Component Location. (Group 9025-15.) 15. Connect all electrical connectors to auxiliary function pilot control valve. 16. Remove vacuum or fill hydraulic reservoir. See Check Hydraulic Oil Level or see Drain and Refill Hydraulic System Oil. (Operator’s Manual.)

31 3160 45

17. Start machine. Operate controls and check for leaks. 18. Install switch pad and pilot control trim panel. 19. Install right armrest assembly. 20. Turn battery disconnect switch to the ON position. 21. Remove frame articulation lock bar.

SW03989,00006DF –19–11AUG08–4/4

Auxiliary Function Pilot Control Valve Disassemble and Assemble

1. Perform Auxiliary Function Pilot Control Valve Remove and Install. (Group 3160.)

2. Disassemble and assemble parts as shown. Not all the parts shown are serviceable individually.

Bottom View of Auxiliary Function Pilot Control Valve

Continued on next page

TM10687 (14OCT08)

TX1029138

1—Auxiliary 2—Auxiliary 3—Pressure Oil 4—Return Oil

–UN–10SEP07

NOTE: Parts shown are for reference only.

31-3160-45

SW03989,000044D –19–24APR08–1/2

524K Loader 101408

PN=405

Hydraulic System

TX1029139

–UN–10SEP07

31 3160 46

Auxiliary Control Lever 5—Auxiliary Control Lever 6—Boot

7—Armature

8—Plate

9—Plate

SW03989,000044D –19–24APR08–2/2

TM10687 (14OCT08)

31-3160-46

524K Loader 101408

PN=406

Hydraulic System

Pilot Accumulator Remove and Install 1. Lower boom and attachment to the ground. CAUTION: Prevent possible injury from unexpected machine movement. Install articulation lock bar before working in frame hinge area. 2. Install frame articulation lock bar. SW03989,00006E0 –19–13AUG08–1/3

CAUTION: Escaping fluid under pressure can penetrate the skin causing serious injury.

–UN–23AUG88

Avoid the hazard by relieving pressure before disconnecting hydraulic or other lines. Tighten all connections before applying pressure.

X9811

Continued on next page

TM10687 (14OCT08)

31-3160-47

SW03989,00006E0 –19–13AUG08–2/3

524K Loader 101408

PN=407

31 3160 47

Hydraulic System 5. Disconnect hydraulic line (2) from pilot accumulator (1). See Hydraulic System Component Location. (Group 9025-15.) 6. Remove cap screws and clamps holding pilot accumulator to engine frame. NOTE: Accumulator is not serviceable.

1 7. Remove pilot accumulator.

9. Install pilot accumulator. 2

TX1037493

10. Connect hydraulic line. 11. Turn battery disconnect to ON position. 31 3160 48

–UN–28FEB08

8. Repair or replace parts as necessary.

12. Remove frame articulation lock bar. 1—Pilot Accumulator 2—Hydraulic Line

SW03989,00006E0 –19–13AUG08–3/3

Hydraulic Pump Manifold Remove and Install NOTE: Disassembly and assembly of hydraulic pump manifold can be performed with-out removing hydraulic pump manifold. See Hydraulic Pump Manifold Disassemble and Assemble. (Group 3160.)

CAUTION: Prevent possible injury from unexpected machine movement. Install frame articulation lock bar before working in frame hinge area. 1. Install frame articulation lock bar.

Continued on next page

TM10687 (14OCT08)

31-3160-48

SW03989,00006E1 –19–11AUG08–1/3

524K Loader 101408

PN=408

Hydraulic System

CAUTION: Escaping fluid under pressure can penetrate the skin, causing serious injury.

–UN–23AUG88

Avoid the hazard by relieving pressure before disconnecting hydraulic or other lines. Tighten all connections before applying pressure.

X9811

Escaping Fluid Under Pressure

31 3160 49

2. Perform Hydraulic System Pressure and Accumulators Discharge. (Group 9025-25.) 3. Turn battery disconnect switch to the OFF position. 4. Apply vacuum or drain hydraulic reservoir. If draining hydraulic reservoir, see Drain and Refill Hydraulic System Oil. (Operator’s Manual.) 5. Identify and disconnect electrical connectors from hydraulic pump manifold. 6. Identify and disconnect hydraulic lines from hydraulic pump manifold. Close all openings using caps or plugs. 7. Remove hydraulic pump manifold. 8. Inspect for contamination, wear, or damage. See Hydraulic Pump Manifold Disassemble and Assemble. (Group 3160.) 9. Repair or replace parts as necessary. 10. Install hydraulic pump manifold. 11. Connect hydraulic lines to hydraulic pump manifold.

Continued on next page

TM10687 (14OCT08)

31-3160-49

SW03989,00006E1 –19–11AUG08–2/3

524K Loader 101408

PN=409

Hydraulic System 12. Connect electrical connectors to hydraulic pump manifold. 13. Remove vacuum pump and check hydraulic oil level. Fill hydraulic oil reservoir if drained. See Check Hydraulic Oil Level or see Drain and Refill Hydraulic System Oil. (Operator’s Manual.) 14. Turn battery disconnect switch to the ON position. 15. Remove frame articulation lock bar.

31 3160 50

SW03989,00006E1 –19–11AUG08–3/3

TM10687 (14OCT08)

31-3160-50

524K Loader 101408

PN=410

Hydraulic System

31 3160 51

TM10687 (14OCT08)

31-3160-51

524K Loader 101408

PN=411

Hydraulic System

Hydraulic Pump Manifold Disassemble and Assemble

6 3

7 12

14 31 3160 52

13 9

18 19

TX1037494

TX1037494 Continued on next page

TM10687 (14OCT08)

–UN–28FEB08

31-3160-52

SW03989,00006E2 –19–01OCT08–1/2

524K Loader 101408

PN=412

Hydraulic System 1—Pilot Pressure Port 2—Hydraulic Reservoir Port 3—Transmission Pressure Port 4—Main Hydraulic Pump Load Sense Port 5—Pilot Accumulator Check Valve (CV1) 6—Steering Compensator Valve 7—Loader Control Valve Pressure Port

8—Transmission Return Port 9—Pilot Pressure Reducing Valve (PR1) 10—Differential Lock Pressure Port 11—Park Brake Pressure Port 12—Loader Control Valve Load Sense Port 13—Park Brake Pressure Switch 14—Main Hydraulic Pump Pressure Test Port

NOTE: Disassembly and assembly of hydraulic pump manifold can be done with-out removing hydraulic pump manifold from loader. If removable is necessary see Hydraulic Pump Manifold Remove and Install. (Group 3160.) 1. Remove parts from hydraulic pump manifold as necessary. 2. Inspect parts for contamination, wear, or damage. Clean parts of any contaminants. 3. Repair or replace parts as necessary. IMPORTANT: Apply clean hydraulic oil to all internal parts before assembling and apply petroleum jelly to backup rings and O-rings before installation. 4. Install new O-rings and backup rings.

15—Pilot Pressure Test Port 16—Pilot Accumulator Solenoid Valve 17—Pilot Pressure Solenoid Valve 18—Park Brake Solenoid Valve 19—Park Brake Check Valve (CV2) 20—Load Sense Shuttle Valve (LS1) 21—Differential Lock Solenoid Valve

22—Main Hydraulic Pump Inlet Port 23—System Pressure and Spin Control Transducer 24—Steering Load Sense Port 25—Service Brake Accumulator Port 26—Orbital Steering Valve Port 27—Pilot Accumulator Port

Steering Compensator Valve— Torque...................................................................................... 68 N•m 50 lb-ft Park Brake Solenoid Valve Mounting Screw—Torque ....................................................... 3.5 N•m 31.2 lb-in Park Brake Check Valve (CV2)—Torque...................................................................... 27.1 N•m 20 lb-ft Pilot Pressure Solenoid Valve Mounting Screw—Torque ....................................................... 3.5 N•m 31.2 lb-in Differential Lock Solenoid Valve Mounting Screw—Torque ....................................................... 3.5 N•m 31.2 lb-in Load Sense Shuttle Valve (LS1)—Torque ...................................................................... 27.1 N•m 20 lb-ft Pilot Accumulator Valve Mounting Screw—Torque ..................................................... 27.1 N•m 20 lb-ft Pilot Pressure Reducing Valve (PR1)—Torque...................................................................... 33.8 N•m 25 lb-ft

5. Install parts in hydraulic pump manifold and tighten to specification. Specification Pilot Accumulator Check Valve (CV1)—Torque...................................................................... 27.1 N•m 20 lb-ft

SW03989,00006E2 –19–01OCT08–2/2

TM10687 (14OCT08)

31-3160-53

524K Loader 101408

PN=413

31 3160 53

Hydraulic System

Ride Control Valve Remove and Install 4

5 6

3 31 3160 54

TX1029031

–UN–07SEP07

TX1029031 Ride Control Valve and Plumbing 1—Ride Control Valve 2—Ride Control Valve-to-Loader Control Valve Tee Line

3—Ride Control Valve-to-Loader Control Valve Tee Line 4—Ride Control Valve-to-Loader Control Valve Line

CAUTION: Prevent possible injury from unexpected machine movement. Install frame articulation lock bar before working in frame hinge area.

5—Ride Control Valve-to-Ride Control Accumulator Line 6—Ride Control Accumulator

1. Install frame articulation lock bar.

Continued on next page

TM10687 (14OCT08)

7—Loader Control Valve 8—Pin Disconnect Valve

31-3160-54

SW03989,00006E3 –19–04AUG08–1/2

524K Loader 101408

PN=414

Hydraulic System

CAUTION: Escaping fluid under pressure can penetrate the skin causing serious injury.

–UN–23AUG88

Avoid the hazard by relieving pressure before disconnecting hydraulic or other lines. Tighten all connections before applying pressure.

X9811

Search for leaks with a piece of cardboard. Protect hands and body from high-pressure fluids. Escaping Fluid Under Pressure

31 3160 55

2. Perform Hydraulic System Pressure and Accumulators Discharge. (Group 9025-25.) 3. Turn battery disconnect switch to the OFF position. 4. Identify and disconnect electrical connectors from ride control valve (1). 5. Identify and disconnect hydraulic lines from ride control valve. Close all openings using caps and plugs. 6. Remove ride control valve. 7. Repair or replace parts as necessary. See Ride Control Valve Disassemble and Assemble. (Group 3160.) 8. Install ride control valve. 9. Connect hydraulic lines. 10. Connect electrical connectors. 11. Turn battery disconnect switch to the ON position. 12. Remove frame articulation lock bar.

SW03989,00006E3 –19–04AUG08–2/2

TM10687 (14OCT08)

31-3160-55

524K Loader 101408

PN=415

Hydraulic System

Ride Control Valve Disassemble and Assemble

NOTE: Ride control valve components can be replaced while ride control valve is on machine. Internal parts of solenoid and check valves are not serviceable.

1. Remove solenoids (1—3). 5

2. Remove valves (5—7).

–UN–07SEP07

3. Inspect parts for contamination, wear, or damage. Clean parts of any contaminants.

31 3160 56

NOTE: Apply clean hydraulic oil to all internal parts before assembling and apply petroleum jelly to backup rings and O-rings before installation. 5. Install new O-rings and backup rings. 6. Install solenoids (1—3) and valves (5—7) in ride control valve and tighten to specification. Specification On/Off Solenoid Valve—Torque .................................................. 27.1 N•m 20 lb-ft Bucket Dump Solenoid Valve— Torque ......................................................................................... 27.1 N•m 20 lb-ft Ride Control Shuttle Valve— Torque ......................................................................................... 33.8 N•m 25 lb-ft High Flow Spool Valve—Torque ................................................. 47.4 N•m 35 lb-ft Low Flow Spool Valve—Torque .................................................. 33.8 N•m 25 lb-ft

TX1029054

4. Repair or replace parts as necessary. 7 Ride Control Valve 1—On/Off Solenoid Valve 2—Bucket Dump Solenoid Valve 3—On/Off Solenoid Valve 4—Ride Control Valve 5—Ride Control Shuttle Valve 6—High Flow Spool Valve 7—Low Flow Spool Valve

SW03989,00006E4 –19–04AUG08–1/1

TM10687 (14OCT08)

31-3160-56

524K Loader 101408

PN=416

Hydraulic System

Pin Disconnect Valve Remove and Install CAUTION: Escaping fluid under pressure can penetrate the skin causing serious injury. –UN–23AUG88

Avoid the hazard by relieving pressure before disconnecting hydraulic or other lines. Tighten all connections before applying pressure.

X9811

Search for leaks with a piece of cardboard. Protect hands and body from high-pressure fluids.

Escaping Fluid Under Pressure

31 3160 57

CAUTION: Prevent possible injury from unexpected machine movement. Install frame articulation lock bar before working in frame hinge area. 1. Install frame articulation lock bar. CAUTION: To avoid injury from escaping fluid under pressure, stop engine and relieve the pressure in the system before disconnecting or connecting hydraulic or other lines. Tighten all connections before applying pressure. 2. Perform Hydraulic System Pressure and Accumulators Discharge. (Group 9025-25.) 3. Turn battery disconnect switch to the OFF position. 4. Identify and disconnect hydraulic lines. Close all openings using caps and plugs. 5. Identify and disconnect electrical connectors. 6. Remove pin disconnect valve.

Continued on next page

TM10687 (14OCT08)

31-3160-57

SW03989,00006E5 –19–04AUG08–1/2

524K Loader 101408

PN=417

Hydraulic System 7. Repair or replace parts as necessary. See Pin Disconnect Valve Disassemble and Assemble. (Group 3160.) 8. Install pin disconnect valve. 9. Connect hydraulic lines. 10. Connect electrical connectors. 11. Turn battery disconnect switch to the ON position. 12. Remove frame articulation lock bar.

31 3160 58

SW03989,00006E5 –19–04AUG08–2/2

TM10687 (14OCT08)

31-3160-58

524K Loader 101408

PN=418

Hydraulic System

Pin Disconnect Valve Disassemble and Assemble

6 5

4 –UN–28FEB08

TX1037732

TX1037732 1—Fitting 2—O-Ring (2 used) 3—O-Ring (2 used)

4—Pin Disconnect Valve 5—Pin Disconnect Solenoid Valve

NOTE: Pin disconnect valve components can be replaced while valve is on machine. Internal parts of solenoid and check valves are not serviceable. For removal of pin disconnect valve from machine, see Pin Disconnect Valve Remove and Install. (Group 3160.) 1. Remove parts from pin disconnect valve (4). 2. Inspect parts for contamination, wear, or damage. Clean parts of any contaminants. 3. Repair or replace parts as necessary. IMPORTANT: Apply clean hydraulic oil to all internal parts before assembling and apply petroleum jelly to backup rings and O-rings before installation.

6—Pin Disconnect Pressure Reducing Valve

7—Elbow Fitting

4. Apply clean hydraulic oil to all internal surfaces. 5. Replace all O-rings. Apply petroleum jelly to new O-rings. 6. Install fittings and tighten securely. 7. Install pin disconnect solenoid valve (5) and pin disconnect pressure reducing valve (6). Tighten to specification. Specification Pin Disconnect Solenoid Valve—Torque ...................................................................... 33.8 N•m 25 lb-ft Pin Disconnect Pressure Reducing Valve—Torque...................................................... 33.8 N•m 25 lb-ft

SW03989,00006E6 –19–04AUG08–1/1

TM10687 (14OCT08)

31-3160-59

524K Loader 101408

PN=419

31 3160 59

Hydraulic System

Hydraulic Fan Pump and Axle Circulation Pump Remove and Install

–UN–23AUG88

CAUTION: Escaping fluid under pressure can penetrate the skin causing serious injury.

X9811

Avoid the hazard by relieving pressure before disconnecting hydraulic or other lines. Tighten all connections before applying pressure. Search for leaks with a piece of cardboard. Protect hands and body from high-pressure fluids.

31 3160 60

Escaping Fluid Under Pressure

Continued on next page

TM10687 (14OCT08)

31-3160-60

SW03989,00006E7 –19–11AUG08–1/2

524K Loader 101408

PN=420

Hydraulic System 4. Identify and disconnect axle circulation pump hydraulic lines (1). Close all openings using caps and plugs. 5. Identify and disconnect hydraulic fan pump hydraulic lines (2). Close all openings using caps and plugs.

–UN–09APR07

NOTE: The hydraulic fan pump and axle circulation pump is removed and installed as a unit.

TX1021561A

6. Remove hydraulic fan pump and axle circulation pump retaining cap screws (3). 7. Repair or replace parts as necessary. 8. Replace hydraulic fan pump mounting flange seal. 9. Install hydraulic fan pump and axle circulation pump. Tighten to specification. Specification Hydraulic Fan Pump and Axle Circulation Pump Mounting Cap Screw—Torque ............................................................................. 130 N•m 95 lb-ft

Hydraulic Fan Pump and Axle Circulation Pump 1—Axle Circulation Pump Hydraulic Line (4 used) 2—Hydraulic Fan Pump Hydraulic Line (2 used) 3—Hydraulic Fan Pump and Axle Circulation Pump Retaining Cap Screw (2 used)

31 3160 61

10. Connect hydraulic fan pump hydraulic lines. 11. Connect axle circulation pump hydraulic lines. 12. Remove vacuum pump and check hydraulic oil level. Fill hydraulic oil reservoir if drained. See Check Hydraulic Oil Level or see Drain and Refill Hydraulic System Oil. (Operator’s Manual.) 13. Turn battery disconnect switch to the ON position.

SW03989,00006E7 –19–11AUG08–2/2

TM10687 (14OCT08)

31-3160-61

524K Loader 101408

PN=421

Hydraulic System

Hydraulic Fan Motor Remove and Install

1 2

3 7

6 18

17 16

31 3160 62

12 8 13

9 11

TX1047738

–UN–25AUG08

TX1047738 Hydraulic Fan Motor Remove and Install Continued on next page

TM10687 (14OCT08)

31-3160-62

AA95137,0001B54 –19–02OCT08–1/2

524K Loader 101408

PN=422

Hydraulic System 1—Fan Guard Retaining Cap Screw (6 used) 2—Washer (6 used) 3—Nut (2 used) 4—Hydraulic Fan Motor 5—Bracket

6—Hydraulic Fan Motor Mounting Cap Screw (2 used) 7—Fan Housing 8—Washer (11 used) 9—Grille Retaining Cap Screw (11 used)

1. Turn battery disconnect switch to OFF position or disconnect negative battery cable.

10—Grille 11—Fan Blade Mounting Cap Screw (6 used) 12—Fan Blade 13—Hub Retaining Nut 14—Hub

15—Nut (6 used) 16—Washer (4 used) 17—Bracket Mounting Cap Screw (4 used) 18—Fan Guard

11. Repair or replace parts as necessary. 12. Install hydraulic fittings to hydraulic fan motor.

2. Remove axle oil cooler (if equipped) and set aside. See Power Train Component Location. (Group 9020-15.) 3. Remove grille retaining cap screws (9), disconnect rear light electrical connectors, and remove grille (10). 4. Remove fan blade mounting cap screws (11) and remove fan blade (12). 5. Apply vacuum or drain hydraulic reservoir into appropriate container for storage or disposal. See Drain and Refill Capacities. (Operator’s Manual.) 6. Tag and disconnect hydraulic lines to hydraulic fan motor. Close all openings using caps and plugs. 7. Remove fan guard retaining cap screws (1) and remove fan guard (18). 8. Remove hydraulic fan motor (4) with bracket (5) and hub (14). 9. Remove hub (14) and bracket (5) from hydraulic fan motor (4). 10. Remove hydraulic fittings from hydraulic fan motor.

13. Install bracket to hydraulic fan motor. IMPORTANT: Avoid machine damage. Install new fan hub retaining lock nut. 14. Install hub to hydraulic fan motor. Tighten hub retaining nut (13) to specification. Specification Hub Retaining Nut—Torque .................................................... 81 N•m 60 lb-ft

15. Install hydraulic fan motor (4) to fan housing (7). 16. Connect hydraulic lines. 17. Remove vacuum or fill hydraulic oil reservoir. See Drain and Refill Capacities. (Operator’s Manual.) 18. Install fan guard (18). 19. Install fan blade (12) to hub (14). 20. Connect rear light electrical connectors and install grille (10). 21. Install axle oil cooler (if equipped).

AA95137,0001B54 –19–02OCT08–2/2

TM10687 (14OCT08)

31-3160-63

524K Loader 101408

PN=423

31 3160 63

Hydraulic System

Reversing Fan Valve Remove and Install CAUTION: Escaping fluid under pressure can penetrate the skin causing serious injury. –UN–23AUG88

Avoid the hazard by relieving pressure before disconnecting hydraulic or other lines. Tighten all connections before applying pressure.

31 3160 64

X9811

Search for leaks with a piece of cardboard. Protect hands and body from high-pressure fluids.

Escaping Fluid Under Pressure

If an accident occurs, see a doctor immediately. Any fluid injected into the skin must be surgically removed within a few hours or gangrene may result. Doctors unfamiliar with this type of injury should reference a knowledgeable medical source. Such information is available from Deere & Company Medical Department in Moline, Illinois, U.S.A CAUTION: To avoid injury from escaping fluid under pressure, stop engine and relieve the pressure in the system before disconnecting or connecting hydraulic or other lines. Tighten all connections before applying pressure. 1. Perform Hydraulic System Pressure and Accumulators Discharge. (Group 9025-25.) 2. Turn battery disconnect switch to the OFF position. 3. Apply vacuum or drain hydraulic reservoir. If draining hydraulic reservoir, see Drain and Refill Hydraulic System Oil. (Operator’s Manual.)

Continued on next page

TM10687 (14OCT08)

31-3160-64

SW03989,00006E8 –19–11AUG08–1/2

524K Loader 101408

PN=424

Hydraulic System 4. Identify and disconnect electrical connectors (1) from fan reversing valve. 5. Identify and disconnect hydraulic lines (2) from reversing fan valve. Close all openings using caps and plugs. 6. Remove retaining cap screws (3). –UN–17MAR08

7. Repair or replace parts as necessary.

TX1038750A

8. Install reversing fan valve and retaining cap screws. Tighten securely. 9. Connect hydraulic lines to reversing fan valve. 10. Connect electrical connectors to reversing fan valve.

Reversing Fan Valve

11. Remove vacuum pump and check hydraulic oil level. Fill hydraulic oil reservoir if drained. See Check Hydraulic Oil Levelsee Drain and Refill Hydraulic System Oil. (Operator’s Manual.)

1—Electrical Connectors (2 used) 2—Hydraulic Lines (4 used) 3—Cap Screw (2 used)

31 3160 65

12. Turn battery disconnect switch to the ON position.

SW03989,00006E8 –19–11AUG08–2/2

TM10687 (14OCT08)

31-3160-65

524K Loader 101408

PN=425

Hydraulic System

Reversing Fan Valve Disassemble and Assemble

NOTE: Reversing fan valve components can be replaced while reversing fan valve is on machine. Internal parts of solenoid valves and check valves are not serviceable.

1. Remove and inspect fan proportional/relief solenoid valve (1) and reversing fan solenoid valve (2) for contamination, wear, or damage.

TX1038791

31 3160 66

2. Remove and inspect reversing fan spool valve (3) and check valves (4) for contamination, wear, or damage.

–UN–17MAR08

To remove and install reversing fan valve, see Reversing Fan Valve Remove and Install. (Group 3160.)

3. Remove hydraulic fittings (5).

Reversing Fan Valve

4. Clean and inspect all parts for any contaminants.

1—Fan Proportional/Relief Solenoid Valve 2—Reversing Fan Solenoid Valve 3—Reversing Fan Spool Valve 4—Check Valves (4 used) 5—Hydraulic Fittings (4 used)

5. Replace parts as necessary. IMPORTANT: Apply clean hydraulic oil to all internal parts before assembling and apply petroleum jelly to backup rings and O-rings before installation. 6. Apply clean hydraulic oil to all internal surfaces during installation. 7. Apply petroleum jelly to O-rings and backup rings before installation. 8. Install new O-rings and backup rings. 9. Install hydraulic fittings. Tighten securely 10. Install fan proportional/relief solenoid valve, reversing fan solenoid valve, check valves and reversing fan spool valve. Tighten to specifications. Specification Fan Proportional/Relief Solenoid Valve—Torque ............................................................................. 27.1 N•m 20 lb-ft

Continued on next page

TM10687 (14OCT08)

31-3160-66

SW03989,00006E9 –19–04AUG08–1/2

524K Loader 101408

PN=426

Hydraulic System Specification Reversing Fan Solenoid Valve— Torque ......................................................................................... 27.1 N•m 20 lb-ft Specification Reversing Fan Spool Valve— Torque ......................................................................................... 67.7 N•m 50 lb-ft Specification Check Valves—Torque................................................................ 27.1 N•m 20 lb-ft

SW03989,00006E9 –19–04AUG08–2/2

TM10687 (14OCT08)

31-3160-67

524K Loader 101408

PN=427

31 3160 67

Hydraulic System

31 3160 68

TM10687 (14OCT08)

31-3160-68

524K Loader 101408

PN=428

Section 99

Dealer Fabricated Tools Contents Page

Group 9900—Dealer Fabricated Tools DFT1132 Hydraulic Pump Removal and Installation Tool . . . . . . . . . . . . . . . . . . . . .99-9900-1

TM10687 (14OCT08)

99-1

524K Loader 101408

PN=1

Contents

TM10687 (14OCT08)

99-2

524K Loader 101408

PN=2

Group 9900

Dealer Fabricated Tools

T8366AC

–UN–10JUL95

DFT1132 Hydraulic Pump Removal and Installation Tool

A—1 in. Nut B—Pipe 2134 mm (7 ft) long

C—Pipe 457 mm (18 in.) long D—1 in. ID heavy Wall Steel Pipe

This tool is used to remove hydraulic motor from machine.

E—Pipe F—Weld

G—Pipe

• 1 in. ID piece heavy wall steel pipe 8 ft. x 6 in. long • Weld (E) to (G)

Material required:

AA95137,0001B4D –19–14AUG08–1/1

TM10687 (14OCT08)

99-9900-1

524K Loader 101408

PN=431

99 9900 1

Dealer Fabricated Tools

99 9900 2

TM10687 (14OCT08)

99-9900-2

524K Loader 101408

PN=432

Index Page

Page

A Accumulator Service brake, remove and install . . . . . .10-1060-2 Air cleaner Remove and install . . . . . . . . . . . . . . . . .05-0520-1 Air conditioner system Purge . . . . . . . . . . . . . . . . . . . . . . . . . .18-1830-11 Air conditioning Blower motor assembly. . . . . . . . . . . . .18-1830-21 Charge R134a system . . . . . . . . . . . . . .18-1830-9 Cleaning procedures . . . . . . . . . . . . . . .18-1830-10 Component oil charge . . . . . . . . . . . . . . .18-1830-3 Compressor oil removal . . . . . . . . . . . . .18-1830-2 Compressor, remove and install . . . . . .18-1830-27 Condenser . . . . . . . . . . . . . . . . . . . . . .18-1830-23 Evacuate R134a system . . . . . . . . . . . . .18-1830-7 Expansion valve . . . . . . . . . . . . . . . . . .18-1830-16 Flush. . . . . . . . . . . . . . . . . . . . . . . . . . .18-1830-12 Freeze control switch . . . . . . . . . . . . . .18-1830-17 Freeze control switch bench test. . . . . .18-1830-18 Heater control valve . . . . . . . . . . . . . . .18-1830-19 Heater control valve leak check . . . . . .18-1830-20 Heater/evaporator coil, remove and install. . . . . . . . . . . . . . . . . . . . . . . . .18-1830-15 Leak testing . . . . . . . . . . . . . . . . . . . . . .18-1830-4 Module with heater/evaporator coil . . . .18-1830-14 Receiver-dryer . . . . . . . . . . . . . . . . . . .18-1830-22 Recover R134a system. . . . . . . . . . . . . .18-1830-6 Refrigerant hoses and tubing inspection . . . . . . . . . . . . . . . . . . . . . .18-1830-4 Refrigerant R134a caution . . . . . . . . . . .18-1830-1 Air conditioning high-low pressure switch Remove and install . . . . . . . . . . . . . . . .18-1830-24 Air conditioning R134a component oil Charge . . . . . . . . . . . . . . . . . . . . . . . . . .18-1830-3 Air conditioning R134a compressor oil Removal . . . . . . . . . . . . . . . . . . . . . . . . .18-1830-2 Air conditioning R134a compressor oil charge Check . . . . . . . . . . . . . . . . . . . . . . . . . . .18-1830-2 Air conditioning R134a refrigerant Cautions . . . . . . . . . . . . . . . . . . . . . . . . .18-1830-1 Air conditioning R134a system Evacuate. . . . . . . . . . . . . . . . . . . . . . . . .18-1830-7 Recover . . . . . . . . . . . . . . . . . . . . . . . . .18-1830-6 Air conditioning, R134a refrigerant, recovery, recycling and charging Station installation . . . . . . . . . . . . . . . . . .18-1830-5 Air conditioning, R134a system Charge . . . . . . . . . . . . . . . . . . . . . . . . . .18-1830-9 Anticavitation valve Disassemble and assemble . . . . . . . . .31-3160-24 TM10687 (14OCT08)

Assemble Hydraulic pump manifold. . . . . . . . . . . .31-3160-52 Steering column . . . . . . . . . . . . . . . . . . .09-0960-8 Attachments Adding safely . . . . . . . . . . . . . . . . . . . .00-0001-14 Operating safely . . . . . . . . . . . . . . . . . .00-0001-14 Auxiliary control valve Disassemble and assemble . . . . . . . . .31-3160-45 Auxiliary function pilot control valve Remove and install . . . . . . . . . . . . . . . .31-3160-42 Auxiliary section Disassemble and assemble . . . . . . . . .31-3160-19 Axle Circulation system, exploded view . . . . .02-0260-2 Oil coolers. . . . . . . . . . . . . . . . . . . . . . . .05-0510-8 Axle and differential Front, remove and install . . . . . . . . . . . .02-0200-2 Rear, remove . . . . . . . . . . . . . . . . . . . . .02-0200-6 Axle circulation pump Remove and install . . . . . . . . . . . . . . . .31-3160-60 Axle circulation system Remove and install . . . . . . . . . . . . . . . . .02-0260-2 Axle disconnect Disassemble and Assemble . . . . . . . . .03-0350-76 Remove and Install . . . . . . . . . . . . . . . .03-0350-74 Axle disconnect solenoid Remove and install . . . . . . . . . . . . . . . .03-0360-29 Axle oscillating supports Disassemble and assemble . . . . . . . . .02-0200-11

B Battery explosions Prevent . . . . . . . . . . . . . . . . . . . . . . . . . .00-0001-6 Belt Serpentine, remove and install . . . . . . .04-0400-10 Blower motor assembly Remove and install . . . . . . . . . . . . . . . .18-1830-21 Boom Remove and install . . . . . . . . . . . . . . . . .31-3140-4 Boom cylinder Disassemble and assemble . . . . . . . . .31-3160-30 Loader start-up procedure. . . . . . . . . . .31-3160-32 Remove and install . . . . . . . . . . . . . . . .31-3160-25 Boom cylinder bushings and seals Remove and install . . . . . . . . . . . . . . . .31-3160-31 Boom section Disassemble and assemble . . . . . . . . .31-3160-17 Brake Park, disassemble and assemble . . . . . .11-1111-4 Park, remove and install . . . . . . . . . . . . .11-1111-1

Index-1

524K Loader 101408

PN=1

Indx 1

Index

Page

Brake assembly Install . . . . . . . . . . . . . . . . . . . . . . . . . . .10-1011-1 Remove . . . . . . . . . . . . . . . . . . . . . . . . .10-1011-1 Bucket Remove and install . . . . . . . . . . . . . . . . .31-3102-1 Bucket bolt-on cutting edges Remove and install . . . . . . . . . . . . . . . . .31-3102-3 Bucket cylinder Disassemble and assemble . . . . . . . . .31-3160-30 Remove and install . . . . . . . . . . . . . . . .31-3160-27 Bucket cylinder bushings and seals Remove and install . . . . . . . . . . . . . . . .31-3160-31 Bucket linkage seals and bushings Remove and install . . . . . . . . . . . . . . . . .31-3140-2 Bucket section Disassemble and assemble . . . . . . . . .31-3160-18 Bucket tilt linkage Remove and install . . . . . . . . . . . . . . . . .31-3140-1 Bucket welded-on cutting edge Remove and install . . . . . . . . . . . . . . . . .31-3102-2 Bushings Steering cylinder, remove and install. . .09-0960-12 Bushings and seals, boom or bucket cylinders Remove and install . . . . . . . . . . . . . . . .31-3160-31 Bushings and seals, loader boom Remove and install . . . . . . . . . . . . . . . . .31-3140-3

Clutch Compressor . . . . . . . . . . . . . . . . . . . . .18-1830-28 Compressor, check hub clearance . . . .18-1830-29 Clutch pack KV and KR Assemble . . . . . . . . . . . . . . . . . . . . . . .03-0350-37 Disassemble . . . . . . . . . . . . . . . . . . . . .03-0350-33 Clutch pack K1, K2, and K3 Assemble . . . . . . . . . . . . . . . . . . . . . . .03-0350-49 Disassemble . . . . . . . . . . . . . . . . . . . . .03-0350-46 Clutch pack K4 Assemble . . . . . . . . . . . . . . . . . . . . . . .03-0350-62 Disassemble . . . . . . . . . . . . . . . . . . . . .03-0350-61 Clutches and input and output shafts Install . . . . . . . . . . . . . . . . . . . . . . . . . .03-0350-19 Compressor Clutch hub clearance . . . . . . . . . . . . . .18-1830-29 Clutch, disassemble and assemble . . . .18-1830-28 Remove and install . . . . . . . . . . . . . . . .18-1830-27 Compressor, air conditioning, R134a oil Removal . . . . . . . . . . . . . . . . . . . . . . . . .18-1830-2 Compressor, R134a oil charge Check . . . . . . . . . . . . . . . . . . . . . . . . . . .18-1830-2 Compressor, R134a, component oil Charge . . . . . . . . . . . . . . . . . . . . . . . . . .18-1830-3 Condenser Remove and install . . . . . . . . . . . . . . . .18-1830-23 Control valve Disassemble and assemble . . . . . . . . .03-0360-11 Converter minimum pressure regulator valve Install . . . . . . . . . . . . . . . . . . . . . . . . . . .03-0360-5 Remove . . . . . . . . . . . . . . . . . . . . . . . . .03-0360-5 Converter relief valve Disassemble . . . . . . . . . . . . . . . . . . . . .03-0360-23 Install . . . . . . . . . . . . . . . . . . . . . . . . . .03-0360-23 Remove . . . . . . . . . . . . . . . . . . . . . . . .03-0360-23 Converter, torque and housing Install . . . . . . . . . . . . . . . . . . . . . . . . . . .03-0350-6 Remove . . . . . . . . . . . . . . . . . . . . . . . . .03-0350-1 Cooling package Plenum Grille Remove and install . . . . . . . . . . . . .05-0510-9 Counterweights Remove and install . . . . . . . . . . . . . . . . .17-1749-1 Crankshaft dampner Remove and install . . . . . . . . . . . . . . . .04-0400-11 Cutting edge Crack repair . . . . . . . . . . . . . . . . . . . . . .31-3102-4 Cutting edge, welded-on Remove and install . . . . . . . . . . . . . . . . .31-3102-2 Cutting edges, bucket bolt-on Remove and install . . . . . . . . . . . . . . . . .31-3102-3

Indx 2

C Cab Fresh air filter . . . . . . . . . . . . . . . . . . . .18-1830-25 Install . . . . . . . . . . . . . . . . . . . . . . . . . . .18-1800-1 Recirculating air filter . . . . . . . . . . . . . .18-1830-26 Remove . . . . . . . . . . . . . . . . . . . . . . . . .18-1800-1 Cab door Adjust hold-open release . . . . . . . . . . . .18-1810-1 Cab door hold-open release Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . .18-1810-1 Charging station, R134a refrigerant Recovery, recycling and charging . . . . . .18-1830-5 Chemical products Handling . . . . . . . . . . . . . . . . . . . . . . . . .00-0001-6 Circuit relief with anticavitation valve Disassemble and assemble . . . . . . . . .31-3160-22 Circulation system Axle, exploded view . . . . . . . . . . . . . . . .02-0260-2 Cleanup Procedure General oil . . . . . . . . . . . . . . . . . . . . . . .31-3160-1 Cleanup procedure Hydraulic component failure . . . . . . . . . .31-3160-4

TM10687 (14OCT08)

Index-2

524K Loader 101408

PN=2

Index

Page

Cylinder Boom cylinder remove and install . . . . .31-3160-25 Bucket cylinder remove and install . . . .31-3160-27 Cylinder bushings and seals, boom or bucket Remove and install . . . . . . . . . . . . . . . .31-3160-31 Cylinder bushings, steering Remove and install . . . . . . . . . . . . . . . .09-0960-12 Cylinder, boom Loader start-up procedure. . . . . . . . . . .31-3160-32

Engine and loader frame Separate . . . . . . . . . . . . . . . . . . . . . . . . .17-1740-3 Engine coolant heater Remove and install . . . . . . . . . . . . . . . . .05-0505-3 Engine side shields Remove and install . . . . . . . . . . . . . . . . .19-1910-2 Evaporator Remove and install . . . . . . . . . . . . . . . .18-1830-15 Exhaust fumes . . . . . . . . . . . . . . . . . . . . . .00-0001-5 Expansion valve Remove and install . . . . . . . . . . . . . . . .18-1830-16 Explosion Battery . . . . . . . . . . . . . . . . . . . . . . . . . .00-0001-6

D Dampener, output Install . . . . . . . . . . . . . . . . . . . . . . . . . . .07-0752-1 Remove . . . . . . . . . . . . . . . . . . . . . . . . .07-0752-1 Dealer fabricated tool DFT1132 hydraulic pump removal tool . . . . . . . . . . . . . . . . . . . . . . . . . . .99-9900-1 Differential Front remove and install . . . . . . . . . . . . .02-0200-2 Differential lock solenoid valve Remove and install . . . . . . . . . . . . . . . . .02-0260-1 Differential, rear Remove . . . . . . . . . . . . . . . . . . . . . . . . .02-0200-6 Disassemble Hydraulic pump manifold. . . . . . . . . . . .31-3160-52 Steering column . . . . . . . . . . . . . . . . . . .09-0960-8 Disassemble and assemble Auxiliary section . . . . . . . . . . . . . . . . . .31-3160-19 Boom section . . . . . . . . . . . . . . . . . . . .31-3160-17 Bucket section . . . . . . . . . . . . . . . . . . .31-3160-18 Circuit relief with anticavitation valve. . .31-3160-22 Hi-Vis coupler . . . . . . . . . . . . . . . . . . . . .31-3140-8 Load sense relief valve . . . . . . . . . . . . .31-3160-21 Loader control valve . . . . . . . . . . . . . . .31-3160-16 Main hydraulic pump. . . . . . . . . . . . . . .31-3160-12 Main relief valve . . . . . . . . . . . . . . . . . .31-3160-20 Pin disconnect valve . . . . . . . . . . . . . . .31-3160-59 Reversing fan valve . . . . . . . . . . . . . . .31-3160-66 Serve brake pedal and linkage . . . . . . . .10-1011-2 Drive shaft Remove and install . . . . . . . . . . . . . . . . .02-0225-2 Driving metal pins. . . . . . . . . . . . . . . . . . .00-0001-18

F Filter Cab air recirculating . . . . . . . . . . . . . . .18-1830-26 Cab fresh air . . . . . . . . . . . . . . . . . . . . .18-1830-25 Fuel, remove and install . . . . . . . . . . . . .05-0560-5 Primary fuel, remove and install . . . . . . .05-0560-5 Fire prevention . . . . . . . . . . . . . . . . . . . . . .00-0001-5 Frame Separate . . . . . . . . . . . . . . . . . . . . . . . . .17-1740-3 Frame pivot bearing Lower, remove and install . . . . . . . . . . . .17-1740-9 Upper, remove and install . . . . . . . . . . . .17-1740-7 Freeze control switch Remove and install . . . . . . . . . . . . . . . .18-1830-17 Freeze control switch bench test . . . . . . .18-1830-18 Front axle and differential Remove and install . . . . . . . . . . . . . . . . .02-0200-2 Front axle guard Remove and install . . . . . . . . . . . . . . . . .17-1746-1 Front wiper motor Remove and install . . . . . . . . . . . . . . . . .18-1810-2 Fuel tank Remove and install . . . . . . . . . . . . . . . . .05-0560-1

G Guard, front axle Ramove and install . . . . . . . . . . . . . . . . .17-1746-1 Guard, transmission bottom Remove and install . . . . . . . . . . . . . . . . .17-1746-2

E Emergency preparation . . . . . . . . . . . . . . .00-0001-7 Engine Remove and install . . . . . . . . . . . . . . . . .04-0400-2 TM10687 (14OCT08)

H Handhold use . . . . . . . . . . . . . . . . . . . . . . .00-0001-7

Index-3

524K Loader 101408

PN=3

Indx 3

Index

Page

Heater coil Remove and install . . . . . . . . . . . . . . . .18-1830-15 Heater control valve Leak check . . . . . . . . . . . . . . . . . . . . . .18-1830-20 Remove and install . . . . . . . . . . . . . . . .18-1830-19 Hi-Vis coupler Disassemble and assemble . . . . . . . . . .31-3140-8 High-pressure oils Avoid . . . . . . . . . . . . . . . . . . . . . . . . . . .00-0001-4 Hood Remove and install . . . . . . . . . . . . . . . . .19-1910-1 Hydraulic Component failure cleanup procedure. . .31-3160-4 General oil cleanup procedure . . . . . . . .31-3160-1 Oil cleanup procedure follow-up . . . . . . .31-3160-7 Hydraulic control valve Cross section view . . . . . . . . . . . . . . . .03-0360-10 Disassemble and assemble . . . . . . . . .03-0360-11 Remove and install . . . . . . . . . . . . . . . . .03-0360-6 Hydraulic fan motor Remove and install . . . . . . . . . . . . . . . .31-3160-62 Hydraulic fan pump Remove and install . . . . . . . . . . . . . . . .31-3160-60 Hydraulic fan pump and axle circulation pump Remove and install . . . . . . . . . . . . . . . .31-3160-60 Hydraulic oil cooler Remove and install hydraulic oil cooler . . . . . . . . . . . . . . . . . . . . . . . . .05-0510-5 Indx 4 Hydraulic pump manifold Disassemble and assemble . . . . . . . . .31-3160-52 Remove an install . . . . . . . . . . . . . . . . .31-3160-48 Hydraulic reservoir remove and install. . . . . . . . . . . . . . . . .31-3160-33

Page

L Load sense relief valve Disassemble and assemble . . . . . . . . .31-3160-21 Loader boom bushings and seals Remove and install . . . . . . . . . . . . . . . . .31-3140-3 Loader control valve Disassemble and assemble . . . . . . . . .31-3160-16 Remove and install . . . . . . . . . . . . . . . .31-3160-13 Lower pivot bearing and seals Remove and install . . . . . . . . . . . . . . . . .17-1740-9

M Machine modifications Avoid . . . . . . . . . . . . . . . . . . . . . . . . . . .00-0001-2 Main hydraulic pump Disassemble and assemble . . . . . . . . .31-3160-12 Remove and install . . . . . . . . . . . . . . . . .31-3160-8 Main relief valve Disassemble and assemble . . . . . . . . .31-3160-20 Metal pins. . . . . . . . . . . . . . . . . . . . . . . . .00-0001-18 Muffler Remove and install . . . . . . . . . . . . . . . . .05-0530-1

N NeverGrease Pin joints and bushings . . . . . . . . . . . . . .09-0960-1

I Input and output clutches Install . . . . . . . . . . . . . . . . . . . . . . . . . .03-0350-19 Input shaft Assemble . . . . . . . . . . . . . . . . . . . . . . .03-0350-70 Disassemble . . . . . . . . . . . . . . . . . . . . .03-0350-69 Remove . . . . . . . . . . . . . . . . . . . . . . . .03-0350-10 Install Hydraulic pump manifold. . . . . . . . . . . .31-3160-48 Steering column . . . . . . . . . . . . . . . . . . .09-0960-7 Intercooler Remove and install . . . . . . . . . . . . . . . . .05-0510-1 Internal transmission oil tube Remove and install . . . . . . . . . . . . . . . .03-0360-25

TM10687 (14OCT08)

Oil cleanup procedure Follow-up . . . . . . . . . . . . . . . . . . . . . . . .31-3160-7 Oil cooler Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . .05-0510-8 Oil, component, R134a air conditioning Charge . . . . . . . . . . . . . . . . . . . . . . . . . .18-1830-3 Orbital steering valve Remove and install . . . . . . . . . . . . . . . . .09-0960-4 Oscillating supports Disassemble and assemble . . . . . . . . .02-0200-11 Output and input clutches Install . . . . . . . . . . . . . . . . . . . . . . . . . .03-0350-19 Output shaft Remove . . . . . . . . . . . . . . . . . . . . . . . .03-0350-10

Index-4

524K Loader 101408

PN=4

Index

Page

Park brake Assemble and disassemble. . . . . . . . . . .11-1111-4 Release solenoid valve, remove and install. . . . . . . . . . . . . . . . . . . . . . . . . .11-1160-1 Remove and install . . . . . . . . . . . . . . . . .11-1111-1 Pilot accumulator Remove and install . . . . . . . . . . . . . . . .31-3160-47 Pilot control valve Disassemble and assemble . . . . . . . . .31-3160-40 Remove and install . . . . . . . . . . . . . . . .31-3160-37 Pin disconnect disconnect Remove and install . . . . . . . . . . . . . . . .31-3160-57 Pin disconnect valve Disassemble and assemble . . . . . . . . .31-3160-59 Pivot bearing and seals Lower, remove and install . . . . . . . . . . . .17-1740-9 Upper, remove and install . . . . . . . . . . . .17-1740-7 Precleaner Remove and install . . . . . . . . . . . . . . . . .05-0520-3 Pressure switch Air conditioning high-low . . . . . . . . . . . .18-1830-24 Pump, transmission Remove and install . . . . . . . . . . . . . . . . .03-0360-1

Remove and install Auxiliary function pilot control valve. . . .31-3160-42 Axle disconnect solenoid. . . . . . . . . . . .03-0360-29 Counterweights . . . . . . . . . . . . . . . . . . . .17-1749-1 Hydraulic fan motor. . . . . . . . . . . . . . . .31-3160-62 Loader control valve . . . . . . . . . . . . . . .31-3160-13 Main hydraulic pump. . . . . . . . . . . . . . . .31-3160-8 Pilot control valve . . . . . . . . . . . . . . . . .31-3160-37 Reversing fan valve . . . . . . . . . . . . . . .31-3160-64 Ride control valve . . . . . . . . . . . . . . . . .31-3160-54 Reservoir, hydraulic Remove and install . . . . . . . . . . . . . . . .31-3160-33 Reversing fan valve Disassemble and assemble . . . . . . . . .31-3160-66 Remove and install . . . . . . . . . . . . . . . .31-3160-64 Ride control valve Disassemble and assemble . . . . . . . . .31-3160-56 Remove and install . . . . . . . . . . . . . . . .31-3160-54 Roads Operating or traveling . . . . . . . . . . . . . .00-0001-14 ROPS Inspect . . . . . . . . . . . . . . . . . . . . . . . . .00-0001-14 Maintain . . . . . . . . . . . . . . . . . . . . . . . .00-0001-14 R134a compressor oil charge Check . . . . . . . . . . . . . . . . . . . . . . . . . . .18-1830-2

Radiator Remove and install . . . . . . . . . . . . . . . . .05-0510-2 Rear axle and differential Remove . . . . . . . . . . . . . . . . . . . . . . . . .02-0200-6 Rear counterweight Remove and install . . . . . . . . . . . . . . . . .17-1749-3 Rear wiper motor Remove and install . . . . . . . . . . . . . . . . .18-1810-2 Receiver-dryer Remove and install . . . . . . . . . . . . . . . .18-1830-22 Refrigerant cautions, air conditioning R134a . . . . . . . . . . . . . . . . . . . . . . . . . . .18-1830-1 Refrigerant handling . . . . . . . . . . . . . . . . . .18-1830-1 Refrigerant, air conditioning R134a system Evacuate. . . . . . . . . . . . . . . . . . . . . . . . .18-1830-7 Recover . . . . . . . . . . . . . . . . . . . . . . . . .18-1830-6 Refrigerant, R134a Recovery, recycling and charging . . . . . .18-1830-5 Refrigerant, R134a system Charge . . . . . . . . . . . . . . . . . . . . . . . . . .18-1830-9 Remove Hydraulic pump manifold. . . . . . . . . . . .31-3160-48 Steering column . . . . . . . . . . . . . . . . . . .09-0960-7

Safety Add cab guarding for special uses . . . . .00-0001-3 Follow safety instructions . . . . . . . . . . . .00-0001-1 Inspect machine . . . . . . . . . . . . . . . . . . .00-0001-3 Operate only if qualified . . . . . . . . . . . . .00-0001-2 Operator’s seat . . . . . . . . . . . . . . . . . . . .00-0001-8 Recognize safety information . . . . . . . . .00-0001-1 Stay clear of moving parts . . . . . . . . . . .00-0001-3 Wear protective equipment . . . . . . . . . . .00-0001-2 Seals and bushings Bucket linkage, remove and install . . . . .31-3140-2 Seals and bushings, boom or bucket cylinder Remove and install . . . . . . . . . . . . . . . .31-3160-31 Seals and bushings, loader boom Remove and install . . . . . . . . . . . . . . . . .31-3140-3 Seat Belt remove and install . . . . . . . . . . . . . .18-1821-2 Remove and install . . . . . . . . . . . . . . . . .18-1821-1 Seat belt Remove and install . . . . . . . . . . . . . . . . .18-1821-2 Use and maintenance . . . . . . . . . . . . . . .00-0001-8 Secondary steering pump Remove and install . . . . . . . . . . . . . . . .09-0960-13

TM10687 (14OCT08)

Index-5

Indx 5

524K Loader 101408

PN=5

Index

Page

Secondary steering valve Remove and install . . . . . . . . . . . . . . . .09-0960-16 Serpentine belt Remove and install . . . . . . . . . . . . . . . .04-0400-10 Serve brake pedal linkage Disassemble and assemble . . . . . . . . . .10-1011-2 Service brake accumulator Remove and install . . . . . . . . . . . . . . . . .10-1060-2 Service brake linkage Disassemble and assemble . . . . . . . . . .10-1011-2 Service brake valve Remove and install . . . . . . . . . . . . . . . . .10-1060-1 Shields, engine side Remove and install . . . . . . . . . . . . . . . . .19-1910-2 Solenoid valve Differential lock, remove and install. . . . .02-0260-1 Start aid Nozzle, remove and install . . . . . . . . . . .05-0505-1 Solenoid, remove and install . . . . . . . . . .05-0505-2 Start-up procedure Steering cylinder . . . . . . . . . . . . . . . . . .09-0960-18 Steering Valve, remove and install . . . . . . . . . . . .09-0960-4 Steering column Disassemble and assemble . . . . . . . . . .09-0960-8 Remove and install . . . . . . . . . . . . . . . . .09-0960-7 Steering cylinder Remove and install . . . . . . . . . . . . . . . . .09-0960-9 Indx Steering cylinder bushings 6 Remove and install . . . . . . . . . . . . . . . .09-0960-12 Steps use . . . . . . . . . . . . . . . . . . . . . . . . . .00-0001-7 Structure Welding. . . . . . . . . . . . . . . . . . . . . . . . . .17-1740-1

Transmission hydraulic control valve Disassemble and assemble . . . . . . . . .03-0360-11 Transmission internal oil pipes and tube Remove and install . . . . . . . . . . . . . . . .03-0360-25 Transmission internal oil tubes Remove and install . . . . . . . . . . . . . . . .03-0360-25 Transmission oil cooler Remove and Install . . . . . . . . . . . . . . . . .05-0510-7 Transmission pump Remove and install . . . . . . . . . . . . . . . . .03-0360-1 Traveling On public roads. . . . . . . . . . . . . . . . . . .00-0001-14

T Tilt linkage Bucket, remove and install . . . . . . . . . . .31-3140-1 Tire Remove and install . . . . . . . . . . . . . . . . .01-0110-2 Torque converter and housing Install . . . . . . . . . . . . . . . . . . . . . . . . . . .03-0350-6 Remove . . . . . . . . . . . . . . . . . . . . . . . . .03-0350-1 Torque converter relief valve Remove . . . . . . . . . . . . . . . . . . . . . . . .03-0360-23 Transmission Input shaft assemble. . . . . . . . . . . . . . .03-0350-70 Install . . . . . . . . . . . . . . . . . . . . . . . . . . .03-0300-1 Remove . . . . . . . . . . . . . . . . . . . . . . . . .03-0300-1 Transmission bottom guard Remove and install . . . . . . . . . . . . . . . . .17-1746-2

TM10687 (14OCT08)

U Universal joint Remove and install . . . . . . . . . . . . . . . . .02-0225-2 Upper pivot bearing and seals Remove and install . . . . . . . . . . . . . . . . .17-1740-7

V Valve Minimum pressure regulator . . . . . . . . . .03-0360-5 Orbital steering, remove and install . . . . .09-0960-4 Service Brake remove and install . . . . . .10-1060-1 Valve, pilot control Remove and install . . . . . . . . . . . . . . . .31-3160-37 Valve, pin disconnect disconnect Remove and install . . . . . . . . . . . . . . . .31-3160-57 Valve, ride control Disassemble and assemble . . . . . . . . .31-3160-56 Remove and install . . . . . . . . . . . . . . . .31-3160-54 Valve, transmission control Remove and install . . . . . . . . . . . . . . . . .03-0360-6

W Waste disposal . . . . . . . . . . . . . . . . . . . . . .00-0001-7 Welding Structure . . . . . . . . . . . . . . . . . . . . . . . . .17-1740-1 Welding repairs . . . . . . . . . . . . . . . . . . . .00-0001-18 Wheel Remove and Install . . . . . . . . . . . . . . . . .01-0110-1 Windowpanes Remove and install . . . . . . . . . . . . . . . . .18-1810-1

Index-6

524K Loader 101408

PN=6