John Deere 750J, 850J Crawler Dozers Repair Manual 10FEB06 (1) by www.heydownloads.com

750J, 850J Crawler Dozer Repair

TECHNICAL MANUAL 750J, 850J Crawler Dozers 10FEB06 (ENGLISH)

For complete service information also see: 750J, 850J Crawler Dozer Operation and Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TM2260 750J, 850J Crawler Dozer Operator’s Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OMT202117 Alternators and Starting Motors . . . . . . . . . . CTM77 POWERTECH 4.5L and 6.8L Diesel Engines Base Engine . . . . . . . . . . . . . . . . . . CTM104 POWERTECH 4.5L and 6.8L Diesel Engines Level 12 Electronic Fuel System with DE10 Pump . . . . . . . . . . . . . . . . . . . . . . CTM331 POWERTECH 8.1L Diesel Engines Base Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CTM86 POWERTECH 8.1L Diesel Engines Level 9 Electronic Fuel System with High Pressure Common Rail . . . . . . . . . . . . . . . . . . . . . . . . . CTM255 Super Caddy Oil Cleanup Procedure . . . . . . CTM310 120 Series Hydraulic Cylinders . . . . . . . . . . TM-H120A 125 Series Hydraulic Cylinders . . . . . . . . . . TM-H125A Service ADVISOR System Computer Connection. . . . . . . . . . . . . . . . . . . . . . . . . . . T133991 Undercarriage Appraisal Manual . . . . . . . . . SP326 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 problems 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 problems and their causes.

TX,750C,SS2406 –19–13JUL95–1/1

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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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563-589-5800

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

TX,TM,FAX –19–03JUL01–1/1

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Introduction

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Contents 00

SECTION 00—General Information Group 01—Safety Group 03—Torque Values

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 01—Tracks Group 0130—Track System

SECTION 19—Sheet Metal Group 1910—Hood and Engine Enclosures

SECTION 02—Axles and Suspension Systems Group 0201—Drive Axle Housing and Support Group 0250—Axle Shaft, Bearings and Reduction Gears

SECTION 20—Safety, Convenience and Miscellaneous Group 2004—Horn and Warning Devices

SECTION 03—Transmission Group 0300—Remove and Install Group 0315—Control Linkage Group 0360—Hydrostatic System

SECTION 32—Bulldozer Group 3201—Blade Group 3240—Frames Group 3260—Hydraulic System

SECTION 04—Engine Group 0400—Removal and Installation

SECTION 9900—Dealer Fabricated Tools Group 0999—Dealer Fabricated Tools

SECTION 05—Engine Auxiliary Systems Group 0505—Cold Weather Starting Aid Group 0510—Cooling System Group 0515—Engine Speed Control Group 0530—External Exhaust Systems Group 0560—External Fuel Supply Systems

SECTION 07—Dampener Drive Group 0752—Elements SECTION 11—Park Brake Group 1100—Park Brake Group 1115—Control Linkage Group 1160—Hydraulic System

SECTION 15—Equipment Attaching Group 1511—Drawbar Group 1540—Ripper

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

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 01—Safety . . . . . . . . . . . . . . . . . . . . . .00-01-1 Group 03—Torque Values Torque Value Metric Bolt and Cap Screw . . . . . . . . . . . . . .00-03-1 Additional Metric Cap Screw Torque Values . . .00-03-2 Torque Value Unified Inch Bolt and Cap Screw . . . . . . . . . .00-03-4 Service Recommendations for 37° Flare and 30° Cone Seat Connectors . . . . . . . . . . .00-03-5 Service Recommendations for O-Ring Boss Fittings . . . . . . . . . . . . . . . . . . . . . . . . .00-03-6 Service Recommendation O-Ring Boss Fittings In Aluminum Housing—Excavators . . . . . . . . . . . . . . . . .00-03-8 Service Recommendations For Flared Connections—Straight or Tapered Threads . . . . . . . . . . . . . . . . . . . . . . . . . . . .00-03-10 Service Recommendations For Flat Face O-Ring Seal Fittings. . . . . . . . . . . . . . . . . . .00-03-11 Service Recommendation O-Ring Face Seal Fittings with SAE Inch Hex Nut and Stud End for High Pressure. . . . . . . . . . . . . . . . . . . . . . . . . .00-03-12 O-Ring Face Seal Fittings with Metric Hex Nut and Stud End for Standard Pressure. . . . . . . . . . . . . . . . . . . . . . . . . .00-03-14 O-Ring Face Seal Fittings with Metric Hex Nut and Stud End for High Pressure. . . . . . . . . . . . . . . . . . . . . . . . . .00-03-16 Service Recommendations for Metric Series Four Bolt Flange Fitting . . . . . . . . . .00-03-18 Service Recommendations For Inch Series Four Bolt Flange Fittings. . . . . . . . . .00-03-19 Service Recommendation Inch Series Four Bolt Flange For High Pressure. . . . . . . . . . . . . . . . . . . . . . . . . .00-03-20 Service Recommendations For Non-Restricted Banjo (Adjustable) Fittings. . . . . . . . . . . . . . . . . . . . . . . . . . . . .00-03-21 Service Recommendations For O-Ring Boss Fittings With Shoulder . . . . . . . . . . . . .00-03-23 Service Recommendation Metric 24° O-Ring Seal DIN 20078 . . . . . . .00-03-26

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Group 01

Safety 00 01 1

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.

T133555

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

–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 –19–21AUG00–1/1

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. Be sure new equipment components and repair parts include the current safety signs. Replacement safety signs are available from your 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 –19–12AUG03–1/1

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Safety

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 –19–07OCT05–1/1

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 01 2

TX03679,00016D0 –19–30OCT00–1/1

Avoid Unauthorized Machine Modifications Modifications of this machine, or addition of unapproved products or attachments, may affect machine stability or reliability, and may create a hazard for the operator or others near the machine. The installer of any modification which may affect the electronic controls of this machine is responsible for establishing that the modification does not adversely affect the machine or its performance.

Always contact an authorized dealer before making machine modifications that change the intended use, weight or balance of the machine, or that alter machine controls, performance or reliability.

TX03679,00016B7 –19–12AUG03–1/1

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Safety 00 01 3

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 –19–20OCT05–1/1

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 –19–30OCT00–1/1

Avoid High-Pressure Fluids

T133509 T133840

If hydraulic fluid penetrates your skin, see a doctor immediately. Injected fluid 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 fluid. Stop engine and relieve pressure before disconnecting lines or working on hydraulic system.

–UN–17MAR06

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

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Safety

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

T133546

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

–UN–24AUG00

Beware Of Exhaust Fumes

TX03679,00016D4 –19–14SEP00–1/1

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 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

TX03679,00016F5 –19–25SEP00–1/1

Prevent Battery Explosions

Never check battery charge by placing a metal object across the posts. Use a voltmeter or hydrometer. Do not charge a frozen battery; it may explode. Warm 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.

TS204

00 01 4

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Safety 00 01 5

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.

T133580

Exposure to hazardous chemicals can cause serious injury. Under certain conditions, lubricants, coolants, paints and adhesives used with this machine may be hazardous.

–UN–25AUG00

Handle Chemical Products Safely

TX03679,00016D7 –19–07OCT05–1/1

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 authorized dealer for more information.

TX03679,0001733 –19–17APR01–1/1

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.

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Safety

Forestry protection packages or special screens should be installed when working in areas where logs or branches may strike the operator. A rear screen should always be used with a winch to protect against a snapping cable. Contact your authorized dealer for information on protective guarding before operating in any hazardous environment.

T139005

Special work situations or machine attachments may expose the operator to intruding or flying objects. Using this machine in a forestry application or woods environment, or with attachments such as a winch, requires added guarding to protect the operator.

–UN–05MAR01

Add Cab Guarding For Special Uses

TX03768,0000B77 –19–06MAR01–1/1

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 you get 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 –19–14SEP00–1/1

Avoid unexpected machine movement. Start engine only while sitting in operator’s seat. Ensure all controls and working tools are in proper position for a parked machine. Never attempt to start engine from the ground. Do not attempt to start engine by shorting across the starter solenoid terminals.

–UN–07SEP00

Start Only From Operator’s Seat

T133715

00 01 6

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Safety 00 01 7

Use And Maintain Seat Belt

T133716

–19–14SEP00

Use seat belt when operating machine. Remember to fasten seat belt when loading and unloading from trucks and during other uses. Examine seat belt frequently. Be sure webbing is not cut or torn. Replace seat belt immediately if any part is damaged or does not function properly. The complete seat belt assembly should be replaced every three years, regardless of appearance.

TX03679,00016DD –19–17OCT00–1/1

Be careful not to accidentally actuate controls when co-workers are present. Engage park lock and lower work equipment to the ground during work interruptions. Stop the engine before allowing anyone to approach the machine. Follow these same precautions before standing up, leaving the operator’s seat, or exiting the machine.

(UNLOCKED) DOWN POSITION

–19–30AUG02

Always move the park lock lever to the “lock” position before leaving the operator’s seat for any reason.

(LOCKED) UP POSITION

T159027

Prevent Unintended Machine Movement

TX03768,0000B72 –19–01MAY01–1/1

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Safety

Avoid Work Site Hazards

Operate only on solid footing Use extra care when operating on stockpiles or near banks or excavations that may cave in and cause machine to tip or fall. Never allow the machine on a floor or structure until you are sure it will support the weight. Avoid contact with overhead electrical wires. Stay clear of electrical lines. Never move any part of machine or load closer than 3 m (10 ft.) plus twice the line insulator length to overhead wires.

T139002 –UN–05MAR01

Keep bystanders clear at all times. Use barricades or a signal person to keep vehicles and pedestrians away. Always keep signal person in view. Instruct co-workers and bystanders not to approach the machine while it is operating.

T139003

Avoid or correct hazardous work situations. Avoid operating near structures or objects that could fall onto the machine. Clear away debris that could move unexpectedly if run over.

–UN–05MAR01

Avoid contact with gas lines, buried cables and water lines. Call utility line location services to identify all underground utilities before working below ground level.

TX03768,0000B76 –19–06MAR01–1/1

Keep Riders Off Machine

Riders are subject to injury. They may fall from machine, be caught between machine parts, or be struck by foreign objects. Riders may obstruct operator’s view or impair his ability to operate machine safely.

–UN–22FEB01

Only allow operator on machine.

T137580

00 01 8

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Safety 00 01 9

Be certain backup warning alarm is working properly. Use a signal person when backing if view is obstructed or when in close quarters. Keep signal person in view at all times. Use prearranged hand signals to communicate.

T138441

Before moving machine, be sure all persons are clear of the machine path. Turn around and look directly for best visibility. Use mirror to assist in checking behind the machine. Keep windows and mirror clean and in good repair.

–UN–22FEB01

Avoid Backover Accidents

TX03768,0000B69 –19–01MAY01–1/1

Be careful on slopes. Use extra care on soft, rocky or frozen ground because machine may slip sideways in these conditions. When traveling up or down steep slopes, keep the bucket or blade on uphill side and just above ground level.

T133716 T138415

Ensure solid footing. Use extra care when operating on stockpile materials, or near banks or excavations that may cave-in and cause machine to tip or fall.

–UN–22FEB01

Load and unload from trucks or trailers carefully. Be sure truck is wide enough and secured on a firm level surface. Use loading ramps and attach them properly to truck bed. Avoid trucks with steel beds because tracks slip more easily on steel.

T138416

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

–UN–22FEB01

Use seat belt at all times.

–19–14SEP00

Avoid Machine Tip Over

TX03768,0000B6B –19–29JAN01–1/1

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Safety

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 –19–31JAN06–1/1

Park And Prepare For Service Safely

T133332

• Park machine on a level surface and lower blade/bucket and attachments to the ground. • Place park lock lever in “lock” position. Stop engine and remove key. • 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.

• Do not support machine with blade/bucket or attachments. • Do not support machine with cinder blocks or wooden pieces that may crumble or crush. • Do not support machine with a single jack or other devices that may slip out of place. Understand service procedures before beginning repairs. Keep service area clean and dry. Use two people whenever the engine must be running for service work.

–UN–23AUG88

Securely support machine or attachment before working under it.

TS229

00 01 10

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Safety 00 01 11

Service Cooling System Safely

TS281

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.

–UN–23AUG88

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

DX,RCAP –19–04JUN90–1/1

Remove paint to at least 76 mm (3 in.) from area to be heated. Wear an approved respirator when sanding or grinding paint. If a solvent or paint stripper is used, wash area with soap and water. Remove solvent or paint stripper containers from work area and allow fumes to disperse at least 15 minutes before welding or heating.

T133546

Hazardous fumes can be generated when paint is heated by welding or using a torch. Dust from sanding or grinding paint can also be hazardous.

–UN–24AUG00

Remove Paint Before Welding or Heating

Work outside or in a well-ventilated area. Dispose of waste, paint and solvents properly.

TX03679,0001732 –19–06SEP00–1/1

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Safety

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

NOTE: To avoid machine damage, disable electrical power before welding. Turn off main battery switch or disconnect positive battery cable. Separate harness connectors to engine and machine 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 –19–02OCT00–1/1

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 01 12

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Group 03

Torque Values 00 03 1

TORQ2

–UN–07SEP99

Metric Bolt and Cap Screw Torque Values

Top—Property Class and Head Markings; Bottom—Property Class and Nut Markings METRIC BOLT AND CAP SCREW TORQUE VALUES—Tolerance is ±10% unless otherwise specified Class 4.8 Thread Size

Lubricated N•m (lb-ft)

Class 8.8 or 9.8 b

Dry N•m (lb-ft)

Class 10.9 b

Lubricated N•m (lb-ft)

Dry N•m (lb-ft)

Class 12.9 b

Lubricated N•m (lb-ft)

Dry N•m (lb-ft)

Lubricateda N•m (lb-ft)

Dryb N•m (lb-ft)

4.7 (3.5)

6 (4.4)

9 (6.6)

11.5 (8.5)

13 (9.5)

16.5 (12.2)

15.5 (11.5)

19.5 (14.5)

11.5 (8.5)

14.5 (10.7)

22 (16)

28 (20.5)

32 (23.5)

40 (29.5)

37 (27.5)

47 (35)

M10

23 (17)

29 (21)

43 (32)

55 (40)

63 (46)

80 (59)

75 (55)

95 (70)

M12

40 (29.5)

50 (37)

75 (55)

95 (70)

110 (80)

140 (105)

130 (95)

165 (120)

M14

63 (46)

80 (59)

120 (88)

150 (110)

175 (130)

220 (165)

205 (150)

260 (190)

M16

100 (74)

125 (92)

190 (140)

240 (175)

275 (200)

350 (255)

320 (235)

400 (300)

M18

135 (100)

170 (125)

265 (195)

330 (245)

375 (275)

475 (350)

440 (325)

560 (410)

M20

190 (140)

245 (180)

375 (275)

475 (350)

530 (390)

675 (500)

625 (460)

790 (580)

M22

265 (195)

330 (245)

510 (375)

650 (480)

725 (535)

920 (680)

850 (625)

1080 (800)

M24

330 (245)

425 (315)

650 (480)

820 (600)

920 (680)

1150 (850)

1080 (800)

1350 (1000)

M27

490 (360)

625 (460)

950 (700)

1200 (885)

1350 (1000)

1700 (1250)

1580 (1160)

2000 (1475)

M30

660 (490)

850 (625)

1290 (950)

1630 (1200)

1850 (1350)

2300 (1700)

2140 (1580)

2700 (2000)

M33

900 (665)

1150 (850)

1750 (1300)

2200 (1625)

2500 (1850)

3150 (2325)

2900 (2150)

3700 (2730)

M36

1150 (850)

1450 (1075)

2250 (1650)

2850 (2100)

3200 (2350)

4050 (3000)

3750 (2770)

4750 (3500)

"Lubricated" means coated with a lubricant such as engine oil, or fasteners with phosphate and oil coatings.

"Dry" means plain or zinc plated without any lubrication.

CAUTION: Use only metric tools on metric hardware. Other tools may not fit properly. Tool may slip and cause injury.

DO NOT use these values if a different torque value or tightening procedure is given for a specific application. Torque values listed are for general use only. Check tightness of fasteners periodically. Shear bolts are designed to fail under predetermined loads. Always replace shear bolts with identical property class.

Fasteners should be replaced with the same or higher property class. If higher property class fasteners are used, these should only be tightened to the strength of the original. Make sure fastener threads are clean and that you properly start thread engagement. This will prevent them from failing when tightening. Tighten plastic insert or crimped steel-type lock nuts to approximately 50 percent of the dry torque shown in the chart, applied to the nut, not to the bolt head. Tighten toothed or serrated-type lock nuts to the full torque value.

OUT3035,TORQUE2 –19–22MAR04–1/1

TM2261 (10FEB06)

00-03-1

750J, 850J Crawler 032806

PN=21

Torque Values

–UN–18OCT88

Additional Metric Cap Screw Torque Values

T6873AA

CAUTION: Use only metric tools on metric hardware. Other tools may not fit properly. They may slip and cause injury.

–UN–18OCT88

Check tightness of cap screws periodically. Torque values listed are for general use only. Do not use these values if a different torque value or tightening procedure is listed for a specific application. Shear bolts are designed to fail under predetermined loads. Always replace shear bolts with identical grade.

T6873AB

Fasteners should be replaced with the same or higher grade. If higher grade fasteners are used, these should only be tightened to the strength of the original.

–UN–18OCT88

Make sure fastener threads are clean and you properly start thread engagement. This will prevent them from failing when tightening. Tighten cap screws having lock nuts to approximately 50 percent of amount shown in chart.

T6873AC

00 03 2

Continued on next page

TM2261 (10FEB06)

00-03-2

04T,90,M170 –19–29SEP99–1/2

750J, 850J Crawler 032806

PN=22

Torque Values 00 03 3

METRIC CAP SCREW TORQUE VALUESa T-Bolt

H-Bolt

Nominal Dia

N•m

lb-ft

N•m

lb-ft

M-Bolt N•m

lb-ft

108

176

130

137

101

265

195

206

152

392

289

294

217

118

539

398

392

289

167

125

735

542

539

398

216

159

931

687

686

506

274

202

1372

1012

1029

759

392

289

1911

1410

1421

1049

539

398

2548

1890

1911

1410

735

542

3136

2314

2401

1772

931

687

Torque tolerance is ±10%.

04T,90,M170 –19–29SEP99–2/2

TM2261 (10FEB06)

00-03-3

750J, 850J Crawler 032806

PN=23

Torque Values

–UN–27SEP99

Unified Inch Bolt and Cap Screw Torque Values

TORQ1A

00 03 4

Top—SAE Grade and Head Markings; Bottom—SAE Grade and Nut Markings UNIFIED INCH BOLT AND CAP SCREW TORQUE VALUES—Tolerance is ±10% unless otherwise specified Grade 2a (No Mark)

Grade 1 (No Mark) b

Thread Size

Lubricated N•m (lb-ft)

Dry N•m (lb-ft)

Lubricated N•m (lb-ft)

Grade 5, 5.1 or 5.2

Dry N•m (lb-ft)

Grade 8 or 8.2

Dry N•m (lb-ft)

Lubricatedb N•m (lb-ft)

Dryc N•m (lb-ft)

Lubricated N•m (lb-ft)

1/4

3.8 (2.8)

4.7 (3.5)

6 (4.4)

7.5 (5.5)

9.5 (7)

12 (9)

13.5 (10)

17 (12.5)

5/16

7.7 (5.7)

9.8 (7.2)

12 (9)

15.5 (11.5)

19.5 (14.5)

25 (18.5)

28 (20.5)

35 (26)

3/8

13.5 (10)

17.5 (13)

22 (16)

27.5 (20)

35 (26)

44 (32.5)

49 (36)

63 (46)

7/16

22 (16)

28 (20.5)

35 (26)

44 (32.5)

56 (41)

70 (52)

80 (59)

100 (74)

1/2

34 (25)

42 (31)

53 (39)

67 (49)

85 (63)

110 (80)

120 (88)

155 (115)

9/16

48 (35.5)

60 (45)

76 (56)

95 (70)

125 (92)

155 (115)

175 (130)

220 (165)

5/8

67 (49)

85 (63)

105 (77)

135 (100)

170 (125)

215 (160)

240 (175)

305 (225)

3/4

120 (88)

150 (110)

190 (140)

240 (175)

300 (220)

380 (280)

425 (315)

540 (400)

7/8

190 (140)

240 (175)

190 (140)

240 (175)

490 (360)

615 (455)

690 (510)

870 (640)

285 (210)

360 (265)

285 (210)

360 (265)

730 (540)

920 (680)

1030 (760)

1300 (960)

1-1/8

400 (300)

510 (375)

400 (300)

510 (375)

910 (670)

1150 (850)

1450 (1075)

1850 (1350)

1-1/4

570 (420)

725 (535)

570 (420)

725 (535)

1280 (945)

1630 (1200)

2050 (1500)

2600 (1920)

1-3/8

750 (550)

950 (700)

750 (550)

950 (700)

1700 (1250)

2140 (1580)

2700 (2000)

3400 (2500)

1-1/2

990 (730)

1250 (930)

990 (730)

1250 (930)

2250 (1650)

2850 (2100)

3600 (2650)

4550 (3350)

Grade 2 applies for hex cap screws (not hex bolts) up to 6 in. (152 mm) long. Grade 1 applies for hex cap screws over 6 in. (152 mm) long, and for all other types of bolts and screws of any length. b

"Lubricated" means coated with a lubricant such as engine oil, or fasteners with phosphate and oil coatings.

"Dry" means plain or zinc plated without any lubrication.

Make sure fastener threads are clean and that you properly start thread engagement. This will prevent them from failing when tightening.

Shear bolts are designed to fail under predetermined loads. Always replace shear bolts with identical grade.

Tighten plastic insert or crimped steel-type lock nuts to approximately 50 percent of the dry torque shown in the chart, applied to the nut, not to the bolt head. Tighten toothed or serrated-type lock nuts to the full torque value.

Fasteners should be replaced with the same or higher grade. If higher grade fasteners are used, these should only be tightened to the strength of the original.

OUT3035,TORQUE1 –19–14JAN04–1/1

TM2261 (10FEB06)

00-03-4

750J, 850J Crawler 032806

PN=24

Torque Values 00 03 5

Service Recommendations for 37° Flare and 30° Cone Seat Connectors

3. Align tube with fitting before attempting to start nut.

T6234AC

2. Defects in tube flare cannot be repaired. Overtightening a defective flared fitting will not stop leaks.

–UN–18OCT88

1. Inspect flare and flare seat. They must be free of dirt or obvious defects.

4. Lubricate male threads with hydraulic fluid or petroleum jelly. 5. Index angle fittings and tighten by hand. 6. Tighten fitting or nut to torque value shown on torque chart. Do not allow hoses to twist when tightening fittings. STRAIGHT FITTING OR SPECIAL NUT TORQUE CHART Thread Size

N•m

lb-ft

3/8 - 24 UNF 7/16 - 20 UNF

1/2 - 20 UNF

9/16 - 18 UNF

3/4 - 16 UNF

7/8 - 14 UNF

1-1/16 - 12 UN

102

1-3/16 - 12 UN

122

1-5/16 - 12 UN

142

105

1-5/8 - 12

190

140

1-7/8 - 12 UN

217

160

NOTE: Torque tolerance is ± 10%.

T82,BHMA,EL –19–29SEP99–1/1

TM2261 (10FEB06)

00-03-5

750J, 850J Crawler 032806

PN=25

Torque Values

Service Recommendations for O-Ring Boss Fittings Straight Fitting –UN–18OCT88

1. Inspect O-ring boss seat for dirt or defects. 2. Lubricate O-ring with petroleum jelly. Place electrical tape over threads to protect O-ring. Slide O-ring over tape and into O-ring groove of fitting. Remove tape.

T6243AE

00 03 6

3. Tighten fitting to torque value shown on chart.

Continued on next page

TM2261 (10FEB06)

00-03-6

04T,90,K66 –19–29SEP99–1/2

750J, 850J Crawler 032806

PN=26

Torque Values 00 03 7

Angle Fitting

3. Turn fitting head-end counterclockwise to proper index (maximum of one turn).

NOTE: Do not allow hoses to twist when tightening fittings.

T6520AB

2. Turn fitting into threaded boss until back-up washer contacts face of boss.

–UN–18OCT88

1. Back-off lock nut (A) and back-up washer (B) completely to head-end (C) of fitting.

4. Hold fitting head-end with a wrench and tighten locknut and back-up washer to proper torque value. STRAIGHT FITTING OR SPECIAL NUT TORQUE CHART Thread Size

N•m

lb-ft

3/8-24 UNF

7/16-20 UNF

1/2-20 UNF

9/16-18 UNF

3/4-16 UNF

7/8-14 UNF

1-1/16-12 UN

102

1-3/16-12 UN

122

1-5/16-12 UN

142

105

1-5/8-12 UN

190

140

1-7/8-12 UN

217

160

NOTE: Torque tolerance is ± 10%.

04T,90,K66 –19–29SEP99–2/2

TM2261 (10FEB06)

00-03-7

750J, 850J Crawler 032806

PN=27

Torque Values

–UN–17NOV03

O-Ring Boss Fittings In Aluminum Housing Service Recommendations—Excavators

T196315

00 03 8

O-Ring Boss Straight and Adjustable Fittings 1—Straight Fitting 2—O-Ring

3—Stud End 4—Adjustable Fitting

5—Hex Nut

6—Backup Washer

O-RING BOSS STRAIGHT OR ADJUSTABLE FITTING STUD END NUT WITH METRIC THREAD IN ALUMINUM HOUSING TORQUE VALUES—Tolerance is ± 10% unless otherwise specified Thread Size mm

Hex Nut Size mm

N•m (lb-ft)

M12 x 1.5

39 (29)

M14 x 1.5

39 (29)

M16 x 1.5

55 (41)

M22 x 1.5

75 (55)

M27 x 2

110 (81)

M30 x 2

141 (104)

M33 x 2

165 (122)

M38 x 2

165 (122)

M42 x 2

275 (203)

Continued on next page

TM2261 (10FEB06)

00-03-8

OUT3035,0000353 –19–14JAN04–1/2

750J, 850J Crawler 032806

PN=28

Torque Values O-RING BOSS STRAIGHT OR ADJUSTABLE FITTING STUD END NUT WITH INCH THREAD IN ALUMINUM HOUSING TORQUE VALUES—Tolerance is ± 10% unless otherwise specified Thread Size in.

N•m (lb-ft)

1/8

—

1/4

28 (20)

3/8

39 (29)

1/2

75 (55)

3/4

126 (93)

165 (122)

1-1/8

—

1-1/4

259 (191)

1-3/8

—

1-1/2

330 (243)

1-3/4

—

2. Back the stud end hex nut (5) off as far as possible. Push backup washer (6) towards the nut to fully expose the turn down section of stud end. Washer must fit turned down section and not be too loose 3. Wrap electrical tape over threads to protect O-ring. Slide O-ring over the tape into turned down section. Remove tape. Apply hydraulic oil to the threads of stud end, turned down section, and O-ring. 4. Turn fitting into the boss by hand until face of nut or backup washer squeezes O-ring into the seat and contacts face of boss. Loosen an adjustable fitting no more than one turn for alignment.

O-RING BOSS PLUG STUD END WITH INCH THREAD IN ALUMINUM HOUSING TORQUE VALUES—Tolerance is ± 10% unless otherwise specified Thread Size in.

1. Inspect fitting and O-ring boss sealing surfaces and the O-ring. They must be free of dirt, scratches, nicks, or burrs. O-ring must be free of dirt, cuts, cracks, swelling or flatten condition.

5. Tighten straight fitting or hex nut to the torque value given. Hold body of adjustable fitting using a second wrench when tightening hex nut.

N•m (lb-ft)

1/8

7.8 (5.80)

1/4

11.8 (8.70)

3/8

23 (17)

1/2

39 (29)

3/4

55 (41)

86 (64)

1-1/4

126 (93)

1-1/2

157 (116)

204 (150)

OUT3035,0000353 –19–14JAN04–2/2

TM2261 (10FEB06)

00-03-9

750J, 850J Crawler 032806

PN=29

00 03 9

Torque Values

Service Recommendations For Flared Connections—Straight or Tapered Threads

–UN–18OCT88

1. Inspect flare and flare seat. They must be free of dirt or obvious defects.

T6873AE

2. Defects in the tube flare cannot be repaired. Overtightening a defective flared fitting will not stop leaks. 3. Align the tube with the fitting before attempting to start the nut. Straight Thread

4. Lubricate the male threads with hydraulic fluid or petroleum jelly. 5. Index angle fittings and tighten by hand.

–UN–18OCT88

6. Tighten fitting or nut to torque value shown on the chart. Do not allow hoses to twist when tightening fittings. TORQUE CHART a Straight Thread b

Tapered Thread

Thread Size

N•m

lb-ft

N•m

lb-ft

1/8

1/4

3/8

1/2

3/4

176

130

157

116

343

253

1-1/2

196

145

539

398

255

188

588

434

T6873AD

00 03 10

Tapered Thread

Torque tolerance is ±10%.

a b

With seat face.

NOTE: If female thread is cast iron (control valves, brake valves motors, etc.), torque must be reduced approximately 10%.

04T,90,M171 –19–28JAN92–1/1

TM2261 (10FEB06)

00-03-10

750J, 850J Crawler 032806

PN=30

Torque Values 00 03 11

Service Recommendations For Flat Face O-Ring Seal Fittings 1. Inspect the fitting sealing surfaces and O-ring. They must be free of dirt or defects.

fittings, use backup wrench on straight hose couplings.

2. Lubricate O-rings and install into grove using petroleum jelly to hold in place.

IMPORTANT: Tighten fittings to 150% of listed torque value if indexing is necessary or if fitting is attached to an actuating devise.

3. Index angle fittings and tighten by hand pressing joint together to insure O-ring remains in place.

Tighten fittings to 50% of listed torque value if used in aluminum housing.

4. Tighten fitting or nut to torque value shown on the chart. Do not allow hoses to twist when tightening

FLAT FACE O-RING SEAL FITTING TORQUE* Nomial Tube O.D.

Thread Size

Swivel Nut

Bulkhead Nut

in.

N•m

lb-ft

N•m

lb-ft

6.35

0.250

9/16-18

9.52

0.375

11/16-16

12.70

0.500

13/16-16

15.88

0.625

1-14

19.05

0.750

1 3/16-12

102

22.22

0.875

1 3/16-12

102

25.40

1.000

1 7/16-12

142

105

142

105

31.75

1.250

1 11/16-12

190

140

190

140

38.10

1.500

2-12

217

160

217

160

*Torque tolerance is +15 -20% unless otherwise specified. Stud End O-ring Seal Torque for Straight and Adjustable Fittings* Thread Size

Straight Hex Size

Locknut Hex Size

Inch

Straight Fitting or Locknut Toque N•m

lb-ft

3/8-24

5/8

9/16

7/16-20

5/8

1/2-20

3/4

11/16

9/16-18

3/4

3/4-16

7/8

15/16

7/8-14

1 1/16

104

1 1/16-12

1 1/4

1 3/8

176

130

1 3/16-12

1 3/8

1 1/2

230

170

1 5/16-12

1 1/2

1 5/8

285

210

*Torque tolerance is +15 -20% unless otherwise specified.

04T,90,K67 –19–02MAR00–1/1

TM2261 (10FEB06)

00-03-11

750J, 850J Crawler 032806

PN=31

Torque Values

O-Ring Face Seal Fittings With SAE Inch Hex Nut And Stud End For High Pressure Service Recommendations A

–UN–12DEC01

G E F

H F

H70406

00 03 12

A—90° Swivel Elbow and Tube Nut B—90° Adjustable Stud Elbow

C—Stud Straight and Tube Nut D—Bulkhead Union and Nut

E—Stud End F—Tube Nut

G—Swivel Nut H—Hex Nut

O-RING FACE SEAL FITTINGS WITH SAE INCH HEX NUT AND STUD END FOR HIGH PRESSURE, ABOVE 27 600 kPa (276 bar) (4000 psi), TORQUE VALUES—Tolerance is +15 -20% unless otherwise specified Nominal Tube OD or Hose ID Metric Tube OD

Inch Tube OD or Hose ID

O-Ring Face Seal Hose or Tube Swivel Nut

Bulkhead Nut

Thread Size

Hex Size

Torque

Hex Size

Torque

Dash Size

mm (in.)

in.

N•m (lb-ft)

in.

N•m (lb-ft)

-3

4.78 (0.188)

—

-4

6.35 (0.250)

9/16-18

11/16

24 (18)

13/16

32 (24)

-5

7.92 (0.312)

—

-6

9.53 (0.375)

11/16-16

13/16

37 (27)

42 (31)

-8

12.70 (0.500)

13/16-16

15/16

75 (55)

1-1/8

93 (69)

-10

15.88 (0.625)

1-14

1-1/8

103 (76)

1-5/16

118 (87)

-12

19.05 (0.750)

1-3/16-12

1-3/8

152 (112)

1-1/2

175 (129)

-14

22.23 (0.875)

1-3/16-12

—

152 (112)

—

175 (129)

-16

25.40 (1.000)

1-7/16-12

1-5/8

214 (158)

1-3/4

247 (182)

-20

31.75 (1.250)

1-11/16-12

1-7/8

286 (211)

328 (242)

-24

38.10 (1.500)

2-12

2-1/4

326 (240)

2-3/8

374 (276)

Continued on next page

TM2261 (10FEB06)

00-03-12

OUT3035,0000420 –19–14JAN04–1/2

750J, 850J Crawler 032806

PN=32

Torque Values O-RING STRAIGHT, ADJUSTABLE, AND EXTERNAL HEX PLUG WITH SAE INCH STUD END FOR HIGH PRESSURE, ABOVE 27 600 kPa (276 bar) (4000 psi), TORQUE VALUES—Tolerance is +15 -20% unless otherwise specified Thread Size

Straight Hex Sizea

Adjustable Nut Hex Size

Steel or Gray Iron Torque

in.

N•m (lb-ft)

3/8-24

5/8

9/16

18 (13)

7/16-20

5/8

24 (18)

1/2-20

3/4

11/16

30 (22)

9/16-18

3/4

37 (27)

3/4-16

7/8

15/16

75 (55)

7/8-14

1-1/16

103 (76)

1-1/16-12

1-1/4

1-3/8

177 (131)

1-3/16-12

1-3/8

1-1/2

231 (170)

1-5/16-12

1-1/2

1-5/8

270 (199)

1-5/8-12

1-3/4

1-7/8

286 (211)

1-7/8-12

2-1/8

326 (240)

Straight hex size applies to fittings only and may not be the same as the corresponding plug of the same thread size.

1. Inspect fitting and connector sealing surfaces and the O-rings. They must be free of dirt, scratches, nicks, and burrs. O-ring must be free of dirt, cuts, cracks, swelling or flatten condition. 2. Back the stud end hex nut off as far as possible. Push backup washer towards the nut to fully expose the turn down section. Washer must fit turned down section and not be too loose 3. Lubricate O-rings using a thin film of clean hydraulic oil or as needed, petroleum jelly to hold O-ring in place. Install O-ring into groove making sure it is seated at the bottom. Excess petroleum jelly will prevent seating of O-ring and cause it to pop out.

To protect an O-ring from threads, wrap electrical tape over the threads. Slide O-ring over the tape into the turned down section. Remove the tape. 4. Turn fitting into the boss by hand until face of nut or washer squeezes the O-ring into the seat and contacts face of boss. Loosen adjustable fittings no more than one turn for alignment. Hold connections together while tightening nut to ensure O-ring remains in place. 5. Tighten fitting or nut to torque value shown. Use a second wrench to hold the fitting in position or to keep hose from twisting while tightening nut.

OUT3035,0000420 –19–14JAN04–2/2

TM2261 (10FEB06)

00-03-13

750J, 850J Crawler 032806

PN=33

00 03 13

Torque Values

O-Ring Face Seal Fittings With Metric Hex Nut And Stud End For Standard Pressure Service Recommendations 1

T196337

1—90° Swivel Elbow 2—90° Adjustable Stud Elbow 3—Stud Straight

–UN–18NOV03

4—Bulkhead Union and Nut 5—External Hex Stud End Plug 6—Tube Nut

T196337

00 03 14

7—Swivel Nut 8—Stud End 9—Hex Nut

10—O-Ring 11—Identification Groove

O-RING FACE SEAL AND FITTINGS WITH METRIC HEX NUT AND STUD END FOR STANDARD PRESSURE, BELOW 27 600 kPa (275.8 bar) (4,000 psi), TORQUE VALUES—Tolerance is +15 -20% unless otherwise specified Nominal Tube OD or Hose ID Metric Tube OD

Inch Tube OD or Hose ID

O-Ring Face Seal Hose or Tube Swivel Nut

Bulkhead Nut

Thread Size

Hex Size

Torque

Hex Size

Torque

Dash Size

mm (in.)

in.

N•m (lb-ft)

-2

3.18 (0.125)

—

-3

4.78 (0.188)

—

-4

6.35 (0.250)

9/16-18

16 (12)

32 (24)

-5

7.92 (0.312)

—

-6

9.53 (0.375)

11/16-16

24 (18)

42 (31)

-8

12.70 (0.500)

13/16-16

50 (37)

93 (69)

-10

15.88 (0.625

1-14

69 (51)

118 (87)

-12

19.05 (0.750)

1-3/16-12

102 (75)

175 (129)

-14

22.23 (0.875)

1-3/16-12

102 (75)

175 (129)

-16

25.40 (1.000)

1-7/16-12

142 (105)

247 (182)

—

-20

31.75 (1.250)

1-11/16-12

190 (140)

328 (242)

-24

38.10 (1.500)

2-12

217 (160)

374 (276)

-32

50.80 (2.000)

—

Continued on next page

TM2261 (10FEB06)

00-03-14

OUT3035,0000366 –19–14JAN04–1/2

750J, 850J Crawler 032806

PN=34

Torque Values O-RING STRAIGHT, ADJUSTABLE, AND EXTERNAL HEX PLUG WITH METRIC STUD END FOR STANDARD PRESSURE, BELOW 27 600 kPa (275.8 bar) (4,000 psi), TORQUE VALUES—Tolerance is +15 -20% unless otherwise specified Thread Sizea

Straight Hex Sizeb

Adjustable Nut Hex Size

Steel or Gray Iron Torque

Aluminum or Brass Torque

mm.

N•m (lb-ft)

M8 x 1

8 (6)

5 (4)

M10 x 1

15 (11)

10 (7)

M12 x 1.5

25 (18)

17 (12)

M14 x 1.5

40 (30)

27 (20)

M16 x 1.5

45 (33)

30 (22)

M18 x 1.5

50 (37)

33 (25)

M22 x 1.5

69 (51)

46 (34)

M27 x 2

100 (74)

67 (49)

M30 x 2

130 (96)

87 (64)

M33 x 2

160 (118)

107 (79)

M38 x 2

176 (130)

117 (87)

M42 x 2

210 (155)

140 (103)

M48 x 2

260 (192)

173 (128)

M60 x 2

315 (232)

210 (155)

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

Straight hex size applies to fittings only and may not be the same as the corresponding plug of the same thread size.

OUT3035,0000366 –19–14JAN04–2/2

TM2261 (10FEB06)

00-03-15

750J, 850J Crawler 032806

PN=35

00 03 15

Torque Values

O-Ring Face Seal Fittings With Metric Hex Nut And Stud End For High Pressure Service Recommendations 1

T196337

1—90° Swivel Elbow 2—90° Adjustable Stud Elbow 3—Stud Straight

–UN–18NOV03

4—Bulkhead Union and Nut 5—External Hex Stud End Plug 6—Tube Nut

T196337

00 03 16

7—Swivel Nut 8—Stud End 9—Hex Nut

10—O-Ring 11—Identification Groove

O-RING FACE SEAL FITTINGS WITH METRIC HEX NUT AND STUD END FOR HIGH PRESSURE, ABOVE 27 600 kPa (275.8 bar) (4,000 psi), TORQUE VALUES—Tolerance is +15 -20% unless otherwise specified Nominal Tube OD or Hose ID Metric Tube OD

O-Ring Face Seal Hose or Tube Swivel Nut

Inch Tube OD or Hose ID

Bulkhead Nut

Thread Size

Hex Size

Torque

Hex Size

Torque

Dash Size

mm (in.)

in.

N•m (lb-ft)

-2

3.18 (0.125)

—

-3

4.78 (0.188)

—

-4

6.35 (0.250)

9/16-18

24 (18)

32 (24)

-5

7.92 (0.312)

—

-6

9.53 (0.375)

11/16-16

37 (27)

42 (31)

-8

12.70 (0.500)

13/16-16

75 (55)

93 (69)

-10

15.88 (0.625)

1-14

103 (76)

118 (87)

-12

19.05 (0.750)

1-3/16-12

152 (112)

175 (129)

-14

22.23 (0.875)

1-3/16-12

152 (112)

175 (129)

-16

25.40 (1.000)

1-7/16-12

214 (158)

247 (182)

—

-20

31.75 (1.250)

1-11/16-12

—

286 (211)

328 (242)

-24

38.10 (1.500)

2-12

—

326 (240)

374 (276)

Continued on next page

TM2261 (10FEB06)

00-03-16

OUT3035,0000421 –19–14JAN04–1/2

750J, 850J Crawler 032806

PN=36

Torque Values 00 03 17

O-RING STRAIGHT, ADJUSTABLE, AND EXTERNAL HEX PLUG WITH METRIC STUD END FOR HIGH PRESSURE, ABOVE 27 600 KPA (275.8 BAR) (4,000 PSI), TORQUE VALUES—Tolerance is +15 -20% unless otherwise specified Thread Sizea

Straight Hex Sizeb

Adjustable Nut Hex Size

Steel or Gray Iron Torque

mm.

N•m (lb-ft)

M8 x 1

8 (6)

M10 x 1

15 (11)

M12 x 1.5

35 (26)

M14 x 1.5

45 (33)

M16 x 1.5

55 (41)

M18 x 1.5

70 (52)

M22 x 1.5

100 (74)

M27 x 2

170 (125)

M30 x 2

215 159)

M33 x 2

260 (192)

M38 x 2

320 (236)

M42 x 2

360 (266)

M48 x 2

420 (310)

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

Straight hex size applies to fittings only and may not be the same as the corresponding plug of the same thread size.

OUT3035,0000421 –19–14JAN04–2/2

TM2261 (10FEB06)

00-03-17

750J, 850J Crawler 032806

PN=37

Torque Values

–UN–01MAR90

Service Recommendations for Metric Series Four Bolt Flange Fitting

T6890BB

00 03 18

A—Sealing Surface

B—Split Flange

C—Pinched O-Ring

D—Single Piece Flange

then tighten the diagonally opposite cap screw. Tighten two remaining cap screws. Tighten all cap screws as specified in the chart below.

1. Clean sealing surfaces (A). Inspect. Scratches cause leaks. Roughness causes seal wear. Out-of-flat causes seal extrusion. If defects cannot be polished out, replace component.

DO NOT use air wrenches. DO NOT tighten one cap screw fully before tightening the others. DO NOT over tighten.

2. Install the correct O-ring (and backup washer if required) into groove using petroleum jelly to hold it in place.

TORQUE CHARTa

3. Split flange: Loosely assemble split flange (B) halves. Make sure split is centrally located and perpendicular to the port. Hand tighten cap screws to hold parts in place. Do not pinch O-ring (C).

Thread

N•m

lb-ft

4. Single piece flange (D): Place hydraulic line in center of flange and install four cap screws. Flange must be centrally located on port. Hand tighten cap screws to hold flange in place. Do not pinch O-ring.

M12

M14

157

116

M16

217

160

M18

334

246

M20

421

318

5. After components are properly positioned and cap screws are hand tightened, tighten one cap screw,

M10

Tolerance ± 10%. The torques given are enough for the given size connection with the recommended working pressure. Increasing cap screw torque beyond these amounts will result in flange and cap screw bending and connection failures. a

Metric standard thread.

04T,90,K175 –19–29SEP99–1/1

TM2261 (10FEB06)

00-03-18

750J, 850J Crawler 032806

PN=38

Torque Values 00 03 19

T6890BB

–UN–01MAR90

Service Recommendations For Inch Series Four Bolt Flange Fittings

A—Sealing Surface

B—Split Flange

C—Pinched O-Ring

1. Clean sealing surfaces (A). Inspect. Scratches cause leaks. Roughness causes seal wear. Out-of-flat causes seal extrusion. If defects cannot be polished out, replace component. 2. Install O-ring (and backup washer if required) into groove using petroleum jelly to hold it in place. 3. Split flange: Loosely assemble split flange (B) halves. Make sure split is centrally located and perpendicular to port. Hand tighten cap screws to hold parts in place. Do not pinch O-ring (C). 4. Single piece flange (D): Place hydraulic line in center of flange and install cap screws. Flange must be centrally located on port. Hand tighten cap screws to hold flange in place. Do not pinch O-ring. 5. Tighten one cap screw, then tighten the diagonally opposite cap screw. Tighten two remaining cap screws. Tighten all cap screws as specified in the chart below.

D—Single Piece Flange TORQUE CHART N•m

Nominal Flange Size

Cap Screw Size

1/2

5/16-18 UNC

lb-ft

Min

Max

Min

Max

3/4

3/8-16 UNC

1-1/4

7/16-14 UNC

1-1/2

1/2-13 UNC

131

1/2-13 UNC

131

2-1/2

1/2-13 UNC

107

131

5/8-11 UNC

158

264

117

195

3-1/2

5/8-11 UNC

158

264

117

195

5/8-11 UNC

158

264

117

195

5/8-11 UNC

158

264

117

195

DO NOT use air wrenches. DO NOT tighten one cap screw fully before tightening the others. DO NOT over tighten.

04T,90,K174 –19–01AUG94–1/1

TM2261 (10FEB06)

00-03-19

750J, 850J Crawler 032806

PN=39

Torque Values

–UN–01MAR90

Inch Series Four Bolt Flange Fitting For High Pressure Service Recommendations

T6890BB

00 03 20

A—Sealing Surface

B—Split Flange

C—Pinched O-Ring

INCH SERIES FOUR BOLT FLANGE FITTING FOR 41 400 kPa (414 bar) (6000 psi) PRESSURE SERIES TORQUE VALUES— Tolerance is ± 10% unless otherwise specified Nominal Flange Size

Cap Screw Sizea

Min—Max Torque

in.

N•m (lb-ft)b

1/2

5/16-18 UNC

20—31 (15—23)

3/4

3/8-16 UNC

34—54 (25—40)

7/16-14 UNC

57—85 (42—63)

1-1/4

1/2-13 UNC

85—131 (63—97)

1-1/2

5/8-11 UNC

159—264 (117—195)

3/4-10 UNC

271—468 (200—345)

D—Single Piece Flange

2. Install the O-ring (and backup ring, if used) into groove. Use petroleum jelly to hold it in place. IMPORTANT: DO NOT use air wrenches. DO NOT tighten one cap screw fully before tightening the others. DO NOT over tighten. 3. Split flange: Loosely assemble split flange (B) halves. Make sure split is centrally located and perpendicular to port. Hand tighten cap screws to hold flange halves and line in place. Do not pinch O-ring (C).

JDM A17D, SAE Grade 5 or better cap screws with plated hardware. Lock washers are permissible but not recommended. b

Minimum torques given are enough for the given size connection with the recommended working pressure. Torques can be increased to the maximum shown for each cap screw size if desired. Increasing cap screw torque beyond the maximum will result in flange and cap screw bending and connection failures.

1. Clean sealing surfaces (A). Inspect. Scratches, nicks, and burrs cause leaks. Roughness causes O-ring wear. Out-of-flat causes O-ring extrusion. If imperfection cannot be polished out, replace component.

Single piece flange (D): Make sure flange is centrally located on port and line is centered in flange. Install the cap screws. Hand tighten cap screws to hold flange and line in place. Do not pinch O-ring. 4. Tighten one cap screw and then the diagonally opposite cap screw. Tighten the two remaining cap screws. Tighten cap screws within the specified torque values.

OUT3035,0000422 –19–14JAN04–1/1

TM2261 (10FEB06)

00-03-20

750J, 850J Crawler 032806

PN=40

Torque Values 00 03 21

Service Recommendations For Non-Restricted Banjo (Adjustable) Fittings 1. Inspect all fitting sealing surfaces. They must be free of dirt and defects. 2. Inspect O-ring (A). It must be free of damage or defects. 3. Inspect sealing ring (B) for damage or defects.

–UN–06MAR98

4. Hold body in desired position while tightening stud by hand. 5. Tighten stud (C) to torque value shown on the chart. Do not allow body to twist when tightening stud.

T113948

NOTE: The L in the Tube Fitting OD Size column indicates “light” designed fitting and the S indicates “heavy” designed fitting. Torque Value Tube Fitting O.D. Size

Metric Thread

N•m

lb-ft

M 10 x 1

M 12 x 1.5

10 L

M 14 x 1.5

12 L

M 16 x 1.5

100

15 L

M 18 x 1.5

130

18 L

M 22 x 1.5

160

118

22 L

M 26 x 1.5

250

184

28 L

M 33 x 2

400

295

35 L

M 42 x 2

600

443

42 L

M48 x 2

800

590

M 12 x 1.5

M 14 x 1.5

10 S

M 16 x 1.5

100

12 S

M 18 x 1.5

130

14 S

M 20 x 1.5

160

118

16 S

M 22 x 1.5

160

118

20 S

M 27 x 2

250

184

25 S

M 33 x 2

400

295

30 S

M 42 x 2

600

443

38 S

M 48 x 2

800

590

Continued on next page

TM2261 (10FEB06)

00-03-21

CED,OUO1002,562 –19–09MAR98–1/2

750J, 850J Crawler 032806

PN=41

Torque Values 00 03 22

Torque Value Tube Fitting O.D. Size

Inch Size

N•m

lb-ft

1/8

1/4

10 L

1/4

12 L

3/8

15 L

1/2

130

18 L

1/2

150

111

22 L

3/4

250

184

28 L

400

295

35 L

1-1/4

600

443

42 L

1-1/2

800

590

1/4

10 S

3/8

12 S

3/8

100

14 S

1/2

130

16 S

1/2

150

111

20 S

3/4

250

184

25 S

400

295

30 S

1-1/4

600

443

38 S

1-1/2

800

590

CED,OUO1002,562 –19–09MAR98–2/2

TM2261 (10FEB06)

00-03-22

750J, 850J Crawler 032806

PN=42

Torque Values 00 03 23

Service Recommendations For O-Ring Boss Fittings With Shoulder 1. Inspect component seal boss seat for dirt or defects. –UN–06MAR98

2. Inspect EOlastic seal (A) for damage. Replace seal or fitting as necessary.

T113957

To replace seal, put electrical tape over threads to protect seal. Slide seal over tape and into seal groove of fitting. Remove tape. 3. Tighten fitting to torque value shown on chart. IMPORTANT: Do not allow hoses to twist when tightening fittings.

NOTE: The L in the Tube Fitting OD Size column indicates “light” designed fitting and the S indicates “heavy” designed fitting. Torque Value Tube Fitting O.D. Size

Metric Thread

N•m

lb-ft

M 10 x 1

M 12 x 1.5

10 L

M 14 x 1.5

12 L

M 16 x 1.5

15 L

M 18 x 1.5

18 L

M 22 x 1.5

130

22 L

M 26 x 1.5

190

140

28 L

M 33 x 2

300

221

35 L

M 42 x 2

600

443

42 L

M48 x 2

800

590

M 12 x 1.5

M 14 x 1.5

10 S

M 16 x 1.5

12 S

M 18 x 1.5

110

14 S

M 20 x 1.5

140

103

16 S

M 22 x 1.5

170

125

20 S

M 27 x 2

250

184

25 S

M 33 x 2

450

332

30 S

M 42 x 2

600

443

38 S

M 48 x 2

800

590

Continued on next page

TM2261 (10FEB06)

00-03-23

CED,OUO1002,563 –19–09MAR98–1/3

750J, 850J Crawler 032806

PN=43

Torque Values 00 03 24

Torque Value Tube Fitting O.D. Size

Inch Size

N•m

lb-ft

1/8

1/4

10 L

1/4

12 L

3/8

15 L

1/2

140

103

18 L

1/2

100

22 L

3/4

180

133

28 L

300

221

35 L

1-1/4

600

443

42 L

1-1/2

800

590

1/4

10 S

3/8

12 S

3/8

14 S

1/2

160

118

16 S

1/2

140

103

20 S

3/4

250

184

25 S

400

295

30 S

1-1/4

650

479

38 S

1-1/2

800

590

Continued on next page

TM2261 (10FEB06)

00-03-24

CED,OUO1002,563 –19–09MAR98–2/3

750J, 850J Crawler 032806

PN=44

Torque Values 00 03 25

Hex Socket Head Plugs Only Torque Value Thread Size

N•m

lb-ft

M 10 x 1

M 12 x 1.5

M 14 x 1.5

M 16 x 1.5

M 18 x 1.5

M 20 x 1.5

M 22 x 1.5

100

M 26 x 1.5

120

M 27 x 2

150

111

M 33 x 2

250

184

M 42 x 2

400

295

M 48 x 2

500

369

1/8

1/4

3/8

1/2

3/4

150

111

220

162

1-1/4

600

443

1-1/2

800

590

CED,OUO1002,563 –19–09MAR98–3/3

TM2261 (10FEB06)

00-03-25

750J, 850J Crawler 032806

PN=45

Torque Values

Metric 24° O-Ring Seal DIN 20078 Service Recommendations METRIC 24° O-RING SEAL DIN 20078 TORQUE VALUES Heavy Fitting Size

Light Fitting Size

Turns

—

M12 x 1.5

Hand tighten so O-ring contacts seat plus an additional 1/4—1/3 turn using a wrench

M16 x 1.5

M14 x 1.5

M18 x 1.5

M16 x 1.5

M20 x 1.5

M18 x 1.5

M22 x 1.5

—

M22 x 1.5

M24 x 1.5

—

M26 x 1.5

M30 x 2

—

M30 x 2

M36 x 2

—

M36 x 2

M42 x 2

—

M45 x 2

M52 x 2

—

Torque

–UN–06MAR98

Fitting Tube OD Size

NOTE: These fittings are also referred to as EO and EO-2 Bite Type or Ermeto style fittings.

T113889

00 03 26

IMPORTANT: In this style of fittings, there are “heavy” and “light” designs. Usually “heavy” is used for pressure lines and “light” for return lines. Some “heavy” and “light” sizes can be threaded together but do not seal properly. Be sure not to mix “heavy” and “light” fittings. 1. Inspect the fitting sealing surfaces. They must be free of dirt scratches, nicks, and burrs.

Continued on next page

TM2261 (10FEB06)

00-03-26

CED,OUO1002,517 –19–07FEB06–1/2

750J, 850J Crawler 032806

PN=46

Torque Values 00 03 27

2. Inspect the O-ring. It must be free dirt, cuts, cracks, swelling or flatten condition. 3. Lubricate O-rings using a thin film of clean hydraulic oil. 4. Align an adjustable fitting with the tube. Hold connections together while tightening nut to ensure proper seal. 5. Tighten nut (A) hand tight so O-ring contacts seat and then an additional 1/4—1/3 turn using a wrench.

CED,OUO1002,517 –19–07FEB06–2/2

TM2261 (10FEB06)

00-03-27

750J, 850J Crawler 032806

PN=47

Torque Values 00 03 28

TM2261 (10FEB06)

00-03-28

750J, 850J Crawler 032806

PN=48

Section 01

Tracks Contents

Page

Group 0130—Track System Welding On Machine . . . . . . . . . . . . . . . . . . .01-0130-1 Track Guides and Rock Guards Remove and Install . . . . . . . . . . . . . . . . . . . . . . . . .01-0130-1 Carrier Roller Wear Inspection . . . . . . . . . . .01-0130-5 Carrier Roller Remove and Install . . . . . . . . .01-0130-5 Carrier Roller Disassemble and Assemble . .01-0130-7 Metal Face Seals Inspection . . . . . . . . . . . .01-0130-10 Carrier Roller Leakage Test . . . . . . . . . . . .01-0130-11 Track Roller Wear Inspection . . . . . . . . . . .01-0130-12 Track Roller Remove and Install . . . . . . . . .01-0130-14 Track Roller Disassemble and Assemble . .01-0130-16 Track Roller Leakage Test . . . . . . . . . . . . .01-0130-26 Track Shoe Grouser Wear Inspection . . . . .01-0130-27 Track Shoe Remove and Install . . . . . . . . .01-0130-28 Pivot Shaft Remove and Install . . . . . . . . . .01-0130-30 Crossbar Remove and Install . . . . . . . . . . .01-0130-30 Crossbar Disassemble and Assemble . . . . .01-0130-36 Track Link Height Inspection . . . . . . . . . . . .01-0130-37 Bushing Outside Diameter for Lubricated Track Chain Inspection . . . . . . . . . . . . . .01-0130-38 Track Pitch for Lubricated Track Chain Inspection . . . . . . . . . . . . . . . . . . . . . . . .01-0130-40 Lubricated Track Chain Remove and Install. . . . . . . . . . . . . . . . . . . . . . . . . . . .01-0130-41 Lubricated Track Chain to Turn Bushings and Lubricate Chain Disassemble . . . . . .01-0130-45 Lubricated Track Chain to Turn Bushings and Lubricate Chain Assemble . . . . . . . .01-0130-48 Lubricated Track Chain to Turn Pins and Bushings and Not Lubricate Disassemble and Assemble. . . . . . . . . . . . . . . . . . . . . . . . .01-0130-55 Track Sag Adjustment . . . . . . . . . . . . . . . . .01-0130-62 Track Adjuster Cylinder and Recoil Spring Remove and Install . . . . . . . . . . . . . . . . .01-0130-64 Track Adjuster Recoil Spring Disassemble and Assemble . . . . . . . . . . . . . . . . . . . . .01-0130-65 Track Adjuster Cylinder Disassemble and Assemble. . . . . . . . . . . . . . . . . . . . . . . . .01-0130-75 Track Frame Remove and Install . . . . . . . .01-0130-77 Front Idler Wear Inspection . . . . . . . . . . . . .01-0130-85 Front Idler Remove and Install . . . . . . . . . .01-0130-85 Front Idler Disassemble and Assemble . . . .01-0130-93 Front Idler Vertical Movement Adjustment. . . . . . . . . . . . . . . . . . . . . . . 01-0130-102 Front Idler Oil Leakage Test . . . . . . . . . . . 01-0130-104

Sprocket Segment Remove and Install . . . 01-0130-105

TM2261 (10FEB06)

01-1

750J, 850J Crawler 032806

PN=1

Contents

TM2261 (10FEB06)

01-2

750J, 850J Crawler 032806

PN=2

Group 0130

Track System Welding On Machine IMPORTANT: Disconnect battery ground strap or turn battery disconnect switch to OFF (if applicable). Disconnect both negative and positive battery cables and microprocessor unit (if applicable). IMPORTANT: Have only a qualified welder do this job. Connect welder ground clamp close to each weld area so electrical current does not pass through any bearings. Remove or protect all parts that can be damaged by heat or weld splatter.

WELD METAL SPECIFICATIONS

Item

Specification

Tensile Strength

482.6 mPa (70 000 psi)

Yield Strength

413.7 mPa (60 000 psi)

Elongation

22%

01 0130 1

Use one of the following weld processes: • AWS-E-7018 covered electrode with shielded metal arc welding (SMAW) process. • AWS-ER-70S-3f wire electrode with gas metal arc welding (GMAW) process. • AWS-E70T-1 or E71T-1 wire electrode with flux core arc welding (FCAW) process.

TX,WELD,II –19–11APR95–1/1

Track Guides and Rock Guards Remove and Install

–UN–28JAN05

NOTE: Removal and installation of track guides and rock guards are similar for both 750J and 850J. Track Guides Remove and Install

T206819C

Track Adjuster Check Valve 1—Grease Fitting 2—Relief Valve 3—Check Valve

1. Slowly turn check valve fitting (3) counterclockwise one turn to release track tension. See Adjust Track Sag. (Operators Manual.)

Continued on next page

TM2261 (10FEB06)

01-0130-1

TE14778,000008A –19–20JUN05–1/5

750J, 850J Crawler 032806

PN=51

Track System

2. Raise machine off the ground and support with 20-Ton Floor Stands. Lower blade to ground.

T205099A

–UN–04DEC04

1—20-Ton Floor Stand (4 used) 2—Floor Stand Adapter (2 used) 3—Floor Stand Rod 4—Washer (2 used) 5—Cap Screw (2 used)

750J/850J Floor Stand Kit

TE14778,000008A –19–20JUN05–2/5

3. Remove cap screws (5) and washers (8) to remove front track guides (10).

2 8

Remove cap screws (2) and washers (8) to remove rear track guides (1 and 4).

7 Remove cap screws (3) and washers (6) to remove rear sprocket guards (7 and 9).

9 8

1 4

2 8

1—Guide, Left Rear (2 used) 2—Cap Screw (28 used) 3—Cap Screw (12 used) 4—Guide, Right Rear (2 used) 5—Cap Screw (20 used) 6—Washer (12 used) 7—Guard, Left Sprocket (2 used) 8—Washer (48 used) 9—Guard, Right Sprocket (2 used) 10—Guide, Front Track (4 used)

Front and Rear Track Guides and Guards

Continued on next page

TM2261 (10FEB06)

–UN–15MAR05

T209551

01 0130 2

CAUTION: Prevent possible injury from unexpected track movement. Raise the machine off the ground and support with 20-Ton Floor Stands. Tracks MUST be free to rotate in either direction.

01-0130-2

TE14778,000008A –19–20JUN05–3/5

750J, 850J Crawler 032806

PN=52

Track System

Specification Center Track Guide—Weight ....................................... 45 kg Approximate 100 lb Approximate

T209238

4. Remove cap screws (11) and washers (12) to remove center track guide (13).

–UN–15MAR05

CAUTION: Center Track Guide is heavy and can cause injury if not moved properly. Use adequate lifting device to move Center Track Guide.

Center Track Guide

5. Inspect track guides and sprocket guards for wear and damage. Repair or replace as necessary.

11—Cap Screw (8 used) 12—Washer (8 used) 13—Guide, Center (2 used)

6. Apply high strength thread lock and sealer to cap screws. 7. Install sprocket guards, washers, and cap screws. Tighten cap screws to specification. Specification Sprocket Guard Cap Screw-to-Track Frame—Torque ................................................... 530 N•m 390 lb-ft

8. Install track guides, washers, and cap screws. Tighten cap screws to specification. Specification Track Guide Cap Screw-to-Track Frame—Torque ............................................................................ 275 N•m 200 lb-ft

9. Adjust track sag. See Adjust Track Sag. (Operators Manual.)

Continued on next page

TM2261 (10FEB06)

01-0130-3

TE14778,000008A –19–20JUN05–4/5

750J, 850J Crawler 032806

PN=53

01 0130 3

Track System

01 0130 4

CAUTION: Rock Guard is heavy and can cause injury if not moved properly. Use adequate lifting device to move Rock Guard. Specification Rock Guard—Weight.................................................... 73 kg Approximate 160 lb Approximate

10 4 9

9 1

1. Remove parts (1—10).

2. Inspect rock guards (1 and 2) for wear and damage. Repair or replace parts as necessary. 3. Apply high strength thread lock and sealer to cap screws (4, 8, and 10). 4. Install inner and outer rock guard, washers, and cap screws. 5. Put cap screws through inner guard, spacer, outer guard, washer, and nut. Tighten nuts to specification. Specification Rock Guard Cap Screw-to-Track Frame—Torque ............................................................................ 275 N•m 200 lb-ft

–UN–03MAR05

T209074

Rock Guards Remove and Install

Rock Guards 1—Guard (Left side, outside/Right side, inside) (2 used) 2—Guard (Right side, outside/Left side, inside) (2 used) 4—Cap Screw (10 used on standard track) —Cap Screw (12 used on long track) 5—Spacer (10 used on standard track) —Spacer (12 used on standard track) 6—Nut (10 used on standard track) —Nut (12 used on standard track) 8—Cap Screw (12 used on standard track) —Cap Screw (14 used on standard track) 9—Washer (16 used on standard track) —Washer (18 used on standard track) 10—Cap Screw (4 used)

Specification Inner Rock Guard Cap Screw-to-Outer Rock Guard Nut—Torque ................................................................................. 530 N•m 390 lb-ft

TE14778,000008A –19–20JUN05–5/5

TM2261 (10FEB06)

01-0130-4

750J, 850J Crawler 032806

PN=54

Track System

Carrier Roller Wear Inspection NOTE: For additional information see 750J Carrier Roller Tread Diameter. (SP326.) –UN–01NOV88

Also see 850C, 850C-LGP, 850C Series II, and 850J Carrier Roller Tread Diameter. (SP326.)

T5819AC

1. Position an outside calipers over the most worn area of roller running surface, and close until caliper tips just touch tread surface. 2. Measure caliper tip spread using the scale to the nearest 0.5 mm (0.002 in.) 750J—Specification New Carrier Roller—OD ............................................................. 171.5 mm 6.75 in. 100 Percent Worn Carrier Roller—OD .................................................................................... 158 mm 6.22 in. 850J—Specification New Carrier Roller—OD ............................................................. 187.5 mm 7.38 in. 100 Percent Worn Carrier Roller—OD .................................................................................... 168 mm 6.61 in.

3. Check for flat spots on carrier roller thread, which indicate roller is not free to turn.

TE14778,000008D –19–14JUL05–1/1

Carrier Roller Remove and Install

T206819C

–UN–28JAN05

CAUTION: Escaping fluid under pressure can penetrate the skin causing serious injury. DO NOT remove grease fitting to increase sag. DO NOT tamper with relief valve. It is fitted with a cover. Slowly loosen check valve fitting to release grease from track tension adjuster. 1. Slowly turn check valve fitting (3) counterclockwise one turn to release track tension. See Adjust Track Sag. (Operators Manual.)

Track Adjuster Check Valve

2. Raise and support track chain using a chain and hoist.

1—Grease Fitting 2—Relief Valve 3—Check Valve

Continued on next page

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Track System

CAUTION: Carrier roller is heavy and can cause injury if not moved properly. Use adequate lifting device to move carrier roller. –UN–15MAR05

Specification Carrier Roller—Weight ................................................. 34 kg Approximate 74 lb Approximate

3. Loosen cap screws (1) to remove front or rear carrier rollers.

T209559A

01 0130 6

4. Install carrier roller into support. Tighten cap screws. 1—Cap Screw (2 used)

5. Check for proper alignment of carrier rollers. 6. If out of alignment loosen cap screws (1) and adjust outward. 7. Adjust track sag. See Adjust Track Sag. (Operators Manual.)

TE14778,000009B –19–31MAR05–2/2

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PN=56

Track System

Carrier Roller Disassemble and Assemble 12 Carrier Roller Disassemble 10 1. Remove snap ring (1).

01 0130 7

8 2. Remove cover (3) using slide hammer.

3. Drain oil from housing.

5. Press outer bearing cone (7) and shaft (12) out of roller shell (9) using a press.

6 9

–UN–10MAR05

4. Remove retainer plate cap screws (5) and retainer plate (6).

7 5

6. Press inner bearing cone (7) from shaft using a press. 7. Press shaft (12) out of seal retainer (11) using a press.

T209436

3 1 Carrier Roller Assembly

IMPORTANT: Metal face seals can be reused if they are not worn or damaged. A used seal must be kept together as a set because of wear patterns on seal ring face.

1—Snap Ring 2—Pipe Plug 3—Cover 4—O-Ring 5—Cap Screw (2 used) 6—Retainer Plate 7—Bearing Cone (2 used) 8—Bearing Cup (2 used) 9—Roller Shell 10—Metal Face Seal 11—Seal Retainer 12—Shaft

8. Remove metal face seals (10). Keep seal rings together as a matched set with faces together to protect lapped surfaces. See Metal Face Seals Inspection. (Group 0130.) 9. Remove bearing cups (8) from roller shell. Inspect roller shell for grooved, burred or galled condition. 10. Replace parts as necessary.

Continued on next page

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PN=57

Track System Carrier Roller Assemble

1. Cool bearing cups (8) to specification and press into roller shell. Specification Bearing Cups—Temperature............................................................. -18°C 0°F

8 11

2. Heat inner bearing cone (7) to specification and install tight against shoulder on shaft. 4

6 9

–UN–10MAR05

Specification Inner Bearing Cone— Temperature ..................................................................................... 121°C 250°F

7 5

3. Install shaft (12) in roller shell. 3 4. Heat outer bearing cone (7) to specification and install on shaft so bearing is even with end of shaft.

T209436

01 0130 8

1 Carrier Roller Assembly

Specification

Outer Bearing Cone— Temperature ..................................................................................... 121°C 250°F

5. Install retainer plate (6) and cap screws (5). Tighten cap screws to specification. Specification Retainer Plate Cap Screws— Torque ............................................................................................ 47 N•m 35 lb-ft

IMPORTANT: O-ring and seat surfaces must be clean, dry and oil free so O-rings do not slip when roller is turning. 6. Thoroughly clean O-rings and seat surfaces in roller, cover, and seal rings using a volatile, non-petroleum base solvent and lint-free tissues.

Continued on next page

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PN=58

Track System 7. Install one half of metal face seal using JDG205 Seal Installation tool (13) into seal retainer (11). Install other half of seal (10) into roller shell.

–UN–16MAR05

8. Apply equal pressure with the fingers at four equally spaced points on seal ring face. O-ring and seal ring should seat squarely in bore.

9. Wipe both metal seal ring faces dry with a lint-free tissue. 10. Apply a thin film of oil, as used in the roller, to the shiny sealing area on both metal seal rings.

T209590A

NOTE: A volatile, non-petroleum base solvent or talcum powder may be used as a lubricant. Metal Face Seal Installation Tool 10—Metal Face Seal 11—Seal Retainer 13—JDG205 Installation Tool

11. Apply high strength thread lock and sealer to shoulder area of shaft to bond seal retainer. 12. Install seal retainer (11) on shaft. Cover is a press fit. 13. Fill roller with clean oil. See Track Rollers, Front Idler, Carrier Roller and Track Frame Outer Pivot Oil. (Operators Manual.) See Checking Carrier Roller Oil Level. (Operators Manual.) 14. Apply NEVER-SEEZ Lubricant or an equivalent to outside diameter of cover (3) and snap ring (1). 15. Install cover (3) with O-ring (4) into carrier roller (9). 16. Install snap ring (1). 17. Perform Carrier Roller Leakage Test. (Group 0130.) 18. Apply TY9375 Pipe Sealant to carrier roller oil fill pipe plug. Install plug.

NEVER-SEEZ is a trademark of Emhart Chemical Group.

TM2261 (10FEB06)

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750J, 850J Crawler 032806

PN=59

01 0130 9

Track System

Metal Face Seals Inspection 1. Inspect for the following conditions to determine if seals can be reused: • The narrow, highly polished sealing area (E) must be in the outer half of seal ring face (D). • Sealing area must be uniform and concentric with the ID and OD of seal ring (A). • Sealing area must not be chipped, nicked, or scratched.

T85079

–UN–24AUG93

A—Seal Ring B—Worn Area (shaded area) C—Seal Ring Face D—Outer Half of Seal Ring Face E—Sealing Area (dark line)

T47,0130,5939HQ –19–25AUG93–1/3

2. Illustration shows examples of worn seal rings (A). I—Sealing area (D) is in inner half of seal ring face (C).

–UN–05DEC96

II—Sealing area (D) not concentric with ID and OD of seal ring. A—Seal Ring B—Worn Area (shaded area) C—Inner Half of Seal Ring Face D—Sealing Area (dark line)

T85080

01 0130 10

Continued on next page

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750J, 850J Crawler 032806

PN=60

Track System

Apply a thin film of oil to seal ring face. Put face of seal rings together and hold using tape.

T82840

4. Wash seal rings and O-rings using a volatile, non-petroleum base solvent to remove all oil. Thoroughly dry parts using a lint-free tissue.

–UN–23FEB89

3. Clean reusable seals by removing all foreign material from seal rings, except seal face (A), using a scraper or a stiff bristled fiber brush.

T47,0130,5939HQ –19–25AUG93–3/3

Carrier Roller Leakage Test 1. Turn roller several times to seat metal face seals. 2. Remove plug and install parts (1—6). 3. Pressurize roller to specification using air pressure. Specification Carrier Roller Leakage Test—Air Pressure .............................................................................. 107—127 kPa 0.8—1.2 bar 14—20 psi

6. Install and tighten plug. 1—Pressure Gauge 0—689 kPa (0—6.89 bar) (0—100 psi) 2—T80937 Adapter (-6 M 9/16-18UNF-2A ORFS x 1/8-27 NPTF) 3—JT03456 O-Ring Face Seal (2 used) (17/16 -20 M JIC x 11/16-16 F ORFS) 4—Shut-Off Valve 5—Regulator 6—38H1030 Tee (-6 F ORFS x -6 M ORFS x -6 M ORFS) Parker No. (6R6LOS)

T211091A

5. If roller leaks oil or does not maintain pressure, check O-ring or seals. Repair as necessary and recheck for leaks.

–UN–11MAY05

4. Close valve and wait for two minutes. Make sure roller maintains air pressure and oil does not leak past O-ring or metal face seals.

TE14778,0000090 –19–07JUL05–1/1

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750J, 850J Crawler 032806

PN=61

01 0130 11

Track System

Track Roller Wear Inspection

–UN–04DEC04

1. Raise machine off the ground and support with 20-Ton Floor Stands. Lower blade to ground.

T205099A

1—20-Ton Floor Stand (4 used) 2—Floor Stand Adapter (2 used) 3—Floor Stand Rod 4—Washer (2 used) 5—Cap Screw (2 used)

750J/850J Floor Stand Kit

TX,9020,YY994 –19–14JUL05–1/3

–UN–28JAN05

CAUTION: Escaping fluid under pressure can penetrate the skin causing serious injury. DO NOT remove grease fitting to increase track sag. DO NOT tamper with relief valve. It is fitted with a cover. Slowly loosen check valve fitting to release grease from track tension adjuster. 2. Slowly turn check valve fitting (3) counterclockwise one turn to release track tension. See Adjust Track Sag. (Operators Manual.)

T206819C

01 0130 12

CAUTION: Prevent possible injury from unexpected track movement. Raise the machine off the ground and support with 20-Ton Floor Stands.

Track Adjuster Check Valve

1—Grease Fitting 2—Relief Valve 3—Check Valve

Continued on next page

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Track System

Track Roller Tread Diameter—Specification 750J New—OD.............................................................................. 203 mm 7.99 in. 750J 100 Percent Worn—OD .................................................... 184.2 mm 7.25 in. 850J New—OD.............................................................................. 227 mm 8.94 in. 850J 100 Percent Worn—OD .................................................... 188.4 mm 7.42 in.

T6813AM

3. Measure roller tread diameter using a caliper such as JT07193 Special Roller Caliper from JT05518A Undercarriage Inspection Kit.

–UN–29JAN98

NOTE: Minimum used is the maximum allowable wear for rebuilding roller tread.

Under some conditions roller wear can be uneven. If wear is uneven, the single flange rollers may be interchanged with other single flange rollers to even out wear. Double flange rollers may be interchanged with other double flange rollers.

NOTE: Reference Undercarriage Appraisal Manual SP326 for additional information. See Track Rollers. (SP326.) See 750J Track Roller Tread Diameter. (SP326.) See 850J Track Roller Tread Diameter. (SP326.)

TX,9020,YY994 –19–14JUL05–3/3

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750J, 850J Crawler 032806

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01 0130 13

Track System

Track Roller Remove and Install

–UN–28JAN05 T206819C

1. Slowly turn check valve fitting (3) counterclockwise one turn to release track tension. Put a piece of pipe between the sprocket and the track chain and rotate track to retract the adjusting cylinder if required.See Adjust Track Sag. (Operators Manual.)

Track Adjuster Check Valve 1—Grease Fitting 2—Relief Valve 3—Check Valve

TE14778,0000099 –19–31MAR05–1/3

CAUTION: Prevent possible injury from unexpected track movement. Raise the machine off the ground and support with 20-Ton Floor Stands. 2. Raise machine off the ground and support with 20-Ton Floor Stands. Lower blade to ground.

–UN–04DEC04

3. Remove center track guide or inner and outer rock guards if installed. See Track Guides and Rock Guards Remove and Install. (Group 0130.) 1—20-Ton Floor Stand (4 used) 2—Floor Stand Adapter (2 used) 3—Floor Stand Rod 4—Washer (2 used) 5—Cap Screw (2 used)

T205099A

01 0130 14

750J/850J Floor Stand Kit

Continued on next page

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Track System

CAUTION: Track roller is heavy and can cause injury if not moved properly. Use adequate lifting device to move track roller. –UN–17MAR05

Specification Track Roller—Weight ................................................... 59 kg Approximate 129 lb Approximate

5. All machines with 40 link chains have seven track rollers. Single and double flange rollers are used alternately starting at idler with a single flange roller. All machines with 45 link chains have eight track rollers. Single and double flange rollers are used alternately starting at idler with two single flange rollers.

T209622A

4. Remove cap screws (1) to remove roller (2).

Track Roller Cap Screws 1—Cap Screw 2—Track Roller

6. Install track roller (2) with oil fill plug toward outside of unit. 7. Carefully lower crawler until roller cap screws can be installed. 8. Apply Thread Lock and Sealer (High Strength) to track roller cap screws before installing rollers onto track frame. 9. Tighten cap screws (1) to specification. Specification 750J Track Roller-to-Track Frame Cap Screw—Torque ..................................................................... 275 N•m 200 lb-ft Specification 850J Track Roller-to-Track Frame Cap Screw—Torque .................................................................... 530 N•m. 390 lb-ft

10. See Adjust track sag. (Operators Manual.)

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750J, 850J Crawler 032806

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01 0130 15

Track System

Track Roller Disassemble and Assemble 18 12

01 0130 16

4 5

2 3

11 14

16 1

T210108

–UN–05APR05

T210108 1—Cap Screw (4 used) 2—Inner Bracket 3—O-Ring (4 used) 4—Metal Face Seal (4 used) 5—Bushing Case (2 used)

6—O-Ring (2 used) 7—Dowel Pin (2 used) 8—Bushing (2 used) 9—Snap Ring (2 used) 10—Roller Shaft

11—O-Ring (2 used) 12—Roller Shell 13—Outer Bracket 14—Plug (Rubber)

15—Plug (Plastic) 16—Lock Washer (4 used) 17—Cap Screw (12 used) 18—Lock Washer (12 used)

Track Roller Disassemble

Continued on next page

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PN=66

Track System NOTE: Single and double flange rollers are of the same design. Disassembly procedures are the same for both types of rollers. 1. Compress the metal face seals slightly using a 1 3/8 inch diameter disk (1) from D01045AA Bushing, Bearing, and Seal Driver Set and a press. Remove the snap ring (2) from both sides of roller shaft (3).

T80426

–UN–26OCT88

01 0130 17

TE14778,000009A –19–14JUL05–2/16

2. Remove outer and inner brackets (1).

NOTE: Metal face seals are a matched set. Seals are not interchangeable with other seals.

T80427

–UN–26OCT88

3. Remove metal face seal from inner and outer brackets.

TE14778,000009A –19–14JUL05–3/16

4. Remove and inspect metal face seals. See Metal Face Seals Inspection. (Group 0130.) 5. Remove O-rings (2) from both ends of shaft.

T6018BC

–UN–26OCT88

6. Remove cap screws (1) from bushing case at both ends of roller.

Continued on next page

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PN=67

Track System 7. Remove roller shaft (1) and bushing case (2) using 2 3/8 inch diameter disk (3) and press. 8. Remove roller shaft from bushing case. 9. Turn roller over. Use 4 inch diameter disk to remove bushing case from roller housing. 10. Remove O-rings from bushing cases. 11. Inspect bushing in bushing case for excessive wear, pitting or scoring. Replace, if necessary.

–UN–26OCT88

12. Remove plastic and rubber plugs from shaft using twist drill. Flush oil passages in shaft with part cleaner solvent.

T80432

01 0130 18

Continued on next page

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Track System Track Roller Assemble 1—O-Ring (2 used) 2—Plug (Rubber) 3—Washer (4 used) 4—Cap Screw (4 used) 5—Snap Ring (2 used) 6—Plug (Plastic) 7—Metal Face Seal (2 used) 8—Cap Screw (12 used) 9—Lock Washer (12 used) 12—Dowel Pin (2 used) 13—Bushing (2 used) 14—O-Ring (2 used) 15—Roller Shell 16—Bushing Case (2 used) 17—Shaft 18—Bracket (2 used)

T209988

–UN–31MAR05

01 0130 19

Double Flange Track Roller Shown

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Track System NOTE: Assembly of single and double flange roller is the same. Single flange shown.

Specification Bushing—Temperature...................................................................... -18°C 0°F Specification Bushing Case—Temperature ........................................................... 121°C 250°F

2. Using a straight edge, mark bushing (1) from center line of dowel pin hole to center line of dowel pin (2). Align mark on bushing with dowel pin in bushing case.

–UN–31MAR05

3. Press bushing into case using 4 inch diameter disk from D01045AA Bushing, Bearing, and Seal Driver Set and a press. 4. When bushing case cools, install O-ring (5) on bushing case.

T210063A

01 0130 20

1. Cool bushing (1) and heat bushing case (3) to specification.

1—Bushing 2—Dowel Pin 3—Bushing Case 4—Disk (4 inch diameter) 5—O-Ring 6—Alignment Mark

Continued on next page

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Track System 5. Install bushing case (1) using aligning studs (2), 89 mm (3 1/2 inch) diameter x 6.3 mm (1/4 inch) wall pipe (5), 3 9/16 inch diameter disk (4), and a press. 6. Remove aligning studs. Install cap screws and lock washers. Tighten cap screws.

01 0130 21

7. Turn roller (3) over and carefully install roller shaft. 8. Install bushing case (1) using aligning studs (2), 89 mm (3 1/2 inch) diameter x 6.3 mm (1/4) inch wall pipe (5), 3 9/16 inch diameter disk (4), and a press. 9. Remove studs. Install cap screws and lock washers. Tighten cap screws.

T80440

–UN–26OCT88

1—Bushing Case 2—Stud 3—Roller 4—Disk (3 9/16 inch diameter) 5—Pipe

TE14778,000009A –19–14JUL05–8/16

10. Install new O-ring in shaft groove (1).

T6018BA

–UN–26OCT88

11. Degrease seal bore in bushing case, inner collar, and outer collar using a volatile, non-petroleum base type solvent. Make sure seal bores are clean and dry.

Continued on next page

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Track System

–UN–26OCT88 T80574

12. Install rubber seal (1) on the metal seal ring (2). Make sure the rubber seal sits evenly on metal seal ring.

TE14778,000009A –19–14JUL05–10/16

NOTE: A volatile, non-petroleum base solvent or talcum powder may be used as a lubricant. Solvent MUST NOT damage the O-rings or leave an oil residue. –UN–26OCT88

13. Install seal assembly in the JDG205 Seal Installation Tool (2) so tool lip is between seal ring flange (1) and O-ring (3). 1—Seal Ring Flange 2—JDG205 Seal Installation Tool 3—O-Ring

T6077AV

01 0130 22

IMPORTANT: The metal face seal must be extremely clean during assembly. Use a volatile, non-petroleum base type solvent to clean the metal seal ring (2) and rubber seal (1). DO NOT keep the rubber seal in a volatile, non-petroleum base type solvent for more than one minute. Wipe the seals dry with lint-free tissue to remove finger prints and foreign material.

Continued on next page

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Track System

–UN–26OCT88

14. Push seal ring and O-ring into bore using tool (1). After O-ring (2) is pushed past retainer lip, turn tool clockwise and counterclockwise to seat O-ring uniformly. Install seal rings and O-rings in the outer and inner brackets using the same procedure.

T80577

15. Check to make sure seal ring is sitting squarely in bore. Make sure rubber seal is seated uniformly in seal bore below the retainer lip. 1—JDG205 Seal Installation Tool 2—O-Ring

TE14778,000009A –19–14JUL05–12/16

16. Wipe metal seal rings dry with a lint free tissue. 17. Apply a thin film of oil, as used in the roller, to the shiny sealing area on metal seal rings.

T80578

–UN–26OCT88

18. Be sure the rubber seals are free of oil.

Continued on next page

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01 0130 23

Track System 19. Install outer bracket. 20. Compress metal face seals slightly using a 1 3/8 inch diameter disk (1) and press. 21. Install snap ring (2) on shaft (3). 22. Remove roller from press. Install inner bracket and snap ring using same procedure.

T80426

–UN–26OCT88

1—Disk (1 3/8 inch diameter) 2—Snap Ring 3—Shaft

TE14778,000009A –19–14JUL05–14/16

23. Thoroughly clean nozzle (1), from JD313A Front Idler Lube Nozzle Kit, and around the plug end of track roller shaft.

–UN–26OCT88

24. Insert nozzle in roller shaft with flat side up, as far as possible. 25. Slowly pump recommended oil into shaft using adapter (2) and grease gun (3) until oil without air bubbles is seen leaking past the flat on nozzle. See Track Rollers, Front Idler, Carrier Roller and Track Frame Outer Pivot Oil. (Operators Manual.)

T6090AI

01 0130 24

1—JD313-1 Lube Nozzle 2—JD313-2 Adapter 3—Grease Gun

NOTE: Perform Track Roller Leakage Test BEFORE installing plugs. 26. Perform Track Roller Leakage Test. (Group 0130.)

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Track System

19 14

Specification Track Roller Oil Plug—Depth .......................................................... 10 mm 0.39 in.

T210171

28. Install track roller. See Track Roller Remove and Install . (Group 0130.)

–UN–07APR05

27. Install new plastic plug (15) into rubber plug (14). Install plug assembly into shaft to specified depth (19).

14—Plug (rubber) 15—Plug (plastic) 19—Track Roller Oil Plug Depth

TE14778,000009A –19–14JUL05–16/16

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750J, 850J Crawler 032806

PN=75

01 0130 25

Track System

Track Roller Leakage Test 1. Remove plug from track roller. 2. Fill track roller with recommended oil. See Track Rollers, Front Idler, Carrier Roller and Track Frame Outer Pivot Oil. (Operators Manual.) 3. Turn roller several times to seal metal face seals. 4. Assemble parts (1—5) as shown. 5. Pressurize roller with compressed air to specification and close valve (4).

–UN–11MAY05

Specification Track Roller Leakage Test—Air Pressure .............................................................................. 107—127 kPa 0.8—1.2 bar 14—20 psi

T211097A

6. Track roller must maintain air pressure for two minutes. Oil must not leak past metal seals or rubber plug. If oil leaks past seals, repair as necessary. 1—Pressure Gauge 207 kPa (2.07 bar) (0—30 psi) 2—T149247 Rubber Plug 3—Male Barb-to-Male pipe Fitting (1/8-27 NPTF) Park No. (125HBL-4-2) 4—Shut-Off Valve 5—Regulator

TE14778,00000D1 –19–14JUL05–1/2

7. Install new plastic plug (15) into rubber plug (14). Install plug assembly into shaft to specified depth (19).

–UN–07APR05

Specification Track Roller Oil Plug—Depth .......................................................... 10 mm 0.39 in.

14—Plug (rubber) 15—Plug (plastic) 19—Track Roller Oil Plug Depth

T210171

01 0130 26

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TM2261 (10FEB06)

01-0130-26

750J, 850J Crawler 032806

PN=76

Track System

Track Shoe Grouser Wear Inspection 100 percent worn is the maximum allowable wear for rebuilding grouser bars with weld.

T6813AN

–UN–29JAN98

Measure grouser height of several track shoes to find an average using a depth gauge such as the JT05521 200 mm Ruler, JT05534 Right Angle Attachment, and D-05231ST 300 mm Ruler from JT05518A Undercarriage Inspection Kit.

NOTE: Reference Undercarriage Appraisal Manual SP326 for additional information. See Grouser Wear. (SP326.) See Grouser Bar Height. (SP326.) See 750C, 750C-LGP, 750C Series II, and 750J Single Bar Grouser Height—Moderate Duty. (SP326.) See 750C, 750C-LGP and 750C Series II, and 750J Single Bar Grouser Height—Extreme Duty. (SP326.) See 755A, 755B, 850, 850-LGP, 850B, 850B-LGP, 850B-LT, 850C, 850C-LGP, 850C Series II, and 850J Single Bar Grouser Height— Moderate Duty. (SP326.) See 755A, 755B, 850, 850-LGP, 850B, 850B-LGP, 850B-LT, 850C, 850C-LGP, 850C Series II , and 850J Single Bar Grouser Height— Extreme Duty. (SP326.) GROUSER HEIGHT SPECIFICATIONS Model

Moderate Duty Shoes

Extreme Duty Shoes

750J (New)

55.5 mm 2.19 in.

67.5 mm 2.66 in.

850J (New)

65.5 mm 2.58 in.

71.5 mm 2.81 in.

750J (100 percent worn)

18 mm 0.71 in.

21.5 mm 0.85 in.

850J (100 percent worn)

25.4 mm 1.0 in.

Continued on next page

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PN=77

01 0130 27

Track System Use plate thickness specifications below to help identify (Moderate Duty) and (Extreme Duty) grousers.

01 0130 28

Single Grouser—Specification 750J Moderate Duty—Plate Thickness...................................................................................... 13.5 mm 0.53 in. 750J Extreme Duty—Plate Thickness...................................................................................... 14.5 mm 0.57 in. 850J Moderate Duty—Plate Thickness......................................................................................... 12 mm 0.47 in. 850J Extreme Duty—Plate Thickness...................................................................................... 14.7 mm 0.58 in.

TE14778,0000092 –19–12JUL05–2/2

Track Shoe Remove and Install NOTE: Cap screws hold the master shoe and split master link together. Link side of master shoe has machined surfaces. 1. Remove nuts and cap screws using DFT1041 Track Nut Removal Tool. For instructions to make tool see DFT1041 Track Nut Removal Tool. (Group 9900.) 2. Before installing shoes, clean paint, dirt, and debris from mounting surfaces of shoes and links. 3. For all cap screws except those for split master links and shoe, apply oil (SAE 30) to threads and bearing surface under head. For split master link and shoe cap screws, apply John Deere NEVER-SEEZ Lubricant or an equivalent to threads and bearing surface under head.

NEVER-SEEZ is a registered trademark of Emhart Chemical Group

TM2261 (10FEB06)

Continued on next page

01-0130-28

TE14778,0000093 –19–11JUL05–1/2

750J, 850J Crawler 032806

PN=78

Track System

5. Tighten cap screws to the initial torque using a crisscross sequence. Then repeat sequence for the additional turn.

T96291

4. Install new cap screws. Install new nuts using DFT1041 tool with rounded edges (A) against link and chamfered edges (B) away from link.

–UN–23FEB89

IMPORTANT: Never use an impact wrench to start cap screws in split master link to avoid cross-threading.

Track Shoe Cap Screw:

Split Master Link Shoe Cap Screw—Specification 750J (5/8 in.)—Torque Turn ............................ 163 N•m + 1/2 Turn (180°) 120 lb-ft + 1/2 Turn (180°) 850J (3/4 in.)—Torque Turn ............................ 270 N•m + 1/2 Turn (180°) 199 lb-ft + 1/2 Turn (180°)

T96292

Split Master Link Shoe Cap Screw:

–UN–23FEB89

Track Shoe Cap Screw—Specification 750J (5/8 in.)—Torque Turn ............................ 163 N•m + 1/3 Turn (120°) 120 lb-ft + 1/3 Turn (120°) 850J (3/4 in.)—Torque Turn ............................ 270 N•m + 1/3 Turn (120°) 199 lb-ft + 1/3 Turn (120°)

6. Check torque after 50—100 hours of operation to make sure cap screws are tightened to minimum torque.

T6352AH

Track Shoe Cap Screws 50—100 Hour Check—Specification 750J—Minimum Torque ............................................................... 380 N•m 280 lb-ft 850J—Minimum Torque ............................................................... 597 N•m 440 lb-ft

–UN–23FEB89

Track Shoe Cap Screws 50—100 Hour Check:

TE14778,0000093 –19–11JUL05–2/2

TM2261 (10FEB06)

01-0130-29

750J, 850J Crawler 032806

PN=79

01 0130 29

Track System

Pivot Shaft Remove and Install

2 3

–UN–29MAR05

Specification Pivot Shaft—Approximate Weight ..................................................... 85 kg 188 lb

1. Remove pivot shaft cap screws (3), washers (2), and pivot shaft (1).

T209976

01 0130 30

CAUTION: Pivot shaft is heavy and can cause injury if not moved properly. Use adequate lifting device to move pivot shaft.

Pivot Shaft

2. Apply high strength thread lock and sealer to pivot shaft mounting capscrews (3).

1—Pivot Shaft (2 used) 2—Washer (42 used) 3—Cap Screw (42 used)

3. Install pivot shaft onto main frame using hoist. Tighten cap screws to specification. Specification Pivot Shaft Cap Screws—Torque ................................................ 530 N•m 390 lb-ft

TE14778,0000091 –19–24MAR05–1/1

Crossbar Remove and Install Crossbar Removal 1. Remove push beam and blade assembly (Outside Dozer). See Outside Dozer Push Beams Remove and Install. (Group 3240.)

Continued on next page

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750J, 850J Crawler 032806

PN=80

Track System

CAUTION: Prevent possible injury from unexpected track movement. Raise the machine off the ground and support with 20-Ton Floor Stands. Tracks must be free to rotate in either direction.

01 0130 31

2. Raise machine off the ground and support with 20-Ton Floor Stands. Lower blade to ground. –UN–04DEC04

3. Remove track chain. See Lubricated Track Chain Remove and Install. (Group 0130.)

T205099A

1—20-Ton Floor Stand (4 used) 2—Floor Stand Adapter (2 used) 3—Floor Stand Rod 4—Washer (2 used) 5—Cap Screw (2 used)

750J/850J Floor Stand Kit

Continued on next page

TM2261 (10FEB06)

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750J, 850J Crawler 032806

PN=81

Track System 4. Disconnect crossbar lube hose (6) from track frame on both sides. 4 CAUTION: Prevent possible injury from unexpected crossbar and track frame movement. Track frame on opposite side will pivot down. Before removing track frame always block track frame on opposite side.

5. Remove track frame from one side. See Track Frame Remove and Install. (Group 0130.)

Specification Front Bottom Guard— Approximate Weight .......................................................................... 41 kg 90 lb

1—Crossbar 2—Pivot Pin, Crossbar-to-Main Frame 3—Pivot Pin, Crossbar-to-Track Frame (2 used) 4—Cap Screw (3 used) 5—Bushing (3 used) 6—Lubrication Hose (2 used) 7—Nut (2 used)

6. Remove front and middle bottom guards.

Continued on next page

TM2261 (10FEB06)

–UN–28MAR05

6 7

CAUTION: Front bottom guard is heavy and can cause injury if not moved properly. Use adequate lifting device to move front bottom guard.

T209845

01 0130 32

01-0130-32

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PN=82

Track System

CAUTION: Crossbar is heavy and can cause injury if not moved properly. Use adequate lifting device to move crossbar. –UN–24MAR05

Specification Crossbar—Approximate Weight ...................................................... 227 kg 500 lb

T209808A

7. Support crossbar (1) with hoist. 8. Remove crossbar-to-main frame pivot pin (2). 9. Remove crossbar-to-track frame pivot pin (3) from opposite track frame. 10. Pull crossbar partially out and attach second sling. 11. Remove crossbar.

TE14778,0000096 –19–12JUL05–4/8

Crossbar Installation 1. Apply NEVER-SEEZ Lubricant or an equivalent to inside diameter of crossbar-to-track frame bushings and corresponding pivot pins (3).

5 6 7

T209845

–UN–28MAR05

1—Crossbar 2—Pivot Pin, Crossbar-to-Main Frame 3—Pivot Pin, Crossbar-to-Track Frame (2 used) 4—Cap Screw (3 used) 5—Bushing (3 used) 6—Lubrication Hose (2 used) 7—Nut (2 used)

NEVER-SEEZ is a trademark of Emhart Chemical Group.

TM2261 (10FEB06)

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750J, 850J Crawler 032806

PN=83

01 0130 33

Track System

CAUTION: Crossbar is heavy and can cause injury if not moved properly. Use adequate lifting device to move crossbar. –UN–28MAR05

Specification Crossbar—Approximate Weight ...................................................... 227 kg 500 lb

2. Guide crossbar (1) into main frame using hoist.

T209846A

01 0130 34

3. Push crossbar through main frame and align crossbar self-aligning bushing with track frame bore. 4. Apply high strength thread lock and sealer to crossbar-to-track frame capscrews (4). 5. Install crossbar-to-track frame pin (3), bushing (5), and cap screw (4). Tighten cap screw to specification. Specification Pivot Pin-To-Track Frame Cap Screw—Torque ............................................................................. 275 N•m 200 lb-ft

6. Align crossbar synthetic bushing with main frame bore. 7. Apply high strength thread lock and sealer to crossbar-to-main frame cap screw (4). 8. Install crossbar-to-main frame pin (3), bushing (5), and cap screw (4). Tighten cap screw to specification. Specification Pivot Pin-To-Main Frame Cap Screw—Torque ............................................................................. 275 N•m 200 lb-ft

CAUTION: Front bottom guard is heavy and can cause injury if not moved properly. Use adequate lifting device to move front bottom guard. Specification Front Bottom Guard— Approximate Weight .......................................................................... 41 kg 90 lb

9. Install front and middle bottom guards.

Continued on next page

TM2261 (10FEB06)

01-0130-34

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750J, 850J Crawler 032806

PN=84

Track System 10. Install track frame. See Track Frame Remove and Install. (Group 0130.) 11. Connect crossbar lube hose (6) to track frame on both sides.

01 0130 35

TE14778,0000096 –19–12JUL05–7/8

12. Remove plug (12) from top of track frame. Remove pipe plug (10).)

–UN–28MAR05

13. Fill track frame with oil. See Check Track Frame Pivot Shaft Oil. (Operators Manual. 14. Apply pipe sealant to pipe plug (10) and install. Install plug (12).

16. Install trunnion (Outside Dozer). See Trunnion Remove and Install. (Group 3200.)

T209856

15. Install track chain. See Lubricated Track Chain Remove and Install. (Group 0130.) Track Frame Oil Fill 10—Pipe Plug 12—Plug

17. Install pushbeam and blade assembly (Outside Dozer). See Pushbeam Remove and Install. (Group 3240.)

TE14778,0000096 –19–12JUL05–8/8

TM2261 (10FEB06)

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750J, 850J Crawler 032806

PN=85

Track System

Crossbar Disassemble and Assemble

1. Remove seals (2 and 4), snap rings (5), lubrication hoses (7), and elbow fittings (8).

1 2. Remove synthetic bushing (3) using 3 7/16 inch diameter disk from D01045AA Bushing, Bearing, and Seal Driver Set. 3. Remove self-aligning bushings (6) using 83 mm (3 1/4 in.) diameter pipe and 3 7/16 inch diameter disk.

2 6 4 4

5 3

5 1—Crossbar 2—Seal (2 used) 3—Synthetic Bushing 4—Seal (4 used) 5—Snap Ring (4 used) 6—Self-Aligning Bushing (2 used) 7—Lubrication Hose (2 used) 8—Elbow Fitting (2 used)

–UN–10MAR05

4. Inspect bushings (3 and 6). Replace if necessary. 2

T209376

6 4 Crossbar

TE14778,000008C –19–08MAR05–1/3

5. Install synthetic bushing to specified depth (9) using 3 7/16 inch diameter disk.

–UN–10MAR05

Specification Synthetic Bushing—Depth............................................. 17.45—19.45 mm 0.687—0.766 in.

6. Install seal (2) on both sides of bushing with lip facing outward. Press in seal using 3 7/16 inch diameter disk to specified depth (10). Specification Synthetic Bushing Seal—Depth ............................................ 4.5—5.5 mm 0.18—0.22 in.

T209384

01 0130 36

2 Synthetic Bushing and Seals Cross Section 2—Seal (2 used) 3—Synthetic Bushing 9—Synthetic Bushing Depth 10—Seal Depth

Continued on next page

TM2261 (10FEB06)

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750J, 850J Crawler 032806

PN=86

Track System 7. Install one snap ring (5) in groove.

9. Install second snap ring.

6 5

10. Install seal (4) on both sides of bushing with lip facing outward. Press in seal using 4 5/16 inch diameter disk. 11. Install elbow fittings and lubrication hoses.

T209385

8. Install self-aligning bushing (6) against snap ring using 83 mm (3 1/4 in.) diameter pipe and 3 7/16 inch diameter disk.

–UN–10MAR05

Self-Aligning Bushing and Seals 4—Seal (4 used) 5—Snap Ring (4 used) 6—Self-Aligning Bushing (2 used)

TE14778,000008C –19–08MAR05–3/3

Track Link Height Inspection

T5802AD

Track Link Height—Specification 750J New Chain Link—Height ...................................................... 119 mm 4.69 in. 850J New Chain Link—Height ...................................................... 132 mm 5.20 in. 750J 100 Percent Worn Link— Height ............................................................................................ 108 mm 4.25 in. 850J 100 Percent Worn Link— Height ......................................................................................... 118.5 mm 4.67 in.

–UN–02NOV88

1. Measure link height to the nearest 0.5 mm (0.020 in.) using depth gauge from JT05518A Undercarriage Inspection Kit.

2. Put the depth gauge on outside of track link against pin boss as shown. Measure two links to the nearest 0.5 mm (0.020 in.).

TX,9020,YY1004 –19–27JUN05–1/1

TM2261 (10FEB06)

01-0130-37

750J, 850J Crawler 032806

PN=87

01 0130 37

Track System

Bushing Outside Diameter for Lubricated Track Chain Inspection

TE14778,00000A3 –19–12JUL05–1/3

–UN–26OCT88

NOTE: Lubricated track chain bushings are measured for vertical wear only using calipers. Bushing vertical wear can be measured using the depth gauge method only after bushing turn procedure is used. Reference Undercarriage Appraisal Manual, SP326 . 2. For caliper method put caliper from JT05518A Undercarriage Inspection Service Tool Kit around bushing at area of vertical wear as shown. Measure several different bushings to nearest 0.5 mm (0.020 in.).

T5802AB

01 0130 38

1. Clean surfaces to be measured of two adjacent bushings and underside of track shoe in the area between bushings.

Specification 750J New Bushing—OD ................................................................. 65 mm 2.56 in. 850J New Bushing—OD .............................................................. 72.9 mm 2.87 in. 750J 100 Percent Worn Bushing (High Shock Impact)—OD ............................................................ 57.3 mm 2.26 in. 850J 100 Percent Worn Bushing (High Shock Impact)—OD ............................................................ 66.3 mm 2.61 in. 750J 100 Percent Worn Bushing (Normal Impact)—OD ................................................................... 54.8 mm 2.16 in. 850J 100 Percent Worn Bushing (Normal Impact)—OD ................................................................... 62.7 mm 2.47 in.

Continued on next page

TM2261 (10FEB06)

01-0130-38

TE14778,00000A3 –19–12JUL05–2/3

750J, 850J Crawler 032806

PN=88

Track System NOTE: Reference Undercarriage Appraisal Manual SP326 for additional information. See 750J Bushing Outer Diameter—Normal Impact, Sealed and Lubricated Chain (Caliper). (SP326.)

01 0130 39

See 750J Bushing Outer Diameter—High Impact, Sealed and Lubricated Chain (Caliper). (SP326.) See 750J Bushing Outer Diameter—Normal Impact, Sealed and Lubricated Chain (Depth Gauge). (SP326.) See 750J Bushing Outer Diameter—Normal Impact, Sealed and Lubricated Chain (Depth Gauge). (SP326.) See 850C, 850C Series II, and 850J Bushing Outer Diameter—Normal Impact, Heavy-Duty Sealed and Lubricated Chain (Caliper). (SP326.) See 850C, 850C Series II, and 850J Bushing Outer Diameter—High Impact, Heavy-Duty Sealed and Lubricated Chain (Caliper). (SP326.) See 850C, 850C Series II, and 850J Bushing Outer Diameter—Normal Impact, Heavy-Duty Sealed and Lubricated Chain (Depth Gauge). (SP326.) See 850C, 850C Series II, and 850J Bushing Outer Diameter—High Impact, Heavy-Duty Sealed and Lubricated Chain (Depth Gauge). (SP326.)

TE14778,00000A3 –19–12JUL05–3/3

TM2261 (10FEB06)

01-0130-39

750J, 850J Crawler 032806

PN=89

Track System

IMPORTANT: Track pin may be operated with a dry joint until it reaches wear limit specified. Then it must be repaired. A dry joint will not hold lubrication until it is repaired. Track pin may break if joint is not repaired after it reaches wear limit.

T6813AL

01 0130 40

NOTE: Track pitch does not extend unless there is lubrication leakage, which causes a dry joint. Measure pitch only when there is a lubrication leakage or a visible extension of a joint.

–UN–29JAN98

Track Pitch for Lubricated Track Chain Inspection

1. Place a pin or block between sprocket and chain. Then move unit in reverse until chain is tight. 2. Measure from left side of pin in dry joint across four links to left side of pin (as shown). Track Pitch—Specification 750J New Chain—Length ............................................................. 760 mm 29.92 in. 850J New Chain—Length ............................................................. 812 mm 31.97 in. 750J 100 Percent Worn Chain— OD .............................................................................................. 772.7 mm 30.42 in. 850J 100 Percent Worn Chain— OD .............................................................................................. 824.7 mm 32.47 in.

TX,9020,YY1001 –19–13JUN95–1/1

TM2261 (10FEB06)

01-0130-40

750J, 850J Crawler 032806

PN=90

Track System

Lubricated Track Chain Remove and Install CAUTION: Prevent possible injury from unexpected track movement. Raise the machine off the ground and support with 20-Ton Floor Stands. Tracks MUST be free to rotate in either direction.

01 0130 41

–UN–04DEC04

1. Raise machine off the ground and support with 20-Ton Floor Stands. Lower blade to ground.

T205099A

1—20-Ton Floor Stand (4 used) 2—Floor Stand Adapter (2 used) 3—Floor Stand Rod 4—Washer (2 used) 5—Cap Screw (2 used)

750J/850J Floor Stand Kit

TE14778,000009C –19–14JUL05–1/7

–UN–28JAN05

T206819C

2. Slowly turn check valve fitting (3) counterclockwise one turn to release track tension. Put a piece of pipe between the sprocket and the track chain and rotate track to retract the adjusting cylinder if required.See Track Sag Adjustment. (Group 0130.)

Track Adjuster Check Valve 1—Grease Fitting 2—Relief Valve 3—Check Valve

Continued on next page

TM2261 (10FEB06)

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PN=91

Track System 3. Rotate track until master split link is positioned in front of idler. 4. To prevent track from falling, block track as shown. 5. Remove four track bolts (1) to remove master track shoe (2) and disassemble master split link. 6. Slowly drive unit in reverse direction to move track off drive sprocket.

–UN–11MAY05

IMPORTANT: Track chain MUST be installed under track frame with wide end of links toward rear of machine or accelerated wear to track chain will occur.

T211292A

7. Install track chain by putting chain under track frame with the wide end of links toward rear of machine. 8. Block track shoes so master split link is positioned directly over idler. 1—Track Bolt (4 used) 2—Track Shoe

TE14778,000009C –19–14JUL05–3/7

9. Attach chain and hoist to track near the end of chain to support track chain. Guide track over sprocket while operator drives machine slowly forward guiding track chain over carrier rollers and front idler. –UN–31MAR05

10. Stop machine when ends of master links meet. 11. Remove any foreign material from master link tooth racks and ramp surfaces (1). Clean surface with wire brush if necessary.

T210051A

01 0130 42

12. Check for burrs, especially at tips (2) of master link ramps. Remove all burrs so ramp surfaces are flat. 1—Ramp Surface 2—Tip of Master Link Ramp 3—Holes

13. Check bolt holes (3) in each master link. Bolt holes must be clean and free of foreign material.

Continued on next page

TM2261 (10FEB06)

01-0130-42

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750J, 850J Crawler 032806

PN=92

Track System IMPORTANT: To prevent damage to threads, DO NOT use a pry bar in holes to align split master link.

–UN–31MAR05

14. Carefully assemble master links together and align bolt holes. 15. Install track bolts by hand to check alignment.

T210052A

16. Apply John Deere NEVER-SEEZLubricant or an equivalent to cap screw threads and bearing surface under head. 1—Master Link

NEVER-SEEZ is a registered trademark of Emhart Chemical Group

TE14778,000009C –19–14JUL05–5/7

IMPORTANT: DO NOT use impact wrench to start the master shoe cap screws to avoid cross-threading. 17. Remove any foreign material from master shoe and link mounting surfaces. Install master shoe (2) on master links and start cap screws by hand to avoid cross-threading.

T211292A

–UN–11MAY05

1—Track Bolt (4 used) 2—Track Shoe

Continued on next page

TM2261 (10FEB06)

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PN=93

01 0130 43

Track System

19. Check torque after 50—100 hours of operation to make sure cap screws are tightened to the minimum torque specification.

T210112

01 0130 44

–UN–01APR05

18. Initially tighten master cap screws (1) in a cross sequence as shown. Repeat sequence per specification.

Crisscross Tightening Sequence

Lubricated Track Chain, Track Shoes 50—100 Hour Check— Specification 750J—Minimum Torque ............................................................... 380 N•m 280 lb-ft 850J—Torque ............................................................................... 597 N•m 440 lb-ft

20. Adjust track sag. See Track Sag Adjustment. (Group 0130.)

TE14778,000009C –19–14JUL05–7/7

TM2261 (10FEB06)

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750J, 850J Crawler 032806

PN=94

Track System

Lubricated Track Chain to Turn Bushings and Lubricate Chain Disassemble NOTE: The following procedure is for disassembly of track chain to inspect, clean, replace damaged or worn parts, turn bushings, and lubricate chain.

01 0130 45

If track chain is disassembled only to turn pins and bushings and no parts will be replaced, see Lubricated Track Chain to Turn Pins and Bushings and Not Lubricate Disassemble and Assemble. (Group 0130.) 1. Remove track shoes and track chain. See Track Shoe Remove and Install. (Group 0130.) See Lubricated Track Chain Remove and Install. (Group 0130.)

NOTE: A clean track is necessary for proper disassembly. 2. Wash chain with high pressure water. It will not be necessary to wash links before reassembly if chain is thoroughly cleaned. 3. Use the appropriate track press tool set. “91” Series (Adjustable Camlock) Tooling 750J

913019—Pin Disassembly Tool (2 used) 914133—Bushing Disassembly Tool (2 used) 915080—Pin Assembly Tool (2 used) 916242—Bushing Assembly Tool (2 used)

850J

913013—Pin Disassembly Tool (2 used) 914015—Bushing Disassembly Tool (2 used) 915175—Pin Assembly Tool (2 used) 916240—Bushing Assembly Tool (2 used)

750J

(A2656-302).

850J

(A2656-303).

“C” Style (Spring Loaded) Tooling

Continued on next page

TM2261 (10FEB06)

01-0130-45

TX,0130,SS2441 –19–13JUN95–1/5

750J, 850J Crawler 032806

PN=95

Track System IMPORTANT: Track press disassembly tools must be in proper alignment with links to prevent broaching of pin and bushing. Damaged link bores cannot be reused.

–UN–27OCT88

4. Start disassembly at pin-end half of split link. Check for proper alignment of tools with pin and bushing.

T96266

5. Make an index mark on bushings to aid in reassembly, when turning bushings 1/2 turn (180°) to expose a new wear surface. CAUTION: Always wear safety glasses when operating the press. Parts may break or chip, which could create a risk of personal injury.

A—Left Ram B—Saddle C—Right Ram D—Right Link E—Bushing F—Left Link G—Pin

6. Extend right ram (C) to push pin (G) and bushing (E) from the right link (D). The right link is forced against the side of saddle (B) as pin and bushing are pushed out. 7. Retract right ram. The right link, with seals and thrust ring, will stay on the ram tools.

TX,0130,SS2441 –19–13JUN95–2/5

8. Extend left ram (A) to push the pin (C) and bushing (F) from left link (G). The left link is forced against the side of saddle (B) as pin and bushing are pushed out.

–UN–27OCT88

9. Retract left ram. The left link, with seal and thrust ring, will remain on the ram tools. 10. Remove links, bushing, and thrust rings from press. A—Left Ram B—Saddle C—Pin D—Right Ram E—Right Link F—Bushing G—Left Link

T96267

01 0130 46

Continued on next page

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750J, 850J Crawler 032806

PN=96

Track System 11. Inspect parts as they are disassembled to determine which ones can be reused.

–UN–01NOV88

If there is internal wear at any joint, replace seal ring, pin, bushing, thrust ring, and load ring. These parts must be replaced to successfully lubricate chain.

13. Repeat steps 4—12 to disassemble rest of chain. 14. Remove rubber plug (F) from pins using a drill.

T6682AJ

12. If pin and bushing contains oil when disassembled, new pins, seals, bushings, or thrust rings are not necessary. Do not remove usable seals from link counterbore. Do not remove any dirt from around seals. A—Bushing B—Seal Ring C—Load Ring D—Thrust Ring E—Pin F—Rubber Plug

TX,0130,SS2441 –19–13JUN95–4/5

15. Inspect pin ends. If the chamfer is missing due to wear, grind a 3 mm (0.12 in.) x 15° chamfer on pin. If chamfer is missing in plug hole, add new 4 mm (0.16 in.) x 30° chamfer.

–UN–27OCT88

16. Clean pins, bushings, and thrust rings in solvent.

T96269

A—4 mm (0.16 in.) B—30° C—15° D—3 mm (0.12 in.)

TX,0130,SS2441 –19–13JUN95–5/5

TM2261 (10FEB06)

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750J, 850J Crawler 032806

PN=97

01 0130 47

Track System

Lubricated Track Chain to Turn Bushings and Lubricate Chain Assemble

–UN–27OCT88

CAUTION: Make sure all control levers of press are in the NEUTRAL position. 1. Assemble track using the following track press tool sets.

850J

T96272

“91” Series (Adjustable Camlock) Tooling 750J

913019—Pin Disassembly Tool (2 used) 914133—Bushing Disassembly Tool (2 used) 915080—Pin Assembly Tool (2 used) 916242—Bushing Assembly Tool (2 used)

A—Rubber Plug B—JDG190 Plug Installer

913013—Pin Disassembly Tool (2 used) 914015—Bushing Disassembly Tool (2 used) 915175—Pin Assembly Tool (2 used) 916240—Bushing Assembly Tool (2 used) “C” Style (Spring Loaded) Tooling

750J

(A2656-302).

850J

(A2656-303).

2. Apply a mixture of 50% alcohol and 50% water to rubber plug (A) and install using JDG190 Plug Installer (B).

TX,0130,SS2442 –19–13JUL05–1/14

–UN–27OCT88

NOTE: The pin end halves of master split link must be temporarily assembled to bushing end halves of link for proper positioning on plungers. Pin end halves will later have to be separated for installation at end of chain. 3. Assemble master split link halves using master shoe bolts and washers (as required). Tighten bolts just enough to hold links together. Split links are a matched set and must be assembled as a set.

T96273

01 0130 48

4. Install assembled split links on ram plungers. A—Bushing B—Saddle

5. Install bushing (A) in front seat of saddle (B) so the mark is 180° opposite original location to expose a new wear surface.

Continued on next page

TM2261 (10FEB06)

01-0130-48

TX,0130,SS2442 –19–13JUL05–2/14

750J, 850J Crawler 032806

PN=98

Track System 6. Adjust track press pressure relief valve setting. Track Press Relief Valve Settings: Track Press Relief Valve Settings—Specification 750J—Force ............................................................. 378 080 N Maximum 85,000 lb force Maximum 850J—Force ............................................................. 444 800 N Maximum 100,000 lb force Maximum

01 0130 49

T96274

–UN–27OCT88

7. Advance left ram until left split link contacts the saddle. Advance right ram until it stops to press split link and bushing assembly together.

TX,0130,SS2442 –19–13JUL05–3/14

8. Measure bushing projection from shoulder of link using a depth micrometer. Bushing projection determines clearance between overlapping links and proper spacing of link bolt holes.

–UN–27OCT88

Specification Bushing Projection—Height.................................................... 2 ± 0.25 mm 0.079 ± 0.010 in.

T96275

9. If bushing projection does not meet specification, check pressure setting or adjust shim packs behind plungers. Only the first two joints must be checked for proper bushing projection.

Continued on next page

TM2261 (10FEB06)

01-0130-49

TX,0130,SS2442 –19–13JUL05–4/14

750J, 850J Crawler 032806

PN=99

Track System 10. Apply track chain lubricant to bushing ends before next set of links are installed.

T96276

–UN–27OCT88

01 0130 50

TX,0130,SS2442 –19–13JUL05–5/14

–UN–27OCT88

IMPORTANT: Pins must be installed so cross-drilled hole is toward link wear surface or they may break when chain is used. To make assembly easier, install all pins so holes in the end are toward the same side of chain.

T96277

11. Install pin in bushing so cross-drilled hole (B) is toward link wear surface. Install all pins so end hole (A) is toward the same side of chain, either left or right. A—End Hole B—Cross-Drilled Hole

TX,0130,SS2442 –19–13JUL05–6/14

12. Install a thrust ring on each end of pin.

T96278

–UN–27OCT88

13. Move completed split link assembly to rear seat of saddle.

Continued on next page

TM2261 (10FEB06)

01-0130-50

TX,0130,SS2442 –19–13JUL05–7/14

750J, 850J Crawler 032806

PN=100

Track System

T96279

–UN–27OCT88

14. Apply TY15934 John Deere Gasket Maker #3 or an equivalent to the link bore. The sealant prevents loss of vacuum or lubricant leakage through the pin to link joint.

TX,0130,SS2442 –19–13JUL05–8/14

15. Install bushing (F) in front saddle seat. Install left link (B) and right link on ram plungers. Assemble the load ring (C) and seal ring (D). Install the assembly into link (B) counterbore so pointed lip of seal ring is toward bushing (F).

T96280

–UN–27OCT88

B—Link C—Load Ring D—Seal Ring F—Bushing

Continued on next page

TM2261 (10FEB06)

01-0130-51

TX,0130,SS2442 –19–13JUL05–9/14

750J, 850J Crawler 032806

PN=101

01 0130 51

Track System 16. Advance left ram until left link contacts the saddle. Advance right ram until it stops (plungers in both rams against shim pack).

T96283

–UN–27OCT88

T96282

–UN–27OCT88

A—Left Ram B—Saddle C—Pin D—Plunger E—Right Ram F—Right Link G—Bushing H—Shims I—Left Link

TX,0130,SS2442 –19–13JUL05–10/14

NOTE: To ensure zero end play in joint, special spacers must be fabricated using a section of bushing. A different size spacer is used for 750J and 850J.

–UN–27OCT88

17. Retract left ram. Install special spacer (A) between the joint in rear seat of saddle and ram. IMPORTANT: Too much pressure will crush the thrust rings

T96284

01 0130 52

18. Advance left ram using only minimum force required to push joint tight. Pressure must be approximately one half the relief valve setting. Remove spacer. A—Special Spacer

Continued on next page

TM2261 (10FEB06)

01-0130-52

TX,0130,SS2442 –19–13JUL05–11/14

750J, 850J Crawler 032806

PN=102

Track System 19. After one complete joint has been assembled, check end play of track links to make sure bushing, thrust rings, and link counterbore faces are pressed solid against each other. Position base of dial indicator on one link assembly and pointer against the other link assembly.

01 0130 53

20. Pry link assemblies in one direction then in opposite direction to measure the amount of end play. End play must be zero.

T96285

–UN–27OCT88

21. As track chain is being further assembled, end play may be checked by manually prying upward on each link. If link rotates downward increase press force and re-press.

Continued on next page

TM2261 (10FEB06)

01-0130-53

TX,0130,SS2442 –19–13JUL05–12/14

750J, 850J Crawler 032806

PN=103

Track System 22. As chain is being assembled, check to make sure there is some clearance between the overlapping face of links, using a feeler gauge. If links contact each other, check bushing projection.

–UN–27OCT88

Specification Bushing Projection—Height.................................................... 2 ± 0.25 mm 0.079 ± 0.010 in.

T96286

23. Add oil (SAE 80W 90) using a Seal Tester and Lubricator for S.A.L.T. Crawler Equipment. Push nozzle through plug all the way into pin. Depress control lever on the handle enough to draw specified vacuum as indicated on the gauge.

–UN–01NOV88

Specification Lubricated Track Chain Seal Test—Vacuum ....................................................................... 68—102 kPa 2—30 in. Hg

T96287

24. Release lever. If there is no decrease in vacuum for a minimum of five seconds, the joints are sealed. If there is a vacuum decrease, seals are not sealing and the joint must be taken apart and repaired. 25. Add oil by depressing the second lever. Oil pressure (read on the same gauge) must be to specification after both levers are released.

–UN–01NOV88

Specification Lubricated Track Chain Oil— Pressure .............................................................................. 140—205 kPa 1.4—2.05 bar (20—30 psi

T6465AY

26. For pins using rubber plug and plastic plug, immediately install plug using JDG190 Plug Installer after adding oil. For pins using self-sealing plug, slowly pull nozzle (C) out to allow any compressed air to escape through nozzle from first hole (A) to second hole (B). Add oil to each joint after assembling so only one joint would have to be disassembled if a vacuum leak occurs.

–UN–27OCT88

A—First Hole B—Second Hole C—Nozzle

T96288

01 0130 54

Continued on next page

TM2261 (10FEB06)

01-0130-54

TX,0130,SS2442 –19–13JUL05–13/14

750J, 850J Crawler 032806

PN=104

Track System 27. Repeat step 10—26 for all joints. 28. Install assembled split links on ram plungers, and advance rams to press split links together. 01 0130 55

29. Install track shoes and track chain. See Track Shoe Remove and Install. (Group 0130.) See Lubricated Track Chain Remove and Install. (Group 0130.)

TX,0130,SS2442 –19–13JUL05–14/14

Lubricated Track Chain to Turn Pins and Bushings and Not Lubricate Disassemble and Assemble NOTE: The following procedure is for disassembly of track chain only to turn pins and bushings. (Chain is not lubricated after assembly.) If this procedure does not apply to the repair job, see Lubricated Track Chain to Turn Bushings and Lubricate Chain Disassemble. (Group 0130.) 1. Remove track shoes and track chain. See Track Shoe Remove and Install. (Group 0130.) See Lubricated Track Chain Remove and Install. (Group 0130.) 2. Use the appropriate track press tool set. “91” Series (Adjustable Camlock) Tooling 750J

913019—Pin Disassembly Tool (2 used) 914133—Bushing Disassembly Tool (2 used) 915080—Pin Assembly Tool (2 used) 916242—Bushing Assembly Tool (2 used)

850J

913013—Pin Disassembly Tool (2 used) 914015—Bushing Disassembly Tool (2 used) 915175—Pin Assembly Tool (2 used) 916240—Bushing Assembly Tool (2 used) “C” Style (Spring Loaded) Tooling

750J

(A2656-302).

850J

(A2656-303).

Continued on next page

TM2261 (10FEB06)

01-0130-55

TX,0130,SS2440 –19–13JUL05–1/11

750J, 850J Crawler 032806

PN=105

Track System IMPORTANT: Track press disassembly tools must be in proper alignment with links to prevent broaching of pin and bushing. Damaged links cannot be reused.

–UN–27OCT88

3. Check for proper alignment of tools with pin and bushing. 4. Make an index mark on bushings and pins to aid in reassembly, when turning bushings 1/2 turn (180°) to expose a new wear surface.

T96266

01 0130 56

CAUTION: Always wear safety glasses when operating the press. Parts may break or chip, which could create a risk of personal injury.

A—Left Ram B—Saddle C—Right Ram D—Right Link E—Bushing F—Left Link G—Pin

5. Extend right ram (C) to push pin (G) and bushing (E) from the right link (D). The right link is forced against the side of saddle (B) as the pin and bushing are pushed out. 6. Retract right ram. The right link, with seals and thrust ring, will stay on the ram tools.

Continued on next page

TM2261 (10FEB06)

01-0130-56

TX,0130,SS2440 –19–13JUL05–2/11

750J, 850J Crawler 032806

PN=106

Track System 7. Extend left ram (A) to push the pin (C) and bushing (F) from the left link (G). The left link is forced against the side of saddle (B) as pin and bushing are pushed out.

–UN–27OCT88

8. Retract left ram. The left link, with seal and thrust ring, will remain on the ram tools. 9. Remove links and bushing from press.

T96267

10. Repeat steps 4—9 to disassemble rest of chain. IMPORTANT: Pins must be installed so cross-drilled hole is toward link wear surface or they may break when chain is used.

A—Left Ram B—Saddle C—Pin D—Right Ram E—Right Link F—Bushing G—Left Link

11. All pins, bushings, seals, and thrust rings are used for reassembly, because chain is not lubricated. Do not remove rubber plug and plastic plug from pins. Do not remove seals from track links. Turn pin end-for-end to get a new wear surface, then install it into bushing so cross-drilled hole is toward link wear surface. Install all pins so hole in end of pin is toward the same side of chain, either left or right side.

TX,0130,SS2440 –19–13JUL05–3/11

12. Inspect pin ends for wear. If there is no chamfer (A and B), grind a new chamfer to specification.

–UN–26OCT88

Specification Lubricated Track Pin End— Chamfer ................................................................................... 3 mm x 15° 0.12 in. x 15°

T5798AJ

A—15° B—3 mm (0.12 in.)

Continued on next page

TM2261 (10FEB06)

01-0130-57

TX,0130,SS2440 –19–13JUL05–4/11

750J, 850J Crawler 032806

PN=107

01 0130 57

Track System 13. Smooth area of track link wear (A) using a grinder, if necessary. A—Track Link

T96289

–UN–27OCT88

01 0130 58

TX,0130,SS2440 –19–13JUL05–5/11

14. Assemble track links using the following track press tool sets.

850J

913013—Pin Disassembly Tool (2 used) 914015—Bushing Disassembly Tool (2 used) 915175—Pin Assembly Tool (2 used) 916240—Bushing Assembly Tool (2 used)

T96273

913019—Pin Disassembly Tool (2 used) 914133—Bushing Disassembly Tool (2 used) 915080—Pin Assembly Tool (2 used) 916242—Bushing Assembly Tool (2 used)

–UN–27OCT88

“91” Series (Adjustable Camlock) Tooling 750J

“C” Style (Spring Loaded) Tooling 750J

(A2656-302).

850J

(A2656-303).

A—Bushing B—Saddle

NOTE: The pin end halves of master split link must be temporarily assembled to bushing end halves of link for proper positioning of plungers. Pin end halves will later have to be separated for installation at end of chain. 15. Assemble master split link halves using master shoe bolts and washers (as required). Tighten bolts just enough to hold link together. 16. Install assembled split links on ram plungers. 17. Install bushing (A) in front seat of saddle (B) so the mark is 180° opposite original location to expose a new wear surface.

Continued on next page

TM2261 (10FEB06)

01-0130-58

TX,0130,SS2440 –19–13JUL05–6/11

750J, 850J Crawler 032806

PN=108

Track System 18. Adjust track press pressure relief valve setting. Specification 750J—Track Press Relief Valve— Force ........................................................................ 378 080 N Maximum 85,000 lb force Maximum 850J—Track Press Relief Valve— Force ........................................................................ 444 800 N Maximum 100,000 lb force Maximum

01 0130 59

T96274

–UN–27OCT88

19. Advance rams to press split links together until the correct bolt spacing is obtained for the master shoe.

TX,0130,SS2440 –19–13JUL05–7/11

IMPORTANT: Pins must be installed so cross-drilled hole is toward link wear surface or they may break when chain is used.

T96277

–UN–27OCT88

20. Turn pin end-for-end to get a new wear surface, then install it into bushing so cross-drilled hole (B) is toward link wear surface. Install all pins so hole (A) in end of pin is toward the same side of chain, either left or right side. A—Pin End Hole B—Cross-Drilled Hole

Continued on next page

TM2261 (10FEB06)

01-0130-59

TX,0130,SS2440 –19–13JUL05–8/11

750J, 850J Crawler 032806

PN=109

Track System 21. Install a thrust ring on each side of pin. 22. Move completed link assembly to rear seat of saddle.

T96278

–UN–27OCT88

01 0130 60

TX,0130,SS2440 –19–13JUL05–9/11

23. Install bushing (G) in front saddle seat. Install right and left links (E and I) on ram plungers (D).

–UN–27OCT88

24. Advance left ram (A) until left link contacts the saddle (B). Advance right ram until link is pressed together and bolts can be installed through 23058 Track Shoe Gauge (J).

T96290

–UN–27OCT88

T96283

A—Left Ram B—Saddle C—Pin D—Plunger E—Right Ram F—Right Link G—Bushing H—Plunger Shims I—Left Link J—23058 Track Shoe Gauge

Continued on next page

TM2261 (10FEB06)

01-0130-60

TX,0130,SS2440 –19–13JUL05–10/11

750J, 850J Crawler 032806

PN=110

Track System

26. Repeat steps 14—25 to assemble rest of chain. 27. The last link assembled is the split link pin ends. Assemble a set of extra "slave" split link bushing ends to pin ends using bolts and washers used in step 15. Tighten bolts just enough to hold together link.

T96286

Specification Bushing Projection—Height.................................................... 2 ± 0.25 mm 0.079 ± 0.010 in.

–UN–27OCT88

25. As chain is being assembled, check to make sure there is some clearance between the overlapping face of links using a feeler gauge. If links contact each other, check bushing projection.

28. Install assembled split links on ram plungers and advance rams to press split links together. 29. Install track shoes and track chain. See Track Shoe Remove and Install. (Group 0130.) See Lubricated Track Chain Remove and Install. (Group 0130.)

TX,0130,SS2440 –19–13JUL05–11/11

TM2261 (10FEB06)

01-0130-61

750J, 850J Crawler 032806

PN=111

01 0130 61

Track System

Track Sag Adjustment Check Track Sag 1. Allow machine to slowly roll forward so track pin (1) is centered over rear carrier roller (2). 2. Measure track sag between two carrier rollers. Measure track sag (3) from top of track grouser to a straightedge (4). If adjustment is needed, see Adjust Track Sag in this chapter. Specification Track Sag—Distance................................................................ 45—57 mm 1.75—2.25 in.

–UN–01FEB05

T207501

–UN–15FEB05

1—Track Pin 2—Carrier Rollers 3—Track Sag 4—Straightedge

T207100A

01 0130 62

Continued on next page

TM2261 (10FEB06)

01-0130-62

TE14778,00000A2 –19–11APR05–1/3

750J, 850J Crawler 032806

PN=112

Track System Adjust Track Sag

T206820A

–UN–07JAN05

CAUTION: Escaping fluid under pressure can penetrate the skin causing serious injury. DO NOT remove grease fitting to increase track sag. DO NOT tamper with relief valve. It is fitted with a cover. Slowly loosen check valve fitting to release grease from track tension adjuster. 1. Loosen two cap screws and remove access cover (1). 1—Access Cover

TE14778,00000A2 –19–11APR05–2/3

T206819C

–UN–28JAN05

2. To Decrease Track Sag: To decrease sag, apply grease to fitting (1) using an 52 200 kPa (552 bar) (8000 psi) capacity grease gun. After adding grease, operate unit to allow track adjuster cylinder to fully adjust and then check sag again. To Increase Track Sag: To increase sag, turn check valve (3) two turns counterclockwise to release grease through vent hole. Turn check valve clockwise to close it. After releasing grease, operate unit to allow track adjuster cylinder to fully adjust and then check sag again.

1—Grease Fitting 2—Relief Valve 3—Check Valve

TE14778,00000A2 –19–11APR05–3/3

TM2261 (10FEB06)

01-0130-63

750J, 850J Crawler 032806

PN=113

01 0130 63

Track System

Track Adjuster Cylinder and Recoil Spring Remove and Install CAUTION: Spring or rod may break if dropped while handling, transporting or disassembling. Nicks or weld craters in spring and rod assembly can cause stress concentration resulting in a weak spot. Weak spots can result in immediate or eventual failure creating a risk of personal injury. Put a heavy protective covering around spring assembly when handling, transporting, or disassembling. A compression tool must be used for disassembly and assembly because of the extreme preload on spring. 1. Remove track chain. See Lubricated Track Chain Remove and Install. (Group 0130.) 2. Remove front idler. See Front Idler Remove and Install. (Group 0130.)

TE14778,000009F –19–11JUL05–1/4

3. Slide track adjuster forward from rear of track frame using a pry bar.

–UN–06APR05

CAUTION: Track Adjuster Cylinder And Recoil Spring is heavy and can cause injury if not moved properly. Use adequate lifting device to move track adjuster cylinder and recoil spring. Specification Track Adjuster Cylinder And Recoil Spring—Approximate Weight.............................................................................................. 300 kg 660 lb

T210131A

01 0130 64

4. Attach track adjuster to hoist and remove from track frame.

Continued on next page

TM2261 (10FEB06)

01-0130-64

TE14778,000009F –19–11JUL05–2/4

750J, 850J Crawler 032806

PN=114

Track System

–UN–11JUL05

5. Inspect rubber shields (1) and track adjuster recoil spring. Repair or replace parts as necessary. See Track Adjuster Recoil Spring Disassemble and Assemble. (Group 0130.) See Track Adjuster Cylinder Disassemble and Assemble. (Group 0130.)

T212765A

1—Rubber Shield (2 used)

TE14778,000009F –19–11JUL05–3/4

6. Attach track adjuster to hoist and slide into track frame. 7. Install front idler. See Front Idler Remove and Install. (Group 0130.)

T210131A

–UN–06APR05

8. Install track chain. See Lubricated Track Chain Remove and Install. (Group 0130.)

TE14778,000009F –19–11JUL05–4/4

Track Adjuster Recoil Spring Disassemble and Assemble

11 10

Track Adjuster Recoil Spring Disassemble 1—Cap Screw 2—Relief Valve 3—Check Valve 4—Cylinder 5—Wiper Seal 6—Wear Ring (2 used) 7—Seal Kit 8—Piston 9—Spring 10—Plate 11—Nut 12—Retaining Ring (2 used) 13—Guard

2 13 1

5 8

T210132

–UN–29JUN05

Track Adjuster Cylinder and Recoil Spring Continued on next page

TM2261 (10FEB06)

01-0130-65

TE14778,00000A1 –19–02FEB06–1/21

750J, 850J Crawler 032806

PN=115

01 0130 65

Track System

–UN–11MAY05 T211045A

A compression tool must be used for disassembly and assembly because of the extreme preload on spring. 1. Install JDG10022 Track Recoil Spring Kit onto JT07368 Track Adjuster Recoil Spring Compressor.

TE14778,00000A1 –19–02FEB06–2/21

–UN–05APR05

CAUTION: Track adjuster cylinder and recoil spring are heavy and can cause injury if not moved properly. Use adequate lifting device to move track adjuster cylinder and recoil spring. Track Adjuster Cylinder and Recoil Spring—Specification 750J—Approximate Weight ............................................................. 192 kg 423 lb 850J—Approximate Weight ............................................................. 245 kg 539 lb

T210145A

01 0130 66

CAUTION: Spring or rod may break if dropped while handling, transporting, or disassembling. Nicks or weld craters in spring and rod assembly can cause stress concentration resulting in a weak spot that may result in immediate or eventual failure, creating a risk of personal injury. Put a heavy protective covering around spring assembly when handling, transporting, or disassembling.

2. Place track adjuster recoil spring assembly (2) into spring compressor so that the rod nut is centered in hole in spring compressor end plate (1).

1—Spring Compressor End Plate 2—Track Adjuster Cylinder and Recoil Spring

3. Place blocks under spring assembly to prevent parts from falling after spring assembly is disassembled.

Continued on next page

TM2261 (10FEB06)

01-0130-66

TE14778,00000A1 –19–02FEB06–3/21

750J, 850J Crawler 032806

PN=116

Track System

–UN–16NOV99

IMPORTANT: Do NOT compress spring when extending the hydraulic rams to the specified position. If spring is compressed, relieve hydraulic pressure and thread adjustment collar away from hydraulic rams.

T125867B

Do NOT extend hydraulic rams more than 114 mm (4.5 in.). Additional travel is required after spring compressor is adjusted with adjustment collar. 4. Extend hydraulic rams (5) 101.6 mm (4 in.) as shown.

TE14778,00000A1 –19–02FEB06–4/21

5. Install 50.8 mm (2.00 in.) wide spacer (19) between spring assembly (2) and disk (3) as shown.

–UN–05APR05

6. Thread retaining collar (4) tight against disk (3) to ensure adequate clearance during disassembly.

T210146A

2—Track Adjuster Recoil Spring Assembly 3—Disk 4—Retaining Collar 19—JT07368-4 Spacer

TE14778,00000A1 –19–02FEB06–5/21

7. Thread adjustment collar (6) toward hydraulic rams until collar is tight and there is no end play in the spring compressor.

–UN–16NOV99

8. Apply only enough hydraulic pressure to spring compressor to hold spring assembly in position.

T125868B

9. Remove lifting strap and close protective shields on spring compressor. 6—Adjustment Collar

Continued on next page

TM2261 (10FEB06)

01-0130-67

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750J, 850J Crawler 032806

PN=117

01 0130 67

Track System 10. Increase pressure in hydraulic rams until nut (8) is loose.

–UN–05APR05

12. Remove nut from shaft (7).

T210147A

7—Shaft 8—Nut 9—Retaining Rings

TE14778,00000A1 –19–02FEB06–7/21

13. Slowly release hydraulic pressure so spring is allowed to decompress. Close valve when hydraulic rams (5) are 12.7 mm (0.5 in.) from bottoming out as shown.

T125871B

–UN–16NOV99

5—Ram

TE14778,00000A1 –19–02FEB06–8/21

–UN–16NOV99

CAUTION: Use only the handles on the retaining collar to thread it against end plate. Do NOT place hands on threaded push rod between retaining collar and end plate. 14. Carefully reach in access door and thread the retaining collar (4) tight against the end plate as shown.

T125872B

01 0130 68

11. Thread nut onto shaft until retaining rings (9) can be removed.

4—Retaining Collar

Continued on next page

TM2261 (10FEB06)

01-0130-68

TE14778,00000A1 –19–02FEB06–9/21

750J, 850J Crawler 032806

PN=118

Track System 15. Release hydraulic pressure from hydraulic rams (5) so adjustment collar (6) is free to turn.

T125919B

–UN–16NOV99

5—Hydraulic Ram 6—Adjustment Collar

TE14778,00000A1 –19–02FEB06–10/21

16. Thread adjustment collar (6) away from hydraulic rams far enough to extend hydraulic rams (5) 114 mm (4.5 in.) as shown without applying load to spring.

T125867B

–UN–16NOV99

5—Hydraulic Ram

TE14778,00000A1 –19–02FEB06–11/21

–UN–16NOV99

17. With hydraulic rams extended, thread adjustment collar (6) toward hydraulic rams until adjustment collar (6) is tight and there is no end play in spring compressor.

T125868B

6—Adjustment Collar

Continued on next page

TM2261 (10FEB06)

01-0130-69

TE14778,00000A1 –19–02FEB06–12/21

750J, 850J Crawler 032806

PN=119

01 0130 69

Track System 18. Increase hydraulic pressure in hydraulic rams until retaining collar (4) is free to turn.

–UN–16NOV99

CAUTION: Use only the handles on the retaining collar to thread it against end plate. Do NOT place hands on threaded push rod between retaining collar and end plate. 19. Carefully reach in access door and thread the retaining collar (4) away from spring compressor end plate until it is tight against the disk.

T125872B

01 0130 70

20. Slowly release pressure in hydraulic rams.

4—Retaining Collar

21. Fully retract hydraulic rams. Spring should now be completely decompressed. 22. Replace parts as required. 23. Disassemble track adjuster cylinder. See Track Adjuster Cylinder Disassemble and Assemble. (Group 0130.)

Continued on next page

TM2261 (10FEB06)

01-0130-70

TE14778,00000A1 –19–02FEB06–13/21

750J, 850J Crawler 032806

PN=120

Track System Track Adjuster Recoil Spring Assemble

10 01 0130 71

A compression tool must be used for disassembly and assembly because of the extreme preload on spring.

2 13 1

–UN–29JUN05

1—Cap Screw 2—Relief Valve 3—Check Valve 4—Cylinder 5—Wiper Seal 6—Wear Ring (2 used) 7—Seal Kit 8—Piston 9—Spring 10—Plate 11—Nut 12—Retaining Ring (2 used) 13—Plate

5 8

T210132

1. Install JDG10022 Track Recoil Spring Kit onto JT07368 Track Adjuster Recoil Spring Compressor.

Track Adjuster Cylinder and Recoil Spring

Continued on next page

TM2261 (10FEB06)

01-0130-71

TE14778,00000A1 –19–02FEB06–14/21

750J, 850J Crawler 032806

PN=121

Track System

T210145A

Track Adjuster Cylinder and Recoil Spring—Specification 750J—Approximate Weight ............................................................. 192 kg 423 lb 850J—Approximate Weight ............................................................. 245 kg 539 lb

2. Place track adjuster recoil spring assembly (2) into spring compressor so that the rod nut is centered in hole in spring compressor end plate (1).

1—Spring Compressor End Plate 2—Track Adjuster Cylinder and Recoil Spring

TE14778,00000A1 –19–02FEB06–15/21

3. Install 50.8 mm (2.00 in.) wide spacer (19) between spring assembly (2) and disk (3) as shown.

T210146A

–UN–05APR05

2—Track Adjuster Recoil Spring Assembly 3—Disk 4—Retaining Collar 19—JT07368-4 Spacer

TE14778,00000A1 –19–02FEB06–16/21

4. With hydraulic rams (5) fully retracted, thread adjustment collar (6) toward hydraulic rams until collar is tight and there is no end play in the spring compressor. –UN–16NOV99

5. Apply only enough hydraulic pressure to hydraulic rams to hold spring assembly in position. 6. Remove lifting strap and close protective shields on spring compressor.

T125919B

01 0130 72

–UN–05APR05

CAUTION: Track adjuster cylinder and recoil spring are heavy and can cause injury if not moved properly. Use adequate lifting device to move track adjuster cylinder and recoil spring.

5—Hydraulic Ram 6—Adjustment Collar

Continued on next page

TM2261 (10FEB06)

01-0130-72

TE14778,00000A1 –19–02FEB06–17/21

750J, 850J Crawler 032806

PN=122

Track System

–UN–16NOV99

IMPORTANT: Monitor hydraulic pressure in cylinder to be sure assembly is not binding while compressing spring. Pressure should gradually increase and rod guide should slowly extend through hole in end plate while compressing spring.

T125867B

7. Increase pressure in hydraulic rams to begin compressing spring. Extend hydraulic rams (5) 101.6 mm (4 in.) as shown. 5—Hydraulic Ram

TE14778,00000A1 –19–02FEB06–18/21

–UN–16NOV99

CAUTION: Use only the handles on the retaining collar to thread it against end plate. Do NOT place hands on threaded push rod between retaining collar and end plate. 8. Carefully reach in access door and thread the retaining collar (4) tight against the end plate as shown.

T125872B

4—Retaining Collar

TE14778,00000A1 –19–02FEB06–19/21

9. Fully retract hydraulic rams (5) and thread adjustment collar (6) towards hydraulic rams until collar is tight and there is no end play in the spring compressor.

T125919B

–UN–16NOV99

5—Hydraulic Ram 6—Adjustment Collar

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PN=123

01 0130 73

Track System 10. Increase pressure in hydraulic rams until nut (8) can be threaded onto shaft (7). 11. Apply grease to threads of nut. –UN–05APR05

12. Thread nut onto shaft until retaining rings (9) can be installed. Back nut off until top of nut is flush with top of retaining rings. Retaining rings fit into recess in nut. 13. Slowly release pressure in spring compressor and fully retract hydraulic rams. 14. Remove track adjuster cylinder and recoil spring from spring compressor.

T210147A

01 0130 74

7—Shaft 8—Nut 9—Retaining Rings

TE14778,00000A1 –19–02FEB06–21/21

TM2261 (10FEB06)

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PN=124

Track System

Track Adjuster Cylinder Disassemble and Assemble

11 10

CAUTION: Spring or rod may break if dropped while handling, transporting or disassembling. Nicks or weld craters in spring and rod assembly can cause stress concentration resulting in a weak spot. Weak spots can result in immediate or eventual failure creating a risk of personal injury. Put a heavy protective covering around spring assembly when handling, transporting, or disassembling.

01 0130 75

2 13 1

A compression tool must be used for disassembly and assembly because of the extreme preload on spring.

–UN–29JUN05

5 2. Remove guard (13), relief valve (2), and check valve (3). CAUTION: Piston Rod is heavy and can cause injury if not moved properly. Use adequate lifting device to move piston rod.

T210132

1. Remove track adjuster cylinder and recoil spring. See Track Adjuster Recoil Spring Disassemble and Assemble. (Group 0130.)

Track Adjuster Cylinder and Recoil Spring Components 1—Cap Screw 2—Relief Valve 3—Check Valve 4—Cylinder 5—Wiper Seal 6—Wear Ring (2 used) 7—Seal Kit 8—Piston Rod 9—Spring 10—Plate 11—Nut 12—Retaining Ring (2 used) 13—Guard

Track Adjuster Cylinder Piston Rod—Specification 750J—Approximate Weight ............................................................... 46 kg 101 lb 850J—Approximate Weight ............................................................... 54 kg 119 lb

3. Remove piston rod (8) from cylinder (4). 4. Remove wiper seal (5) and wear rings (6). 5. Remove retaining ring from inner seal (7) before removing seal. 6. Replace parts as required. 7. Install relief valve (2) and tighten to specification. Install guard (13).

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PN=125

Track System Specification Relief Valve—Torque .............................................................. 49—68 N•m 36—50 lb-ft

01 0130 76

TE14778,00000A0 –19–29JUN05–2/5

8. Install wear rings (6) into cylinder.

T211282A

–UN–11MAY05

6—Wear Ring (2 used)

TE14778,00000A0 –19–29JUN05–3/5

9. Install inner seal (15) with retaining ring groove facing outward.

–UN–11MAY05

10. Install retaining ring (16) into groove of inner seal .

T211284A

15—Inner Seal 16—Retaining Ring

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PN=126

Track System 11. Install wiper seal (5) with lip facing outward. Use JDG840-4 Seal Installer from JDG840 Hydraulic Cylinder Piston Installation Kit.

–UN–11MAY05

IMPORTANT: Add grease before installing piston rod to completely bleed air from cylinder. 12. Add 296 ml (10 oz) of grease into cylinder cavity.

T211285A

13. Apply grease to piston rod (8) and install into cylinder (4). 14. Compress piston rod until grease comes out of check valve hole.

17—JDG840-4 Seal Installer

15. Install check valve and apply grease until piston moves 13 mm (0.51 in.) 16. Loosen check valve and completely compress piston. 17. Tighten check valve to specification. Specification Check Valve—Torque ................................................................. 58.5 N•m 43 lb-ft

TE14778,00000A0 –19–29JUN05–5/5

Track Frame Remove and Install Track Frame Removal 1. Remove pushbeam and blade assembly (Outside Dozer). See Pushbeam Remove and Install. (Group 3240.) 2. Remove trunnion (Outside Dozer). See Trunnion Remove and Install. (Group 3200.)

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01 0130 77

Track System

3. Raise machine off the ground and support with 20-Ton Floor Stands. Lower blade to ground.

T205099A

–UN–04DEC04

CAUTION: Prevent possible injury from unexpected crossbar and track frame movement. Track frame on opposite side will pivot down. Before removing track frame always block track frame on opposite side. 5. Remove track chain. See Lubricated Track Chain Remove and Install. (Group 0130.)

750J/850J Floor Stand Kit 1—20-Ton Floor Stand (4 used) 2—Floor Stand Adapter (2 used) 3—Floor Stand Rod 4—Washer (2 used) 5—Cap Screw (2 used)

TE14778,0000098 –19–14JUL05–2/14

6. Remove two sprocket sections (1). Rotate final drive so inner guard will clear planetary housing.

–UN–07APR05

1—Sprocket Section 2—Cap Screw

T210009A

01 0130 78

CAUTION: Prevent possible injury from unexpected track movement. Raise the machine off the ground and support with 20-Ton Floor Stands. Tracks must be free to rotate in either direction.

Two Sprocket Sections Removed

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Track System

T210010A

–UN–31MAR05

7. Disconnect crossbar lube line from track frame.

Crossbar Lube Line

TE14778,0000098 –19–14JUL05–4/14

CAUTION: Track frame is heavy and can cause injury if not moved properly. Use adequate lifting device to move track frame.

T210011A

–UN–31MAR05

Specification Track Frame with Carrier Rollers, Track Rollers, Idler, and Track Chain Tension Adjuster— Approximate Weight ...................................................................... 2166 kg 4775 lb

8. Support track frame with hoist. Support Track Frame with Hoist

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PN=129

01 0130 79

Track System 9. Remove pivot shaft cover and track frame retainers. 1—Track Frame Retainers (2 used)

T210013A

–UN–31MAR05

01 0130 80

Track Frame Retainers

TE14778,0000098 –19–14JUL05–6/14

10. Remove crossbar-to-track frame pivot pin. 11. Remove track frame.

–UN–31MAR05

12. Inspect pivot shaft for wear or damage. Replace if necessary.

T210015A

13. Inspect track frame bushings and seal for wear or damage. Replace if necessary. 14. Inspect crossbar self-aligning bushing for wear or damage. Replace if necessary. See Crossbar Remove and Install. (Group 0130.) See Crossbar Disassemble and Assemble. (Group 0130.)

crossbar-to-track frame pivot pin

Track Frame Installation 1. Apply TY24425 Special Purpose HD Water Resistant Grease to track frame bushings before assembling onto pivot shaft.

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Track System

CAUTION: Track frame is heavy and can cause injury if not moved properly. Use adequate lifting device to move track frame.

T210011A

–UN–31MAR05

2. Lift track frame with hoist and carefully slide onto pivot shaft.

Support Track Frame with Hoist

TE14778,0000098 –19–14JUL05–8/14

3. Apply petroleum jelly to track frame retainers (1) and install on pivot shaft.

–UN–31MAR05

4. Apply T43514 Rigid Form-In-Place Gasket to pivot shaft cover.

T210013A

5. Apply T43513 Thread Lock and Sealer (High Strength) to pivot shaft cover capscrews. 1—Track Frame Retainer (2 used)

Track Frame Retainers

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PN=131

01 0130 81

Track System 6. Install pivot shaft cover (1), washers (2), and cap screws (3). Tighten cap screws to specification.

–UN–31MAR05 T210014A

1—Pivot Shaft Cover 2—Washer (7 used) 3—Cap Screw (7 used)

Pivot Shaft Cover

TE14778,0000098 –19–14JUL05–10/14

7. Install crossbar-to-track frame pin, bushing, and cap screw. Tighten cap screw to specification.

–UN–31MAR05

Specification Pivot Pin-To-Track Frame Cap Screw—Torque ............................................................................. 275 N•m 200 lb-ft

T210015A

01 0130 82

Specification Pivot Shaft Cover Cap Screw— Torque .......................................................................................... 130 N•m 96 lb-ft

Crossbar-To-Track Frame Pivot Pin

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Track System

T210010A

–UN–31MAR05

8. Connect crossbar lube line to track frame.

Crossbar lube Line

TE14778,0000098 –19–14JUL05–12/14

T210018A

–UN–31MAR05

9. Remove fill plug cover and fill plug.

T210019A

–UN–31MAR05

Track Frame Oil Fill Plug Cover

Track Frame Oil Fill Plug Continued on next page

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01 0130 83

Track System

–UN–31MAR05

11. Apply TY9375 Pipe Sealant to track frame oil fill pipe plug. Install fill plug and fill plug cover. 12. Install sprocket segments. See Sprocket Segment Remove and Install. (Group 0130.) 13. Connect track chain. See Lubricated Track Chain Remove and Install. (Group 0130.)

T210020A

01 0130 84

10. Add recommended oil until oil reaches top of oil fill plug hole. (See See Track Rollers, Front Idler, Carrier Roller and Track Frame Outer Pivot Oil. (Operators Manual.) See Check Track Frame Pivot Shaft Oil. (Operators Manual.)

Track Frame Oil Fill

14. Install trunnion (Outside Dozer). See Trunnion Remove and Install. (Group 3200.) 15. Lower machine to ground and adjust track sag. See Adjust Track Sag. (Operators Manual.) 16. Install pushbeam and blade assembly (Outside Dozer). See Pushbeam Remove and Install. (Group 3240.)

TE14778,0000098 –19–14JUL05–14/14

TM2261 (10FEB06)

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Track System

Front Idler Wear Inspection 100 percent worn is the maximum allowable height of flange for rebuilding wear surface.

T96419

–UN–27OCT88

Measure height of flange using a depth gauge such as the JT05521 200 mm Ruler, JT05534 Right Angle Attachment, and D05231ST 300 mm Ruler from JT05518A Undercarriage Inspection Kit. Specification 750J New Flange—Height .............................................................. 20 mm 0.79 in. 850J New Flange—Height .............................................................. 22 mm 0.87 in. 750J 100 Percent Worn Flange— Height ........................................................................................... 27.5 mm 1.08 in. 850J 100 Percent Worn Flange— Height ........................................................................................... 30.6 mm 1.20 in.

NOTE: Reference Undercarriage Appraisal Manual SP326 for additional information. See 750J Front Idler Flange Height. (SP326.) See 850J Front Idler Flange Height. (SP326.)

TX,9020,YY996 –19–12JUL05–1/1

Front Idler Remove and Install Front Idler Removal 1. Disconnect track chain. See Lubricated Track Chain Remove and Install. (Group 0130.)

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01 0130 85

Track System NOTE: Make sure track frame is level before removing front idler.

–UN–28MAR05 T209871A

1—Cap Screw (3 used) 2—T-Bar Bracket 3—Idler

Front Idler Side Plate

TE14778,0000095 –19–19JAN06–2/15

3. Pull idler out of track frame until you can loosen tension adjusting cap screw (9).

–UN–05APR05

9—Cap Screw (4 used) 10—Washer (4 used)

T210065A

01 0130 86

2. Remove side plate cap screws (1) and T-bar bracket (2).

Front Idler Tension Adjusting Cap Screws

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Track System 4. Pull idler out farther to remove cover (6).

T209872A

–UN–28MAR05

4—Cap Screw (4 used) 5—Washer (4 used) 6—Cover

Front Idler Dirt Cover

TE14778,0000095 –19–19JAN06–4/15

CAUTION: Front idler is heavy and can cause injury if not moved properly. Use adequate lifting device to move front idler. –UN–28MAR05

Specification Front Idler—Approximate Weight .................................................... 175 kg 385 lb

T209873A

5. Attach idler to hoist using chain.

Attach Front Idler to Hoist

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01 0130 87

Track System 6. Remove cap screws (7) holding idler to track spring adjuster.

T209874A

7—Cap Screw (4 used) 8—Washer (4 used)

Front Idler Mounting Cap Screws

TE14778,0000095 –19–19JAN06–6/15

Front Idler Installation

–UN–31MAR05

CAUTION: Front idler is heavy and can cause injury if not moved properly. Use adequate lifting device to move front idler. Specification Front Idler—Weight .................................................... 175 kg Approximate 385 lb Approximate

T210055A

01 0130 88

–UN–28MAR05

7. Remove idler.

1. Attach idler to hoist using chain. Attach Front Idler to Hoist

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Track System 2. Use a C-Clamp (1) to secure middle wear bar (2) to track frame.

T210057A

–UN–31MAR05

T210056A

–UN–31MAR05

1—C-Clamp 2—Middle Wear Bar

Middle Wear Bar TE14778,0000095 –19–19JAN06–8/15

3. Use tie wraps (3) to secure upper wear bar (4) to bracket.

T210059A

–UN–31MAR05

3—Tie Wrap 4—Upper Wear Bar

Upper Wear Bar

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01 0130 89

Track System 4. Carefully guide idler into track frame.

T209873A

–UN–28MAR05

01 0130 90

TE14778,0000095 –19–19JAN06–10/15

5. Apply T43513 Thread Lock and Sealer (High Strength) to track chain tension adjuster-to-idler cap screws and install. Tighten to specification.

T209874A

–UN–28MAR05

Specification Track Chain Tension Adjuster-to-Idler Cap Screw— Torque ................................................................................. 500—600 N•m 369—443 lb-ft

7—Cap Screw (4 used) 8—Washer (4 used)

Front Idler Mounting Cap Screws

TE14778,0000095 –19–19JAN06–11/15

6. Slide idler into track frame and install cap screws (4), washers (5), and dirt cover (6). Tighten to specification.

–UN–28MAR05

Specification Dirt Cover-to-Idler Cap Screw— Torque .......................................................................................... 110 N•m 80 lb-ft

T209872A

4—Cap Screw (4 used) 5—Washer (4 used) 6—Dirt Cover

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Track System 7. Slide idler farther into track frame to tighten tension adjusting cap screws (9). Tighten to specification.

–UN–05APR05

Specification Idler Tension Adjusting Screws— Torque .......................................................................................... 115 N•m 85 lb-ft

T210065A

8. Slide idler further into track frame until idler wheel contacts track frame opening. 9—Cap Screw (4 used) 10—Washer (4 used)

TE14778,0000095 –19–19JAN06–13/15

9. Install side plate cap screws (1) and T-bar bracket (2). Tighten to specification.

–UN–28MAR05

Specification T-bar Bracket Cap Screws— Torque ................................................................................. 500—600 N•m 369—443 lb-ft

T209871A

1—Cap Screw (3 used) 2—T-Bar Bracket 3—Idler

Front Idler Side Plate

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01 0130 91

Track System 10. Visually check to ensure track adjuster check valve (3) is visible through track frame access door.

–UN–28JAN05

1—Grease Fitting 2—Relief Valve 3—Check Valve

T206819C

01 0130 92

11. Connect track chain. See Lubricated Track Chain Remove and Install. (Group 0130.)

Track Adjuster Check Valve

TE14778,0000095 –19–19JAN06–15/15

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Track System

Front Idler Disassemble and Assemble

T210217

–UN–07APR05

01 0130 93

T210217 1—Idler 2—Shaft 3—O-ring (2 used) 4—O-ring (2 used) 5—O-ring 6—Plug 7—Bracket (left) 8—Bushing Cover (2 used)

9—Bushing (2 used) 10—Dowel Pin (2 used) 11—Lock Washer (12 used) 12—Cap Screw (12 used) 13—Metal Face Seal (2 used) 14—Bracket (right) 15—Wear Strip (lower) (2 used)

Front Idler Disassembly

16—Shim (as required) 17—Lock (2 used) 18—Nut (2 used) 19—Washer (2 used) 20—Cap Screw (2 used) 21—Washer (20 used) 22—Cap Screw (6 used) 23—Bushing (rubber) (4 used)

24—Washer (4 used) 25—Wear Strip (upper) (2 used) 26—Plate (2 used) 27—Bolt (6 used) 28—Wear Strip (middle) (2 used)

4. Remove nut (9) and push lock (17) down to remove lock and washer (19).

1. Remove wear plates (28), bushings (23), and washers (24).

5. Remove cap screws (20), washers (21), shims (16), and plate (15).

2. Remove cap screws (22) and washers (21). 3. Loosen nut (18). Strike head of nut to dislodge lock (17).

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Track System 6. Remove bracket (7 or 14) using puller. 7. Remove cap screws (12) and washers (11).

T211338A

–UN–19MAY05

01 0130 94

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Track System 8. Remove shaft (2) and bushing cover (8) from idler using a 2 inch disk from D01045AA Bushing, Bearing, and Seal Driver Set and a press. 9. Remove shaft from bushing case. Remove O-rings from shaft and bushing case.

01 0130 95

NOTE: Tape metal face seals together to keep them in matched sets. 10. Remove metal face seals (13) and tape together.

–UN–19MAY05

11. Lift second bracket off idler. 12. Remove cap screws (12) and washers (11) from second bushing case.

T211339A

13. Turn idler over. Use a 4 inch disk to remove second bushing case from idler. Remove O-ring from bushing case.

NOTE: Tape metal face seals together to keep them in matched sets. 14. Remove metal face seals (13) and tape together. 15. Inspect all parts for excessive wear or damage. Replace if necessary.

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Track System

T210217

–UN–07APR05

01 0130 96

T210217 1—Idler 2—Shaft 3—O-ring (2 used) 4—O-ring (2 used) 5—O-ring 6—Plug 7—Bracket (left) 8—Bushing Cover (2 used)

9—Bushing (2 used) 10—Dowel Pin (2 used) 11—Lock Washer (12 used) 12—Cap Screw (12 used) 13—Metal Face Seal (2 used) 14—Bracket (right) 15—Wear Strip (lower) (2 used)

16—Shim (as required) 17—Lock (2 used) 18—Nut (2 used) 19—Washer (2 used) 20—Cap Screw (2 used) 21—Washer (20 used) 22—Cap Screw (6 used) 23—Bushing (rubber) (4 used)

24—Washer (4 used) 25—Wear Strip (upper) (2 used) 26—Plate (2 used) 27—Bolt (6 used) 28—Wear Strip (middle) (2 used)

Front Idler Assembly

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Track System NOTE: Track roller and front idler procedures are similar. Track roller shown where noted. 1. Cool bushing (1) and heat bushing case (3) to specification.

01 0130 97

2. Using a straight edge, mark bushing (1) from center line of dowel pin hole to center line of dowel pin (2). Align mark on bushing with dowel pin in bushing case.

–UN–31MAR05

3. Press bushing into case using 4 inch diameter disk from D01045AA Bushing, Bearing, and Seal Driver Set and a press.

T210063A

4. When bushing case cools, install O-ring (5) on bushing case. 1—Bushing 2—Dowel Pin 3—Bushing Case 4—Disk (4 inch diameter) 5—O-Ring 6—Alignment Mark

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Track System 5. Install bushing case (1) using aligning studs (2), 4 inch diameter disk (4), and a press.

Specification Front Idler Bushing Case Cap Screw—Torque ..................................................................... 40.2—47 N•m 30—35 lb-ft

7. Turn idler over and carefully install shaft.

–UN–19MAY05

8. Install bushing case (1) using aligning studs (2), 101.6 mm (4 inch) diameter x 6.3 mm (1/4 inch) wall pipe, 4 inch diameter disk (4), and a press.

T211330A

9. Remove studs. Install cap screws and lock washers. Tighten cap screws to specification. Specification Front Idler Bushing Case— Torque .................................................................................. 40.2—47 N•m 30—35 lb-ft

1—Bushing Case 2—Stud 3—Front Idler 4—Disk (3 9/16 inch diameter)

TE14778,00000D3 –19–12JUL05–6/12

10. Install new O-ring in shaft groove (1).

–UN–26OCT88

11. Degrease seal bore in bushing case, inner collar, and outer collar using a volatile, non-petroleum base type solvent. Make sure seal bores are clean and dry.

T6018BA

01 0130 98

6. Remove aligning studs. Install cap screws and lock washers. Tighten cap screws to specification.

O-Ring (Track Roller Shown)

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Track System

T80574

–UN–26OCT88

TE14778,00000D3 –19–12JUL05–8/12

NOTE: A volatile, non-petroleum base solvent or talcum powder may be used as a lubricant. Solvent MUST NOT damage the O-rings or leave an oil residue. –UN–26OCT88

13. Install seal assembly in the JDG205 Seal Installation Tool (2) so tool lip is between seal ring flange (1) and O-ring (3).

T6077AV

1—Seal Ring Flange 2—JDG205 Seal Installation Tool 3—O-Ring

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01 0130 99

Track System

–UN–26OCT88

15. Check to make sure seal ring is sitting squarely in bore. Make sure rubber seal is seated uniformly in seal bore below the retainer lip.

T80577

01 0130 ,100

1—JDG205 Seal Installation Tool 2—O-Ring

Seal Installation (Track Roller Shown)

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Track System 16. Wipe metal seal rings dry with a lint free tissue. 17. Apply a thin film of oil, as used in the idler, to the shiny sealing area on metal seal rings.

–UN–26OCT88

18. Be sure the rubber seals are free of oil. 19. Install bracket.

T80578

20. Install dowel pin (17), washer (19), and nut (18). Tighten nut to specification. Metal Seal Rings (Track Roller Shown)

Specification Front Idler Shaft Lock Nut— Torque ................................................................................. 140—180 N•m 103—133 lb-ft

21. Turn idler over and install new O-ring, metal face seals, bracket, dowel pin, washer, and nut. 22. Slowly pump recommended oil into shaft. See Track Rollers, Front Idler, Carrier Roller and Track Frame Outer Pivot Oil. (Operators Manual.) Specification Front Idler—Capacity....................................................................... 330 ml 11.2 oz

NOTE: Perform Front Idler Leakage Test BEFORE installing plug. 23. Perform Front Idler Oil Leakage Test. (Group 0130.) 24. Install plug. Tighten to specification. Specification Front Idler Oil Plug—Torque ............................................... 152—190 N•m 112—140 lb-ft

25. Install shims (16), lower wear strip (15) , washers (21), and cap screws (20). Tighten cap screws to specification. Specification Front Idler Lower Wear Strip Cap Screw—Torque ...................................................................... 90—110 N•m 66—81 lb-ft

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01 0130 ,101

Track System 26. Install washers (12 and 24), rubber bushings (23), upper wear strips (25), and cap screws (22). Do not tighten cap screws. 27. Install idler assembly. See Front Idler Remove and Install. (Group 0130.)

TE14778,00000D3 –19–12JUL05–12/12

Front Idler Vertical Movement Adjustment IMPORTANT: If front idler vertical gap is excessive, the ability to finish grade with the crawler is affected. Also track adjuster damage may result. 1. Drive crawler so front idler is on a block of wood or a pile of dirt approximately 153 mm (6 in.) high.

TE14778,00000E7 –19–11JUL05–1/3

2. Check the distance (1) between top surface of track chain (2) and bottom wear surface of front idler (3) on both sides of idler. Specification Front Idler-to-Track Chain— Distance .................................................................................... 15—18 mm 0.59—0.71 in.

3. If distance is less than specification disconnect track chain. See Lubricated Track Chain Remove and Install. (Group 0130.)

–UN–06JUL05

1—Front Idler To Track Chain Distance

Continued on next page

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T212312

01 0130 ,102

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PN=152

Track System 4. Remove one washer (5) from under each cap screw (4). Install cap screws and tighten to specification. Repeat procedure until distance (1) is at high end of specification.

6. If lower wear bar thickness is less than specification, install new lower and middle wear bars. Add four washers for each screw. Add shims until distance (1) is at high end of specification.

T212583A

5. If all washers have been removed and distance is less than specification, remove shims (6) and add washers until four washers have been added and distance (1) is at high end of specification.

–UN–05JUL05

Specification Idler Tension Adjusting Screw— Torque .......................................................................................... 115 N•m 85 lb-ft

4—Cap Screw (4 used) 5—Washer (16 used) 6—Shim (8 used) 7—Lower Wear Bar (2 used) 8—Middle Wear Bar (2 used)

Specification Lower Wear Bar—Minimum Thickness......................................................................................... 10 mm 0.39 in.

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01 0130 ,103

Track System

Front Idler Oil Leakage Test 1. Remove plug from idler shaft. 2. Slowly pump recommended oil into shaft. See Track Rollers, Front Idler, Carrier Roller and Track Frame Outer Pivot Oil. (Operators Manual.) Specification Front Idler—Capacity....................................................................... 330 ml 11.2 oz

3. Turn idler several times to seat metal face seals. 4. Assemble test equipment as shown. 5. Pressurize idler with air to specification.

–UN–19MAY05

Specification Front Idler Leakage Test—Air Pressure .............................................................................. 107—127 kPa 0.8—1.2 bar 14—20 psi

6. Close shut-off valve (4) and wait for two minutes. Make sure idler maintains air pressure and oil does not leak past the metal face seals or O-rings. 7. If idler leaks oil or does not maintain pressure, check O-rings or seals. Repair as necessary and recheck for leaks. 8. Install plug in end of idler shaft and tighten to specification. Specification Idler Shaft Plug—Torque ..................................................... 152—190 N•m 112—140 lb-ft

T211345A

01 0130 ,104

1—Pressure Gauge 0—689 kPa (0—6.89 bar) (0— 100 psi) 2—Adapter 3—JT03456 O-Ring Face Seal (2 used) (17/16 -20 M JIC x 11/16-16 F ORFS) 4—Shut-Off Valve 5—Regulator 6—38H1030 Tee (-6 F ORFS x -6 M ORFS x -6 M ORFS) Parker No. (6R6LOS)

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Track System

Sprocket Segment Remove and Install 1. Move machine forward to locate sprocket segment to be removed. 01 0130 ,105

2. Lower equipment to the ground and stop engine. 3. Remove cap screws (2) and remove sprocket segment (1).

–UN–07APR05

NOTE: If the machine is driven in one direction the majority of the time, most of the wear will occur on one side of the teeth. To extend life, the sprockets can be switched from one side of the machine to the other, which causes the chain to wear on the opposite face of the tooth.

5. Apply NEVER-SEEZ Anti-Seize Lubricant or an equivalent to threads of cap screws.

T210009A

4. Remove all paint, oil, grease, or other foreign material from the mounting surface of the sprocket and planetary housing. 1—Sprocket Segment (5 used) 2—Cap Screw (25 used)

6. Install sprocket segment and cap screws. Tighten cap screws to specification. Specification Sprocket Segment Cap Screws, Normal Conditions—Torque ......................................................... 495 N•m 365 lb-ft

For machines run in extreme conditions or with rear mounted equipment, apply NEVER-SEEZ Anti-Seize Lubricant or an equivalent to threads of cap screws and tighten to specification. Specification Sprocket Segment Cap Screws, Extreme Conditions or Rear Mounted Equipment—Torque Turn ................................................................. 136 N•m + 1/3 Turn (120°) 100 lb-ft + 1/3 Turn (120°)

7. Continue this procedure until all sprocket segments are removed and installed.

NEVER-SEEZ is a trademark of Emhart Chemical Group.

TM2261 (10FEB06)

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Track System

01 0130 ,106

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Section 02

Axles and Suspension Systems Contents Page

Group 0201—Drive Axle Housing and Support Final Drive Remove and Install . . . . . . . . . .02-0201-1

Group 0250—Axle Shaft, Bearings and Reduction Gears Planet Carrier Remove and Install. . . . . . . . .02-0250-1 Planet Carrier Disassemble and Assemble. . . . . . . . . . . . . . . . . . . . . . . . . .02-0250-4 Ring Gear and Hub Remove and Install . . . .02-0250-7 Ring Gear and Hub Disassemble and Assemble. . . . . . . . . . . . . . . . . . . . . . . . .02-0250-11 Planet Housing Remove and Install. . . . . . .02-0250-12 Planet Housing Disassemble and Assemble. . . . . . . . . . . . . . . . . . . . . . . . .02-0250-14 Inner Final Drive Housing Remove and Install. . . . . . . . . . . . . . . . . . . . . . . . . . . .02-0250-17 Inner Final Drive Housing Disassemble and Assemble. . . . . . . . . . . . . . . . . . . . . . . . .02-0250-20

TM2261 (10FEB06)

02-1

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PN=1

Contents

TM2261 (10FEB06)

02-2

750J, 850J Crawler 032806

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Group 0201

Drive Axle Housing and Support Final Drive Remove and Install Final Drive Removal

–UN–04DEC04

CAUTION: Prevent possible injury from unexpected track movement. Raise the machine off the ground and support with 20-Ton Floor Stands. Tracks must be free to rotate in either direction. 1. Raise machine off the ground and support with 20-Ton Floor Stands. Lower blade to ground.

T205099A

2. Disconnect track chain. See Lubricated Track Chain Remove and Install. (Group 0130.) 3. Remove rear transmission access cover and bottom main frame access covers.

750J/850J Floor Stand Kit 1—20-Ton Floor Stand (4 used) 2—Floor Stand Adapter (2 used) 3—Floor Stand Rod 4—Washer (2 used) 5—Cap Screw (2 used)

4. Drain final drive housing and planetary housing. See Change Final Drive Oil. (Operator’s Manual.) 750J and 750J-LT—Specification Inner Final Drive (each side)— Approximate Capacity ........................................................................... 8 L 2.1 gal Outer Final Drive (each side)— Approximate Capacity ...................................................................... 15.1 L 4 gal 750J-WT and 750J-LGP—Specification Inner Final Drive (each side)— Approximate Capacity ...................................................................... 15.1 L 4 gal Outer Final Drive (each side)— Approximate Capacity ...................................................................... 15.1 L 4 gal 850J and 850J-LT—Specification Inner Final Drive (each side)— Approximate Capacity ........................................................................... 8 L 2.1 gal Outer Final Drive (each side)— Approximate Capacity ...................................................................... 16.3 L 4.3 gal 850J-WT and 850J-WLT—Specification Inner Final Drive (each side)— Approximate Capacity ...................................................................... 15.5 L 4.1 gal

Continued on next page

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02 0201 1

Drive Axle Housing and Support Outer Final Drive (each side)— Approximate Capacity ...................................................................... 16.3 L 4.3 gal 850J-LGP—Specification Inner Final Drive (each side)— Approximate Capacity ...................................................................... 18.9 L 5 gal Outer Final Drive (each side)— Approximate Capacity ...................................................................... 16.3 L 4.3 gal

5. Remove sprocket segments. See Sprocket Segment Remove and Install. (Group 0130.)

TE14778,00000D5 –19–01SEP05–2/8

NOTE: Final drive shown removed for clarity of location of cap screws. 6. Remove exterior final drive to main frame cap screws (1) except for two (2).

–UN–07JUN05

1—Cap Screw (10 used) 2—Cap Screw (2 used) 3—Cap Screw (4 used) 4—Cap Screw (9 used)

T211662A

02 0201 2

Continued on next page

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Drive Axle Housing and Support

CAUTION: Final drive is heavy and can cause injury if not moved properly. Use adequate lifting device to move final drive. –UN–25MAY05

Specification 850J-LGP Final Drive— Approximate Weight ........................................................................ 794 kg 1750 lb

T211664A

7. Attach DFT1260 Final Drive Lifting Fixture (5) using cap screws (6) to the top two M16 tapped holes in final drive housing. For instructions to make tool see DFT1260 Final Drive Lifting Fixture. (Group 9900.)

DFT1260 Final Drive Lifting Fixture 5—DFT1260 Final Drive Lifting Fixture 6—Cap Screw (2 used)

8. Attach DFT1250 Lifting Bracket to hoist. For instructions to make tool see DFT1250 Lifting Bracket. (Group 9900.)

Continued on next page

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02 0201 3

Drive Axle Housing and Support 9. Attach DFT1250 Lifting Bracket to DFT1260 Final Drive Lifting Fixture using M20 Cap Screws.

–UN–25MAY05

10. Remove internal cap screws (4) which attach final drive to main frame. 11. Remove cap screws (3) from hydrostatic motor to park brake plate.

T211666A

12. Remove park brake line from final drive. 02 0201 4

13. Place blocking between bottom of main frame and hydrostatic motor to support motor. 14. Pry motor inward away from park brake. 15. Remove remaining exterior cap screws (2). Pry final drive housing away from main frame. Remove final drive assembly. 16. Thoroughly clean final drive housing and main frame surfaces. 17. Inspect O-ring on hydrostatic transmission motor flange. Replace if necessary. Final Drive Installation 1. Thoroughly clean final drive housing and main frame surfaces. 2. Apply T43514 Rigid Form-In-Place Gasket on mating surfaces of final drive and main frame.

Continued on next page

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Drive Axle Housing and Support

CAUTION: Final drive is heavy and can cause injury if not moved properly. Use adequate lifting device to move final drive. –UN–25MAY05

Specification Final Drive—Approximate Weight ................................................... 794 kg 1750 lb

T211664A

3. Attach DFT1260 Final Drive Lifting Fixture (5) to the top two M16 tapped holes (6) in final drive housing. For instructions to make tool see DFT1260 Final Drive Lifting Fixture. (Group 9900.) DFT1260 Final Drive Lifting Fixture

4. Attach DFT1250 Lifting Bracket to hoist. For instructions to make tool see DFT1250 Lifting Bracket. (Group 9900.)

Continued on next page

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02 0201 5

Drive Axle Housing and Support NOTE: Final drive removed for clarity of cap screws location. 5. Install final drive housing to main frame. Install exterior cap screws (1 and 2).

6. Align hydrostatic motor output shaft with final drive splines. Install motor.

–UN–07JUN05

7. Apply T43512 Thread Lock and Sealer (Medium Strength) to threads of cap screws (3) and install. 8. Install interior main frame to final drive housing cap screws (4). 9. Remove final drive lifting brackets and install remaining cap screws (1).

T211662A

02 0201 6

IMPORTANT: When installing the final drive assembly, all of the transmission to final drive cap screws must be tightened evenly until flange gap is closed. Then tighten cap screws to specifications.

10. Tighten all cap screws evenly to specification. 1—Cap Screw (10 used) 2—Cap Screw (2 used) 3—Cap Screw (4 used) 4—Cap Screw (9 used)

Specification M20 Final Drive-to-Main Frame (Exterior) Cap Screws—Torque ................................................... 678 N•m 500 lb-ft M20 Transmission Motor-to-Park Brake Plate Cap Screws—Torque ............................................... 319 N•m 235 lb-ft M20 Final Drive-to-Main Frame (Interior) Cap Screws—Torque .................................................... 678 N•m 500 lb-ft

11. Connect park brake line.

NOTE: After servicing park brake release park brake for two minutes with the machine running to allow for the brake cavity to fill. This may cause a brake pressure low code. If this occurs, delete this code. 12. Install sprocket segments. See Sprocket Segment Remove and Install. (Group 0130.)

Continued on next page

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Drive Axle Housing and Support IMPORTANT: O-rings must be seated in grooves of fill plugs to prevent leakage. 13. Install final drive and planetary housing drain plugs. Tighten plugs to specification. Specification Final Drive Housing and Planetary Housing Drain Plugs— Torque ............................................................................................ 74 N•m 54 lb-ft 02 0201 7

14. Fill final drive and planetary housings with recommended oil. Fill to bottom edge of fill plug holes. See Change Final Drive Oil. (Operator’s Manual.) See Inner and Outer Final Drive Oil. (Operator’s Manual.) 15. Install and tighten fill plugs. Tighten plugs to specification. Specification Final Drive Housing and Planetary Housing Fill Plugs— Torque ............................................................................................ 74 N•m 54 lb-ft

16. Connect track chain. See Lubricated Track Chain Remove and Install. (Group 0130.)

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Drive Axle Housing and Support

02 0201 8

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Group 0250

Axle Shaft, Bearings and Reduction Gears Planet Carrier Remove and Install NOTE: Planet carrier with pinions can be removed without removing planet housing assembly. –UN–05JUL05

1. Position crawler so oil level line (3) is parallel to ground and drain plug (2) is at lowest position.

T212505A

NOTE: Planet housing oil capacity is approximately: Planet Housing—Specification 750J—Capacity ................................................................................ 15.1 L 4 gal 850J—Capacity ................................................................................ 16.3 L 4.3 gal

1—Fill plug 2—Drain plug 3—Oil level line 4—Cap Screw

2. Remove drain plug (2) to drain oil from planet housing.

Continued on next page

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02 0250 1

Axle Shaft, Bearings and Reduction Gears

CAUTION: Planet carrier is heavy and can cause injury if not moved properly. Use adequate lifting device to move planet carrier. Specification 850J Planet Carrier—Weight........................................................... 132 kg 290 lb

3. Attach planet carrier to hoist using JT01748 Lifting Bracket (5) and strap. 4. Remove cap screws (4). –UN–06JUL05

5. Carefully remove housing assembly. 6. Remove, clean, and inspect O-ring. Replace if necessary.

T212706A

02 0250 2

7. Clean planet carrier and planet housing cover mating surfaces. 5—JT01748 Lifting Bracket

8. Install O-ring. 9. Align planet gears with sun pinion shaft and ring gear and install planetary carrier. 10. Install and tighten cap screws (4) to specification. Specification Planet Carrier-to-Planet Housing Cap Screws—Torque ................................................................... 130 N•m 95 lb-ft

11. Remove fill plug (1). IMPORTANT: O-rings must be seated in groove of plugs (1 and 2) to prevent leakage. 12. Install and tighten drain plug (2). Tighten plug to specification. Specification Drain Plug—Torque ........................................................................ 74 N•m 54 lb-ft

13. Fill planet housing with recommended oil to bottom edge of fill plug (1) hole. See Change Final Drive Oil. (Operator’s Manual.) See Inner and Outer Final Drive Oil. (Operator’s Manual.)

Continued on next page

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Axle Shaft, Bearings and Reduction Gears 14. Install and tighten fill plug (1). Tighten plug to specification. Specification Fill Plug—Torque ............................................................................ 74 N•m 54 lb-ft

TX,0250,SS2366 –19–27JUN05–3/3

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02 0250 3

Axle Shaft, Bearings and Reduction Gears

Planet Carrier Disassemble and Assemble

02 0250 4

7 6

8 10

9 5 6

–UN–22JUN05

13 2

T212140

12 Planet Carrier Exploded View 1—O-Ring 2—Planet Carrier 3—Cap Screw 4—Cap Screw (3 used)

5—Planet Pinion Pin (3 used) 6—Planet Pinion (3 used) 7—Planet Pinion Bearing Cone (6 used)

8—Spacer 9—Planet Pinion Bearing Cup (6 used) 10—Snap Ring (2 used)

11—Roller Bearing Kit (3 used) 12—Plug (2 used) 13—O-Ring (2 used) 35—O-Ring

Planet Carrier Disassembly 1. Drain planet housing and remove planet carrier. See Change Final Drive Oil. (Operator’s Manual.) See Planet Carrier Remove and Install. (Group 0201.)

Continued on next page

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Axle Shaft, Bearings and Reduction Gears 2. Remove cap screws (4). 3. Remove planet pinion pin (5) using puller.

–UN–10JUN05

NOTE: Planet pinion bearings are a matched set and cannot be serviced separately. Keep bearing cones together with corresponding cups.

T211853A

4. Slide planet pinion (6) partially out of carrier (2) and secure bearings to pinion with a tie wrap. Remove planet pinion from carrier 5. Remove remaining planet pinions. 2—Planet Carrier 4—Cap Screw (3 used) 5—Planet Pinion Pin (3 used) 6—Planet Pinion (3 used)

CED,OUO1020,3144 –19–27JUN05–2/9

6. Remove planet pinion bearing cones (7) and spacer (8).

T211866A

–UN–10JUN05

7—Planet Pinion Bearing Cone (2 used) 8—Spacer

CED,OUO1020,3144 –19–27JUN05–3/9

7. Bearing cups (9) are a press fit. Remove bearing cups from planet pinion using a puller.

T211876A

–UN–10JUN05

9—Planet Pinion Bearing Cup (2 used)

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02 0250 5

Axle Shaft, Bearings and Reduction Gears 8. Remove, snap rings (10). 9. Inspect all parts. Replace if necessary.

T211877A

–UN–10JUN05

10—Planet Pinion Snap Ring (2 used)

02 0250 6

CED,OUO1020,3144 –19–27JUN05–5/9

Planet Carrier Assembly

–UN–10JUN05

NOTE: Planet pinion bearings are a matched set and cannot be serviced separately. Keep bearing cones together with corresponding cups.

T211877A

1. Install snap rings (10) with openings in different locations. 10—Planet Pinion Snap Ring (2 used)

CED,OUO1020,3144 –19–27JUN05–6/9

2. Install bearing cups (9) against snap rings using press.

T211876A

–UN–10JUN05

9—Planet Pinion Bearing Cup (2 used)

CED,OUO1020,3144 –19–27JUN05–7/9

3. Install one bearing cone (7) into corresponding cup. Install spacer (8) and remaining bearing cone.

T211866A

–UN–10JUN05

7—Planet Pinion Bearing Cone (2 used) 8—Spacer

Continued on next page

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02-0250-6

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Axle Shaft, Bearings and Reduction Gears 4. Slide planet pinion assembly into carrier. Install pinion pin (5) using press. 5. Install cap screw (4) and tighten to specification. Specification Planet Carrier Cover Cap Screws—Torque ........................................................................... 319 N•m 235 lb-ft

6. Install remaining planet pinions.

02 0250 7 –UN–10JUN05

7. Rotate planet pinions. Pinions should rotate freely.

T211853A

–UN–10JUN05

T211880A

2—Planet Carrier 4—Cap Screw (3 used) 5—Planet Pinion Pin (3 used) 6—Planet Pinion (3 used)

CED,OUO1020,3144 –19–27JUN05–9/9

Ring Gear and Hub Remove and Install Ring Gear and Hub Removal 1. Drain planet housing and remove planet carrier. See Change Final Drive Oil. (Operator’s Manual.) See Planet Carrier Remove and Install. (Group 0201.)

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Axle Shaft, Bearings and Reduction Gears

–UN–14JUN05

CAUTION: Planet housing is heavy and can fall from tractor causing injury if not supported properly. Use adequate supports under planet housing BEFORE removing ring gear and hub. Specification Planet Housing—Weight ................................................................. 188 kg 415 lb

T212115A

2. Support planet housing (1) with blocks. CAUTION: Ring gear and hub is heavy and can cause injury if not moved properly. Use adequate lifting device to move ring gear and hub.

1—Planet Housing 2—Ring Gear and Hub

Specification Ring Gear and Hub—Weight ............................................................ 70 kg 155 lb

3. Attach ring gear and hub (2) to hoist using eyebolt and sling.

TX,0250,SS2365 –19–27JUN05–2/7

4. Remove retainer plate cap screws (3) and retainer plate (4).

T212111A

–UN–14JUN05

3—Cap Screws (12 used) 4—Retainer Plate

TX,0250,SS2365 –19–27JUN05–3/7

5. Remove shims (5). 6. Remove ring gear and hub using hoist.

–UN–14JUN05

5—Shims (As required)

T212113A

02 0250 8

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Axle Shaft, Bearings and Reduction Gears Ring Gear and Hub Installation 1. Apply grease to splines and align ring gear hub (2) with final drive cover splines and install. –UN–14JUN05

NOTE: If roller bearings were replaced go to next step. Otherwise, assemble with current shim pack.

T212115A

2. Adjust bearing preload using the following procedure: a. Install shim pack equal to 1.35 mm (0.053 in.) 1—Ring Gear Housing 2—Ring Gear and Hub

TX,0250,SS2365 –19–27JUN05–5/7

b. Install retainer plate (4) and four cap screws (3). Cross tighten to specification.

T212111A

–UN–14JUN05

Specification Retainer Plate-to-Final Drive Housing—Torque.......................................................................... 130 N•m 95 lb-ft

c. Rotate planet housing two revolutions in both directions. d. Torque cap screws to above specification.

3—Cap Screws (12 used) 4—Retainer Plate

e. Repeat above two steps until cap screw torque stays at specification.

Continued on next page

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02 0250 9

Axle Shaft, Bearings and Reduction Gears IMPORTANT: Install DFT1261 Rolling Torque Measurement Tool (1) with cap screw (2) centered over sun pinion shaft (3).

Specification Planet Housing—Rolling Drag Torque ..................................................................................... 40—50 N•m 29—37 lb-ft

T212304A

02 0250 10

–UN–20JUN05

f. Install DFT1261 Rolling Torque Measurement Tool (1). Measure rolling torque using torque wrench on cap screw (2). Rolling torque must be within specification. For instructions to make tool see DFT1261 Rolling Torque Measurement Tool. (Group 9900.)

1—DFT1261 Rolling Torque Measurement Tool 2—Cap Screw and Washer 3—Sun Pinion Shaft

If rolling torque is not to specification, adjust shim pack thickness. 3. Install remaining cap screws. Tighten to specification. Specification Retainer Plate-to-Final Drive Housing—Torque.......................................................................... 130 N•m 95 lb-ft

4. Install planet carrier. See Planet Carrier Remove and Install. (Group 0201.) 5. Fill planet housing with recommended oil to fill plug level. See Inner and Outer Final Drive Oil. (Operator’s Manual.) See Change Final Drive Oil. (Operator’s Manual.)

TX,0250,SS2365 –19–27JUN05–7/7

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Axle Shaft, Bearings and Reduction Gears

Ring Gear and Hub Disassemble and Assemble

3 6

1. Remove ring gear and hub from planet housing. See Ring Gear and Hub Remove and Install. (Group 0201.)

2 1—Snap Ring 2—Hub 3—Ring Gear 4—Retainer Plate 5—Cap Screw (12 used) 6—Bearing Cone

T212141

–UN–22JUN05

Ring Gear and Hub Exploded View

TX,0250,SS2381 –19–12JUL05–1/2

2. Remove snap ring (1) holding hub (2) in ring gear (3). Remove hub from ring gear.

–UN–14JUN05

3. Remove bearing cone (4) from ring gear hub. Bearing cone is a press fit. 4. Install bearing cone tight against shoulder of ring gear hub using press.

T212125A

5. Install hub into ring gear. Secure with snap ring. 6. Install ring gear and hub into planet housing. See Ring Gear and Hub Remove and Install. (Group 0201.) 1—Snap Ring 2—Hub 3—Ring Gear 4—Bearing Cone

TX,0250,SS2381 –19–12JUL05–2/2

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02 0250 11

Axle Shaft, Bearings and Reduction Gears

Planet Housing Remove and Install 1. Remove outer seal guard socket head cap screws (1) and outer seal guards (2) (if installed). Remove inner seal guards in the same manner. 2. Remove sprocket segments. See Sprocket Segment Remove and Install. (Group 0130.)

–UN–06JUL05

CAUTION: Planet housing is heavy and can fall from tractor causing injury if not supported properly. Use adequate supports under planet housing BEFORE removing ring gear and hub.

T212628A

3. Remove planet carrier, ring gear, and hub from planet housing. See Planet Carrier Remove and Install. (Group 0201.) See Ring Gear and Hub Remove and Install. (Group 0201.) 1—Socket Head Cap Screw (2 used) 2—Outer Seal Guard

TE14778,00000D8 –19–12JUL05–1/3

CAUTION: Planet housing is heavy and can cause injury if not moved properly. Use adequate lifting device to move planet housing.

–UN–15JUN05

Specification 850J Planet Housing—Weight ........................................................ 188 kg 415 lb

4. Remove planet housing using hoist.

T212147A

02 0250 12

Continued on next page

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02-0250-12

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750J, 850J Crawler 032806

PN=178

Axle Shaft, Bearings and Reduction Gears 5. Inspect bearing cones and cups. Replace if necessary.

–UN–15JUN05

6. Inspect metal face seals for wear. Replace if necessary. See Metal Face Seals Inspection. (Group 0130.) See Planet Housing Disassemble and Assemble. (Group 0260.)

T212146A

7. Install planet housing onto inner final drive using hoist. Support with blocks. 8. Install ring gear and hub. See Ring Gear and Hub Remove and Install. (Group 0201.) 9. Install planet carrier. See Planet Carrier Remove and Install. (Group 0201.)

1—Planet Housing 2—Metal Face Seal 3—Bearing Cup (2 used)

10. Install sprocket segments. See Sprocket Segment Remove and Install. (Group 0130.) 11. Install seal guards if removed. 12. Fill planet housing with recommended oil to fill plug level. See Inner and Outer Final Drive Oil. (Operator’s Manual.) See Change Final Drive Oil. (Operator’s Manual.)

TE14778,00000D8 –19–12JUL05–3/3

TM2261 (10FEB06)

02-0250-13

750J, 850J Crawler 032806

PN=179

02 0250 13

Axle Shaft, Bearings and Reduction Gears

Planet Housing Disassemble and Assemble 6 5

1. Remove planet housing from inner final drive. See Planet Housing Remove and Install. (Group 0200.)

4 3 1

T212142

–UN–22JUN05

Planet Housing Exploded View

TE14778,00000D9 –19–12JUL05–1/5

IMPORTANT: Use extreme care not to scratch metal face seal surface throughout this procedure.

–UN–15JUN05

2. Remove and inspect metal face seal (2) by prying on edge. See Metal Face Seals Inspection. Group (0130.) 3. Inspect bearing cups (3). Replace if necessary. 4. Thoroughly clean O-ring pockets of both seals and exposed surfaces using TY16041 brake and clutch cleaner.

T212146A

02 0250 14

1—Bearing Cup (2 used) 2—Planet Housing 3—Metal Face Seal 4—Shim 0.01 mm (0.004 in.) (as required) 5—Shim 0.05 mm (0.002 in.) (as required) 6—Shim 0.15 mm (0.006 in.) (as required)

1—Planet Housing 2—Metal Face Seal 3—Bearing Cup (2 used)

Continued on next page

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750J, 850J Crawler 032806

PN=180

Axle Shaft, Bearings and Reduction Gears NOTE: Metal face seal installation tool is shown expanded to show proper installation.

–UN–18AUG03

5. Clamp JDG10081 Seal Installation Tool (7) onto seal (9). Check that lip (8) is fully inserted around entire seal.

T194164A

IMPORTANT: Use only rubbing alcohol on seals. Damage could occur to seals if other lubricants are used. 6. Spray rubbing alcohol on O-ring seal and pockets for lubrication.

JDG10081 Metal Face Seal Installation Tool 7—JDG10081 Seal Installation Tool 8—JDG10081 Tool Lip 9—Metal Face Seal

TE14778,00000D9 –19–12JUL05–3/5

7. Before alcohol evaporates, install seal (8) by pushing evenly and firmly on tool (7) until tool bottoms out all way around housing.

–UN–20JUN05

IMPORTANT: Damage will occur to O-ring seal if unseated during tool removal. Use care when removing tool from seal.

T212297A

8. Remove tool (7). 9. Inspect O-ring to see that it is seated at same height all the way around. JDG10081 Metal Face Seal Installation Tool 7—JDG10081 Seal Installation Tool 9—Metal Face Seal

Continued on next page

TM2261 (10FEB06)

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750J, 850J Crawler 032806

PN=181

02 0250 15

Axle Shaft, Bearings and Reduction Gears IMPORTANT: Failure to properly lubricate outer zone of seals may result in seal failure.

–UN–20AUG03

10. Lubricate outer zone (13) of metal face on seal using TY6354 HY-GARD oil. 11. Repeat procedure for remaining seal.

02 0250 16

13—Outer Zone of Metal Face Seal

Metal Face of Seal

HY-GARD is a trademark of Deere & Company

TM2261 (10FEB06)

T194304A

12. Install planet housing onto inner final drive. See Planet Housing Remove and Install. (Group 0200.)

TE14778,00000D9 –19–12JUL05–5/5

02-0250-16

750J, 850J Crawler 032806

PN=182

Axle Shaft, Bearings and Reduction Gears

Inner Final Drive Housing Remove and Install 1. Disconnect track chain. See Lubricated Track Chain Remove and Install. (Group 0130.) –UN–24JAN05

2. Drain final drive housing and planet housing. See Change Final Drive Oil. (Operator’s Manual.)

T206849A

750J and 750J-LT—Specification Inner Final Drive (each side)— Approximate Capacity ........................................................................... 8 L 2.1 gal Planet Housing (each side)— Approximate Capacity ...................................................................... 15.1 L 4 gal 750J-WT and 750J-LGP—Specification Inner Final Drive (each side)— Approximate Capacity ...................................................................... 15.1 L 4 gal Planet Housing (each side)— Approximate Capacity ...................................................................... 15.1 L 4 gal 850J and 850J-LT—Specification Inner Final Drive (each side)— Approximate Capacity ........................................................................... 8 L 2.1 gal Planet Housing (each side)— Approximate Capacity ...................................................................... 16.3 L 4.3 gal

–UN–20MAY95

850J-WT and 850J-WLT—Specification Inner Final Drive (each side)— Approximate Capacity ...................................................................... 15.5 L 4.1 gal Planet Housing (each side)— Approximate Capacity ...................................................................... 16.3 L 4.3 gal

T8398AO

850J-LGP—Specification Inner Final Drive (each side)— Approximate Capacity ...................................................................... 18.9 L 5 gal Outer Final Drive (each side)— Approximate Capacity ...................................................................... 16.3 L 4.3 gal

A—M16 Guide Studs (2 used) B—Final Drive Cap Screw (22 used) C—Jack Screw (2 used)

3. Remove planet housing. See Planet Housing Remove and Install. (Group 0260.) 4. Remove two cap screws and install two M16 guide studs (A).

Continued on next page

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02-0250-17

TX,0250,SS2382 –19–28JUN05–1/4

750J, 850J Crawler 032806

PN=183

02 0250 17

Axle Shaft, Bearings and Reduction Gears 5. Clean threaded holes on back side of final drive housing and install two M16 x 50 jack screws (C) to remove final drive housing.

TX,0250,SS2382 –19–28JUN05–2/4

Specification Inner Final Drive—Weight ............................................................... 188 kg 415 lb

6. Attach a JT01748 Lifting Bracket to threaded hole in final drive cover and attach chain and hoist. 7. Remove final drive cap screws (B). 8. Slowly remove final drive housing by using the two jack screws (C) to separate housing. 9. Clean final drive housing and cover mating surfaces with cure primer. –UN–20MAY95

10. Apply plastic gasket to final drive housing and cover mating surfaces. 11. Install final drive housing cover assembly.

T8398AO

02 0250 18

CAUTION: Inner final drive is heavy and can cause injury if not moved properly. Use adequate lifting device to move inner final drive.

12. Install all cover cap screws (B), remove guide studs and install remaining cap screws and tighten cap screws to specification. A—M16 Guide Studs (2 used) B—Final Drive Cap Screw (22 used) C—Jack Screw (2 used) D—Drain Plug E—Fill Plug

Specification Final Drive Housing Cover Cap Screws—Torque ........................................................................... 320 N•m 236 lb-ft

13. Install ring gear and hub. See Ring Gear and Hub Remove and Install. (Group 0201.) Install planet housing. Fill inner planet housing with recommended oil to bottom edge of fill plug. See Planet Housing Remove and Install. (Group 0260.)

Continued on next page

TM2261 (10FEB06)

02-0250-18

TX,0250,SS2382 –19–28JUN05–3/4

750J, 850J Crawler 032806

PN=184

Axle Shaft, Bearings and Reduction Gears 14. Install and tighten drain plug (2) with O-ring. Tighten plug to specification.

–UN–24JAN05

Specification Final Drive Housing Drain Plug— Torque ............................................................................................ 74 N•m 54 lb-ft

16. Install and tighten fill plug with O-ring (1). Tighten plug to specification.

T206849A

15. Fill inner final drive housing with recommended oil to bottom edge of fill plug (1) hole. See Change Final Drive Oil. (Operator’s Manual.) See Inner and Outer Final Drive Oil. (Operator’s Manual.) 1—Fill Plug 2—Drain Plug

Specification Final Drive Housing Fill Plug— Torque ............................................................................................ 74 N•m 54 lb-ft

17. Reconnect track chain. See Lubricated Track Chain Remove and Install. (Group 0130.)

TX,0250,SS2382 –19–28JUN05–4/4

TM2261 (10FEB06)

02-0250-19

750J, 850J Crawler 032806

PN=185

02 0250 19

Axle Shaft, Bearings and Reduction Gears

Inner Final Drive Housing Disassemble and Assemble

T211817

–UN–13JUN05

02 0250 20

1—Final Drive Housing Cover 2—Sun Pinion Shaft 3—Oil Seal 4—Bearing Cone (4 used) 5—Retaining Ring

6—Final Drive Gear 7—Snap Ring 8—Bearing Cup (4 used) 9—Washer (22 used) 10—Cap Screw (22 used)

11—Final Drive Pinion Shaft 12—Pinion Shaft Quill 13—Cap Screw (8 used) 14—Final Drive Housing

Continued on next page

TM2261 (10FEB06)

02-0250-20

15—Shim 0.1 mm (0.004 in.) (as required) 16—Shim 0.15 mm (0.006 in.) (as required)

TX,0250,SS2383 –19–28JUN05–1/7

750J, 850J Crawler 032806

PN=186

Axle Shaft, Bearings and Reduction Gears 1. Remove snap ring (7). Remove sun pinion shaft (2) using a press. 2. Remove final drive gear (6). –UN–20MAY95

3. Remove cap screws (13), final drive shaft quill (12), and pinion shaft (11).

T8398AA

4. Remove bearing cup (8) from quill (12). 5. Remove retaining ring (5). 6. Remove bearing cones (4), cups (8), and oil seal (3) from final drive housing cover (1) using a driver.

4—Bearing Cones (2 used) 11—Pinion Shaft

7. Remove bearing cup (8) from final drive pinion shaft (11) hole in final drive housing cover (1). 8. Remove bearing cones (4) from final drive pinion shaft (11).

TX,0250,SS2383 –19–28JUN05–2/7

9. Install bearing cup (8) tight against shoulder in final drive housing cover.

–UN–13JUN05

10. Install oil seal (3) 6 mm (0.24 in.) below bearing bore with lip (spring side) toward bearing. 11. Install cup (8), two bearing cones (4), and cup (8) using a press.

T211821A

12. Install retaining ring (5). 3—Oil Seal 4—Bearing Cone (2 used) 5—Retaining Ring 8—Bearing Cup (3 used)

Continued on next page

TM2261 (10FEB06)

02-0250-21

TX,0250,SS2383 –19–28JUN05–3/7

750J, 850J Crawler 032806

PN=187

02 0250 21

Axle Shaft, Bearings and Reduction Gears 13. Install bearing cones (4) tight against shoulders on final drive pinion shaft (11) using press.

T8398AA

–UN–20MAY95

4—Bearing Cone (2 used) 11—Final Drive Pinion Shaft

02 0250 22

TX,0250,SS2383 –19–28JUN05–4/7

14. Install pinion shaft assembly (11), shims (15 and 16), and quill (12).

T211822A

–UN–13JUN05

8—Bearing Cup 11—Final Drive Pinion Shaft 12—Quill 15—Shim 0.1 mm (0.004 in.) (as required) 16—Shim 0.15 mm (0.006 in.) (as required)

Continued on next page

TM2261 (10FEB06)

02-0250-22

TX,0250,SS2383 –19–28JUN05–5/7

750J, 850J Crawler 032806

PN=188

Axle Shaft, Bearings and Reduction Gears 15. Install cap screws (13) and tighten to specification. Specification Final Drive Shaft Quill-to-Final Drive Housing Cover Cap Screws—Torque ............................................................................. 73 N•m 54 lb-ft

16. To assure proper assembly of the final drive pinion shaft, measure shaft end play with dial indicator. End play should be to specification. Add or subtract shims as required.

02 0250 23

Specification Final Drive Shaft Assembly End Play—Bearing Setting ................................................... 0.051—0.356 mm 0.002—0.014 in.

T211825A

–UN–13JUN05

11—Final Drive Pinion Shaft 12—Quill 13—Cap Screw (8 used)

Continued on next page

TM2261 (10FEB06)

02-0250-23

TX,0250,SS2383 –19–28JUN05–6/7

750J, 850J Crawler 032806

PN=189

Axle Shaft, Bearings and Reduction Gears 17. Install final drive gear (6) with lip side of gear toward bearings.

19. Install snap ring (7). 20. To set bearings, tap on ring gear side of sun pinion shaft with a soft faced hammer.

Specification Sun Pinion Shaft—End Play .................................................. 0—0.28 mm 0.0—0.011 in.

22. Rotate input shaft. Shaft should rotate freely.

–UN–13JUN05

21. To assure proper assembly of sun pinion shaft. Check shaft end play with dial indicator. End play should be to specification.

T211824A

02 0250 24

T211823A

18. Install sun pinion shaft (B) through bearing assembly and into ring gear using a press.

–UN–13JUN05

NOTE: Support final drive gear hub while pressing pinion shaft into position.

2—Sun Pinion Shaft 6—Final Drive Gear 7—Snap Ring

TX,0250,SS2383 –19–28JUN05–7/7

TM2261 (10FEB06)

02-0250-24

750J, 850J Crawler 032806

PN=190

Section 03

Transmission Contents Page

Group 0300—Remove and Install Hydrostatic Pump Remove and Install. . . . . .03-0300-1 Hydrostatic Motor Remove and Install . . . . . .03-0300-8 Group 0315—Control Linkage Transmission Control Lever (TCL) Remove and Install . . . . . . . . . . . . . . . . . . . . . . . . .03-0315-1 Transmission Control Lever (TCL) Disassemble and Assemble. . . . . . . . . . . .03-0315-2

Group 0360—Hydrostatic System Hydrostatic Pump Disassemble . . . . . . . . . . .03-0360-2 Charge Pump Disassemble and Assemble. . . . . . . . . . . . . . . . . . . . . . . . . .03-0360-9 Pump Displacement Control Valve (PDCV) Disassemble and Assemble. . . . . . . . . . .03-0360-14 Multi-Function Valve Remove and Install. . .03-0360-15 Multi-Function Valve Disassemble and Assemble. . . . . . . . . . . . . . . . . . . . . . . . .03-0360-16 Hydrostatic Pump Assemble . . . . . . . . . . . .03-0360-17 Hydrostatic Motor Disassemble . . . . . . . . . .03-0360-27 Hydrostatic Motor Assemble . . . . . . . . . . . .03-0360-32 Hydraulic Integrated Circuit (HIC) Valve Remove and Install . . . . . . . . . . . . . . . . .03-0360-44 Hydraulic Integrated Circuit (HIC) Valve Disassemble and Assemble. . . . . . . . . . .03-0360-46 Hydrostatic Reservoir Remove and Install. . . . . . . . . . . . . . . . . . . . . . . . . . . .03-0360-48 Hydraulic Fan Motor Remove and Install. . .03-0360-51 Hydraulic Fan Pump Remove and Install. . .03-0360-55 Hydraulic Fan Reversing Valve Remove and Install . . . . . . . . . . . . . . . . . . . . . . . .03-0360-56 Hydraulic Fan Reversing Valve Disassemble and Assemble . . . . . . . . . . . . . . . . . . . . .03-0360-58

TM2261 (10FEB06)

03-1

750J, 850J Crawler 032806

PN=1

Contents

TM2261 (10FEB06)

03-2

750J, 850J Crawler 032806

PN=2

Group 0300

Remove and Install Hydrostatic Pump Remove and Install Hydrostatic Pump Removal 1. Lower all equipment to ground. 2. Stop engine. Operate all hydraulic controls to release pressure in hydraulic system. 3. Turn battery disconnect switch to OFF. 4. Drain reservoir or apply vacuum to reservoir. Specification Hydrostatic Reservoir—Capacity.................................................... 105.6 L 27.9 gal 03 0300 1

5. Tilt cab or ROPS.

Continued on next page

TM2261 (10FEB06)

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PN=193

Remove and Install

T211198A

–UN–11MAY05

03 0300 2

1—Line (Hydraulic Suction) 2—Line (Hydraulic Pressure) 3—Line (Hydraulic Case Drain) 4—Line (Hydraulic Load Sense) 5—Hydraulic Pump 6—Line (Hydraulic Left Lift Cylinder)

7—Line (Fuel) 8—Pressure Control Pilot (PCP) Connector (2 used) 9—Line (Hydrostatic Suction) (2 used) 10—Line (Hydrostatic Closed Loop) (4 used)

11—Line (Charge Pump-to-HIC Valve) (2 used) 12—Line (HIC Valve-to-Pump) (2 used) 13—Line (Hydrostatic Pump Case Drain)

14—Line (Hydrostatic Motor Case Drain 15—Line (Hydrostatic Pump Case Supply)

8. Disconnect Pressure Control Pilot (PCP) connectors (8) from front and rear pumps. 9. Disconnect lines (9-14) from hydrostatic pumps. 10. Remove cap screws (4) from hydraulic pump and remove pump. Set pump aside.

6. Disconnect lines (1-4) from hydraulic pump (5). Close all openings using caps and plugs. 7. Cut tie wraps from fuel line (7) and move line off to the side.

Continued on next page

TM2261 (10FEB06)

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750J, 850J Crawler 032806

PN=194

Remove and Install 11. Disconnect hydrostatic pump case supply line (15).

–UN–11MAY05

For ease of removal and installation of pumps, lines can be tied together and pulled up and out of the way.

T211199A

12—Line (HIC Valve-to-Pump) (2 used) 15—Line (Hydrostatic Pump Case Supply)

TE14778,00000CE –19–06SEP05–3/11

12. Remove cap screws (1 and 2) and remove rear pump mounting bracket.

03 0300 3

T211299A

–UN–11MAY05

1—Cap Screws (Hydrostatic Pump-to-Rear Mounting Bracket) (4 used) 2—Cap Screws (Rear Mounting Bracket-to-Main Frame) (4 used)

Continued on next page

TM2261 (10FEB06)

03-0300-3

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750J, 850J Crawler 032806

PN=195

Remove and Install IMPORTANT: Damage to pump may occur if eyebolt interferes with components in pump. Ensure that eye bolt threads are no longer than case drain fitting threads. –UN–28APR05

13. Drill and tap two 1-1/16 plugs to accommodate a 1/2 in. eye bolt.

T210872A

Remove case drain fittings and install eyebolts as shown. 14. Connect hydrostatic pumps to hoist using chains.

03 0300 4

CAUTION: Track hydrostatic pump assembly is heavy and can cause injury if not moved properly. Use adequate lifting device to move pump assembly. Dual Hydrostatic Pump Assembly—Specification 750J—Approximate Weight ............................................................. 150 kg 330 lb 850J—Approximate Weight ............................................................. 197 kg 435 lb

15. 850J: Remove flywheel housing cover cap screws and pull pumps back far enough for dampener hub to clear flywheel dampener. 750J: Remove four pump-to-flywheel housing cover cap screws and pull pumps back far enough for dampener hub to clear flywheel housing cover. 16. Carefully remove pumps from machine. 17. Remove hydraulic lines and fittings from pumps. Tag lines and mark orientation of fittings to aid in reassembly.

Continued on next page

TM2261 (10FEB06)

03-0300-4

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750J, 850J Crawler 032806

PN=196

Remove and Install

–UN–08JAN99

18. Remove cap screws (1) joining the two pumps and separate pumps.

T118271B

1—Socket Head Cap Screw (4 used)

TE14778,00000CE –19–06SEP05–6/11

19. Loosen set screw (2) and remove dampener hub (3) from pump drive shaft.

03 0300 5

20. If flywheel housing cover was removed with pumps, remove four pump mounting cap screws holding flywheel housing cover (1) to pumps. Hydrostatic Pump Installation

T211211

1. If flywheel housing cover was removed with pumps, install cover onto pump. Oil cap screw threads and tighten to specification.

–UN–10MAY05

Hydrostatic Pump-to-Flywheel Housing Cover—Specification 750J—Torque ............................................................................... 113 N•m 83 lb-ft 850J—Torque ............................................................................... 396 N•m 292 lb-ft

1—Flywheel Housing Cover 2—Set Screw 3—Dampener Hub

2. Position dampener hub (3) with spline away from pump. Slide hub onto shaft until snap ring contacts end of shaft. 3. Tighten dampener hub set screw (2) to specification. Dampener Hub-to-Hydrostatic Pump Shaft Set Screws— Specification 750J—Torque ............................................................................... 120 N•m 89 lb-ft 850J—Torque ............................................................................... 210 N•m 155 lb-ft

Continued on next page

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03-0300-5

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750J, 850J Crawler 032806

PN=197

Remove and Install 4. Assemble pumps using four cap screws (1). –UN–08JAN99

5. Install hydraulic lines in position as marked during removal.

T118271B

6. Install hydrostatic pumps. Adjust chains as necessary when installing pumps to align dampener hub with dampener. 1—Cap Screw (4 used)

Clean threads of flywheel housing cover plate cap screws and install. Tighten cap screws to specification.

7. Remove lift eyes from pumps and reinstall fittings.

TE14778,00000CE –19–06SEP05–8/11

8. Install rear pump mount bracket and tighten cap screws (1 and 2).

T211299A

–UN–11MAY05

1—Cap Screws (Hydrostatic Pump-to-Rear Mounting Bracket) (4 used) 2—Cap Screws (Rear Mounting Bracket-to-Main Frame) (4 used)

TE14778,00000CE –19–06SEP05–9/11

9. Install hydrostatic pump case flushing line (15).

–UN–11MAY05

12—Line (HIC Valve-to-Charge Pump) (2 used) 15—Line (Hydrostatic Pump Case Flushing)

T211199A

03 0300 6

Flywheel Housing Cover Plate—Specification 750J—Torque ................................................................................. 73 N•m 54 lb-ft 850J—Torque ................................................................................. 57 N•m 42 lb-ft

Continued on next page

TM2261 (10FEB06)

03-0300-6

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750J, 850J Crawler 032806

PN=198

Remove and Install

T211198A

–UN–11MAY05

03 0300 7

1—Line (Hydraulic Suction) 2—Line (Hydraulic Pressure) 3—Line (Hydraulic Case Drain) 4—Line (Hydraulic Load Sense) 5—Hydraulic Pump 6—Line (Hydraulic Left Lift Cylinder)

7—Line (Fuel) 8—Pressure Control Pilot (PCP) Connector (2 used) 9—Line (Hydrostatic Suction) (2 used) 10—Line (Hydrostatic Closed Loop) (4 used)

10. Connect lines (9-14) onto hydrostatic pumps.

11—Line (Charge Pump-to-HIC Valve) (2 used) 12—Line (HIC Valve-to-Charge Pump) (2 used) 13—Line (Hydrostatic Pump Case Drain)

14—Line (Hydrostatic Motor Case Drain 15—Line (Hydrostatic Pump Case Flushing)

Manual.)

11. Connect Pressure Control Pilot (PCP) connectors (8) onto front and rear pumps.

Specification Hydrostatic Reservoir— Capacity ................................................................................... 105.6 L 27.9 gal

12. Route fuel line to original location and secure with tie wraps.

16. Return cab or ROPS to operating position.

13. Connect lines (1-6) onto hydraulic pumps.

17. Turn battery disconnect switch to ON.

14. Install access plate on bottom of hydrostatic reservoir compartment.

18. Perform Hydrostatic Pump and Motor Initial Start-Up Procedure. (Group 9026-25.)

15. Fill hydrostatic reservoir. See Transmission and Hydraulic Reservoir Oil. (Operators Manual.) Also Change Hydrostatic Transmission Oil and Replace Hydrostatic Charge and Fan Oil Filters. (Operators

19. Calibrate transmission controller. See Transmission Control Unit (TCU) Calibration. (Group 9015-20.)

TE14778,00000CE –19–06SEP05–11/11

TM2261 (10FEB06)

03-0300-7

750J, 850J Crawler 032806

PN=199

Remove and Install

Hydrostatic Motor Remove and Install 1. Lower all equipment to ground. 2. Stop engine. Operate all hydraulic controls to release pressure in hydraulic system. 3. Turn battery disconnect switch to OFF. 4. Drain reservoir or apply a vacuum to reservoir. Specification Hydrostatic Reservoir—Capacity.................................................... 105.6 L 27.9 gal

5. Remove rear access cover or rear mounted optional equipment from rear of machine.

TE14778,00000D0 –19–14JUL05–1/4

–UN–19MAY05

CAUTION: Escaping fluid under pressure can penetrate the skin causing serious injury. Stop engine and relieve pressure in system before disconnecting or connecting hydraulic or other lines. Tighten all connections before applying pressure. 6. Tag and mark hose locations to aid in assembly.

T211388A

03 0300 8

7. Disconnect case drain hose (1), diagnostic pressure hoses (4) and forward and reverse hoses (2 and 3). 8. Close all openings using caps and plugs.

1—Case Drain Hose 2—Forward Direction Hose 3—Reverse Direction Hose 4—Diagnostic Hose (2 used) 5—Motor Shift Solenoid Connector 6—Motor Speed Sensor Connector 7—Cap Screw (4 used) 8—Washer (4 used)

9. Disconnect wire connectors from motor shift solenoid (5) and motor speed sensor (6).

Continued on next page

TM2261 (10FEB06)

03-0300-8

TE14778,00000D0 –19–14JUL05–2/4

750J, 850J Crawler 032806

PN=200

Remove and Install

–UN–15JUN05

CAUTION: Hydrostatic Motor is heavy and can cause injury if not moved properly. Use adequate lifting device to move hydrostatic motor.

T211467A

Hydrostatic Motor—Specification 750J—Approximate Weight ............................................................... 61 kg 134 lb 850J—Approximate Weight ............................................................... 94 kg 207 lb

10. Attach DFT1243 Lifting Bracket Extension (1) to DFT1250 Lifting Bracket (2) using M20 x 2.5 x 130 cap screws, washers, and nuts (3). Attach to hoist. See DFT1250 Lifting Bracket. (Group 9900.) See DFT1243 Lifting Bracket Extension. (Group 9900.)

1—DFT1243 Lifting Bracket Extension 2—DFT1250 Lifting Bracket 3—Cap Screws, Washers, and Nuts (2 used) 4—DFT1137 Hydrostatic Motor Removal and Installation Tool

11. Attach DFT1137 Hydrostatic Motor Removal and Installation Tool to motor. See DFT1137 Hydrostatic Motor Removal and Installation Tool. (Group 9900.)

03 0300 9

12. Attach DFT1243 to eyebolt in DFT1137. 13. Remove four cap screws and washers from motor mounting flange. 14. Carefully pry motor away from mounting plate. 15. Remove through hole in rear of machine. 16. Repair or replace motor. 17. Install aligning studs to aid assembly. 18. Apply petroleum jelly to new O-ring and install on transmission motor pilot. 19. Guide hydrostatic motor through frame opening. 20. Position motor on aligning studs. Align splines in coupler and slide motor into position. 21. Apply TY16285 Cure Primer and T43512 Thread Lock and Sealer (Medium Strength) to threads of cap screws and install. Tighten to specification.

Continued on next page

TM2261 (10FEB06)

03-0300-9

TE14778,00000D0 –19–14JUL05–3/4

750J, 850J Crawler 032806

PN=201

Remove and Install Specification Hydrostatic Motor Mounting Cap Screws—Torque ........................................................................... 320 N•m 236 lb-ft

22. Remove hydrostatic motor removal and installation tools. 23. Connect hydrostatic lines and wiring connectors. 24. Install rear access plate or rear mounted optional equipment. 25. Replace bottom access plates if removed.

03 0300 10

26. Fill reservoir if drained. See Transmission and Hydraulic Oil. (Operators Manual.) 27. Turn battery disconnect switch to ON. 28. Perform Hydrostatic Pump and Motor Initial Start-Up Procedure. (9026-25.) 29. Calibrate machine. See Transmission Control Unit (TCU) Calibration. (9015-20)

TE14778,00000D0 –19–14JUL05–4/4

TM2261 (10FEB06)

03-0300-10

750J, 850J Crawler 032806

PN=202

Group 0315

Control Linkage Transmission Control Lever (TCL) Remove and Install 1. Turn battery disconnect switch to the OFF position.

NOTE: Mark electrical connectors to aid in assembly. 2. Disconnect rotary sensors (1 and 3) and neutral start switch (2).

–UN–16APR04

3. Disconnect harness connectors (4 and 5) to transmission speed control switch and horn button.

T199271A

1—Steer Sensor 2—Neutral Start Switch 3—FNR Sensor 4—Harness to Horn Switch 5—Harness to Transmission Switch

CED,TX03543,2276 –19–12JUL05–1/2

4. Remove four hex flange screws and transmission control lever (TCL) assembly. 5. Install transmission control lever (TCL) assembly using four hex flange screws. 6. Connect rotary sensors (1 and 3) and neutral start switch (2).

8. Adjust transmission control lever (TCL). See Transmission Control Lever (TCL) Adjustment. (Group 9015-20.)

T199276A

9. Recalibrate transmission controller. See Transmission Control Unit (TCU) Calibration. (Group 9015-20.)

–UN–16APR04

7. Turn battery disconnect switch to the ON position.

1—Hex Flange Screw

CED,TX03543,2276 –19–12JUL05–2/2

TM2261 (10FEB06)

03-0315-1

750J, 850J Crawler 032806

PN=203

03 0315 1

Control Linkage

Transmission Control Lever (TCL) Disassemble and Assemble

T199250

–UN–15APR04

03 0315 2

T199250 Transmission Control Lever (TCL) Continued on next page

TM2261 (10FEB06)

03-0315-2

CED,OUTX547,108 –19–14JUL05–1/31

750J, 850J Crawler 032806

PN=204

Control Linkage 1—Transmission Control Lever (TCL) 2—(TCL) Harness, Switch and Cover 3—Switch Cover 4—Cap Screw (4 used) 5—Screw kit For Handle 6—Not Used 7—Spring Pin (3 used) 8—Cable Clamp 9—Tie Band 10—Not Used 11—Not Used 12—Not Used 13—Not Used 14—Not Used 15—Ball Joint 16—Nut 17—Nut (2 used) 18—Spring

19—Spacer (2 used) 20—Spring 21—Stepped Washer (2 used) 22—Spring 23—Spring 24—Spring Pack Assembly 25—Linkage 26—Ball Joint 27—Nut (2 used) 28—Ball Joint 29—Rotary Sensor Kit 30—Not Used 31—Cap Screw (2 used) 32—O-Ring 33—Bearing (3 used) 34—Washer (2 used) 35—Plate 36—Washer 37—Socket Head Screw 38—Cap Screw (2 used)

39—Detent Lever Assembly 40—O-Ring (2 used) 41—Cap Screw (6 used) 42—Socket Head Cap Screw 43—Spacer 44—Spacer 45—Spring 46—Nut (2 used) 47—Detent Shaft 48—Neutral Cam 49—Cam Cover 50—SLC Body 51—O-Ring 52—Neutral Start Switch 53—Spring Plate 54—Seal Plug (2 used) 55—Shaft 56—Needle Bearing (2 used) 57—Lip Seal (2 used)

58—Bracket Assembly 59—Lip Seal (2 used) 60—Bearing Block 61—Shaft 62—Needle Bearing 63—Mounting Post (4 used) Longer Threaded Post Shown 64—Mounting Plate And FNR Label 65—Boot Assembly 66—Not Used 67—Not Used 68—Not Used 69—Not Used 70—Screw (4 used) 71—Not Used 72—Transmission Control Lever (TCL) Assembly 03 0315 3

CED,OUTX547,108 –19–14JUL05–2/31

T199273A

–UN–16APR04

1. Remove transmission control lever (TCL) from side console. See Transmission Control Lever (TCL) Remove and Install. (Group 0315.)

Continued on next page

TM2261 (10FEB06)

03-0315-3

CED,OUTX547,108 –19–14JUL05–3/31

750J, 850J Crawler 032806

PN=205

Control Linkage 2.• Separate boot from plate using a screwdriver. • Remove tie bands (1). • Put identification marks (2) on both sides of wire lead to aid in assembly. • Remove clamp (3) from wire lead.

–UN–17SEP99

1—Tie Bands 2—Identification Marks 3—Clamp

T124638B

03 0315 4

CED,OUTX547,108 –19–14JUL05–4/31

• Remove screws (1, 2 and 3) and boot from SLC.

T124645B

–UN–17SEP99

1—Screw (2 used) 2—Screw 3—Screw with nut (2 used)

SLC Assembly With Speed In Grip Shown

Continued on next page

TM2261 (10FEB06)

03-0315-4

CED,OUTX547,108 –19–14JUL05–5/31

750J, 850J Crawler 032806

PN=206

Control Linkage • Split grip halves (1) to remove switch (2). Boot (3) on switch can be replaced, if necessary.

T124646B

–UN–17SEP99

1—Grip 2—Switch 3—Boot

Speed In Grip Switch

CED,OUTX547,108 –19–14JUL05–6/31

3. Loosen lock nut (1). 4. Remove steer shaft (2) from rod end (3). 5. Remove two socket head cap screws (4) and remove steer shaft assembly from body.

T119639B

–UN–19JAN99

1—Lock Nut 2—Steer Shaft 3—Rod End 4—Socket Head Cap Screw (2 used)

Continued on next page

TM2261 (10FEB06)

03-0315-5

CED,OUTX547,108 –19–14JUL05–7/31

750J, 850J Crawler 032806

PN=207

03 0315 5

Control Linkage 6. Remove rod end lock nut (8).

NOTE: Use two wrenches to loosen spring end lock nuts (1). –UN–19JAN99

NOTE: Springs are color coded to aid in assembly.

T119641B

7. Remove one spring end lock nut (1), spring guide (2), spacer (3), spring (4) or (7) and spring seat (5) from one side of steering plate (6). 8. Place steer shaft (9) in soft jaw vise and remove spring end lock nut (1), spring guide (2), spacer (3), spring (4) or (7) and spring seat (5) from other side of steering plate.

–UN–19JAN99

1—Spring End Lock Nut (2 used) 2—Spring Guide (2 used) 3—Spacer (2 used) 4—Springs (chrome) 5—Spring Seat (2 used) 6—Steering Plate 7—Springs (gold) 8—Rod End Lock Nut 9—Steer Shaft

T119642B

03 0315 6

Continued on next page

TM2261 (10FEB06)

03-0315-6

CED,OUTX547,108 –19–14JUL05–8/31

750J, 850J Crawler 032806

PN=208

Control Linkage 9. Remove two socket head cap screws (1), retaining plate (2) and detent spring (3). 10. Remove nut (4), socket head cap screw (8), spacer (5), washer (7) and detent lever (9). 11. Remove tube (6) from detent lever.

T119643B

–UN–19JAN99

1—Socket Head Cap Screws (2 used) 2—Retaining Plate 3—Detent Spring 4—Nut 5—Spacer 6—Tube 7—Washer 8—Socket Head Cap Screw 9—Detent Lever

CED,OUTX547,108 –19–14JUL05–9/31

12. Remove socket head cap screws from steer sensor (1) and forward/reverse sensor (2). Remove sensors and O-rings. –UN–19JAN99

13. Remove cover (3) and neutral start switch (4).

T119645B

–UN–19JAN99

T119644B

1—Steer Sensor 2—Forward/Reverse Sensor 3—Cover 4—Neutral Start Switch

Continued on next page

TM2261 (10FEB06)

03-0315-7

CED,OUTX547,108 –19–14JUL05–10/31

750J, 850J Crawler 032806

PN=209

03 0315 7

Control Linkage 14. Disconnect forward/reverse rod end (1) and remove steer rod end (2) from bracket assembly (3).

T119646B

–UN–19JAN99

1—Forward/Reverse Rod 2—Steer Rod 3—Bracket Assembly

CED,OUTX547,108 –19–14JUL05–11/31

–UN–19JAN99

15. Remove two seal plugs and using a 1/4 in. punch with rounded edges, drive pivot pin (1) from bracket assembly. Remove bracket.

T119649B

1—Pivot Pin

CED,OUTX547,108 –19–14JUL05–12/31

16. Remove steer sensor shaft (2) and bearing block (1).

–UN–19JAN99

1—Bearing Block 2—Steer Sensor Shaft

T119650B

03 0315 8

NOTE: Care should be taken to avoid damaging bearing block, bearings and seals.

Continued on next page

TM2261 (10FEB06)

03-0315-8

CED,OUTX547,108 –19–14JUL05–13/31

750J, 850J Crawler 032806

PN=210

Control Linkage NOTE: When driving pin out of detent plate, support assembly to prevent damage to bearings and seals. 17. With the detent placed at the furthest reverse position, drive spring pin (1) out until detent plate (2) can be rotated around detent shaft (3). –UN–18JAN99

18. Remove detent shaft (3) by pulling on cam (5). Be sure to catch detent plate (2) with rod end assembly and two spacers (4) when removing detent shaft.

T119651B

19. Remove rod end assembly from detent plate, if replacement is required. 20. Remove cam (5) from detent shaft (3) by driving out spring pin, if replacement is required. 21. Remove pin (1) from detent plate.

Continued on next page

TM2261 (10FEB06)

03 0315 9

1—Spring Pin 2—Detent Plate 3—Detent Shaft 4—Spacers (2 used) 5—Cam

03-0315-9

CED,OUTX547,108 –19–14JUL05–14/31

750J, 850J Crawler 032806

PN=211

Control Linkage 22. Remove yoke pivot pin seals (1) and steer shaft seals (3) using a pick. 23. Remove yoke pivot pin bearings (2) using a punch.

T121377B

–UN–11MAY99

24. Remove steer shaft bearings (4) and detent shaft bearings (5) using JDG1303-1 Bearing Driver and JDG1303-2 or JDG1303-3 Sleeve from JDG1303 Bearing Driver Kit. 25. Clean and inspect parts.

–UN–11MAY99 T121378B –UN–11MAY99 T121379B

03 0315 10

1—Yoke Pivot Pin Seal (2 used) 2—Yoke Pivot Pin Bearing (2 used) 3—Steer Shaft Seal (2 used) 4—Steer Shaft Bearing (2 used) 5—Detent Shaft Bearing (2 used)

Continued on next page

TM2261 (10FEB06)

03-0315-10

CED,OUTX547,108 –19–14JUL05–15/31

750J, 850J Crawler 032806

PN=212

Control Linkage IMPORTANT: Drive bearing from lettered side of bearing only.

27. Repeat step 28 for installing other yoke pivot pin bearing.

–UN–11MAY99

IMPORTANT: Lip side of seal must face away from bearing.

T121380B

26. Install yoke pivot pin bearing (3) using JDG1303-4 Driver Disk and JDG1303-5 Driver Rod. Drive bearing until driver disk is fully seated on yoke, this will set bearing to proper depth.

28. Apply petroleum jelly to seal and install seal (5) on JDG1303-7 Driver Disk (4) with lip of seal facing toward driver disk.

03 0315 11

–UN–11MAY99

29. Place seal and driver disk square on yoke. Insert JDG1303-5 Driver Rod and drive seal until driver disk is fully seated on yoke.

T121381B

30. Repeat steps 30 and 31 for installing other yoke pivot pin seals. 1—JDG1305-5 Driver Rod 2—JDG1303-4 Driver Disk 3—Yoke Pivot Pin Bearing (2 used) 4—JDG1303-7 Driver Disk 5—Yoke Pivot Pin (2 used)

Continued on next page

TM2261 (10FEB06)

03-0315-11

CED,OUTX547,108 –19–14JUL05–16/31

750J, 850J Crawler 032806

PN=213

Control Linkage IMPORTANT: Drive bearing from lettered side of bearing only.

–UN–11MAY99

31. Install steer shaft cap bearing (3) using JDG1303-1 Bearing Driver (1) and JDG1303-3 Sleeve (2). Drive bearing until driver is fully seated, this will set bearing to proper depth.

T121382B

32. Install steer shaft bearing (4) using JDG1303-1 Bearing Driver. Drive bearing until driver is fully seated, this will set bearing to proper depth. IMPORTANT: Lip side of seal must face away from bearing. 33. Apply petroleum jelly to seals install seal (5) on JDG1303-6 Driver Disk with lip of seal facing toward driver disk.

–UN–11MAY99

34. Place seal and driver disk square in opening and firmly press with finger pressure to install seal. Press disk driver until fully seated.

T121383B

35. Repeat steps to install other steer shaft seals.

–UN–11MAY99

1—JDG1303-1 Bearing Driver 2—JDG1303-3 Sleeve 3—Steer Shaft Cap Bearing 4—Steer Shaft Bearing 5—Steer Shaft Seal (2 used)

T121384B

03 0315 12

Continued on next page

TM2261 (10FEB06)

03-0315-12

CED,OUTX547,108 –19–14JUL05–17/31

750J, 850J Crawler 032806

PN=214

Control Linkage IMPORTANT: Drive bearing from lettered side of bearing only.

–UN–11MAY99

36. Install detent shaft bearing (3) from the stepped recess side (yellow) opening. Using JDG1303-1 Bearing Driver (1) and JDG1303-2 Sleeve (2), drive bearing through until bearing driver is fully seated. This will set bearing to proper depth.

T121385B

37. Install detent shaft bearing (4) using JDG1303-1 Bearing Driver. Drive bearing until bearing driver is fully seated, this will set bearing to proper depth. 1—JDG1303-1 Bearing Driver 2—JDG1303-2 Sleeve 3—Detent Shaft Bearing 4—Detent Shaft Bearing

T121386B

–UN–11MAY99

03 0315 13

Continued on next page

TM2261 (10FEB06)

03-0315-13

CED,OUTX547,108 –19–14JUL05–18/31

750J, 850J Crawler 032806

PN=215

Control Linkage 38. Install rod on detent plate, if removed. Tighten nut to specifications. Single Lever Control—Specification Detent Plate Rod Ball Joint Nut— Torque ............................................................................................ 19 N•m 168 lb-in.

–UN–18JAN99

39. Install cam (5) on detent shaft and install spring pin.

40. While holding detent plate (2) and spacers (4) in place, install detent shaft (3) as shown with spring pin holes for plate and cam in line. Install spring pin (1) in detent plate.

1—Spring Pin 2—Detent Plate 3—Detent Shaft 4—Spacers (2 used) 5—Cam

CED,OUTX547,108 –19–14JUL05–19/31

NOTE: Align pin bore in bearing block and sensor shaft. 41. Install bearing block (1) and steer sensor shaft (2).

T119650B

–UN–19JAN99

1—Bearing Block 2—Steer Sensor Shaft

CED,OUTX547,108 –19–14JUL05–20/31

NOTE: Care should be taken to avoid damaging bearing block, bearings and seals.

–UN–19JAN99

42. Install lever assembly, and using a 1/4 in. punch with rounded edges, drive pivot pin (1) into bracket assembly. Pin should protrude equally on both ends. 43. Install seal plugs.

T119649B

03 0315 14

T119651B

NOTE: When driving pin in detent plate, support assembly to prevent damage to bearings and seals.

1—Pivot Pin

Continued on next page

TM2261 (10FEB06)

03-0315-14

CED,OUTX547,108 –19–14JUL05–21/31

750J, 850J Crawler 032806

PN=216

Control Linkage

–UN–19JAN99

44. Apply cure primer and thread lock and sealer (medium strength) to threads of rod ends. Connect forward/reverse rod end (1) and install steer rod end (2) on bracket assembly (3). Tighten ball joint nuts to specifications.

T119646B

Single Lever Control—Specification Forward/Reverse Rod Ball Joint Nut—Torque ................................................................................... 14 N•m 124 lb-in. Steer Rod Ball Joint Nut—Torque.................................................... 9 N•m 80 lb-in.

1—Forward/Reverse Rod 2—Steer Rod 3—Bracket Assembly 03 0315 15 CED,OUTX547,108 –19–14JUL05–22/31

NOTE: Steer sensor and forward/reverse sensors are interchangeable.

–UN–19JAN99

45. Install sensors (1 and 2) and O-rings. Tighten cap screws to specifications.

T119644B

Single Lever Control—Specification Steer Sensor Mounting Cap Screws—Torque ............................................................................... 5 N•m 44 lb-in. Forward/Reverse Sensor Mounting Cap Screws—Torque ....................................................... 5 N•m 44 lb-in.

46. Install neutral start switch (4) and tighten to specifications.

–UN–19JAN99

Single Lever Control—Specification Neutral Start Switch—Torque......................................................... 14 N•m 124 lb-in.

T119645B

47. Install cover (3) and tighten cap screws to specifications. Single Lever Control—Specification Neutral Start Switch Cover Cap Screws—Torque ............................................................................... 5 N•m 44 lb-in. 1—Steer Sensor 2—Forward/Reverse Sensor 3—Cover 4—Neutral Start Switch

Continued on next page

TM2261 (10FEB06)

03-0315-15

CED,OUTX547,108 –19–14JUL05–23/31

750J, 850J Crawler 032806

PN=217

Control Linkage 48. Install tube (6), washer (7), spacer (5), socket head cap screw (8) and nut (4). Tighten cap screw first and then nut, to specifications. Single Lever Control—Specification Detent Lever Socket Head Cap Screw and Nut—Torque ................................................................. 19 N•m 168 lb-in.

49. Install detent spring (3), retaining plate (2) and socket head cap screws (1). Tighten cap screws to specifications.

T119643B

03 0315 16

–UN–19JAN99

Single Lever Control—Specification Detent Spring Retaining Plate Cap Screws—Torque ....................................................................... 5 N•m 44 lb-in.

1—Socket Head Cap Screws (2 used) 2—Retaining Plate 3—Detent Spring 4—Nut 5—Spacer 6—Tube 7—Washer 8—Socket Head Cap Screw 9—Detent Lever

Continued on next page

TM2261 (10FEB06)

03-0315-16

CED,OUTX547,108 –19–14JUL05–24/31

750J, 850J Crawler 032806

PN=218

Control Linkage NOTE: Steering plate (6) must be installed so that the flat side faces chrome spring (4).

–UN–19JAN99

50. Place steering shaft in soft jaw vise. Install steering plate (6), spring seat (5), spring (4) or (7), spacer (3) spring guide (2) and spring end lock nut (1). Repeat steps for opposite end, then tighten spring end lock nuts (1) to specifications.

T119641B

Single Lever Control—Specification Steer Shaft Spring End Lock Nuts—Torque ................................................................................... 8 N•m 71 lb-in.

51. Install rod end lock nut (8). 03 0315 17

T119642B

–UN–19JAN99

1—Spring End Lock Nut (2 used) 2—Spring Guide (2 used) 3—Spacer (2 used) 4—Springs (chrome) 5—Spring Seat (2 used) 6—Steering Plate 7—Springs (gold) 8—Rod End Lock Nut 9—Steer Shaft

CED,OUTX547,108 –19–14JUL05–25/31

52. Install steer shaft assembly and two socket head cap screws (4). Tighten cap screws to specifications. Single Lever Control—Specification Steer Shaft Assembly Mounting Cap Screws—Torque ..................................................................... 34 N•m 25 lb-ft

–UN–19JAN99

53. Screw steer shaft into rod end (3) and tighten lock nut (1).

T119639B

1—Lock Nut 2—Steer Shaft 3—Rod End 4—Socket Head Cap Screw (2 used)

Continued on next page

TM2261 (10FEB06)

03-0315-17

CED,OUTX547,108 –19–14JUL05–26/31

750J, 850J Crawler 032806

PN=219

Control Linkage

–UN–17SEP99

54. If removed, install boot (3) and switch (2) in grip (1).

T124646B

03 0315 18

CED,OUTX547,108 –19–14JUL05–27/31

T124645B

–UN–17SEP99

55. Install and tighten screws (1—3).

Continued on next page

TM2261 (10FEB06)

03-0315-18

CED,OUTX547,108 –19–14JUL05–28/31

750J, 850J Crawler 032806

PN=220

Control Linkage IMPORTANT: Tie bands MUST be installed and wire lead MUST be positioned in clamp between assembly marks to provide a loop in wiring harness for steering. 56. Install tie bands (1) on wire harness.

T124638B

–UN–17SEP99

57. Install clamp (3).

CED,OUTX547,108 –19–14JUL05–29/31

58. Install four socket head cap screws (1) and tighten to specification. Specification Transmission Control Lever (TCL) Top Plate Socket Head Cap Screws—Torque ............................................................................... 9 N•m 6.6 lb ft

59. Install boot (2).

T199277A

–UN–16APR04

1—Socket Head Cap Screw (4 used)

Continued on next page

TM2261 (10FEB06)

03-0315-19

CED,OUTX547,108 –19–14JUL05–30/31

750J, 850J Crawler 032806

PN=221

03 0315 19

Control Linkage 60. Install transmission control lever (TCL) assembly inside console. See Transmission Control Lever (TCL) Remove and Install. (Group 0315.) Install four cap screws (1) and tighten to specification. Specification Transmission Control Lever (TCL) Top Plate Cap Screws—Torque .................................................... 37 N•m 27 lb ft

62. Recalibrate transmission controller. See Transmission Control Unit (TCU) Calibration. (Group 9015-20.)

T199276A

03 0315 20

–UN–16APR04

61. Adjust single lever control. See Transmission Control Lever (TCL) Adjustment. (Group 9015-20.)

CED,OUTX547,108 –19–14JUL05–31/31

TM2261 (10FEB06)

03-0315-20

750J, 850J Crawler 032806

PN=222

Group 0360

Hydrostatic System

03 0360 1

TM2261 (10FEB06)

03-0360-1

750J, 850J Crawler 032806

PN=223

Hydrostatic System

Hydrostatic Pump Disassemble

–UN–02JUN95

IMPORTANT: If only shaft and/or shaft seal are being replaced, major disassembly of pump or removal of speed sensor is not required. Pump MUST be positioned with the shaft UP to prevent damage to sensor or speed ring.

NOTE: Displacement control valve can be disassembled for cleaning ONLY. (See procedure in this group.)

–UN–13FEB96

2. Remove six internal hex screws (1) and pump displacement control valve from housing. IMPORTANT: After the seal carrier is removed, the shaft and bearing assembly are free in housing. DO NOT remove shaft unless it is positioned with the shaft UP. If pump is positioned horizontally when the shaft is removed, the cylinder block will move out of place, making shaft installation difficult.

T100315

03 0360 2

T8492AC

1. Remove four internal hex screws (3) and pressure control pilot (PCP) from pump displacement control valve. PCP is serviced as an assembly. DO NOT disassemble.

1—Internal Hex Screw 2—Retainer Plate Screw 3—Internal Hex Screw 4—O-Ring

3. Remove retainer plate screws (2). 4. Remove retainer plate. A spring inside the rotate group will try to overcome the friction from the O-ring on the seal carrier OD. If seal carrier does not move from its bore, use a rubber hammer and tap on top of shaft. Spring inside rotating group will move seal carrier upward from bore. 5. Remove O-ring (4) from carrier. 6. Inspect seal carrier and seal for any damage or nicks.

NOTE: Apply thread lock and sealer (medium strength) to outside diameter of seal prior to installation. 7. Use a press to remove and install new seal when necessary.

Continued on next page

TM2261 (10FEB06)

03-0360-2

TX,0300,YY1123 –19–07JUL05–1/16

750J, 850J Crawler 032806

PN=224

Hydrostatic System

–UN–14JUN95 T8464AD

9. Remove retaining ring and press shaft out of bearing.

–UN–14JUN95

NOTE: On the 750J the front pump shaft (A) is different from the rear pump shaft (B). On the 850J the front pump shaft and rear pump shaft are the same.

T8464AC

8. Remove the shaft and bearing assembly from the housing. The bearing outside diameter is a slip fit in the housing bore.

A—Front Pump Shaft—750J B—Rear Pump Shaft—750J

T100313

–UN–13FEB96

03 0360 3

Continued on next page

TM2261 (10FEB06)

03-0360-3

TX,0300,YY1123 –19–07JUL05–2/16

750J, 850J Crawler 032806

PN=225

Hydrostatic System 10. Place pump with auxiliary mounting flange UP. 11. Remove end cap to pump housing cap screws (1). 12. Remove large cap screws (2) and mounting flange. 1—Pump Housing Cap Screws 2—Large Cap Screws

T8493AB

–UN–02JUN95

03 0360 4

T8464AH

13. Remove end cap from housing. Remove end cap gasket and swash plate leveling spring shims from the spring pockets in the end cap.

NOTE: The two long swash plate leveler springs are nested, with the smaller spring installed into the larger spring.

T8464AI

–UN–14JUN95

IMPORTANT: Note quantity of swash plate leveling spring shims removed from end cap spring pockets. The same quantity MUST be used for assembly.

–UN–14JUN95

TX,0300,YY1123 –19–07JUL05–3/16

14. Remove two long swash plate leveler springs and one short swash plate hold down spring.

Continued on next page

TM2261 (10FEB06)

03-0360-4

TX,0300,YY1123 –19–07JUL05–4/16

750J, 850J Crawler 032806

PN=226

Hydrostatic System

–UN–14JUN95 T8464AM –UN–14JUN95

T8464AL

18. Remove spring seats from swash plate leveler.

T8464AN

17. Remove side cover and swash plate leveler (T-bar) assembly from housing.

T8464AJ

16. Scribe a line on the side cover and the housing.

–UN–14JUN95

15. Remove the alignment pins and valve plate. Note the direction of the arrows on the valve plate for assembly.

TX,0300,YY1123 –19–07JUL05–5/16

T100196

–UN–12FEB96

T8464AO

A—Side Cover B—Guide Post C—Swash Plate Leveler (T-Bar) D—Wear Strips E—O-Ring

T8464CL

–UN–14JUN95

20. Remove swash plate leveler and O-ring from side cover.

–UN–14JUN95

19. Remove two guide posts and sealing nuts holding the leveler to the side cover.

Continued on next page

TM2261 (10FEB06)

03-0360-5

TX,0300,YY1123 –19–07JUL05–6/16

750J, 850J Crawler 032806

PN=227

03 0360 5

Hydrostatic System

T8464AS

23. Carefully pry each cylinder from the housing using a screwdriver in the groove of the cylinder. The servo piston will remain in the housing.

–UN–14JUN95

22. Remove cap screws from each servo piston.

T8464AT

–UN–14JUN95

21. Scribe a line on each servo cylinder and the housing to identify each servo cylinder with its respective side of the housing.

24. Remove the cylinder block through the housing end cap opening. The swash plate and piston assembly will remain in the housing.

03 0360 6 TX,0300,YY1123 –19–07JUL05–7/16

T8464AV

T8464AU

–UN–14JUN95

26. Remove the bearing cage locator link from the swash plate through the control opening. Inspect link for wear or damage and replace as necessary.

–UN–14JUN95

25. Remove the swash plate bearing cage link pin from the housing through the control opening.

T8464AW

28. Remove the servo piston and slider block from housing.

Continued on next page

TM2261 (10FEB06)

03-0360-6

T8464AX

–UN–14JUN95

27. Remove swash plate and pistons through the housing side cover. Disengage the servo arm from the slider block located in the servo piston as the assembly is removed.

–UN–14JUN95

TX,0300,YY1123 –19–07JUL05–8/16

TX,0300,YY1123 –19–07JUL05–9/16

750J, 850J Crawler 032806

PN=228

Hydrostatic System

T8464AZ

T8464AY

–UN–14JUN95

30. Remove the bearing races. The bearing races are a loose fit on two locating pins in the housing.

–UN–14JUN95

29. Remove the swash plate cradle bearing cage.

TX,0300,YY1123 –19–07JUL05–10/16

31. Remove four cap screws holding the slipper guide hold down mechanism to the swash plate.

T8464BB

–UN–14JUN95

03 0360 7

TX,0300,YY1123 –19–07JUL05–11/16

32. Remove the piston assemblies from the slipper guide.

T8464BE

–UN–14JUN95

33. After disassembly all parts should be thoroughly cleaned. Replace all O-rings, gaskets, and the shaft seal. Inspect all parts for damage, nicks, or unusual or excessive wear or discoloration. If the end cap journal bearing needs replacement (as evidenced by large amounts of the metal back of the bearing being visible through the plastic bearing material), replace end cap.

Continued on next page

TM2261 (10FEB06)

03-0360-7

TX,0300,YY1123 –19–07JUL05–12/16

750J, 850J Crawler 032806

PN=229

Hydrostatic System

T8464BF

–UN–05JUL95

34. Clean threaded holes in swash plate that attach slipper guide of all retaining compound prior to assembly.

TX,0300,YY1123 –19–07JUL05–13/16

–UN–14JUN95

35. Inspect servo arm (2) and swash plate guide (4) for wear. Replace as necessary.

T8500AB

03 0360 8

NOTE: Servo arm and swash plate guide are both retained with the same special locking screw. Servo arm alignment is critical to proper pump operation. For this reason, removal of the servo arm from the swash plate is not recommended. Swash plate is serviced as an assembly.

36. Inspect headed roll pin and washer (1) for the bearing cage locator link. 1—Headed Roll Pin and Washer 2—Swash Plate Guide 3—Feedback Link 4—Servo Arm

37. Remove cap screw securing feedback link (3) and inspect for wear or damage. Clean cap screw threads with clean and cure primer. Apply thread lock and sealer (high strength) to threads. Install feedback link. Tighten cap screw to specification. Feedback Link Cap Screw—Specification 750J—Torque .............................................................................. 32.5 N•m 24 lb-ft 850J—Torque .............................................................................. 54.2 N•m 40 lb-ft

Continued on next page

TM2261 (10FEB06)

03-0360-8

TX,0300,YY1123 –19–07JUL05–14/16

750J, 850J Crawler 032806

PN=230

Hydrostatic System

T8464BI

40. Lubricate seal rings and carefully slide the servo piston into the servo cylinders. Allow the assembly to sit 5—10 minutes to allow the seal rings to return to their original size. Remove servo cylinders.

T8464BJ

–UN–14JUN95

39. Install new expander O-rings and seal rings into the grooves of the servo piston.

–UN–14JUN95

38. Inspect servo piston and sealing rings for wear and replace as necessary.

TX,0300,YY1123 –19–07JUL05–15/16

41. Compress the cylinder block spring and remove the spiral retaining ring, retainer, spring and spring seat. Clean cylinder block components and reassemble.

T8492AA

–UN–14JUN95

03 0360 9

TX,0300,YY1123 –19–07JUL05–16/16

Charge Pump Disassemble and Assemble IMPORTANT: Absolute cleanliness is essential when working on hydrostatic components. –UN–17MAY04

1. Remove socket head cap screws (1), adapter (2) and O-ring.

T199994A

1—Socket Head Cap Screw (4 used) 2—Adaptor Plate

CED,OUO1008,146 –19–07JUL05–1/10

2. Remove cap screws (3) and retaining plate (4).

T199995A

–UN–17MAY04

3—Cap Screw (6 used) 4—Retaining Plate

Continued on next page

TM2261 (10FEB06)

03-0360-9

CED,OUO1008,146 –19–07JUL05–2/10

750J, 850J Crawler 032806

PN=231

Hydrostatic System IMPORTANT: Wear patterns develop between pump gerotor assembly (5) and eccentric ring (6). Components must be installed in proper position with original orientation. –UN–17MAY04

3. Tag or identify visible side of pump gerotor assembly (5) and eccentric ring (6) to aid in proper assembly.

T199996A

4. Remove and inspect parts (1—8) and replace as required. 5. Remove bushing from charge pump cover (1). 1—Charge Pump Cover 2—Auxiliary Drive Coupling 3—Charge Pump Shaft 4—Key 5—Charge Pump Gerotor Assembly1 6—Eccentric Ring1 7—Alignment Pin 8—Port Plate

6. Clean all parts and lightly apply clean hydraulic oil. 03 0360 10

Serviced as an assembly CED,OUO1008,146 –19–07JUL05–3/10

IMPORTANT: Charge pump rotation is determined by the orientation of eccentric ring in the gerotor assembly, and the location of the alignment pin (1). Incorrect assembly will not provide charge oil to the pump and will result in damage to the pump.

–UN–17MAY04

NOTE: One of the large socket head cap screws and four washers must be installed in the end cap, as illustrated, before assembling the charge pump.

T199997A

7. Install charge pump alignment pin (1) in the right rotation hole as illustrated. 8. Install port plate (2). 1—Alignment Pin 2—Port Plate

Continued on next page

TM2261 (10FEB06)

03-0360-10

CED,OUO1008,146 –19–07JUL05–4/10

750J, 850J Crawler 032806

PN=232

Hydrostatic System IMPORTANT: Wear patterns develop between pump gerotor gears (3) and eccentric ring (1). Components must be installed in proper position with original orientation. 9. Install the eccentric ring (1) making sure alignment pin (2) is correctly installed. 10. Install the gerotor gears (3).

T119171B

–UN–07JAN99

1—Eccentric Ring 2—Alignment Pin 3—Gerotor Gears

CED,OUO1008,146 –19–07JUL05–5/10

11. Install charge pump shaft (1) with key (2) aligning with slot in gerotor gear.

T199993A

–UN–17MAY04

1—Pump Shaft 2—Key

CED,OUO1008,146 –19–07JUL05–6/10

12. Install auxiliary drive coupling (1).

T119593B

–UN–15JAN99

1—Auxiliary Drive Coupling

Continued on next page

TM2261 (10FEB06)

03-0360-11

CED,OUO1008,146 –19–07JUL05–7/10

750J, 850J Crawler 032806

PN=233

03 0360 11

Hydrostatic System 13. Install bushing in charge pump cover. 14. Install charge pump cover (2) making sure hole (1) in cover aligns correctly with alignment pin (3).

–UN–07JAN99

1—Hole in Cover 2—Charge Pump Cover 3—Alignment Pin

T119172B

03 0360 12

CED,OUO1008,146 –19–07JUL05–8/10

15. Install retaining plate (1) and cap screws (2). Tighten to specifications.

–UN–22JAN99

Hydrostatic Pump—Specification Charge Pump Retaining Plate Cap Screws—Torque ..................................................................... 14 N•m 120 lb-in.

T119594B

16. Lubricate O-ring (4) with petroleum jelly and install. 17. Remove socket head cap screw and washers (3). 1—Retaining Plate 2—Cap Screw (6 used) 3—Socket Head Cap Screw and Washers 4—O-Ring

Continued on next page

TM2261 (10FEB06)

03-0360-12

CED,OUO1008,146 –19–07JUL05–9/10

750J, 850J Crawler 032806

PN=234

Hydrostatic System 18. Install flange adapter (2). 19. Install socket head cap screws and washers (1). Tighten to specifications.

T199994A

20. Install pumps and calibrate transmission control unit (TCU). See Transmission Control Unit (TCU) Calibration. (Group 9015.)

–UN–17MAY04

Flange Adapter/End Cap-to-Hydrostatic Pump—Specification 750J—Torque ............................................................................... 271 N•m 200 lb-ft 850J—Torque ............................................................................... 298 N•m 220 lb-ft

1—Socket Head Cap Screw and Washer (4 used) 2—Flange Adapter 03 0360 13 CED,OUO1008,146 –19–07JUL05–10/10

TM2261 (10FEB06)

03-0360-13

750J, 850J Crawler 032806

PN=235

Hydrostatic System

Pump Displacement Control Valve (PDCV) Disassemble and Assemble IMPORTANT: DO NOT disassemble the PDCV housing, piston and barrel assembly (9). Correct backlash and neutral adjustment cannot be obtained if disassembled.

NOTE: The pump displacement control valve (PDCV) is serviced as an assembly and should only be disassembled for cleaning.

2. Clean and inspect all parts for wear or damage. –UN–23JUL96

3. Assemble PDCV after cleaning. 4. Perform Pump Displacement Control Valve (PDCV) Neutral (Null) Adjustment. (Group 9026-25.)

T102089

03 0360 14

1. Disassemble pump displacement control valve as shown. DO NOT disassemble the PDCV housing, piston and barrel assembly (9).

IMPORTANT: Calibrate transmission controller whenever a sensor or transmission component is adjusted or replaced. 5. Perform Transmission Control Unit (TCU) Calibration. (Group 9015-20.)

1—Outer Spring 2—Inner Spring 3—Spacer and O-Ring (850J only) 4—Linkage Identification Stamp (750J—10), (850J—13) 5—Feedback Link 6—Chamfered Side of Guide 7—Guide 8—Null Adjustment Screw 9—PDCV Housing, Piston and Barrel Assembly

TX,0300,YY1162 –19–12JUL05–1/1

TM2261 (10FEB06)

03-0360-14

750J, 850J Crawler 032806

PN=236

Hydrostatic System

Multi-Function Valve Remove and Install 1. Remove multi-function valve from hydrostatic pump housing. 2. Inspect valve for wear or damage. 3. Install and tighten valve to specification. Multi-Function Valve—Specification 750J—Torque .............................................................................. 78.6 N•m 58 lb-ft 850J—Torque ............................................................................... 210 N•m 155 lb-ft

4. If valve was disassembled for any reason or a new valve is installed, perform Multi-Function Relief Valve Test. (See procedure in Operation and Test Manual, Group 9026-25.)

03 0360 15

TX,0300,YY1163 –19–12JUL05–1/1

TM2261 (10FEB06)

03-0360-15

750J, 850J Crawler 032806

PN=237

Hydrostatic System

Multi-Function Valve Disassemble and Assemble NOTE: Multi-function valve is serviced as an assembly. 1. Disassemble multi-function valve as shown. Clean and inspect all parts for wear or damage. Replace valve if necessary. 2. Install new O-rings and assemble valve. 3. After multi-function valve is installed on machine, perform Multi-Function Relief Valve Test. (Group 9026-25.)

–UN–07JUN95

1—High Pressure Relief Valve Poppet 2—Check Valve Poppet 3—Pressure Limiter Poppet 4—Bypass Piston 5—Bypass Sleeve 6—O-Ring 7—Lock Nut 8—O-Ring 9—Spring 10—Spring Guide 11—O-Ring 12—Guide 13—Shim 14—Spring 15—O-Ring

T8497AA

03 0360 16

TX,0300,YY1164 –19–12JUL05–1/1

TM2261 (10FEB06)

03-0360-16

750J, 850J Crawler 032806

PN=238

Hydrostatic System

Hydrostatic Pump Assemble –UN–14JUN95

IMPORTANT: Be careful when handling parts with polished surfaces.

T8464BL

NOTE: Apply clean hydrostatic oil to all internal parts before assembly. Either side of slipper guide can be installed against slippers. 1. Install the piston assemblies into the slipper guide. (Pistons can be installed to either side of guide.) 2. Apply clean hydrostatic oil on slippers. Center the pistons and guide on the swash plate.

03 0360 17

NOTE: The split between the slipper guide bearing plates must be located in line with the swash plate arm. The bearing surface of the bearing plates must be located next to the slipper guide.

TX,0300,YY1139 –19–12JUL05–1/19

3. Apply thread lock and sealer (medium strength) on screw threads. Install two new screws and flat washers through the slipper guide bearing and spacers. Finger tighten the screws into the swash plate.

T8464BO

NOTE: Inspect the flat washers for raised edges or burrs. The smooth side of the flat washers must be installed next to the bearing plates.

T8464BP

–UN–14JUN95

Always use new screws to retain slipper guide bearing plates.

–UN–14JUN95

IMPORTANT: Install bearing plates with bronze side away from slipper guide.

In this photo, bronze side of bearing plate will be facing UP (away from slipper guide).

4. Assemble other half of bearing plate.

Continued on next page

TM2261 (10FEB06)

03-0360-17

TX,0300,YY1139 –19–12JUL05–2/19

750J, 850J Crawler 032806

PN=239

Hydrostatic System

6. Lubricate the pistons and cylinder block bores. Install the assembled swash plate and pistons into the cylinder block by inserting the pistons into the cylinder block bores. The pistons and bores are not selectively fitted, therefore no specific piston and bore orientation is required.

T8464BR

T8464BQ

–UN–14JUN95

Hydrostatic Pump Cover-to-Housing—Specification 750J—Torque .............................................................................. 13.5 N•m 119 lb-in. 750J—Torque .............................................................................. 32.5 N•m 24 lb-ft

–UN–14JUN95

5. Torque screws into swash plate. The slipper guide and piston slippers must slide freely on the swash plate.

03 0360 18 TX,0300,YY1139 –19–12JUL05–3/19

T8464AZ

T8464BS

–UN–14JUN95

8. Install the swash plate bearing races into the housing on the locating pins. Retain the races in position using petroleum jelly. The locating pins are offset in the housing to assure proper assembly.

–UN–14JUN95

7. Check that the swash plate bearing race locating pins are secure in the housing.

TX,0300,YY1139 –19–12JUL05–4/19

Continued on next page

TM2261 (10FEB06)

03-0360-18

T8464BV

T8464BU

–UN–14JUN95

10. Install the bronze slider block on the swash plate servo arm.

–UN–14JUN95

9. Assemble and lubricate the bearing cage and install on the bearing races.

TX,0300,YY1139 –19–12JUL05–5/19

750J, 850J Crawler 032806

PN=240

Hydrostatic System

T8464BX

–UN–14JUN95

11. Position the servo piston in the housing.

TX,0300,YY1139 –19–12JUL05–6/19

12. Carefully lower the cylinder block and swash plate assembly into the housing through the end cap opening.

03 0360 19

T8464BY

–UN–14JUN95

T8480AA

–UN–02JUN95

T8500AC

–UN–14JUN95

NOTE: A cap screw (approximately 9 in. long), two flat washers (2-1/2 OD) and nut can also be used to assist in lowering cylinder block into housing.

Continued on next page

TM2261 (10FEB06)

03-0360-19

TX,0300,YY1139 –19–12JUL05–7/19

750J, 850J Crawler 032806

PN=241

T8464CA

14. Move the servo piston on the slider block, taking care not to wedge the block. The parts must slide freely.

T8464CB

–UN–14JUN95

13. Hold the cylinder block and swash plate assembly approximately 13 mm (1/2 in.) above the cradle bearing. Properly position the feedback link in the control opening.

–UN–14JUN95

Hydrostatic System

TX,0300,YY1139 –19–12JUL05–8/19

–UN–14JUN95 T8464CD

NOTE: If an assembly tool was used to install cylinder block, remove nut and washer and allow cap screw and washer to fall through the shaft opening of the housing. 16. Install new O-rings on servo cylinders. Hold the servo piston in position and install the servo cylinders.

NOTE: Be sure to assemble the correct servo cylinder on each side of the housing. 17. Install and tighten servo cylinder cap screws to specification. Specification Servo Cylinder Cap Screw— Torque ............................................................................................ 32 N•m 24 lb-ft

19. Align the hole in the locator link with the hole in the housing and install the link anchor pin though the link and into the housing.

Continued on next page

TM2261 (10FEB06)

03-0360-20

T8464CJ

–UN–14JUN95

18. Align the slot in the swash plate bearing cage with the headed spring pin in the swash plate and the pin hole in the housing. Hook the cage locator link over the spring pin, between the washer and the swash plate. Rotate the link into the slot in the bearing cage.

–UN–14JUN95

TX,0300,YY1139 –19–12JUL05–9/19

T8464CH

03 0360 20

15. Lower the cylinder block and swash plate assembly until the swash plate is properly located on the cradle bearings.

TX,0300,YY1139 –19–12JUL05–10/19

750J, 850J Crawler 032806

PN=242

–UN–14JUN95 T8464CL

21. Install wear strips and position the swash plate leveler (T-bar) on the side cover. Note the orientation of the leveler and the cover.

–UN–14JUN95

20. Push the swash plate assembly toward the control side of the housing until the swash plate guide contacts the bearing race. Check for clearance between the servo arm and the slider block. If no clearance is present, recheck the assembly of the bearing cage and races.

T8464CK

Hydrostatic System

22. Install a new side cover O-ring.

T100196

–UN–12FEB96

A—Side Cover B—Guide Post C—Swash Plate Leveler (T-Bar) D—Wear Strip E—O-Ring

TX,0300,YY1139 –19–12JUL05–11/19

–UN–14JUN95

23. Apply thread lock and sealer (medium strength) to guide post threads. Install leveler, guide posts and sealing nuts. Tighten nuts to specification.

T8464CM

Pump Guide Post Nut—Specification 750J—Torque ................................................................................. 23 N•m 204 lb-in. 850J—Torque ................................................................................. 54 N•m 32 lb-ft

TX,0300,YY1139 –19–12JUL05–12/19

24. Install the leveler spring seats.

–UN–14JUN95

IMPORTANT: Tabs of T-bar MUST be positioned on top of swash plate. Otherwise damage to tabs will occur.

T8464CN

25. Install side cover and swash plate leveler (T-bar). Rotate the side cover to align the marks on the cover and housing that were made at disassembly.

Continued on next page

TM2261 (10FEB06)

03-0360-21

TX,0300,YY1139 –19–12JUL05–13/19

750J, 850J Crawler 032806

PN=243

03 0360 21

Continued on next page

T8464CP

T8464CO

–UN–14JUN95

26. Apply thread lock and sealer (medium strength) to cap screws. Install a cap screw finger tight to each side of swash plate cover while checking the “zero angle” position.

–UN–14JUN95

Hydrostatic System

TX,0300,YY1139 –19–12JUL05–14/19

03 0360 22

TM2261 (10FEB06)

03-0360-22

750J, 850J Crawler 032806

PN=244

Hydrostatic System

–UN–02JUN95

27. Install nested swash plate leveling springs (one small spring and one large spring on each side), servo arm link spring (single short spring) and JDG920-2 for 750J or JDG920-1 for 850J, swash plate leveling tool (1).

NOTE: Depth gauge MUST be located on swash plate and NOT on piston retainer plate.

T8481BL

28. Make sure the swash plate is properly located on its bearings. Using a depth micrometer, measure the distance from the pump housing to the top of swash plate. Take a second measurement on the opposite side of the swash plate. These measurements MUST not vary by more than specification. Rotate the side cover (which will also rotate the leveler and swash plate) until the zero angle position is established, as determined by the depth measurement.

1—Swash Plate Leveling Tool

03 0360 23

When zero angle position has been established, tighten the two side cap screws. Specification Swash Plate—Depth .................................................................. 0.025 mm 0.001 in.

NOTE: The two top cap screws have through holes. 29. Apply thread lock and sealer (medium strength) to screws. Install and tighten remaining cap screws to specification. Swash Plate Cover Cap Screw Blind Hole—Specification 750J—Torque ................................................................................. 32 N•m 24 lb-ft 850J—Torque ................................................................................. 64 N•m 47 lb-ft Swash Plate Cover Cap Screw Through Hole—Specification 750J—Torque ................................................................................. 25 N•m 221 lb-in. 850J—Torque ................................................................................. 50 N•m 37 lb-ft

Continued on next page

TM2261 (10FEB06)

03-0360-23

TX,0300,YY1139 –19–12JUL05–15/19

750J, 850J Crawler 032806

PN=245

Hydrostatic System 30. Install end cap alignment pins into housing.

–UN–14JUN95

31. Apply hydrostatic oil on running surface of cylinder block and install valve plate on alignment pins.

T8464AJ

NOTE: The arrow cutouts in the valve plate must point in the direction of pump rotation when viewed from the shaft end.

TX,0300,YY1139 –19–12JUL05–16/19

–UN–14JUN95

IMPORTANT: Use hardened swash plate leveler spring shims ONLY. Using other shimming materials could cause damage to pump.

T8479AJ

03 0360 24

32. Install new end cap gasket on housing. Be careful that gasket does not get caught on dowel pins.

33. Lubricate end cap journal bearings. Install swash plate leveler spring shims removed during disassembly, into end cap pockets. Retain shims using petroleum jelly. If quantity of shims removed is unknown, consult specifications to determine number of shims needed. Shims are 0.5 mm (0.20 in.) each—Specification 750J—All—Quantity ............................................... One shim each pocket 850J—4.5 mm (0.177 in.) pocket depth—Quantity ...................................................... One shim each pocket 850J—6 mm (0.24 in.) pocket depth—Quantity ...................................... Add enough shims to get 3.5—4 mm (0.14—0.16 in.) pocket depth. 850J—7 or 7.5 mm (0.28 or 0.29 in.) pocket depth—Quantity .................................... One shim each pocket

Continued on next page

TM2261 (10FEB06)

03-0360-24

TX,0300,YY1139 –19–12JUL05–17/19

750J, 850J Crawler 032806

PN=246

Hydrostatic System

T8479AG

T8479AI –UN–14JUN95

Pump End Cap (Large Cap Screw)—Specification 750J—Torque ............................................................................... 271 N•m 200 lb-ft 850J—Torque ............................................................................... 298 N•m 220 lb-ft

–UN–14JUN95

35. Install four large cap screws. Tighten cap screws evenly to specification.

–UN–14JUN95

34. Install end cap. Position springs into pockets in end cap.

T8479AK

Specification Pump End Cap (Small Cap Screw)—Torque.............................................................................. 38 N•m 28 lb-ft

37. Install shaft and bearing assembly.

Continued on next page

TM2261 (10FEB06)

03-0360-25

T8464AC

36. Install and tighten small screws to specification.

TX,0300,YY1139 –19–12JUL05–18/19

750J, 850J Crawler 032806

PN=247

03 0360 25

Hydrostatic System 38. Install new O-ring (4) and carrier. 39. Install retaining plate. Tighten retaining plate screws (2) to specification.

T100315

–UN–13FEB96

Retaining Plate Screw—Specification 750J—Torque .............................................................................. 16.3 N•m 144 lb-in. 850J—Torque .............................................................................. 35.3 N•m 26 lb-ft

40. Install new gasket and displacement control valve on housing. Engage the pin on the control linkage in the mating hole in the link attached to the swash plate. Install and tighten pump displacement control valve (PDCV) screws (1) to specification.

–UN–02JUN95

Specification PDCV Screws—Torque .................................................................. 16 N•m 142 lb-in.

41. Install four new O-rings and pressure control pilot (PCP). Install and tighten screws (3) to specification.

T8492AC

03 0360 26

Specification PCP Screw—Torque ....................................................................... 4 N•m 35 lb-in. 1—Cap Screw 2—Retaining Plate Screw 3—Cap Screw 4—O-Ring

TX,0300,YY1139 –19–12JUL05–19/19

TM2261 (10FEB06)

03-0360-26

750J, 850J Crawler 032806

PN=248

Hydrostatic System

Hydrostatic Motor Disassemble 22

23 18

750J 8

13 15 19 4

35 37

28 27

03 0360 27

29 26

94 25

11 12 10

40 41 –UN–08JUL05

24 96 23

850J

T210835

9 22 T210835 1—Hex Socket Head Cap Screw (3 used) 2—Guard 3—Solenoid Valve 4—Hex Socket Head Cap Screw (4 used) 5—Servo Cover 6—Gasket 7—Spool Valve 8—O-Ring (2 used) 9—Plug Fitting 10—O-Ring 11—Orifice 12—Shuttle Cartridge

13—Spring Seat 14—Spring 15—Spring Retainer 16—Spring 17—Spring Guide 18—Hex Socket Head Cap Screw (M12 x 65) (4 used) 19—Hex Socket Head Cap Screw (M12 x 50) (4 used) 20—End Cap Housing 21—Gasket 22—Plug Fitting (2 used) 23—O-Ring (2 used) 24—Spring and Seat (2 used)

1. Thoroughly clean external surface of motor prior to disassembly. 2. Scribe a line between hydrostatic motor control valve (20) and rotating group housing (58) to aid in assembly.

25—Flushing Valve Spool 26—Hex Socket Head Cap Screw (4 used) 27—Cover 28—O-Ring 29—O-Ring 30—Piston Assembly 31—Ring 32—O-Ring 33—Lever 34—Hex Socket Head Cap Screw 35—Washer 36—Set Screw

Remove eight hex socket head cap screws (18 and 19) and hydrostatic motor control valve from rotating group housing. 3. Remove guard (2) from motor servo cover (5).

Continued on next page

TM2261 (10FEB06)

37—Set Screw 38—Shaft 39—O-Ring 40—Operating Charge Relief Valve 41—O-Ring 42—O-Ring 91—Spring Seat 92—Spring 93—Spring Retainer 94—Spring (2 used) 95—Spring Retainer 96—Spring Guide

03-0360-27

TE14778,000001F –19–08JUL05–1/6

750J, 850J Crawler 032806

PN=249

Hydrostatic System 4. Mark position of motor shift solenoid coil (3) to aid in assembly. Remove coil nut, coil, and armature tube.

5. Remove four hex socket head cap screws (4) and motor servo cover (5) from control valve (20).

TE14778,000001F –19–08JUL05–2/6

7 1

03 0360 28

5 3

11 12 –UN–25APR05

T210516

10 9 Motor Shift Solenoid Valve Assembly 1—Hex Socket Head Cap Screw (3 used) 2—Guard 3—Solenoid Valve

4—Hex Socket Head Cap Screw (4 used) 5—Servo Cover 6—Gasket

7—Spool Valve 8—O-Ring (2 used) 9—Plug Fitting

10—O-Ring 11—Orifice 12—Shuttle Cartridge

6. Disassemble motor shift solenoid valve as shown. 7. Clean and inspect solenoid valve components. Replace as required.

Continued on next page

TM2261 (10FEB06)

03-0360-28

TE14778,000001F –19–08JUL05–3/6

750J, 850J Crawler 032806

PN=250

Hydrostatic System 22 19 38

23 18

24 750J

30 33

35 37

34 20

03 0360 29

40 41 –UN–08JUL05

96 23

850J

T210517

25 24

28 27

22 T210517 Hydrostatic Motor Control Valve 13—Spring Seat 14—Spring 15—Spring Retainer 16—Spring 17—Spring Guide 18—Hex Socket Head Cap Screw (M12 x 65) (4 used) 19—Hex Socket Head Cap Screw (M12 x 50) (4 used) 20—End Cap Housing 21—Gasket

22—Plug Fitting (2 used) 23—O-Ring (2 used) 24—Spring and Seat (2 used) 25—Flushing Valve Spool 26—Hex Socket Head Cap Screw (4 used) 27—Cover 28—O-Ring 29—O-Ring 30—Piston Assembly

31—Ring 32—O-Ring 33—Lever 34—Hex Socket Head Cap Screw 35—Washer 36—Set Screw 37—Set Screw 38—Shaft 39—O-Ring

40—Operating Charge Relief Valve 41—O-Ring 42—O-Ring 91—Spring Seat 92—Spring 93—Spring Retainer 94—Spring (2 used) 95—Spring Retainer 96—Spring Guide

8. Disassemble end cap assembly as shown. 9. Clean and inspect control valve components. Replace as required.

Continued on next page

TM2261 (10FEB06)

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TE14778,000001F –19–08JUL05–4/6

750J, 850J Crawler 032806

PN=251

Hydrostatic System

55 52 57 51 59 56 72 64 68 66

71 70 67

–UN–28APR05

T210518

03 0360 30

Rotating Group Assembly 50—Hex Socket Head Cap Screw (8 used) 51—Flange 52—O-Ring 53—Seal 54—O-Ring 55—Shaft 56—Seal Kit

57—Seal 56—Hex Socket Head Cap Screw 57—Speed Sensor 58—Rotating Group Housing 59—Dowel Pin (2 used) 60—Hex Socket Head Cap Screw (2 used)

IMPORTANT: Special attention should be given to the orientation of the valve segment (65) with end cap (20) and rotating group housing (58). The semicircular recess on valve segment will need to be located on the same side as the speed sensor.

61—Guard 62—Hex Socket Head Cap Screw 63—Motor Speed Sensor 64—O-Ring 65—Valve 66—Plate

67—Bearing 68—Dowel Pin (2 used) 69—Cylinder Block 70—Synchronizer Shaft 71—Support Pin (2 used) 72—Roller (6 used)

12. Scribe a line on housing and flange to aid in assembly. Remove eight socket head cap screws (51) from flange. Remove flange from rotating group housing. 13. Remove old seal (53) from flange. Once removed, the seal is not reusable.

10. Remove hydrostatic motor parts (50—72). 11. Remove socket head cap screw (62) and motor speed sensor (63) from rotating group housing (58).

Continued on next page

TM2261 (10FEB06)

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TE14778,000001F –19–08JUL05–5/6

750J, 850J Crawler 032806

PN=252

Hydrostatic System 14. Pull shaft assembly (55) out of main housing, taking care to not damage the shaft and speed sensor ring. DO NOT damage pistons. Use attachments from the D01173AA 17-1/2 Ton Puller Set and JT01800 Driver Set. 15. Remove piston rings (56) from pistons using a small pair of retaining ring pliers and an O-ring pick. IMPORTANT: Remove speed ring ONLY if replacement is necessary. DO NOT damage sealing surface of cylinder block. 16. Remove speed ring from cylinder block by gently tapping on ring using a hammer and brass drift.

–UN–01APR04 T199010A

17. Clean and rotating group components. Replace as required.

03 0360 31

TE14778,000001F –19–08JUL05–6/6

TM2261 (10FEB06)

03-0360-31

750J, 850J Crawler 032806

PN=253

Hydrostatic System

Hydrostatic Motor Assemble 22 19 38

23 18

24 750J

30 33

35 37

03 0360 32

34 20

40 41 –UN–08JUL05

96 23

850J

T210517

25 24

28 27

22—Plug Fitting (2 used) 23—O-Ring (2 used) 24—Spring and Seat (2 used) 25—Flushing Valve Spool 26—Hex Socket Head Cap Screw (4 used) 27—Cover 28—O-Ring 29—O-Ring 30—Piston Assembly

NOTE: Apply clean hydrostatic oil to all internal parts prior to assembly. 1. Install flushing valve spool (25) into end cap housing (20).

31—Ring 32—O-Ring 33—Lever 34—Hex Socket Head Cap Screw 35—Washer 36—Set Screw 37—Set Screw 38—Shaft 39—O-Ring

Specification Flushing Valve Plug Fitting— Torque...................................................................................... 35 N•m 26 lb-ft

Repeat installation of spring and seat, O-ring, and plug fitting on other side.

2. Install O-ring (23) onto plug fitting (22). 3. Install spring and seat (24) and plug fitting (22) into end cap housing (20). Tighten plug fitting to specification.

4. Install O-ring (41) onto operating charge relief valve plug fitting (40).

Continued on next page

TM2261 (10FEB06)

40—Operating Charge Relief Valve 41—O-Ring 42—O-Ring 91—Spring Seat 92—Spring 93—Spring Retainer 94—Spring (2 used) 95—Spring Retainer 96—Spring Guide

03-0360-32

TE14778,0000020 –19–12JUL05–1/13

750J, 850J Crawler 032806

PN=254

Hydrostatic System 5. Install poppet valve, spring, and plug fitting into operating charge relief valve housing. Tighten plug fitting to specification.

Specification Operating Charge Relief Valve—Torque ......................................................................... 52 N•m 38 lb-ft

Specification Operating Charge Relief Valve Plug Fitting—Torque ................................................................ 35 N•m 26 lb-ft

7. For 750J, install spring guide, springs, retainer, and seat (13—17) into end cap housing (20).

6. Install O-ring (42) onto operating charge relief valve housing. Install relief valve into end cap and tighten to specification.

For 850J, install spring guide, springs, retainers, and seat (91—96) into end cap housing (20).

03 0360 33 Continued on next page

TM2261 (10FEB06)

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750J, 850J Crawler 032806

PN=255

Hydrostatic System

7 1

5 3

03 0360 34

11 12 –UN–25APR05

T210516

10 9 Motor Shift Solenoid Valve Assembly 1—Hex Socket Head Cap Screw (3 used) 2—Guard 3—Solenoid Valve

4—Hex Socket Head Cap Screw (4 used) 5—Servo Cover 6—Gasket

7—Spool Valve 8—O-Ring (2 used) 9—Plug Fitting 10—O-Ring

11—Orifice 12—Shuttle Cartridge 20—End Cap

8. Assemble shuttle cartridge (12) and set screw (11). Tighten set screw to specification.

12. Assemble guard (2) with hex socket head cap screws (1) and tighten to specification.

Specification Shuttle Cartridge Set Screw— Torque....................................................................................... 8 N•m 71 lb-in.

Specification Bracket Hex Socket Head Cap Screw—Torque .................................................................... 15.3 N•m 11.3 lb-in.

9. Install O-Ring (10) onto plug fitting (9). Install plug fitting into housing.

13. Install O-rings (8) onto spool valve (7). Install spool valve into end cap (20).

10. Install solenoid valve (3) in solenoid valve housing (5). Tighten to specification.

14. Install solenoid valve housing (5) and gasket (6) onto end cap with hex socket head cap screws (4). Tighten screws to specification.

Specification Solenoid Valve Spool—Torque ............................................... 30 N•m 22 lb-ft

11. Install solenoid valve coil in position as marked during removal. Install cap.

Specification Solenoid Valve Housing-To-End Cap Hex Socket Head Cap Screw——Torque .................................................................. 110 N•m 81 lb-ft

Continued on next page

TM2261 (10FEB06)

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750J, 850J Crawler 032806

PN=256

Hydrostatic System

55 52 57 51 59 56 72 64

71 70 67

–UN–28APR05

68 66

T210518

03 0360 35

Rotating Group Assembly 50—Hex Socket Head Cap Screw (8 used) 51—Flange 52—O-Ring 53—Seal 54—O-Ring 55—Shaft 56—Seal Kit

57—Seal 56—Hex Socket Head Cap Screw 57—Speed Sensor 58—Rotating Group Housing 59—Dowel Pin (2 used) 60—Hex Socket Head Cap Screw (2 used)

61—Guard 62—Hex Socket Head Cap Screw 63—Motor Speed Sensor 64—O-Ring 65—Valve 66—Plate

67—Bearing 68—Dowel Pin (2 used) 69—Cylinder Block 70—Synchronizer Shaft 71—Support Pin (2 used) 72—Roller (6 used)

15. Install new seal kit (56) on pistons.

NOTE: Shaft assembly (55) with exception to the seal kit (56) is serviced as an assembly.

Continued on next page

TM2261 (10FEB06)

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TE14778,0000020 –19–12JUL05–4/13

750J, 850J Crawler 032806

PN=257

Hydrostatic System 16. Inspect the bronze surface of the bearing plate (66) for damage and excessive wear. The sealing surfaces must be free from scratches and nicks. The locating pin holes must not be worn. Replace the bearing plate if damaged or worn.

17. Inspect the valve segment (65) sealing surfaces and spindle (73) for damage or wear. Check that the spindle is located correctly in the valve segment by measuring dimension “A”. If this dimension is not within the specification, the spindle has moved in the valve segment and the assembly must be replaced.

18. Inspect cylinder block (69) for wear or damage. The piston bores must be smooth. The bearing plate surface must be free from scratches or nicks, and the holes for the bearing plate locating pins must not be worn. The races for the synchronizing shaft rollers must not be worn. 67

IMPORTANT: DO NOT damage sealing surface of cylinder block. 19. Place cylinder block on a clean soft surface (cardboard or shop towel) to replace speed ring. Be careful NOT to damage sealing surface of cylinder block.

20. Place new speed ring on chamfered edge of cylinder block. 65—Valve Segment 66—Bearing Plate 67—Cylinder Block Bearing 69—Cylinder Block 73—Spindle A—Dimension “A” B—Dimension “B”

–UN–19APR05

T210535

03 0360 36

Valve Segment Spindle Dimension “A”—Specification 750J—Length .................................................................... 38.5—39.3 mm 1.52—1.55 in. 850J—Length .................................................................... 43.8—44.6 mm 1.72—1.76 in.

T210535 Valve Segment Spindle

Continued on next page

TM2261 (10FEB06)

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750J, 850J Crawler 032806

PN=258

Hydrostatic System IMPORTANT: To prevent damage to speed ring use installation tool JDG1332 Speed Ring Installer. 21. Carefully place JDG1332 Speed Ring Installer over speed ring and cylinder block. Alternately tap edge of installer using a rubber mallet to seat speed ring. Speed ring will be located correctly when installer is bottomed on cylinder block. 22. Inspect cylinder block bearing (67). If it requires replacement, remove bearing using a suitable puller. DO NOT damage the bearing plate surface of the cylinder block. Press a new bearing (if removed) into the cylinder block until it is located the proper distance (dimension “B”) below the bearing plate.

03 0360 37

Cylinder Block Bearing Dimension “B”—Specification 750J—Depth ...................................................................... 14.5—15.0 mm 0.57—0.59 in. 850J—Depth ...................................................................... 18.5—19.0 mm 0.73—0.75 in.

Continued on next page

TM2261 (10FEB06)

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TE14778,0000020 –19–12JUL05–6/13

750J, 850J Crawler 032806

PN=259

Hydrostatic System NOTE: Apply clean hydrostatic oil to all internal parts prior to assembly. 23. Position shaft assembly (55) in housing (58). Align scribe mark between housing and flange (51). Install flange over shaft assembly as far as possible. Install two screws (M12 x 65 mm) 180° apart on flange. Alternately tighten screws until bottomed to seat flange and shaft assembly. Remove two 65 mm (2.56 in.) screws and repeat procedure using 50 mm (1.97 in.) screws. Remove screws.

Flange-to-Motor Housing Cap Screw—Specification 750J—Torque ............................................................................... 110 N•m 81 lb-ft 850J—Torque ............................................................................... 174 N•m 128 lb-ft

–UN–26APR05

50—Screw (8 used) 51—Flange 53—Seal 54—O-Ring 55—Shaft Assembly 58—Housing

T210536

03 0360 38

Install eight screws (50). Alternately tighten screws to seat shaft assembly and flange against housing. Torque screws to specification.

Continued on next page

TM2261 (10FEB06)

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TE14778,0000020 –19–12JUL05–7/13

750J, 850J Crawler 032806

PN=260

Hydrostatic System 24. Install synchronizing shaft support pin (71) into the motor shaft assembly (70) and retain with petroleum jelly. 25. Install the synchronizing shaft rollers (72) on the journals of the synchronizing shaft and retain with petroleum jelly. Position each roller with its outside edge even with the end of the synchronizing shaft journal. 26. Install the synchronizing shaft and rollers into the motor shaft (55). The cylinder block end of the shaft is larger than the motor shaft end. 72 27. The rollers must enter the races in the motor shaft insert, and the recess in the end of the synchronizing shaft must engage the support pin.

03 0360 39

Tip and rotate the synchronizing shaft in all directions to check for binding. The synchronizing shaft rollers must move freely in the races in the motor shaft insert. 55—Motor Shaft Assembly 70—Synchronizing Shaft 71—Support Pin 72—Rollers

T210569

–UN–25APR05

Continued on next page

TM2261 (10FEB06)

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750J, 850J Crawler 032806

PN=261

Hydrostatic System

T210583

–UN–25APR05

03 0360 40

T210583 55—Motor Shaft

71—Synchronizing Shaft Support Pin

72—Synchronizing Shaft Rollers

28. Position the motor shaft (55) in the housing as shown. Tip the three pistons closest to the highest side of housing. TE14778,0000020 –19–12JUL05–9/13

29. Install the second synchronizing shaft support pin (71) into the recess of the cylinder block and retain with petroleum jelly.

T210592A

–UN–25APR05

30. With the synchronizing shaft supported in the motor shaft, install the cylinder block and its synchronizing shaft support pin (71) onto the pistons and synchronizing shaft. The cylinder block must be positioned so the synchronizing shaft rollers will enter their races in the block, while each piston enters its corresponding bore in the block. 69—Cylinder Block 71—Support Pin

Continued on next page

TM2261 (10FEB06)

03-0360-40

TE14778,0000020 –19–12JUL05–10/13

750J, 850J Crawler 032806

PN=262

Hydrostatic System NOTE: A brass rod may be inserted through the cylinder block to guide the pistons into position.

T200222A

–UN–20MAY04

31. Start with the six pistons closest to the lower part of the end cap mounting surface. After the six pistons enter their bores, tilt the cylinder block so the synchronizing shaft rollers (72) enter their races in the cylinder block, and the support pin enters its recess in the synchronizing shaft.

NOTE: Apply clean hydrostatic oil to all cylinder block bores. 32. Lift the cylinder block slightly and guide the three remaining pistons into their bores.

03 0360 41 –UN–20MAY04

After the last piston is in position, check the position of the rollers at highest side of housing. Maintain an inward force on the cylinder block and carefully push it toward the highest part of the housing to check that all synchronizing shaft rollers are in position.

T200223A

If cylinder block is properly assembled, there will be very little (if any) rotational freeplay between the block and the motor shaft.

Continued on next page

TM2261 (10FEB06)

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TE14778,0000020 –19–12JUL05–11/13

750J, 850J Crawler 032806

PN=263

Hydrostatic System 33. Install the bearing plate alignment pins (68) into cylinder block. The longer end of each shouldered pin is installed into block. 34. Install the bearing plate (66) on the cylinder block with the steel side facing toward the block. Lubricate the bronze side of the plate with clean hydrostatic oil. 35. Install end cap alignment pins (59) and gasket (21). Carefully locate the cylinder block against highest part of housing. IMPORTANT: DO NOT allow the pistons or synchronizing shaft rollers to fall out of position. 36. Apply petroleum jelly to mating surfaces of valve segment and end cap. Install the valve segment (65) with hole (74) on same side as speed sensor, into the end cap (20) so the spindle engages the setting lug in the servo piston. Locate the valve segment and servo piston in the approximate center of its travel.

–UN–25APR05

20—End Cap 21—Gasket 59—Alignment Pin (2 used) 65—Valve Segment 66—Bearing Plate 68—Alignment Pin (2 used) 74—Hole

T210575

03 0360 42

Continued on next page

TM2261 (10FEB06)

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TE14778,0000020 –19–12JUL05–12/13

750J, 850J Crawler 032806

PN=264

Hydrostatic System 37. Apply clean hydrostatic oil to valve segment and bearing plate mating surfaces. Install end cap assembly and valve segment. The spindle must engage the bearing in the cylinder block. IMPORTANT: DO NOT allow the pistons or synchronizing shaft rollers to fall out of position. 38. Install hex socket head cap screws (18 and 19).

NOTE: The internal spring in the motor shaft should hold the end cap away from the housing a short distance. 39. Tighten the screws by hand in the sequence shown (1—8) while rotating the motor shaft to ensure proper positioning of the synchronizing shaft rollers.

T8506AP

40. Tighten screws using sequence shown to approximately 1/2 final torque value. Repeat sequence and tighten to final torque.

–UN–10JUL95

IMPORTANT: DO NOT force the end cap into position on the housing.

03 0360 43

Motor End Cap-to-Housing Screw—Specification 750J—Torque ............................................................................... 135 N•m 100 lb-ft 850J—Torque ............................................................................... 213 N•m 157 lb-ft

T8506AQ

–UN–10JUL95

41. Rotate shaft 360° to check final assembly.

TE14778,0000020 –19–12JUL05–13/13

TM2261 (10FEB06)

03-0360-43

750J, 850J Crawler 032806

PN=265

Hydrostatic System

Hydraulic Integrated Circuit (HIC) Valve Remove and Install Hydraulic Integrated Circuit (HIC) Valve Removal 1. Turn battery disconnect switch to OFF. 2. Tilt cab/ROPS. See Cab or ROPS Tilting Procedure. (Operator’s Manual.) 3. Drain hydrostatic reservoir or apply vacuum. See Change Hydrostatic Transmission Oil and Replace Hydrostatic Charge and Fan Oil Filters. (Operator’s Manual.) Specification Hydrostatic Reservoir—Capacity.................................................... 105.6 L 27.9 gal

4. Label hydraulic lines and electrical harness connections to aid assembly.

TE14778,00000DF –19–07JUL05–1/3

–UN–05JUL05

CAUTION: To avoid injury from escaping fluid under pressure, relieve the pressure in the system before disconnecting or connecting hydraulic or other lines. Tighten all connections before applying pressure. 5. Disconnect hydraulic lines from HIC valve. Close all openings using caps and plugs.

T212453A

03 0360 44

6. Disconnect transmission harness (3) connectors from HIC valve. 1—Cap Screw (3 used) 2—Hydraulic Integrated Circuit (HIC) Valve 3—Transmission Harness

CAUTION: HIC Valve is heavy and can cause injury if not moved properly. Use adequate lifting device to move HIC Valve. Specification HIC Valve—Approximate Weight ................................................... 29.5 kg 65 lb

7. Remove HIC valve mounting cap screws (1). Remove HIC valve (2) using hoist.

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TM2261 (10FEB06)

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TE14778,00000DF –19–07JUL05–2/3

750J, 850J Crawler 032806

PN=266

Hydrostatic System Hydraulic Integrated Circuit (HIC) Valve Installation

–UN–05JUL05

CAUTION: HIC Valve is heavy and can cause injury if not moved properly. Use adequate lifting device to move HIC Valve.

T212453A

Specification HIC Valve—Approximate Weight ................................................... 29.5 kg 65 lb

1. Set Hydraulic Integrated Circuit (HIC) Valve (2) on frame using hoist. Apply oil to HIC valve mounting cap screws (1) and install. Torque to specification. Specification HIC Valve Installation—Torque .................................................... 104 N•m 77 lb-ft

1—Cap Screw (3 used) 2—Hydraulic Integrated Circuit (HIC) Valve 3—Transmission Harness 03 0360 45

2. Connect transmission harness (3) connectors as marked during removal. 3. Connect hydraulic lines as marked during removal. 4. Remove vacuum if used. Fill reservoir to specification. See Change Hydrostatic Transmission Oil and Replace Hydrostatic Charge and Fan Oil Filters. (Operator’s Manual.) See Transmission and Hydraulic Reservoir Oil. (Operator’s Manual.) 5. Lower cab/ROPS to normal operating position. See Cab or ROPS Tilting Procedure. (Operator’s Manual.) 6. Turn battery disconnect switch to ON. 7. Start engine and check for leaks. Repair as necessary.

TE14778,00000DF –19–07JUL05–3/3

TM2261 (10FEB06)

03-0360-45

750J, 850J Crawler 032806

PN=267

Hydrostatic System

Hydraulic Integrated Circuit (HIC) Valve Disassemble and Assemble 51

24 13 39

12 17 19

–UN–08JUL05

03 0360 46

9 T212381 2—Ball Shuttle Valve 8—Hydrostatic Oil Temperature Sensor 9—Park Brake Solenoid 1 10—Park Brake Solenoid 2 11—Hydrostatic Oil Cooler Bypass Solenoid 12—Hydrostatic Oil Cooler Bypass Valve

13—Hydrostatic Oil Reservoir Bypass Solenoid 14—Hydrostatic Oil Reservoir Bypass Valve 16—Hydrostatic Charge Oil Filter Bypass Valve 17—Hydrostatic Charge Oil Filter Restriction Switch 18—Hydrostatic Charge Oil Filter

19—Neutral Charge Relief Valve 20—Hand Pump Park Brake Relief Valve 21—Hand Pump 22—Hand Pump Selector Valve 1 23—Hand Pump Selector Valve 2

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TM2261 (10FEB06)

03-0360-46

T212381

18 21

24—Hand Pump Tilt Relief Valve 39—Hydraulic Integrated Circuit (HIC) Valve 51—Brake Pressure Sensor 52—Hydrostatic Charge Pressure Sensor

TE14778,00000D2 –19–08SEP05–1/4

750J, 850J Crawler 032806

PN=268

Hydrostatic System Item

Name

Torque Value

Ball Shuttle Valve

33.9 N•m (25 lb-ft)

Hydrostatic Oil Temperature Sensor

24 N•m (18 lb-ft)

Park Brake Solenoid 1

Cartridge: 33.9 N•m (25 lb-ft) Coil Nut: 8.1 N•m (72 lb-in.)

Park Brake Solenoid 2

Cartridge: 47.5 N•m (35 lb-ft) Coil Nut: 11.5 N•m (102 lb-in.)

Hydrostatic Oil Cooler Bypass Solenoid

Mounting Screw: 3.5 N•m (31.2 lb-in.)

Hydrostatic Oil Cooler Bypass Valve

95 N•m (70 lb-ft)

Hydrostatic Oil Reservoir Bypass Solenoid

Cartridge: 23.5 N•m (208 lb-in.) Coil Nut: 6.1 N•m (54 lb-in.)

Hydrostatic Oil Reservoir Bypass Valve

95 N•m (70 lb-ft)

Hydrostatic Charge Oil Filter Bypass Valve

162.7 N•m (120 lb-ft)

Hydrostatic Charge Oil Filter Restriction Switch

37 N•m (27 lb-ft)

Neutral Charge Relief Valve

Cartridge: 67.8 N•m (50 lb-ft)

Hand Pump Park Brake Relief Valve

27.1 N•m (20 lb-ft)

Hand Pump

35.3 N•m (26 lb-ft)

Hand Pump Selector Valve 1

25.8 N•m (228 lb-in.)

Hand Pump Selector Valve 2

35.3 N•m (26 lb-ft)

Hand Pump Tilt Relief Valve

27.1 N•m (20 lb-ft)

Brake Pressure Sensor

24 N•m (18 lb-ft)

Hydrostatic Charge Pressure Sensor

24 N•m (18 lb-ft)

The HIC valve contains components for four different hydraulic circuits. For more information on the HIC valve see Hydraulic Integrated Circuit (HIC) Valve Operation. (Group 9026-05.) For information on the charge oil circuit, see Charge Pump Operation. (Group 9026-05.) Also, see Hydrostatic Charge Oil Filter Operation. (Group 9026-05.) For information on the hydrostatic oil cooling circuit, see Oil Cooler and Reservoir Bypass Operation. (Group 9026-05.)

For information on the park brake circuit, see Park Brake Valve Operation. (Group 9026-05.) For information on hand pump operation, see the Operators Manual. For more HIC valve information see Hydrostatic System Schematic—Neutral (Park Brake On). (Group 9026-15.) HIC Valve Threaded Insert Remove and Install 1. Remove hydrostatic charge oil filter.

Continued on next page

TM2261 (10FEB06)

03 0360 47

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PN=269

Hydrostatic System 2. Remove threaded insert using JDG10011 Internal Pipe Wrench.

–UN–05JUL05

3. Clean HIC valve manifold and threaded insert mating surfaces with TY16285 Cure Primer.

T212511A

4. Apply a thin continuous line of TY15969 Retaining Compound (Maximum Strength) around bottom third threads. 1—Threaded Insert 2—HIC Valve Manifold 3—JDG10011 Internal Pipe Wrench

03 0360 48 TE14778,00000D2 –19–08SEP05–3/4

5. Install threaded insert into HIC valve manifold with beveled edge (4) facing inward, until shoulder hits.

T212549

–UN–06JUL05

4—Beveled Edge

TE14778,00000D2 –19–08SEP05–4/4

Hydrostatic Reservoir Remove and Install 1. Turn battery disconnect switch to OFF. 2. Tilt cab/ROPS. See Cab or ROPS Tilting Procedure. (Operator’s Manual.) 3. Remove left and rear fenders. 4. Remove left service door.

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TM2261 (10FEB06)

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750J, 850J Crawler 032806

PN=270

Hydrostatic System 5. Drain reservoir. See Change Hydrostatic Transmission Oil and Replace Hydrostatic Charge and Fan Oil Filters. (Operator’s Manual.)

–UN–26JAN05

Specification Hydrostatic Reservoir—Capacity.................................................... 105.6 L 27.9 gal

T207457A

6. Remove twist ties from windshield washer hoses and harness. Remove washer reservoir cap screws and move washer reservoir out of the way. 7. Disconnect hoses from hydraulic fan oil filter (3). Close all openings using caps and plugs.

1—Filler Plug 3—Hydraulic Fan Oil Filter 4—Hydrostatic Charge Oil Filter 5—Hydrostatic Reservoir Oil Level Sight Glass

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TM2261 (10FEB06)

03-0360-49

03 0360 49

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750J, 850J Crawler 032806

PN=271

Hydrostatic System 8. Disconnect reservoir drain hose (1), hydrostatic pump suction hoses (6 and 3), hydraulic fan pump suction hose (4), Hydraulic Integrated Circuit (HIC) hose (5), and hand pump suction hose (2) from reservoir. 9. Disconnect hydraulic filter restriction switch harness from switch. 10. Support hydrostatic reservoir with hoist. CAUTION: Hydrostatic reservoir is heavy and can cause injury if not moved properly. Use adequate lifting device to move reservoir.

–UN–20JUN05

11. Remove cap screws and remove reservoir using hoist.

NOTE: For cleanout cover repair procedure see Hydraulic Reservoir Cleanout Cover Remove and Install. (Group 3260.)

T212245A

03 0360 50

Specification Hydrostatic Reservoir— Approximate Weight ........................................................................ 176 kg 388 lb

1—Hydrostatic Reservoir Drain Hose 2—Hand Pump Suction Hose 3—Hydrostatic Pump Suction Hose 4—Hydraulic Fan Pump Suction Hose 5—Hydraulic Integrated Circuit (HIC) Valve Suction and Return Hose 6—Hydrostatic Pump Suction Hose

12. Install reservoir with cap screws. Tighten to specification. Specification Hydrostatic Reservoir Mounting Cap Screw—Torque ..................................................................... 319 N•m 235 lb-ft

13. Connect suction and return hoses. 14. Install windshield washer bottle. 15. Route hoses and wiring harnesses back to their original locations. Replace all tie bands that were removed. 16. Install left service door and fenders. 17. Fill reservoir to specification. See Change Hydrostatic Transmission Oil and Replace Hydrostatic Charge and Fan Oil Filters. (Operator’s Manual.)

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TM2261 (10FEB06)

03-0360-50

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750J, 850J Crawler 032806

PN=272

Hydrostatic System See Transmission and Hydraulic Reservoir Oil. (Operator’s Manual.) 18. Lower cab/ROPS to normal operating position. See Cab or ROPS Tilting Procedure. (Operator’s Manual.) 19. Turn battery disconnect switch to ON. 20. Start engine and check for leaks. Repair as necessary.

TE14778,0000089 –19–12JUL05–4/4

Hydraulic Fan Motor Remove and Install 03 0360 51

Hydraulic Fan Motor Removal 1. Turn battery disconnect switch to OFF. 2. Open grille door and label front of fan to aid assembly. Remove fan.

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TM2261 (10FEB06)

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750J, 850J Crawler 032806

PN=273

Hydrostatic System

CAUTION: To avoid injury from escaping fluid under pressure, relieve the pressure in the system before disconnecting or connecting hydraulic or other lines. Tighten all connections before applying pressure. 3. Disconnect forward pressure line (1). 4. Remove cap screws (7). 5. Disconnect reverse pressure line (2) and case drain line (3). Close all openings with caps and plugs.

7. Remove motor assembly.

T212454A

03 0360 52

–UN–05JUL05

6. Disconnect fan drive harness (4) connector from motor.

1—Forward Pressure Line 2—Reverse Pressure Line 3—Case Drain Line 4—Harness 5—Fan Motor Mounting Bracket 6—Fan Motor Hub 7—Mounting Bracket Cap Screw (4 used) 8—Fan Motor Mounting Cap Screw (2 used) 9—Nut

Continued on next page

TM2261 (10FEB06)

03-0360-52

TE14778,00000E1 –19–12JUL05–2/4

750J, 850J Crawler 032806

PN=274

Hydrostatic System 8. Remove fan hub (1) from fan motor (2) using puller (3). 9. Remove mounting bracket (5).

T212461A

–UN–05JUL05

1—Fan Motor Hub 2—Fan Motor 3—Puller

Continued on next page

TM2261 (10FEB06)

03-0360-53

TE14778,00000E1 –19–12JUL05–3/4

750J, 850J Crawler 032806

PN=275

03 0360 53

Hydrostatic System Hydraulic Fan Motor Installation 1. Install mounting bracket (5) onto fan motor. 2. Apply T43512 Thread Lock and Sealer (Medium Strength) to hydraulic fan motor shaft threads. 3. Install fan motor hub and nut. Tighten nut to specification.

4. Connect reverse pressure line (2) and case drain line (3).

T212454A

03 0360 54

–UN–05JUL05

Specification Fan Motor Hub-To-Hydraulic Fan Motor—Torque.............................................................................. 129 N•m 95 lb-ft

5. Connect fan drive harness (4) connector from motor. 6. Install fan motor and bracket assembly onto frame using cap screws (7). 7. Connect forward pressure line (1). 8. Install fan as marked during disassembly. 9. Fill reservoir to specification. See Change Hydrostatic Transmission Oil and Replace Hydrostatic Charge and Fan Oil Filters. (Operator’s Manual.) See Transmission and Hydraulic Reservoir Oil. (Operator’s Manual.)

1—Forward Pressure Line 2—Reverse Pressure Line 3—Case Drain Line 4—Harness 5—Hydraulic Fan Motor Mounting Bracket 6—Fan Motor Hub 7—Mounting Bracket Cap Screw (4 used) 8—Motor Mounting Cap Screw (2 used) 9—Nut

10. Turn battery disconnect switch to ON. 11. Start engine and check for leaks. Repair as necessary.

TE14778,00000E1 –19–12JUL05–4/4

TM2261 (10FEB06)

03-0360-54

750J, 850J Crawler 032806

PN=276

Hydrostatic System

Hydraulic Fan Pump Remove and Install 1. Turn battery disconnect switch to OFF. 2. Apply vacuum to hydrostatic reservoir.

TE14778,00000E3 –19–24JUN05–1/2

03 0360 55

T212466A

3. Disconnect suction line (1) and high pressure line (2). Close all openings with caps and plugs. 4. Remove socket head cap screws and washers (4). 5. Remove fan pump (3) and gasket.

Fan Pump Remove and Install (850J shown)

6. Install gasket and fan pump (3) onto engine using socket head cap screws and washers (4). 7. Connect suction line (1) and high pressure line (2).

1—Suction Line 2—High Pressure Line 3—Fan Pump 4—Hex Socket Head Cap Screw and Washer

8. Remove vacuum if used. Fill reservoir to specification. See Change Hydrostatic Transmission Oil and Replace Hydrostatic Charge and Fan Oil Filters. (Operator’s Manual.) See Transmission and Hydraulic Reservoir Oil. (Operator’s Manual.) 9. Turn battery disconnect switch to ON. 10. Start engine and check for leaks. Repair as necessary.

TE14778,00000E3 –19–24JUN05–2/2

TM2261 (10FEB06)

03-0360-55

750J, 850J Crawler 032806

PN=277

Hydrostatic System

Hydraulic Fan Reversing Valve Remove and Install Hydraulic Fan Reversing Valve Removal 1. Turn battery disconnect switch to OFF. 2. Apply vacuum to hydrostatic reservoir. 3. Label hydraulic lines and electrical harness connections to aid assembly.

03 0360 56 TE14778,00000E5 –19–24JUN05–1/3

CAUTION: To avoid injury from escaping fluid under pressure, relieve the pressure in the system before disconnecting or connecting hydraulic or other lines. Tighten all connections before applying pressure. 4. Disconnect harness connectors from proportional solenoid (6) and reversing solenoid (7). 5. Disconnect hydraulic lines (2—5) from fan reversing valve. Close all openings using caps and plugs.

–UN–05JUL05

6. Remove mounting cap screws, washers, and nuts (8). Remove reversing valve assembly.

T212469A

1—Hydraulic Fan Reversing Valve 2—Reverse Pressure Line 3—Forward Pressure Line 4—Return Line 5—High Pressure Line (from fan pump) 6—Proportional Solenoid 7—Reversing Solenoid 8—Cap Screws, Washers, and Nuts

Continued on next page

TM2261 (10FEB06)

03-0360-56

TE14778,00000E5 –19–24JUN05–2/3

750J, 850J Crawler 032806

PN=278

Hydrostatic System Hydraulic Fan Reversing Valve Installation 1. Install fan reversing valve onto main frame using cap screws, washers, and nuts (8). 2. Connect hydraulic lines (2—5) to fan reversing valve as marked during removal. 3. Connect harness connectors to proportional solenoid (6) and reversing solenoid (7).

T212469A

–UN–05JUL05

4. Remove vacuum if used. Fill reservoir to specification. See Change Hydrostatic Transmission Oil and Replace Hydrostatic Charge and Fan Oil Filters. (Operator’s Manual.) See Transmission and Hydraulic Reservoir Oil. (Operator’s Manual.) 5. Turn battery disconnect switch to ON. 6. Start engine and check for leaks. Repair as necessary. 1—Hydraulic Fan Reversing Valve 2—Reverse Pressure Line 3—Forward Pressure Line 4—Return Line 5—High Pressure Line (from fan pump) 6—Proportional Solenoid 7—Reversing Solenoid 8—Cap Screws, Washers, and Nuts

TE14778,00000E5 –19–24JUN05–3/3

TM2261 (10FEB06)

03-0360-57

750J, 850J Crawler 032806

PN=279

03 0360 57

Hydrostatic System

–UN–05JUL05

Hydraulic Fan Reversing Valve Disassemble and Assemble

T212474A

03 0360 58

1—Fan Reversing Valve Block 2—Reversing Solenoid 3—Directional Valve 4—Proportional Solenoid 5—Check Valve (4 used) 6—Cap Screws, Washers, and Nuts Item

Name

Torque Value

Reversing Solenoid

27 N•m (20 lb-ft) Coil Nut: 6.8 N•m (60 lb-in.)

Directional Valve

Cartridge: 68 N•m (50 lb-ft)

Proportional Solenoid

Cartridge: 34 N•m (25 lb-ft) Coil Nut: 6.1 N•m (54 lb-in.)

Check Valve

Cartridge: 27 N•m (20 lb-ft)

For more information hydraulic fan reversing valve information see Hydraulic Fan Drive Operation. (Group 9026-05.) For more information see Hydrostatic System Schematic—Neutral (Park Brake On). (Group 9026-15.)

TE14778,00000E6 –19–13JUL05–1/1

TM2261 (10FEB06)

03-0360-58

750J, 850J Crawler 032806

PN=280

Section 04

Engine Contents Page

Group 0400—Removal and Installation Engine Remove and Install . . . . . . . . . . . . . .04-0400-1 Oil Pan Remove and Install. . . . . . . . . . . . .04-0400-11 Flywheel Remove and Install. . . . . . . . . . . .04-0400-13 Engine Mounts Remove and Install . . . . . . .04-0400-16

TM2261 (10FEB06)

04-1

750J, 850J Crawler 032806

PN=1

Contents

TM2261 (10FEB06)

04-2

750J, 850J Crawler 032806

PN=2

Group 0400

Removal and Installation Engine Remove and Install NOTE: This procedure was written using an 850J machine. 750J machines will be slightly different. 1. Lower all equipment to ground. 2. Stop engine. Operate all hydraulic controls to relieve pressure in hydraulic system. 3. Turn battery disconnect switch to OFF or disconnect battery ground strap. 4. Raise cab/ROPS. See Cab or ROPS Tilting Procedure. (Operator’s Manual.) 5. Remove engine side shields. See Engine Side Shields Remove and Install. (Group 1910.) 6. Remove hood. See Hood Remove and Install. (Group 1910.) 04 0400 1

7. Remove bottom guards. See Bottom Guards Remove and Install. (Group 1746.) CAUTION: Explosive release of fluids from pressurized cooling system can cause serious burns. Shut off engine. Only remove filler cap when cool enough to touch with bare hands. Slowly loosen cap to first stop to relieve pressure before removing completely. 8. Drain cooling system. See Draining the Cooling System. (Operator’s Manual.) Specification 750J Cooling System—Capacity ...................................................... 21.5 L 5.7 gal 850J Cooling System—Capacity ......................................................... 38 L 10 gal

9. Disconnect ether start aid tube from engine, if equipped. 10. Remove muffler.

Continued on next page

TM2261 (10FEB06)

04-0400-1

TX,0400,SS2277 –19–14JUL05–1/17

750J, 850J Crawler 032806

PN=283

Removal and Installation 11. Remove hood support with air cleaner. See Hood Support Remove and Install. (Group 1910.)

TX,0400,SS2277 –19–14JUL05–2/17

12. Disconnect engine wiring harness (20). 13. Disconnect hydrostatic pump PCP wiring harnesses (18 and 19).

T211004A

16—Hydrostatic Pump-to-Flywheel Mounting Cap Screw 17—Hydrostatic Pump-to-Flywheel Mounting Cap Screw 18—PCP Wiring Harness 19—PCP Wiring Harness 20—Engine Wiring Harness

Engine and PCP Wiring Harnesses (850J Shown)

TX,0400,SS2277 –19–14JUL05–3/17

15. Disconnect wiring harness from horn (1), front lights (2), and quick-drop valve (3).

T210636A

–UN–19APR05

1—Horn Wiring Harness 2—Front Lights Wiring Harness 3—Quick-Drop Valve Wiring Harness (Outside Dozers only)

–UN–19APR05

Front Lights and Horn (850J Shown)

T210637A

04 0400 2

–UN–27APR05

14. Disconnect reversing fan valve wiring harness, if equipped.

Quick-Drop Valve Continued on next page

TM2261 (10FEB06)

04-0400-2

TX,0400,SS2277 –19–14JUL05–4/17

750J, 850J Crawler 032806

PN=284

Removal and Installation 16. Disconnect battery cable (4) and ground strap (5) from starter.

T210643A

–UN–19APR05

4—Battery Cable 5—Ground Strap

Starter (850J Shown)

TX,0400,SS2277 –19–14JUL05–5/17

04 0400 3

17. Remove rear access cover and close fuel shutoff valve (6).

–UN–19APR05

18. Disconnect fuel supply and return lines. Cap and plug all openings.

T210659A

6—Fuel Shutoff Valve

Fuel Shutoff Valve (850J Shown)

Continued on next page

TM2261 (10FEB06)

04-0400-3

TX,0400,SS2277 –19–14JUL05–6/17

750J, 850J Crawler 032806

PN=285

Removal and Installation 19. Disconnect heater hoses, if equipped. Cap and plug all openings. 20. Disconnect hoses from hydraulic fan drive pump (15). Cap and plug all openings. 21. Disconnect radiator hoses. 22. Remove charge air hose and tube. 23. Remove serpentine belt (8).

–UN–25APR05

24. Disconnect wiring harness from air conditioning compressor.

7—Heater Hose 8—Serpentine Belt 9—Air Conditioning Compressor 10—Refrigerant Lines 15—Hydraulic Fan Drive Pump

Left Side of 6081 Engine Shown (850J Shown)

TX,0400,SS2277 –19–14JUL05–7/17

26. Install lifting brackets (13) to engine.

–UN–28APR05

Specification Engine—Approximate Weight ......................................................... 907 kg 2000 lb

27. Attach load leveler (14) to lifting brackets and appropriate lifting device. 13—Lifting Bracket (2 used) 14—Load Leveler

T210787A

04 0400 4

T210749A

25. Remove air conditioning compressor (9) leaving refrigerant lines (10) attached and set off to the side.

Engine Removal (850J Shown)

Continued on next page

TM2261 (10FEB06)

04-0400-4

TX,0400,SS2277 –19–14JUL05–8/17

750J, 850J Crawler 032806

PN=286

Removal and Installation 28. Support hydrostatic pumps using JT07184 Pump Support Bracket and a ratchet lifting device. 29. Remove hydrostatic pump-to-flywheel mounting cap screws (4 used).

T210775A

–UN–21APR05

11—JT07184 Pump Support Bracket 12—Ratchet Lifting Device

Pump Support (850J Shown)

Continued on next page

TM2261 (10FEB06)

04-0400-5

TX,0400,SS2277 –19–14JUL05–9/17

750J, 850J Crawler 032806

PN=287

04 0400 5

Removal and Installation 30. Remove engine mounting hardware (21—23). CAUTION: Prevent possible crushing injury from heavy component. Use an appropriate lifting device to remove engine. 31. Remove engine.

21 22

Specification Engine—Approximate Weight ......................................................... 907 kg 2000 lb

22 24

33. Install engine mounting hardware (21—23).

21—Cap Screw (6 used) 22—Washer (14 used) 23—Cap Screw (8 used) 24—Right Rail Support 25—Left Rail Support

T211086

–UN–05MAY05

32. Install engine.

Engine Cradle Mounting (850J Shown)

04 0400 6

Continued on next page

TM2261 (10FEB06)

04-0400-6

TX,0400,SS2277 –19–14JUL05–10/17

750J, 850J Crawler 032806

PN=288

Removal and Installation 34. Install hydrostatic pump-to-flywheel mounting cap screws (4 used). 35. Remove JT07184 Pump Support Bracket (11) and ratchet lifting device.

T210775A

–UN–21APR05

11—JTO7184 Pump Support Bracket 12—Ratchet Lifting Device

Pump Support (850J Shown)

TX,0400,SS2277 –19–14JUL05–11/17

36. Remove lifting brackets (13) and load leveler (14) from engine.

T210787A

–UN–28APR05

13—Lifting Bracket (2 used) 14—Load Leveler

Engine Installation (850J Shown)

Continued on next page

TM2261 (10FEB06)

04-0400-7

TX,0400,SS2277 –19–14JUL05–12/17

750J, 850J Crawler 032806

PN=289

04 0400 7

Removal and Installation 37. Install air conditioning compressor (9) with refrigerant lines (10) attached. 38. Connect wiring harness to air conditioning compressor. 39. Install serpentine belt (8). 40. Install charge air hose and tube. 41. Connect radiator hoses.

–UN–25APR05

42. Connect hoses from hydraulic fan drive pump (15). 43. Connect heater hoses, if equipped.

T210749A

7—Heater Hose 8—Serpentine Belt 9—Air Conditioning Compressor 10—Refrigerant Lines 15—Hydraulic Fan Drive Pump

Left Side of 6081 Engine Shown (850J Shown)

04 0400 8

TX,0400,SS2277 –19–14JUL05–13/17

44. Connect fuel supply and return lines.

–UN–19APR05

45. Open fuel shutoff valve (6) and install rear access cover.

T210659A

6—Fuel Shutoff Valve

Fuel Shutoff Valve

Continued on next page

TM2261 (10FEB06)

04-0400-8

TX,0400,SS2277 –19–14JUL05–14/17

750J, 850J Crawler 032806

PN=290

Removal and Installation 46. Connect battery cable (4) and ground strap (5) from starter.

T210643A

–UN–19APR05

4—Battery Cable 5—Ground Strap

Starter (850J Shown)

TX,0400,SS2277 –19–14JUL05–15/17

04 0400 9

47. Connect wiring harness to horn (1), front lights (2), and quick-drop valve (3).

T210636A

–UN–19APR05

1—Horn Wiring Harness 2—Front Lights Wiring Harness 3—Quick-Drop Valve Wiring Harness (Outside Dozers only)

T210637A

–UN–19APR05

Front Lights and Horn

Quick-Drop Valve Continued on next page

TM2261 (10FEB06)

04-0400-9

TX,0400,SS2277 –19–14JUL05–16/17

750J, 850J Crawler 032806

PN=291

Removal and Installation 48. Connect reversing fan valve wiring harness, if equipped.

–UN–27APR05

49. Connect hydrostatic pump PCP wiring harnesses (18 and 19). 50. Connect engine wiring harness (20).

T211004A

51. Install hood support with air cleaner. See Hood Support Remove and Install. (Group 1910.) 52. Install muffler. Engine and PCP Wiring Harnesses (850J Shown)

53. Connect ether start aid tube from engine, if equipped. 54. Fill cooling system. See Filling the Cooling System. (Operator’s Manual.)

04 0400 10

Specification 750J Cooling System—Capacity ...................................................... 21.5 L 5.7 gal 850J Cooling System—Capacity ......................................................... 38 L 10 gal

16—Hydrostatic Pump-to-Flywheel Mounting Cap Screw 17—Hydrostatic Pump-to-Flywheel Mounting Cap Screw 18—PCP Wiring Harness 19—PCP Wiring Harness 20—Engine Wiring Harness

55. Install bottom guards. See Bottom Guards Remove and Install. (Group 1746.) 56. Install hood. See Hood Remove and Install. (Group 1910.) 57. Install engine side shields. See Engine Side Shields Remove and Install. (Group 1910.) 58. Lower cab/ROPS. See Cab or ROPS Tilting Procedure. (Operator’s Manual.) 59. Turn battery disconnect switch to ON or connect battery ground strap.

TX,0400,SS2277 –19–14JUL05–17/17

TM2261 (10FEB06)

04-0400-10

750J, 850J Crawler 032806

PN=292

Removal and Installation

Oil Pan Remove and Install NOTE: Oil pan can be removed and installed without removing engine in both 750J and 850J machines. 850J’s will need the engine slightly raised. 1. Remove front oil pan bottom guard. 2. Remove engine side shields. See Engine Side Shields Remove and Install. (Group 1910.) 3. Drain engine oil into a suitable container for storage or disposal. Specification 850J Engine Oil—Capacity .............................................................. 26.5 L 7 gal 750J Engine Oil—Capacity ................................................................. 28 L 7.4 gal

04 0400 11

Continued on next page

TM2261 (10FEB06)

04-0400-11

TX,0400,SS2286 –19–29AUG96–1/3

750J, 850J Crawler 032806

PN=293

Removal and Installation

T211301

–UN–26MAY05

04 0400 12

Engine Oil Pan (750J shown) 1—Gasket 2—Engine Oil Pan

3—Cap Screw (30 used) 5—Drain Plug

6—Drain Valve 8—O-Ring (4 used)

IMPORTANT: Do not pry or gouge the sealing surface of engine oil pan. Tap engine oil pan with a rubber mallet in order to remove. 4. Remove cap screws (3) from engine oil pan (2). 5. Remove engine oil pan (2). 6. Remove gasket (1) from oil pan. 7. Clean mating surface of the engine oil pan and the cylinder block. Apply TY6304 Flexible Form-in-Place Gasket on the sealing surface of oil pan.

9—Drain Plug

9. Install engine oil pan (2). Tighten cap screws to specification. Specification Oil Pan M8 Cap Screws— Torque...................................................................................... 35 N•m 26 lb-ft Oil Pan M10 Cap Screws up to 110 mm—Torque ..................................................................... 70 N•m 52 lb-ft Oil Pan M10 Cap Screws 110 mm and Above—Torque ......................................................... 60 N•m 44 lb-ft

10. Fill engine crankcase with correct grade and viscosity engine oil. See Diesel Engine Oil. (Operator’s Manual.)

8. Install new gasket.

Continued on next page

TM2261 (10FEB06)

04-0400-12

TX,0400,SS2286 –19–29AUG96–2/3

750J, 850J Crawler 032806

PN=294

Removal and Installation Specification 850J Engine Oil—Capacity........................................................ 26.5 L 7 gal

750J Engine Oil—Capacity........................................................... 28 L 7.4 gal

TX,0400,SS2286 –19–29AUG96–3/3

Flywheel Remove and Install 1. Lower equipment to the ground. 2. Raise cab/ROPS. See Cab or ROPS Tilting Procedure. (Operator’s Manual.) 3. Place straps around tandem hydrostatic pumps and hydraulic pump. 4. Using DFT1063, DFT1067, DFT1065, and a load leveler connect lifting straps to hoist. See DFT1063 Pump Lifting Bracket, DFT1167 Spacer, and DFT1065 Pump Lifting Bracket. (Group 9900.) 04 0400 13

5. Remove rear access cover and bottom guard for access to pump assembly. 6. Disconnect PCP electrical connectors on hydrostatic pumps.

Continued on next page

TM2261 (10FEB06)

04-0400-13

BR81691,000001A –19–24JUN05–1/2

750J, 850J Crawler 032806

PN=295

–UN–08JUL05

Removal and Installation

T212464

04 0400 14

T212464 Power Train/Engine Cradle Mounting 9—Flywheel Cover

10—Hydraulic Pump Bracket Mounting Cap Screws M12 x 45 (4 used)

18—Hydraulic Pump Support Bracket

7. Remove cap screws (10) to allow hydraulic and hydrostatic pumps to move towards rear of machine for access to flywheel.

12. Slide flywheel back in place.

8. Connect a ratchet winch strap to hydraulic pump through rear access cover.

14. Install hydraulic pump bracket cap screws (10).

9. Remove flywheel cover (9). Use hoist and winch ratchet strap to pull pump assembly towards rear of machine. 10. Remove flywheel. See Remove Flywheel. (CTM 86.)

13. Install flywheel cover.

15. Connect PCP electrical connectors on hydrostatic pumps. 16. Install rear access cover and bottom guard. 17. Lower cab/ROPS. See Cab or ROPS Tilting Procedure. (Operator’s Manual.)

11. Install flywheel. See Install Flywheel. (CTM 86.)

BR81691,000001A –19–24JUN05–2/2

TM2261 (10FEB06)

04-0400-14

750J, 850J Crawler 032806

PN=296

Removal and Installation

04 0400 15

TM2261 (10FEB06)

04-0400-15

750J, 850J Crawler 032806

PN=297

Removal and Installation

Engine Mounts Remove and Install

T206114

–UN–07JAN05

04 0400 16

Engine Mounts (750J Shown) Continued on next page

TM2261 (10FEB06)

04-0400-16

TX,9025,BS482 –19–20OCT99–1/2

750J, 850J Crawler 032806

PN=298

Removal and Installation 1—Right Rail Assembly 2—Left Rail Assembly 3—Washer (16 used) 4—Cap Screw (12 used) 5—Cap Screw (2 used) 6—Flange Nut (4 used)

7—Cap Screw 8—Cap Screw (6 used) 9—Flywheel Cover 10—Cap Screw (4 used) 11—Washer (12 used)

12—Cap Screw (9 used) 13—Cap Screw (4 used) 14—Washer (4 used) 15—Nut (4 used) 16—Washer (4 used)

17—Isolator (4 used) 18—Rear Power Train/Engine Support/Cradle 19—Washer (8 used) 20—Plate (4 used)

Item

Measurement

Specification

Engine

Approximate Weight

907 kg 2000 lb

Item

Measurement

Specification

Engine Mount Cap Screws

Torque

610 N•m 450 lb-ft

TX,9025,BS482 –19–20OCT99–2/2

04 0400 17

TM2261 (10FEB06)

04-0400-17

750J, 850J Crawler 032806

PN=299

Removal and Installation

04 0400 18

TM2261 (10FEB06)

04-0400-18

750J, 850J Crawler 032806

PN=300

Section 05

Engine Auxiliary Systems Contents Page

Group 0505—Cold Weather Starting Aid Starting Aid Assembly Remove and Install. . . . . . . . . . . . . . . . . . . . . . . . . . . . .05-0505-1 Group 0510—Cooling System Guards, Shroud and Fan Remove and Install. . . . . . . . . . . . . . . . . . . . . . . . . . . . .05-0510-1 Cooling Package Remove and Install . . . . . .05-0510-4 Group 0515—Engine Speed Control Decelerator/Brake Pedal Remove and Install. . . . . . . . . . . . . . . . . . . . . . . . . . . . .05-0515-1 Decelerator/Brake Pedal Disassemble and Assemble. . . . . . . . . . . . . . . . . . . . . . . . . .05-0515-2 Group 0530—External Exhaust Systems Muffler Remove and Install . . . . . . . . . . . . . .05-0530-1 05

Group 0560—External Fuel Supply Systems Fuel Tank Remove and Install. . . . . . . . . . . .05-0560-1

TM2261 (10FEB06)

05-1

750J, 850J Crawler 032806

PN=1

Contents

TM2261 (10FEB06)

05-2

750J, 850J Crawler 032806

PN=2

Group 0505

Cold Weather Starting Aid Starting Aid Assembly Remove and Install 1. Open right side engine service door. 2. Loosen clamp and remove starting fluid container (1). 3. Disconnect starting aid solenoid electrical connector and starting aid tube (4). 4. Remove cap screws (3) and starting aid. 5. Install starting aid solenoid and cap screws. –UN–16MAY05

6. Connect starting aid tube and solenoid electrical connector.

T211402A

7. Install starting fluid container. Tighten clamp. 1—Starting Fluid Container 2—Starting Aid Solenoid 3—Cap Screw (4 used) 4—Starting Aid Tube

Starting Aid

BR81691,0000015 –19–16MAY05–1/2

8. Remove fitting from intake manifold (A) with nozzle holder (B) and nozzle (C). 9. Remove nozzle (C) from nozzle holder (B). –UN–08OCT97

10. Clean or replace nozzle as required.

11. Carefully tighten nozzle in nozzle holder.

T104622

IMPORTANT: Nozzle must be secure in holder to prevent engine damage. Do not overtighten or nozzle may break. Nozzle and Holder Assembly

12. Apply T43513 thread lock and sealer (high strength) to threads of nozzle holder (B).

A—Adapter B—Nozzle Holder C—Nozzle

IMPORTANT: Arrows on nozzle holder should point toward incoming air. 13. Install nozzle holder with nozzle toward center of air inlet allowing fluid to spray into incoming air flow. Arrow on hex flats indicates direction of nozzle.

BR81691,0000015 –19–16MAY05–2/2

TM2261 (10FEB06)

05-0505-1

750J, 850J Crawler 032806

PN=303

05 0505 1

Cold Weather Starting Aid

05 0505 2

TM2261 (10FEB06)

05-0505-2

750J, 850J Crawler 032806

PN=304

Group 0510

Cooling System Guards, Shroud and Fan Remove and Install 1. Lower blade to the ground. 2. Stop engine. Operate all hydraulic controls to relieve hydraulic system pressure. 3. Turn battery disconnect switch to OFF or disconnect battery ground strap. 4. Remove engine side shields. See Engine Side Shields Remove and Install. (Group 1910.) 5. Remove hood. See Hood Remove and Install. (Group 1910.) 6. Drain engine coolant. See Draining the Cooling System. (Operator’s manual.) Specification Cooling System with Recovery Tank—Capacity ................................................................................ 34.5 L 9.1 gal

7. Drain or pull a vacuum on hydrostatic reservoir. 8. Disconnect hoses from oil cooler. Cap and plug all openings.

05 0510 1

TX,0510,SS2290 –19–29AUG96–1/5

9. On Outside Dozer (OSD) machines: Remove grille housing cover for access to quick-drop valve (3).

–UN–25APR05

10. Disconnect quick-drop valve hoses (1 and 2).

T210810A

1—Quick-Drop Valve Hose 2—Quick-Drop Valve Hose 3—Quick-Drop Valve

Quick-Drop Valve (Outside Dozers Only)

Continued on next page

TM2261 (10FEB06)

05-0510-1

TX,0510,SS2290 –19–29AUG96–2/5

750J, 850J Crawler 032806

PN=305

Cooling System 11. Disconnect radiator hoses and charge air cooler hose (7). 12. Remove charge air cooler tube (6). 13. Remove front bottom guard and disconnect hoses. (13—15). Cap and plug all openings.

–UN–25APR05

14. Remove cooling package mounting hardware (11 and 12).

T210811A

CAUTION: Prevent possible crushing injury from heavy cooling package. Use an appropriate lifting device to remove. 15. Remove cooling package using an appropriate lifting strap around cooling package and removing lower mounting hardware.

Cooling Package

Specification Cooling Package—Weight............................................................... 148 kg 325 lb

T210898A

4—Radiator 5—Radiator Hose 6—Charge Air Cooler Tube 7—Charge Air Cooler Hose 8—Oil Cooler Hose 9—Charge Air Cooler 10—Oil Cooler 11—Cooling Package Mounting Hardware 12—Cooling Package Mounting Hardware 13—Hydraulic Hose 14—Hydraulic Hose 15—Hydraulic Hose 16—Cap Screw (4 used)

–UN–27APR05

Cooling Package Mounting Hardware

T211005A

05 0510 2

–UN–27APR05

16. Remove fan shroud from coolers.

Front Bottom Guard Removed

Continued on next page

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05-0510-2

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Cooling System

22 19

05 0510 3

T211221

–UN–26MAY05

T211221 Engine Fan and Support 17—Cap Screw (6 used) 18—Fan 19—Hub

20—Spool Washer 21—Nut 22—Lock Nut

23—Bracket 24—Cap Screw (2 used) 25—Cap Screw (4 used)

26—Cap Screw (4 used) 27—Fan Drive Support

17. Remove fan (18) and bracket (23).

19. Replace parts as necessary.

18. Remove fan drive support (27) from cooler.

20. Install fan drive support (27) to cooler. Continued on next page

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PN=307

Cooling System 21. Install fan (18) and bracket (23).

28. Install grille housing cover.

22. Install fan shroud to coolers.

29. Connect hoses to oil cooler.

23. Install cooling package.

30. Fill engine coolant.

24. Install hydraulic hoses (13—15) and front bottom guard.

31. Install hood. See Hood Remove and Install. (Group 1910.)

25. Install charge air cooler tube (6).

32. Install engine side shields. See Engine Side Shields Remove and Install. (Group 1910.)

26. Connect radiator hoses and charge air cooler hose (7).

33. Turn battery disconnect switch to ON or connect battery ground strap.

27. On Outside Dozer (OSD) Machines: Connect quick-drop valve hoses (1 and 2).

TX,0510,SS2290 –19–29AUG96–5/5

Cooling Package Remove and Install 1. Lower blade to the ground.

05 0510 4

2. Stop engine. Operate all hydraulic controls to relieve hydraulic system pressure. 3. Turn battery disconnect switch to OFF or disconnect battery ground strap. 4. Remove engine side shields. See Engine Side Shields Remove and Install. (Group 1910.) 5. Remove hood. See Hood Remove and Install. (Group 1910.) 6. Drain engine coolant. See Draining the Cooling System. (Operator’s manual.) Specification Cooling System with Recovery Tank—Capacity ................................................................................ 34.5 L 9.1 gal

7. Drain or pull a vacuum on hydrostatic reservoir. 8. Disconnect hoses from oil cooler. Cap and plug all openings.

Continued on next page

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Cooling System 9. On Outside Dozer (OSD) machines: Remove grille housing cover for access to quick-drop valve (3).

–UN–25APR05

10. Disconnect quick-drop valve hoses (1 and 2).

T210810A

1—Quick-Drop Valve Hose 2—Quick-Drop Valve Hose 3—Quick-Drop Valve

Quick-Drop Valve (Outside Dozers Only)

Continued on next page

BR81691,0000013 –19–29MAR05–2/5

05 0510 5

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–UN–25APR05

14. Remove cooling package mounting hardware (11 and 12).

T210811A

Cooling Package

Specification Cooling Package—Weight............................................................... 148 kg 325 lb

T210898A

–UN–27APR05

Cooling Package Mounting Hardware

T211005A

05 0510 6

–UN–27APR05

16. Remove fan shroud from coolers.

Front Bottom Guard Removed

Continued on next page

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Cooling System

22 19

05 0510 7

T211221

–UN–26MAY05

T211221 Engine Fan and Support 17—Cap Screw (6 used) 18—Fan 19—Hub

20—Spool Washer 21—Nut 22—Lock Nut

23—Bracket 24—Cap Screw (2 used) 25—Cap Screw (4 used)

26—Cap Screw (4 used) 27—Fan Drive Support

17. Remove fan (18) and bracket (23).

19. Lay coolers on side and replace as necessary.

18. Remove fan drive support (27) from cooler.

20. Install fan drive support (27) to cooler. Continued on next page

TM2261 (10FEB06)

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PN=311

Cooling System 21. Install fan (18) and bracket (23).

28. Install grille housing cover.

22. Install fan shroud to coolers.

29. Connect hoses to oil cooler.

23. Install cooling package.

30. Fill engine coolant.

24. Install hydraulic hoses (13—15) and front bottom guard.

31. Install hood. See Hood Remove and Install. (Group 1910.)

25. Install charge air cooler tube (6).

32. Install engine side shields. See Engine Side Shields Remove and Install. (Group 1910.)

26. Connect radiator hoses and charge air cooler hose (7).

33. Turn battery disconnect switch to ON or connect battery ground strap.

27. On Outside Dozer (OSD) Machines: Connect quick-drop valve hoses (1 and 2).

BR81691,0000013 –19–29MAR05–5/5

05 0510 8

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Group 0515

Engine Speed Control Decelerator/Brake Pedal Remove and Install

2 1

1. Loosen mounting cap screws (1).

–UN–12MAY04

2. Disconnect harness to decelerator sensor (2). 3. Remove cap screws and assembly.

T199889

4. Inspect and replace parts as necessary.

NOTE: When installing assembly, verify that the round dust seal is in place on rear of support. 1—Cap Screw (4 used) 2—Decelerator Sensor

5. Install assembly and tighten cap screws to specification. Specification Decelerator Mounting Cap Screws—Torque ............................................................................. 73 N•m 54 lb-ft

6. Connect harness to decelerator sensor.

MF82180,00001DA –19–07MAY04–1/1

TM2261 (10FEB06)

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PN=313

05 0515 1

Engine Speed Control

05 0515 2

T199839

–UN–17MAY04

Decelerator/Brake Pedal Disassemble and Assemble

T199839 1—Pedal 2—Shaft 3—Support 4—Spring Pin (7 used) 5—Torsion Spring

6—Nut (3 used) 7—Cap Screw (7 used) 8—Cap Screw (2 used) 9—Hex Socket Head Screw (2 used)

1. Remove assembly from machine. See Decelerator/Brake Pedal Remove and Install. (Group 0515.)

10—Washer (4 used) 11—Washer (3 used) 12—Snap Spring 13—Needle Bearing (2 used) 14—Decelerator Sensor

15—Spring 16—Stop Plate 17—Pin Fastener 18—O-Ring

3. Remove decelerator sensor (14) and O-ring (18).

2. Remove hex socket head cap screws (9) securing decelerator sensor.

Continued on next page

TM2261 (10FEB06)

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PN=314

Engine Speed Control

–UN–19MAY04

CAUTION: Decelerator pedal is under spring pressure. Removing stop plate without relieving spring pressure can cause bodily injury. Relieve spring pressure by slowly loosening cap screws and holding pressure against pedal. 4. Loosen cap screws (8) securing stop plate (16).

T200194A

5. Remove cap screws (8), relieving tension in torsion spring (5).

4—Pin 5—Torsion Spring 8—Cap Screw (2 used) 16—Stop Plate

MF82180,00001DB –19–14JUL05–2/11

6. Remove pins (4) retaining pedal on shaft.

T200195A

–UN–19MAY04

4—Pin (2 used)

MF82180,00001DB –19–14JUL05–3/11

7. Remove shaft (2).

T200196A

–UN–19MAY04

2—Shaft 5—Torsion Spring 11—Washer

Continued on next page

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PN=315

05 0515 3

Engine Speed Control 8. Loosen retaining nuts (6). 9. Remove cap screws (7).

–UN–19MAY04

10. Apply pressure to washer (11) to compress spring (15) enough to remove snap ring (12).

T200197A

6—Retaining Nut (2 used) 7—Cap Screw (2 used) 11—Washer 12—Snap Ring 15—Spring

MF82180,00001DB –19–14JUL05–5/11

11. Remove pin fastener (17) and washer (11).

T200198A

11—Washer 17—Pin Fastener

MF82180,00001DB –19–14JUL05–6/11

13. Press bearings (13) into support (3) to specification.

–UN–19MAY04

Specification Bearing Placement—Distance from inside surface ................................................................ 0.0—1.0 mm 0.0—0.039 in.

14. Apply petroleum jelly to bearing rollers. 15. Install pins (4) into support (3) to specification.

T200199A

05 0515 4

–UN–19MAY04

12. Disassemble remaining parts as necessary. Press out roller bearings (13) if necessary.

Specification Pin Placement—Distance from surface ................................................................................... 0.0—1.0 mm 0.0—0.039 in.

3—Support 4—Pin (4 used) 13—Roller Bearing (2 used)

16. Install pin fastener (17) through washer (11) into back of support (3).

Continued on next page

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PN=316

Engine Speed Control 17. Install spring (15) and washer (11) onto shaft and compress to install snap ring (12).

–UN–19MAY04

18. Install retaining nuts (6) onto cap screws (7). Install cap screws. Tighten nuts to specification.

T200197A

Specification Retaining Nuts—Torque ................................................................. 73 N•m 54 lb-ft

6—Retaining Nut (2 used) 7—Cap Screw (2 used) 11—Washer 12—Snap Ring 15—Spring

MF82180,00001DB –19–14JUL05–8/11

19. Assemble torsion spring (5) onto pedal then rotate spring until spring is stopped by pin.

–UN–19MAY04

20. Place pedal with spring and washer (11) into support and install shaft (2) through assembly.

T200196A

2—Shaft 5—Torsion Spring 11—Washer

MF82180,00001DB –19–14JUL05–9/11

21. Verify torsion spring is installed correctly then install pin (4) into the outer hole on shaft, between washer and pedal. Verify pin has equal length on each side of shaft. –UN–19MAY04

22. Rotate pedal to align the hole in the pedal and shaft. Install pin (4) into hole.

T200195A

4—Pin (2 used)

Continued on next page

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PN=317

05 0515 5

Engine Speed Control 23. Secure pedal assembly and press pedal downwards. Install stop plate (16) and secure with cap screws (8). Tighten cap screws to specification.

–UN–19MAY04

Specification Stop Plate Cap Screws—Torque ................................................... 37 N•m 27 lb-ft

T200194A

24. Install decelerator sensor (14) with O-ring (18) onto shaft. 25. Slowly rotate sensor into position and install hex socket head cap screws (9). Tighten to specifications. Specification Sensor Hex Socket Head Cap Screws—Torque ............................................................................ 6.1 N•m 4.5 lb-ft

4—Pin 5—Torsion Spring 8—Cap Screw (2 used) 16—Stop Plate

26. Install assembly on machine. See Decelerator/Brake Pedal Remove and Install. (Group 0515.) 27. Perform Decelerator/Brake Pedal Adjustment. (Group 9015-20.)

MF82180,00001DB –19–14JUL05–11/11

05 0515 6

TM2261 (10FEB06)

05-0515-6

750J, 850J Crawler 032806

PN=318

Group 0530

External Exhaust Systems Muffler Remove and Install 1. Remove hood. See Hood Remove and Install. (Group 1910.) 2. Loosen clamp (6).

3. Remove muffler assembly (4) with exhaust stack (7). 4. Remove and install parts as necessary. 5. Install muffler assembly (4). 2 5

1—Nut 2—Cap Screw 3—Cap Screw (3 used) 4—Muffler 5—Exhaust Stack Clamp 6—Clamp 7—Exhaust Stack

T209677

4 6

–UN–21MAR05

Muffler (750J Shown)

05 0530 1

TX,0530,SS2361 –19–12JUL95–1/1

TM2261 (10FEB06)

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PN=319

External Exhaust Systems

05 0530 2

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PN=320

Group 0560

External Fuel Supply Systems Fuel Tank Remove and Install 1. Remove cab/ROPS. See Cab/ROPS Remove and Install. (Group 1800.) 2. Remove hydraulic reservoir. See Hydraulic Reservoir Remove and Install. (Group 3260.) 3. Remove hydrostatic reservoir. See Hydrostatic Reservoir Remove and Install. (Group 0360.) 4. Drain fuel from tank. Specification Fuel Tank—Capacity ......................................................................... 371 L 98 gal

TX,9025,BS501 –19–12JUL05–1/4

5. Disconnect fuel supply and return lines from fuel tank. 6. Disconnect wiring from fuel level sensor (1).

–UN–10MAR05

7. Remove wiring harnesses (4) from bulkheads. 8. Remove cab tilt cylinder from fuel tank.

T209431A

1—Fuel Level Sensor 4—Wiring Harness (4 used)

Fuel Tank Removal

Continued on next page

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05 0560 1

T209434

05 0560 2

–UN–11MAR05

External Fuel Supply Systems

T209434 Fuel Tank 2—Cap Screw (8 used) 11—Sealing Washer

12—Ball 13—Plug

14—O-Ring

18—Washer (8 used)

13. Install all ground straps to fuel tank.

9. Remove all ground straps from fuel tank. CAUTION: Prevent possible crushing injury from heavy fuel tank. Use an appropriate lifting device. 10. Remove fuel tank mounting hardware (2 and 18) and slowly remove fuel tank. Specification Fuel Tank—Weight ................................................................... 239 kg 525 lb

11. Install fuel tank using mounting hardware (2 and 18).

14. Install wiring harnesses to bulkheads. 15. Connect wiring to fuel level sensor. 16. Connect fuel supply and return lines to fuel tank. 17. Fill fuel tank. Specification Fuel Tank—Capacity .................................................................. 371 L 98 gal

18. Install cab/ROPS. Cab/ROPS Remove and Install. (Group 1800.)

12. Install cab tilt cylinder to fuel tank.

Continued on next page

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External Fuel Supply Systems 19. Install hydrostatic reservoir. See Hydrostatic Reservoir Remove and Install. (Group 0360.)

20. Install hydraulic reservoir. See Hydraulic Reservoir Remove and Install. (Group 3260.)

TX,9025,BS501 –19–12JUL05–4/4

05 0560 3

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External Fuel Supply Systems

05 0560 4

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Section 07

Dampener Drive Contents Page

Group 0752—Elements Dampener Drive Remove and Install . . . . . . .07-0752-1

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PN=1

Contents

TM2261 (10FEB06)

07-2

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Group 0752

Elements Dampener Drive Remove and Install 1. Lower equipment to the ground. 2. Raise cab/ROPS. See Cab or ROPS Tilting Procedure. (Operator’s Manual.) 3. Place straps around tandem hydrostatic pumps and hydraulic pump. 4. Using DFT1063, DFT1067, DFT1065, and a load leveler connect lifting straps to hoist. See DFT1063 Pump Lifting Bracket, DFT1167 Spacer, and DFT1065 Pump Lifting Bracket. (Group 9900.) 5. Disconnect PCP electrical connectors on hydrostatic pumps.

Continued on next page

TX,0752,SS2306 –19–21SEP05–1/3

07 0752 1

TM2261 (10FEB06)

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T212464

–UN–08JUL05

Elements

T212464 Power Train/Engine Cradle Mounting

T212750

–UN–15JUL05

07 0752 2

Dampener (850J shown) Continued on next page

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Elements 1—Cap Screw (8 used) 2—Washer (8 used) 3—Dampener

4—Socket Head Cap Screw 5—Internal Snap Ring 9—Flywheel Cover

10—Hydraulic Pump Bracket Mounting Cap Screws M12 x 45 (4 used)

18—Hydraulic Pump Support Bracket

6. Remove cap screws (10) to allow hydraulic and hydrostatic pumps to move towards rear of machine for access to flywheel.

11. Install flywheel cover (9).

7. Connect a ratchet winch strap to hydraulic pump through rear access cover.

13. Connect PCP electrical connectors on hydrostatic pumps.

8. Remove flywheel cover (9). Use hoist and winch ratchet strap to pull pump assembly towards rear of machine.

14. Install rear access cover and bottom guard.

12. Install hydraulic pump bracket cap screws (10).

15. Lower cab/ROPS. See Cab or ROPS Tilting Procedure. (Operator’s Manual.)

9. Remove dampener (3). 10. Install dampener (3).

TX,0752,SS2306 –19–21SEP05–3/3

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Elements

07 0752 4

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Section 11

Park Brake Contents Page

Group 1100—Park Brake Park Brake Remove and Install . . . . . . . . . . .11-1100-1 Group 1115—Control Linkage Park Lock Linkage Remove and Install . . . . .11-1115-2 Park Lock Linkage Disassemble and Assemble. . . . . . . . . . . . . . . . . . . . . . . . . .11-1115-3 Group 1160—Hydraulic System Park Brake Disassemble and Assemble . . . .11-1160-1

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Contents

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Group 1100

Park Brake Park Brake Remove and Install NOTE: Park brake assembly can be removed without removing final drive. 1. If final drive is being removed, disconnect hydrostatic motor from final drive and support with blocks. Remove final drive. See Final Drive Remove and Install. (Group 0200.) If final drive is not being removed, remove hydrostatic motor. See Hydrostatic Motor Remove and Install. (Group 0300.)

TE14778,00000D7 –19–12JUL05–1/3

2. Remove cap screws (16) and washers (15).

–UN–20JUN05

CAUTION: Park brake is heavy and can cause injury if not moved properly. Use adequate lifting device to move park brake.

T211631A

Specification Park Brake—Weight ..................................................... 61 kg Approximate 135 lb Approximate

3. Install lifting hooks and remove park brake using hoist. Park Brake Remove and Install

15—Washers (8 used) 16—Cap Screws (8 used)

11 1100 1 Continued on next page

TM2261 (10FEB06)

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Park Brake 4. Remove O-rings (7) from housing (6). 5. Remove gasket.

–UN–25MAY05

6. Disassemble park brake. See Park Brake Disassemble and Assemble. (Group 1160.)

T211655A

7. Lubricate O-rings (7) and gasket and install on park brake. 8. Install park brake assembly into final drive evenly until it bottoms. Park Brake O-rings

9. Install washers (15) and cap screws (16). Tighten cap screws to specification.

6—O-ring (2 used) 7—Housing

Specification Park Brake Mount Cap Screws— Torque .......................................................................................... 129 N•m 95 lb-ft

10. Install hydrostatic motor. See Hydrostatic Motor Remove and Install. (Group 0300.) 11. Fill final drive with recommended oil to fill plug level. See Inner and Outer Final Drive Oil. (Operator’s Manual.) See Change Final Drive Oil. (Operator’s Manual.) 12. Calibrate Transmission Control Unit (TCU). See Transmission Control Unit (TCU) Calibration. (Group 9015-20.)

11 1100 2 TE14778,00000D7 –19–12JUL05–3/3

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PN=334

Group 1115

Control Linkage

11 1115 1

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PN=335

Control Linkage

Park Lock Linkage Remove and Install 1. Lower all equipment to ground and stop engine. 2. Turn battery disconnected switch to OFF.

TE14778,000002D –19–09FEB05–1/3

3. Cut tie band and disconnect park lock lever switch connector (16) from cab harness. 4. Remove control lever knob.

T199669A

–UN–04MAY04

16—Park Lock Lever Switch Connector

11 1115 2 Continued on next page

TM2261 (10FEB06)

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PN=336

Control Linkage 5. Remove two cap screws (8) from front of left side console.

–UN–14APR05

6. Remove park lock lever assembly from left side console. 7. Assemble park lock lever assembly to left side console using two cap screws (8). Tighten to specification.

T208317A

Specification Park Lock Lever Mounting Cap Screw—Torque ............................................................................... 73 N•m 54 lb-ft

Park Lock Lever Remove and Install

8. Assemble control lever knob onto control lever. Tighten nut to specification.

8—Cap Screw (2 used)

Specification Control Lever Knob Nut—Torque .................................................. 23 N•m 204 lb-in.

9. Connect park lock lever switch connector (16) to cab harness. 10. Turn battery disconnect switch to ON.

TE14778,000002D –19–09FEB05–3/3

Park Lock Linkage Disassemble and Assemble

11 1115 3

1. Lower all equipment to ground and stop engine. 2. Turn battery disconnect switch to OFF. 3. Remove park lock assembly. See Park Lock Linkage Remove and Install. (Group 1115.)

Continued on next page

TM2261 (10FEB06)

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PN=337

T199655

–UN–07MAY04

Control Linkage

T199655 1—Cotter Pin 2—Nut 3—Pin Fastener 4—Pin Fastener 5—Washer 6—Spring 7—Hex Socket Head Cap Screw (2 used)

8—Flanged Head Cap Screw (2 used) 9—Lock Nut 10—Washer 11—Washer (2 used) 12—Washer 13—Washer

4. Remove plate (26), spring (25), and washer (10).

11 1115 4

14—Control Lever 15—Stud 16—Switch 17—Bracket 18—Threaded Stud 19—Threaded Stud 20—Spring Washer (5 used)

21—Knob 22—Washer (2 used) 23—Lock Nut 24—Plate (2 used) 25—Compressing Spring 26—Plate

6. Loosen lock nut (9) several turns. Do not remove.

5. Remove lock nut (23), spring washers (20), plate (24), and washer (22).

Continued on next page

TM2261 (10FEB06)

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PN=338

Control Linkage

CAUTION: Park lock control lever is under spring pressure. Removing control lever without relieving spring pressure can cause bodily injury. Relieve spring pressure by SLOWLY removing control lever over stops and rotating lever over center. 7. Using pry bar, lift control lever (14) and pin fastener (3) until control lever is higher than stops (27 and 28). This allows lever to rotate further and relieve spring tension.

–UN–04MAY04

8. Remove control lever (14), pin fastener (4), spring (6), and washer (5). 9. Disassemble remaining parts.

T199670A

10. Assemble pin fastener (4) onto control lever stud (15) using washers (11) and cotter pin (1). 11. Assemble pin fastener (3) onto threaded stud (19) using washers (13 and 12), and lock nut (9). Do not tighten lock nut.

3—Pin Fastener 9—Lock Nut 14—Control Lever 23—Lock Nut 27—Stop 28—Stop

12. Assemble plate (24) and washer (22) onto threaded stud (18). 13. Assemble washer (5) and compression spring (6) onto pin fastener (3). 14. With pin fastener (4) slid into compression spring (6), assemble control lever onto threaded stud (18). 15. Rotate control lever until lever fits over stops (27 and 28). Push into place. 16. Tighten lock nut (9) to specification. Specification Lock Nut (M8)—Torque ............................ Tighten lock nut until solid then loosen 1/2 turn.

11 1115 5

17. Assemble washer (22) and plate (24) onto threaded stud (18).

Continued on next page

TM2261 (10FEB06)

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Control Linkage 18. Assemble spring washers (20) as shown. Assemble lock nut (23) and tighten to specification.

20 Specification Hex Socket Head Cap Screws— Torque ......................................................................................... 10.4 N•m 92 lb-in.

20. Assemble washer (10), and compression spring (25) onto control lever (14).

T199665

19. Assemble switch (16) onto bracket using hex socket head cap screws (7). Tighten to specification.

–UN–04MAY04

Specification Lock Nut (3/8)—Torque ............................ Tighten lock nut until solid then loosen 1/2—2 turns.

20—Spring Washers (5 used) 23—Lock Nut

21. Assemble plate (26) onto control lever (14) with chamfer pointing away from spring. 22. Install park lock assembly. See Park Lock Linkage Remove and Install. (Group 1115.)

TE14778,000002C –19–09FEB05–4/4

11 1115 6

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Group 1160

Hydraulic System Park Brake Disassemble and Assemble 5 6 7 8

10 15

16 –UN–08JUL05

10 14 12

T211563 1—O-Ring 2—Piston 3—O-Ring 4—Spring (16 used) 5—Pressure Plate 6—Housing

T211563

11 11 7—O-Ring (2 used) 8—Gasket 9—Snap Ring 10—Separator Plates (4 used on 750J) —Separator Plates (6 used on 850J)

11—Friction Disk (4 used on 750J) —Friction Disk (6 used on 850J) 12—Hub

13—Gasket 14—Cover 15—Lock Washer (8 used) 16—Cap Screw (8 used) 17—Cap Screw (4 used)

Park Brake Disassembly 11 1160 1 Continued on next page

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Hydraulic System 1. Remove cap screws (17) and cover (14).

T211632A

–UN–06JUL05

14—Cover 17—Cap Screw (4 used)

Brake Cover

TE14778,00000D6 –19–14JUL05–2/16

2. Remove brake hub (12).

T211633A

–UN–25MAY05

12—Hub

Brake Hub

11 1160 2 Continued on next page

TM2261 (10FEB06)

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PN=342

Hydraulic System 3. Remove friction disks (11), pressure plates (10), and gasket (13).

T211634A

–UN–25MAY05

6—Housing 10—Separator Plate (4 used on 750J) —Separator Plate (6 used on 850J) 11—Friction Disk (4 used on 750J) —Friction Disk (6 used on 850J) 13—Gasket

Friction Disks and Separator Plates

TE14778,00000D6 –19–14JUL05–4/16

4. Install two washers (30) and cap screws (31) to compress pressure plate (5) and springs (4). Remove snap ring (9).

T211635A

–UN–25MAY05

4—Compression Springs (16 used) 5—Pressure Plate 9—Snap Ring 30—Washer (2 used) 31—Cap Screw (2 used)

Brake Plate

11 1160 3 Continued on next page

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PN=343

Hydraulic System 5. Loosen cap screws evenly and remove pressure plate and springs (4).

T211637A

–UN–10JUN05

2—Piston 4—Compression Springs (16 used)

Brake Compression Springs

TE14778,00000D6 –19–14JUL05–6/16

6. Remove brake piston (2) and O-rings (1 and 3).

T211781A

–UN–10JUN05

1—O-ring 2—Piston 3—O-ring 6—Housing

Brake Piston

11 1160 4 Continued on next page

TM2261 (10FEB06)

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PN=344

Hydraulic System 7. Remove O-rings (7) and gasket (8) from housing (6).

T211655A

–UN–25MAY05

6—Housing 7—O-ring (2 used)

Housing O-rings

TE14778,00000D6 –19–14JUL05–8/16

5 6 7 8

11 1160 5

10 15

–UN–08JUL05

14 12

T211563 1—O-Ring 2—Piston 3—O-Ring 4—Spring (16 used) 5—Pressure Plate

T211563

11 11 6—Housing 7—O-Ring (2 used) 8—Gasket 9—Snap Ring 10—Separator Plates (4 used)

11—Friction Disk (4 used) 12—Hub 13—Gasket 14—Cover

15—Lock Washer (8 used) 16—Cap Screw (8 used) 17—Lock Washer (4 used) 18—Cap Screw (4 used)

Park Brake Assembly Continued on next page

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PN=345

Hydraulic System 1. Apply clean oil on O-rings (1 and 3) and install on piston (2).

–UN–10JUN05

2. Install piston in housing (6).

T211781A

1—O-ring 2—Piston 3—O-ring 6—Housing

Brake Piston

TE14778,00000D6 –19–14JUL05–10/16

3. Install springs (4).

T211637A

–UN–10JUN05

2—Piston 4—Compression Springs (16 used)

Compression Springs

11 1160 6 Continued on next page

TM2261 (10FEB06)

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Hydraulic System 4. Install pressure plate (5), washers (30), and cap screws (31). Tighten cap screws evenly to compress pressure plate.

–UN–25MAY05

5. Install snap ring (9). 6. Loosen cap screws evenly and remove.

T211635A

4—Compression Springs (16 used) 5—Pressure Plate 9—Snap Ring 30—Washer (2 used) 31—Cap Screw (2 used)

Brake Plate

TE14778,00000D6 –19–14JUL05–12/16

7. Install hub (12).

T211633A

–UN–25MAY05

12—Hub

Brake Hub

11 1160 7 Continued on next page

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Hydraulic System 8. Start with friction disk (11) and alternating install four disks and four separator plates (10).

T211634A

–UN–25MAY05

6—Housing 10—Separator Plate (4 used on 750J) —Separator Plate (6 used on 850J) 11—Friction Disk (4 used on 750J) —Friction Disk (6 used on 850J) 13—Gasket

Friction Disks and Separator Plates

TE14778,00000D6 –19–14JUL05–14/16

9. Install gasket (13) and cover (14). Install and carefully tighten cap screws (17) to compress springs. Tighten to specification.

–UN–06JUL05

Specification Park Brake Cover—Torque ............................................... 66.4—73.2 N•m 49—54 lb-ft

T211632A

14—Cover 17—Cap Screw (4 used)

Brake Cover

11 1160 8 Continued on next page

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Hydraulic System 10. Apply clean oil on O-rings (7) and install on housing (6).

T211655A

–UN–25MAY05

6—Housing 7—O-ring (2 used)

Housing O-rings

TE14778,00000D6 –19–14JUL05–16/16

11 1160 9

TM2261 (10FEB06)

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Hydraulic System

11 1160 10

TM2261 (10FEB06)

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Section 15

Equipment Attaching Contents Page

Group 1511—Drawbar Extended Rigid Drawbar Remove and Install. . . . . . . . . . . . . . . . . . . . . . . . . . . . .15-1511-2 Rigid Drawbar Remove and Install . . . . . . . .15-1511-4 Group 1540—Ripper Ripper Remove and Install . . . . . . . . . . . . . .15-1540-2

TM2261 (10FEB06)

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Contents

TM2261 (10FEB06)

15-2

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Group 1511

Drawbar

15 1511 1

TM2261 (10FEB06)

15-1511-1

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PN=353

Drawbar

Extended Rigid Drawbar Remove and Install

T205332

–UN–29DEC04

15 1511 2

Extended Rigid Drawbar Continued on next page

TM2261 (10FEB06)

15-1511-2

TX,1511,RR5385 –19–01JUN05–1/2

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PN=354

Drawbar 1—Extended Rigid Drawbar 2—Washer (8 used)

3—Quick Lock Pin 4—Retainer

5—Cap Screw (8 used) 7—Lock Nut

CAUTION: Prevent possible crushing injury from heavy component. Use an appropriate lifting device. 1. Remove cap screws (5), washers (2), and extended rigid drawbar (1) from rear of machine. Specification Extended Rigid Drawbar— Weight ......................................................................................... 91 kg 200 lb

8—Cap Screw

2. Install extended rigid drawbar (1) to machine using cap screws (5) and washers (2). Tighten cap screws to specification. Specification Extended Rigid Drawbar-to-Main Frame Cap Screws—Torque ........................................................... Dry 1300 N•m Dry 975 lb-ft Lubricated 1050 N•m Lubricated 750 lb-ft

TX,1511,RR5385 –19–01JUN05–2/2

15 1511 3

TM2261 (10FEB06)

15-1511-3

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PN=355

Drawbar

Rigid Drawbar Remove and Install

T205331

–UN–29DEC04

15 1511 4

Rigid Drawbar Continued on next page

TM2261 (10FEB06)

15-1511-4

TX,1551,RR5386 –19–01JUN05–1/2

750J, 850J Crawler 032806

PN=356

Drawbar 1—Rigid Drawbar 2—Washer (4 used)

3—Quick Lock Pin 4—Cap Screw (4 used)

6—Lock Nut 7—Cap Screw

CAUTION: Prevent possible crushing injury from heavy component. Use an appropriate lifting device. 1. Remove cap screws (4), washers (2), and rigid drawbar (1) from rear of machine. Specification Rigid Drawbar—Weight .............................................................. 32 kg 70 lb

8—Retainer

2. Install rigid drawbar (1) to machine using cap screws (5) and washers (2). Tighten cap screws to specification. Specification Rigid Drawbar-to-Main Frame Cap Screws—Torque ................................................... Dry 1300 N•m Dry 975 lb-ft Lubricated 1050 N•m Lubricated 750 lb-ft

TX,1551,RR5386 –19–01JUN05–2/2

15 1511 5

TM2261 (10FEB06)

15-1511-5

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PN=357

Drawbar

15 1511 6

TM2261 (10FEB06)

15-1511-6

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PN=358

Group 1540

Ripper

15 1540 1

TM2261 (10FEB06)

15-1540-1

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PN=359

Ripper

Ripper Remove and Install

T214936

–UN–29SEP05

15 1540 2

Ripper Continued on next page

TM2261 (10FEB06)

15-1540-2

MS12501,000000E –19–25OCT05–1/2

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PN=360

Ripper 1—Cotter Pin (13 used) 2—Cap Screw (20 used) 3—Cap Screw (6 used) 4—Cap Screw (3 used) 5—Cap Screw (2 used) 6—Washer (3 used) 7—Washer (20 used) 8—Elbow Fitting (2 used) 9—O-Ring (2 used) 10—O-Ring (6 used) 11—Tee Fitting (2 used)

12—Adapter 13—O-Ring 14—Hydraulic Hose - Fabricate (4 used) 15—Pin (4 used) 16—Pin (6 used) 17—Pin (3 used) 18—Link (2 used) 19—Link 20—Frame 21—Shank (3 used)

22—Tooth (3 used) 23—Bushing (3 used) 24—Groove Pin (3 used) 25—Label 26—Reflector 27—Lubrication Fitting 28—Pin Fastener (13 used) 29—Lubrication Fitting (10 used) 30—Plate 31—Bar (3 used)

32—Bar (3 used) 33—Washer (6 used) 34—Bushing (8 used) 35—Bushing (8 used) 36—Support (Left Ripper Mount) 37—Support (Right Ripper Mount) 38—Ripper Assemble (Special Equipment Field Ripper)

CAUTION: Avoid crushing injury. Use appropriate lifting device. Item

Measurement

Specification

Ripper

Approximate Weight

2020 kg 4450 lb

MS12501,000000E –19–25OCT05–2/2

15 1540 3

TM2261 (10FEB06)

15-1540-3

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PN=361

Ripper

15 1540 4

TM2261 (10FEB06)

15-1540-4

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PN=362

Section 17

Frames, Chassis, or Supporting Structure Contents Page

Group 1740—Frame Installation Welding Repair of Major Structures. . . . . . . .17-1740-1 Group 1746—Frame Bottom Guards Bottom Guards Remove and Install. . . . . . . .17-1746-1 Group 1749—Chassis Weights Front Counterweight Remove and Install. . . .17-1749-2 Rear Counterweight Remove and Install . . . .17-1749-4

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Group 1740

Frame Installation Welding Repair of Major Structures IMPORTANT: Disconnect battery ground strap or turn battery disconnect switch to OFF (if applicable).

machine information center, and pump and valve controller electrical connectors before welding on the machine.

Disconnect both negative and positive battery cables and microprocessor unit (if applicable).

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.

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.

2. Use one of the following weld processes: Remove or protect all parts that can be damaged by heat or weld splatter. CAUTION: Avoid potentially toxic fumes and dust. Hazardous fumes can be generated when paint is heated by welding, soldering, or using a torch. Do all work outside or in a well ventilated area. Dispose of paint and solvent properly. If you sand or grind paint, avoid breathing the dust. Wear an approved respirator. If you use solvent or paint stripper, remove stripper with soap and water before welding. Remove solvent or paint stripper containers and other flammable material from area. Allow fumes to disperse at least 15 minutes before welding or heating. 1. Remove paint before welding or heating. IMPORTANT: Electrical current traveling from the welder through the machine electrical system may damage the machine electrical system, including battery, machine information center, and pump and valve controller. Disconnect battery ground cable,

• AWS-E-7018 covered electrode with shielded metal arc welding (SMAW) process. • AWS-ER-70S-3 wire electrode with gas metal arc welding (GMAW) process. • AWS-E70T-1 or E71T-1 wire electrode with flux core arc welding (FCAW) process. Welding Repair of Major Structure—Specification Weld Metal—Tensile Strength ............................................ 482.6 mPa 70,000 psi Yield Strength ..................................................................... 413.7 mPa 60,000 psi Elongation ..................................................................................... 22%

IMPORTANT: Area to be repaired must be preheated to allow better weld penetration. 3. To repair weld metal failure, remove failed weld metal using arc or grinding equipment. Thoroughly clean area to be welded. Preheat structural assemblies to a minimum of 38°C (100°F). Preheat ground engaging tools (cutting edges, skid shoes, and teeth shanks) to 177°C (350°F).

17 1740 1

Continued on next page

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17-1740-1

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Frame Installation To repair base metal failure remove enough material to allow weld to penetrate to the bottom of crack. Preheat structural assemblies to a minimum of 38°C (100°F). Preheat ground engaging tools (cutting edges, skid shoes, and teeth shanks) to 177°C (350°F).

Welding Repair of Major Structure—Specification Structural Assemblies—Preheat Temperature ................................................................................ 38°C 100°F Ground Engaging Tools— Preheat Temperature................................................................. 177°C 350°F

TX,1740,RR5420 –19–29AUG96–2/2

17 1740 2

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PN=366

Group 1746

Frame Bottom Guards Bottom Guards Remove and Install

5 11 14

5 5

T209229

–UN–03MAR05

Bottom Guards 5—Washer 8—Cap Screw

11—Front Bottom Guard 12—Transmission Bottom Guard

13—Oil Pan Bottom Guard

CAUTION: Prevent possible crushing injury from heavy bottom guards. Use appropriate tools to remove.

14—Middle Bottom Guard

2. Clean machine of dirt and debris. 3. Install front and transmission bottom guards (11 and 12).

1. Remove front and transmission bottom guards (11 and 12). Specification Front and Transmission Bottom Guards—Weight ......................................................................... 41 kg 90 lb

TX,1746,RR5426 –19–14JUL05–1/1

17 1746 1

TM2261 (10FEB06)

17-1746-1

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PN=367

Frame Bottom Guards

17 1746 2

TM2261 (10FEB06)

17-1746-2

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PN=368

Group 1749

Chassis Weights

17 1749 1

TM2261 (10FEB06)

17-1749-1

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PN=369

Chassis Weights

–UN–29DEC04

Front Counterweight Remove and Install

T205467

17 1749 2

Front Counterweight Continued on next page

TM2261 (10FEB06)

17-1749-2

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PN=370

Chassis Weights 1—Front Counterweight 2—Washer (4 used)

3—Washer (4 used)

4—Cap Screw M12 x 150 (4 used)

CAUTION: Prevent possible injury from falling counterweight. Use a hoist or suitable lifting device to support weight.

5—Cap Screw M20 x 110 (4 used)

850J Front Counterweight— Weight ....................................................................................... 400 kg 880 lb

2. Install front counterweight and tighten cap screws. 1. Remove cap screws (4 and 5) along with front counterweight (1). Specification 750J Front Counterweight— Weight ....................................................................................... 252 kg 555 lb

TX,1749,RR5425 –19–23APR96–2/2

17 1749 3

TM2261 (10FEB06)

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Chassis Weights

–UN–07JAN05

Rear Counterweight Remove and Install

T205447

17 1749 4

Rear Counterweight Continued on next page

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PN=372

Chassis Weights 1—Rear Counterweight 2—Washer (6 used)

3—Cap Screw 1 in. x 4-1/2 in. (6 used)

CAUTION: Prevent possible injury from falling counterweight. Use a hoist or suitable lifting device to support weight.

4—Cap Screw M12 x 100 (6 used)

5—Washer (6 used)

850J Rear Counterweight— Weight ....................................................................................... 448 kg 987 lb

2. Install rear counterweight and tighten cap screws. 1. Remove cap screws (3 and 4) along with rear counterweight (1). Specification 750J Rear Counterweight— Weight ....................................................................................... 325 kg 717 lb

TX,1749,RR5425 –19–23APR96–2/2

17 1749 5

TM2261 (10FEB06)

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PN=373

Chassis Weights

17 1749 6

TM2261 (10FEB06)

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PN=374

Section 18

Operator’s Station Contents Page

Group 1800—Removal and Installation Cab/ROPS Remove and Install . . . . . . . . . . .18-1800-1 Group 1810—Operator Enclosure Remove and Install Window . . . . . . . . . . . . .18-1810-1 Remove and Install Windowpanes . . . . . . . .18-1810-2 Hand Pump Bleed Procedure . . . . . . . . . . . .18-1810-3 Group 1821—Seat and Seat Belt Disassemble and Assemble Seat . . . . . . . . .18-1821-1 Group 1830—Heating and Air Conditioning R134a Refrigerant Cautions . . . . . . . . . . . . .18-1830-1 R134a Compressor Oil Charge Check . . . . .18-1830-1 R134a Compressor Oil Removal . . . . . . . . . .18-1830-2 R134a Component Oil Charge . . . . . . . . . . .18-1830-3 Leakage Testing . . . . . . . . . . . . . . . . . . . . . .18-1830-4 R134a Refrigerant Recovery, Recycling and Charging Station Installation Procedure . . . . . . . . . . . . . . . . . . . . . . . . .18-1830-5 Recover R134a System . . . . . . . . . . . . . . . .18-1830-6 Evacuate R134a System . . . . . . . . . . . . . . . .18-1830-7 Charge R134a System . . . . . . . . . . . . . . . . .18-1830-9 Air Conditioner System Cleaning Procedures . . . . . . . . . . . . . . . . . . . . . . .18-1830-10 Purge R134a System . . . . . . . . . . . . . . . . .18-1830-11 Flush R134a System . . . . . . . . . . . . . . . . . .18-1830-12 Evaporator or Heater Core Remove and Install. . . . . . . . . . . . . . . . . . . . . . . . . . . .18-1830-14 Expansion Valve Remove and Install . . . . .18-1830-17 A/C Freeze Switch Remove and Install . . . .18-1830-18 Upper Cab Heater Blower Motor and Heater Blower Resistor Remove and Install. . . . . . . . . . . . . . . . . . . . . . . . . . . .18-1830-18 Cab Upper Heater Disassemble and Assemble. . . . . . . . . . . . . . . . . . . . . . . . .18-1830-20 Cab or ROPS Under Seat Heater Disassemble and Assemble. . . . . . . . . . .18-1830-22 Receiver-Dryer Remove and Install . . . . . . .18-1830-24 Condenser Remove and Install . . . . . . . . . .18-1830-25 Compressor Remove and Install . . . . . . . . .18-1830-26 Compressor Clutch Disassemble and Assemble. . . . . . . . . . . . . . . . . . . . . . . . .18-1830-28 Clutch Hub Clearance Check . . . . . . . . . . .18-1830-30 Compressor Manifold Inspect . . . . . . . . . . .18-1830-31 Compressor Disassemble and Assemble . .18-1830-32 TM2261 (10FEB06)

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Contents

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Group 1800

Removal and Installation Cab/ROPS Remove and Install 18 1800 1

1. Recover R134a System. See Recover R134a System. (Group 1830.) –UN–04MAR05

2. Tilt cab/ROPS. See Cab or ROPS Tilting Procedure. (Operator’s Manual.)

T208971A

3. Label and disconnect all pilot control hydraulic hoses from hydraulic control lever (1). 4. Drain coolant. See Draining the Cooling System. (Operator’s Manual.)

Hydraulic Control Lever

5. Disconnect heater hoses (2 and 3).

T208968A

–UN–04MAR05

1—Hydraulic Control Lever 2—Heater Hose 3—Heater Hose

Heater Hoses Continued on next page

TM2261 (10FEB06)

18-1800-1

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PN=377

Removal and Installation 6. Disconnect air conditioning hoses from location (8 and 9).

–UN–04MAR05

7. Disconnect wiring harnesses (4).

T208936A

4—Wiring Harness (4 used) 8—Air Conditioning Hose Location 9—Air Conditioning Hose Location

–UN–04MAR05

Air Conditioning Hoses

T208843A

18 1800 2

Wiring Harnesses

Continued on next page

TM2261 (10FEB06)

18-1800-2

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PN=378

Removal and Installation 8. Disconnect windshield washer hoses (5) from tank. 18 1800 3

9. Disconnect machine ground strap (6) from cab. 10. Lower cab. 11. Remove cab tilt cylinder pin (7). 12. Remove rear cab mounting pins.

–UN–04MAR05

CAUTION: Prevent possible crushing injury from cab/ROPS. Use an appropriate lifting device.

T208847A

13. Install four JT05552 Lifting Eyebolts (A) in top of cab. Attach chain and slowly remove cab/ROPS. Specification Canopy/ROPS—Weight .................................................................. 703 kg 1550 lb Cab/ROPS—Weight ........................................................................ 953 kg 2100 lb

Ground Strap and Windshield Washer Hoses

14. Lower cab/ROPS onto frame. 15. Install rear cab mounting pins. –UN–04MAR05

16. Install cab tilt cylinder pin (7). 17. Tilt cab.

T209059A

18. Connect machine ground strap (6) to cab. 19. Connect windshield washer hoses (5) to tank. Cab Tilt Cylinder Pin 5—Windshield Washer Hose (2 used ) 6—Machine Ground Strap 7—Cab Tilt Cylinder Pin

Continued on next page

TM2261 (10FEB06)

18-1800-3

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PN=379

Removal and Installation 20. Connect wiring harnesses (4). 21. Connect heater hoses (2 and 3). 22. Connect all pilot control hydraulic hoses to hydraulic control lever (1). 23. Connect air conditioning hoses that were previously removed. 24. Fill cooling system. See Filling the Cooling System. (Operator’s Manual.) –UN–04MAR05

25. Lower cab/ROPS. See Cab or ROPS Tilting Procedure. (Operator’s Manual.)

27. Charge R134a System See Charge R134a System. (Group 1830.)

T208843A

26. Evacuate R134a System. See Evacuate R134a System. (Group 1830.)

Wiring Harnesses

T208971A

–UN–04MAR05

1—Hydraulic Control Lever 2—Heater Hose 3—Heater Hose 4—Wiring Harness (4 used)

–UN–04MAR05

Hydraulic Control Lever

T208968A

18 1800 4

Heater Hoses CED,OUO1057,219 –19–14JUL05–4/4

TM2261 (10FEB06)

18-1800-4

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PN=380

Group 1810

Operator Enclosure Remove and Install Window

T8499AT

–UN–26JUN95

18 1810 1

1—Molding 2—Left Side Window

3—Front Window Pane

4—Right Side Window

5—Rear Window

Remove and install windows as shown.

TX,1810,RR5410 –19–23APR96–1/1

TM2261 (10FEB06)

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Operator Enclosure

Remove and Install Windowpanes 18 1810 2

NOTE: Use this procedure to replace all door windowpanes and rear/front windowpanes. Use a Urethane Auto Glass Adhesive Sealant to hold windowpanes in place. Also use the primers, which are recommended for the adhesive formulation which has been selected. DO NOT use any other type of adhesive other than a urethane. It is also recommended that an auto glass dealer install the windowpanes. IMPORTANT: Windowpanes must have an ultraviolet barrier around the edge of the glass since ultraviolet rays will deteriorate the adhesive. Windowpanes ordered through John Deere Parts have the ultraviolet barrier. If the windowpane is purchased through a glass dealer, the dealer must put an ultraviolet 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 and appropriate primers from your local auto glass dealer. 2. If window frame is removable, remove frame from cab. 3. Scrape broken glass off existing adhesive. DO NOT remove adhesive from window frame or cab. 4. Trim existing adhesive so it has a smooth surface. 5. Inspect and clean both replacement glass and window frame. Use water with a mild detergent and allow to dry. 6. Apply primers per adhesive manufacturer’s recommendations 7. Apply a 12.5 mm (1/2 in.) bead of adhesive on top of the existing adhesive. Bead must be high enough to fill gap between frame and installed window.

Continued on next page

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18-1810-2

CED,TX14826,12085 –19–17AUG99–1/2

750J, 850J Crawler 032806

PN=382

Operator Enclosure 8. Put the new windowpane into position. Use light hand pressure to force windowpane down around the edges until even with metal frame. DO NOT over press adhesive.

18 1810 3

9. If windowpane is installed directly on cab, use tape to hold it in place while adhesive cures. 10. Allow adhesive to cure for 24 hours before operating machine.

CED,TX14826,12085 –19–17AUG99–2/2

Hand Pump Bleed Procedure Follow this procedure to bleed air from the hand pump/cab tilt cylinder circuit. TE14778,000006E –19–16NOV04–1/2

1. Remove Test Port 12 (1) plug.

T206573A

2. Operate Hand Pump (2) until all air is out of system.

–UN–04JAN05

IMPORTANT: For satisfactory operation of the cab tilt cylinder it is essential that all air be bled from the system. Therefore, any time air is induced into the system, the bleed procedure MUST be performed.

3. Install and tighten Test Port 12 plug. 1—Test Port 12 2—Hand Pump

TE14778,000006E –19–16NOV04–2/2

TM2261 (10FEB06)

18-1810-3

750J, 850J Crawler 032806

PN=383

Operator Enclosure

18 1810 4

TM2261 (10FEB06)

18-1810-4

750J, 850J Crawler 032806

PN=384

Group 1821

Seat and Seat Belt Disassemble and Assemble Seat

T8388AG

–UN–26JUN95

18 1821 1

1—Seat Support 2—Seat Belt 3—Armrest (2 used)

4—Bracket (2 used) 5—Washer (12 used) 6—Cap Screw (12 used)

7—Pad (2 used) 8—Plate (2 used)

9—Washer (4 used) 10—Cap Screw (4 used)

1. Remove only parts necessary to make repairs. 2. See following illustrations in this group to disassemble and assemble seat.

Continued on next page

TM2261 (10FEB06)

18-1821-1

T52,1821,K120 –19–23AUG93–1/6

750J, 850J Crawler 032806

PN=385

Seat and Seat Belt

–UN–19OCT88

A—Washer (4 used) B—Armrest (2 used) C—Backrest D—Nut (2 used) E—Washer (2 used) F—Spacer (2 used) G—Screw (2 used) H—Washer (2 used) I—Cap Screw (2 used) J—Spring (2 used) K—Seat Cushion L—Cap M—Tilt Latch N—Spring O—Cap Screw (4 used)

T6139AU

18 1821 2

Seat Cushions With Tilt Latch

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TM2261 (10FEB06)

18-1821-2

T52,1821,K120 –19–23AUG93–2/6

750J, 850J Crawler 032806

PN=386

Seat and Seat Belt

A—Bar B—Lock Nut C—Cross Pivot Bearing (2 used) D—Outer Arm E—Shaft F—End G—Bar H—Bar

T6139AT

–UN–19OCT88

18 1821 3

Scissors Suspension Arms With Shafts

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T52,1821,K120 –19–23AUG93–3/6

750J, 850J Crawler 032806

PN=387

Seat and Seat Belt

T6139AS

–UN–19OCT88

18 1821 4

Suspension Housing With Spring and Shock A—Height Adjustment Cap B—Lever C—Pin (3 used) D—Latch Return Spring E—Latch F—Nut (2 used)

G—Bolt (4 used) H—Upper Housing Plate I—Springs (2 used) J—Bushing (2 used) K—Shock Absorber L—Special Shoulder Bolt

M—Gear and Shaft Assembly N—Spring Pad O—Conical Spring P—Spring Washer Q—Special Washer (2 used) R—Isolator

Continued on next page

TM2261 (10FEB06)

18-1821-4

S—Gear and Shaft T—Cap Screw (2 used) U—Outer Arm V—Weight Adjusting Knob W—Weight Decal

T52,1821,K120 –19–23AUG93–4/6

750J, 850J Crawler 032806

PN=388

Seat and Seat Belt

A—Right Side Bracket B—Bar C—Nut (2 used) D—Left Side Bracket E—Washer F—Washer G—Cap Screw (2 used) H—Lock Nut (4 used) I—Washer J—Link (2 used) K—Nut (4 used) L—Link (2 used)

T6139AW

–UN–19OCT88

18 1821 5

Seat Adjustment Link and Side Bracket

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TM2261 (10FEB06)

18-1821-5

T52,1821,K120 –19–23AUG93–5/6

750J, 850J Crawler 032806

PN=389

Seat and Seat Belt

T6139AX

–UN–19OCT88

18 1821 6

Seat Adjuster Assembly A—Lift-To-Side Cap B—Washer C—Latch Link D—Decal E—Spring Pin F—Ride Height Indicator

G—Slide Stop Bolt H—Lower Housing I—Nut (2 used) J—Right Side Latch K—Tension Spring (2 used) L—Left Side Latch

M—Cable N—Strap O—Nut P—Slide Track Q—Cap Screw

R—Roller (4 used) S—Washer (4 used) T—Plug U—Boot V—Latch Rod

T52,1821,K120 –19–23AUG93–6/6

TM2261 (10FEB06)

18-1821-6

750J, 850J Crawler 032806

PN=390

Group 1830

Heating and Air Conditioning R134a Refrigerant Cautions 18 1830 1

develop high pressure which can burst the container.

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.

Keep refrigerant containers away from heat sources. Store refrigerant in a cool place.

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 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 allow refrigerant to contact open flames or very hot surfaces such as electric welding arc, electric heating element and lighted smoking materials. DO NOT heat refrigerant over 52°C (125°F) in a closed container. Heated refrigerant will

CED,OUTX547,172 –19–21OCT98–1/1

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. See R134a Compressor Oil Removal. (Group 1830.)

NOTE: Drain oil and save if this is a new compressor. If the oil drained from a compressor removed from operation is very black or the amount of oil is less than specification, perform the following: Specification Compressor Oil—Volume ........................................................ 6.0 mL 0.2 fl oz

1. Remove and discard the receiver-dryer.

2. Remove, clean, but do not disassemble the valve. 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. 5. Install a new receiver-dryer. 6. Install required amount of TY22025 refrigerant oil in the compressor. See R134a Component Oil Charge. (Group 1830.) 7. Connect all components, evacuate and charge the system.

CED,OUTX547,173 –19–05MAY04–1/1

TM2261 (10FEB06)

18-1830-1

750J, 850J Crawler 032806

PN=391

Heating and Air Conditioning

R134a Compressor Oil Removal 18 1830 2

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.)

CED,OUTX547,174 –19–09FEB05–1/1

TM2261 (10FEB06)

18-1830-2

750J, 850J Crawler 032806

PN=392

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. Compressors can be divided into 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 Use the following procedure to determine the amount of system oil charge prior to installation of compressor on a machine. 1. When the complete system, lines, and components were flushed add the correct amount of oil as described. • New compressor from parts depot contains a amount of new oil. System requires an additional amount of new oil. Specification Oil, New Compressor Installation, Complete System Flushed—Supplied Volume ..................................................... 230 mL 7.77 fl oz Additional Volume .................................................................... 2.4 mL 0.08 fl oz

• Used compressor removed from operation, oil drained, and flushed requires specified amount of new oil.

2. When 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 return specified amount of oil to the compressor. See R134a Compressor Oil Removal. (Group 1830.) Specification Oil, New Compressor Installation, Complete System Not Flushed—Volume.................................... Drain and return 45 mL Drain and return 1.5 fl oz

• Used compressor removed from operation and oil drained. See R134a Compressor Oil Removal. (Group 1830.) Add specified amount of new oil. Specification Oil, Used Compressor Installation, Complete System Not Flushed, Oil Drained— Volume ............................................................................... Add 45 mL Add 1.5 fl oz

• Used compressor removed from operation, oil drained, and flushed add specified amount of new oil. Specification Oil, Used Compressor Installation, Complete System Not Flushed, Oil Drained, Flushed—Volume .............................................................. Add 60 mL Add 2.0 fl oz

Specification Oil, Used Compressor Installation, Complete System Flushed—Volume .................................................................... 260 mL 8.8 fl oz

Continued on next page

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18-1830-3

CED,OUTX547,175 –19–09FEB05–1/2

750J, 850J Crawler 032806

PN=393

18 1830 3

Heating and Air Conditioning

18 1830 4

NOTE: Hoses = 3 mL per 0.3 m (0.1 fl oz per ft). Approximate total length equals 12.5 m (41.0 ft). 3. If any section of hose is removed and flushed or replaced, measure the length of hose and use the formula to determine the correct amount of oil to be added. CAUTION: 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. Components listed below which have been removed, drained or flushed, require the removal of the compressor to determine the correct oil charge. Use the following chart as a guide for adding oil to components:

Item

Measurement

Specification

Evaporator

Oil Charge

32.5 mL 1.1 fl oz

Condenser

Oil Charge

32.5 mL 1.1 fl oz

Receiver/Dryer

Oil Charge

30 mL 1.0 fl oz

Hoses

Oil Charge

121.2 mL approximate 4.1 fl oz approximate

CED,OUTX547,175 –19–09FEB05–2/2

Leakage 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. 2. A soap and water solution can be sprayed on the components in the system to form bubbles at the source of the leak. 3. If a leak detector is used, move the leak detector probe under the hoses and around the connections at specified rate. 4. Some refrigerant manufacturers add dye to refrigerant to aid in leak detection.

CED,OUO1066,309 –19–09FEB05–1/1

TM2261 (10FEB06)

18-1830-4

750J, 850J Crawler 032806

PN=394

Heating and Air Conditioning

R134a Refrigerant Recovery, Recycling and Charging Station Installation Procedure 18 1830 5

CAUTION: Do not remove high pressure relief valve (A). 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. Close both high and low pressure valves on refrigerant recovery, recycling and charging station (H). 2. Remove cap from low pressure test port (G).

–19–22FEB95

3. Connect low pressure blue hose (D) from refrigerant recovery, recycling and charging station (H) to low pressure test port (G) on compressor.

T8422AC

4. Connect high pressure red hose (C) to high pressure quick disconnect (B). 5. Follow the manufacturers instructions when using the refrigerant recovery, recycling and charging station. A—High Pressure Relief Valve B—High Pressure Test Port C—Red Hose D—Blue Hose E—High Pressure Hose F—Low Pressure Hose G—Low Pressure Test Port H—Refrigerant Recovery/Recycling and Charging Station

CED,OUTX547,176 –19–09FEB05–1/1

TM2261 (10FEB06)

18-1830-5

750J, 850J Crawler 032806

PN=395

Heating and Air Conditioning

Recover R134a System CAUTION: Do not remove high pressure relief valve (A). 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. Connect refrigerant recovery, recycling and charging station. See R134a Refrigerant Recovery, Recycling and Charging Station Installation Procedure. (Group 1830.) 2. Follow the manufacturers instructions when using the refrigerant recovery, recycling and charging station.

–19–22FEB95

NOTE: Run the air conditioning system for three minutes to help in the recovery process. Turn air conditioning system off before proceeding with recovery steps.

T8422AC

18 1830 6

A—High Pressure Relief Valve B—High Pressure Test Port C—Red Hose D—Blue Hose E—High Pressure Hose F—Low Pressure Hose G—Low Pressure Test Port H—Refrigerant Recovery/Recycling and Charging Station

CED,OUTX547,177 –19–09FEB05–1/1

TM2261 (10FEB06)

18-1830-6

750J, 850J Crawler 032806

PN=396

Heating and Air Conditioning

Evacuate R134a System 18 1830 7

CAUTION: Do not remove high pressure relief valve (A). 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. Do not run compressor while evacuating. 1. Connect refrigerant recovery, recycling and charging station. See R134a Refrigerant Recovery, Recycling and Charging Station Installation Procedure. (Group 1830.) –19–22FEB95

2. Open low and high pressure valves on refrigerant recovery, recycling and charging station.

T8422AC

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.

4. Evacuate system until low pressure gauge registers specified vacuum. If specified vacuum cannot be obtained in 15 minutes, test the system for leaks. See Leak Testing. (Group 1830.) Correct any leaks. Specification Vacuum—Pressure at Sea Level .................................................... 98 kPa 980 mbar 29 in. Hg Pressure Above Sea Level ................... Subtract 3.4 kPa from 98 kPa for each 300 m elevation Subtract 34 mbar from 980 mbar for each 300 m elevation Subtract 1 in. Hg from 29 in. Hg for each 1000 ft elevation

Continued on next page

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CED,OUTX547,178 –19–09FEB05–1/2

750J, 850J Crawler 032806

PN=397

Heating and Air Conditioning 5. When vacuum reaches specified level, close low-side and high-side valves. Turn vacuum pump off. 18 1830 8

6. If the vacuum decreases more than specified amount in 5 minutes, there is a leak in the system. Specification Leak Present—Decrease in Vacuum .......................................................................................... 3.4 kPa 34 mbar 1 in. Hg

7. Repair leak. 8. Start to evacuate. 9. Open low-side and high-side valves. 10. Evacuate system for 30 minutes after initial specified vacuum is reached. 11. Close low-side and high-side valves. Stop evacuation. 12. See Charge R134a System. (Group 1830.)

CED,OUTX547,178 –19–09FEB05–2/2

TM2261 (10FEB06)

18-1830-8

750J, 850J Crawler 032806

PN=398

Heating and Air Conditioning

Charge R134a System 18 1830 9

CAUTION: Do not remove high pressure relief valve (A). 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. Connect JT02045 R134a refrigerant recovery, recycling and charging station. See R134a Refrigerant Recovery, Recycling and Charging Station Installation Procedure. (Group 1830.) 2. Evacuate the system. See Evacuate R134a System. (Group 1830.)

3. Follow the manufacturers instructions and charge the system. 4. Add refrigerant until system is charged to specification. Specification Refrigerant (Portable Charging Station)—Weight............................................................................... 1.5 kg 3.5 lbs Refrigerant (Automated Charging Station)—Weight............................................................................. 1.47 kg 3.25 lbs

T8422AC

–19–22FEB95

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. A—High Pressure Relief Valve B—High Pressure Test Port C—Red Hose D—Blue Hose E—High Pressure Hose F—Low Pressure Hose G—Low Pressure Test Port H—Refrigerant Recovery/Recycling and Charging Station

5. Perform Air Conditioner Check. See Operational Checkout. (Group 9005-10.)

MG76653,0000002 –19–08FEB05–1/1

TM2261 (10FEB06)

18-1830-9

750J, 850J Crawler 032806

PN=399

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. Following is a list of situations that require a flushing procedure be done: 1. The compressor has an internal failure. 2. No oil remains in used compressor. 3. Oil drained from compressor appears or smells overheated. 4. System was contaminated with a mixture of refrigerant oils. 5. System was left open to the atmosphere long enough for dirt, moisture, or debris to enter the tubing or components. 6. System has an internal blockage. The following solvent is recommended for flushing air conditioner systems. Use only solvents with an equivalent MSDS. • TY16134 Air Conditioning System Flushing Solvent 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 purging procedure be done: • 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.

Continued on next page

TM2261 (10FEB06)

18-1830-10

MF82180,00001DD –19–09FEB05–1/2

750J, 850J Crawler 032806

PN=400

Heating and Air Conditioning Evacuating 18 1830 11

Evacuating the system is a process to remove air and moisture from the system, creating a vacuum. See Evacuate R134a System. (Group 1830.)

MF82180,00001DD –19–09FEB05–2/2

Purge R134a System 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. 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 Specification. Purge system for two minutes. Disconnect nitrogen supply. Specification Nitrogen Purge—Pressure............................ 275 kPa for two minutes 2.75 bar for two minutes 40 psi for two minutes

5. Evacuate system. See Evacuate R134a System. (Group 1830.)

CED,TX03399,2292 –19–09FEB05–1/1

TM2261 (10FEB06)

18-1830-11

750J, 850J Crawler 032806

PN=401

Heating and Air Conditioning

Flush R134a System 18 1830 12

Add flushing solvent to system with JT02075 Air Conditioning Flusher and JT02098 Fitting Kit.

4. Remove and discard receiver-dryer. 5. Divide system into two circuits:

NOTE: Flushing can be performed on vehicle. a. Condenser, including inlet and outlet hoses. 1. Recover refrigerant. See Recover R134a System. (Group 1830.) 2. Remove compressor and measure oil drained from both manifold ports. 3. Clean compressor as follows: a. Pour specified amount of flushing solvent into suction port and Specified amount of flushing solvent into discharge port. Plug both ports in compressor manifold, using Caps. Specification Compressor Flushing Solvent— Quantity in Suction Port........................................................... 240 mL 8 fl oz Quantity in Discharge Port ...................................................... 120 mL 4 fl oz

b. Evaporator, including inlet and outlet hoses. 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. 6. To Flush/Purge Condenser: Connect flusher outlet hose to inlet end of compressor discharge line using JT02102 Adapter. 7. 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. 8. Fill flusher tank with solvent and fasten all connections.

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. e. Invert compressor, roll end for end, and side to side. Drain thoroughly. f. Let compressor sit inverted for three to five minutes.

Specification Flusher Tank—Capacity ................................................................. 4 L 1 gal

NOTE: Air pressure must be at least 620 kPa (6.2 bar) (90 psi) for flushing and purging. 9. Connect a supply line of moisture-free compressed air or dry nitrogen to flusher air valve. Adjust regulator to specification. Specification Regulated Air—Minimum Pressure.................................................................................. 620 kPa 6.2 bar 90 psi

g. Repeat previous two steps at least three times.

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TM2261 (10FEB06)

18-1830-12

CED,TX03399,2293 –19–09FEB05–1/2

750J, 850J Crawler 032806

PN=402

Heating and Air Conditioning 10. 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.

2. Attach a hose and aerator nozzle to compressor inlet line using JT02101 Adapter. Put nozzle in a container to collect solvent.

IMPORTANT: Purging the condenser circuit takes 10—12 minutes to thoroughly remove solvent.

NOTE: Purging the evaporator circuit takes 12—15 minutes to thoroughly remove solvent.

11. Disconnect hose from aeration nozzle to check circuit for solvent. Hold hose close to a piece of cardboard; continue purging until cardboard is dry.

18 1830 13

3. Repeat Steps 8, 9 and 10 to flush evaporator.

4. Disconnect hose from aeration nozzle to check circuit for solvent. Hold hose close to a piece of cardboard. Continue purging until cardboard is dry. 22 Install a new receiver-dryer compatible with R134a refrigerant. Tighten connections and mounting bracket.

Flush Evaporator 1. 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. Remove evaporator. See Evaporator or Heater Core Remove and Install. (Group 1830.) 2. Force flushing solvent through evaporator inlet with compressed air.

23 Add required oil. See R134a Component Oil Charge. (Group 1830.) 24 Install compressor, and connect refrigerant lines to manifold. 25 Connect clutch coil wire. Install drive belt. 26 Purge system. See Purge R134a System. (Group 1830.)

3. Purge system until dry. 4. Reinstall evaporator. Flush Evaporator Through Expansion Valve 1. Connect flusher outlet hose to connection of receiver/dryer outlet hose using JT03188 Adapter.

CED,TX03399,2293 –19–09FEB05–2/2

TM2261 (10FEB06)

18-1830-13

750J, 850J Crawler 032806

PN=403

Heating and Air Conditioning

Evaporator or Heater Core Remove and Install NOTE: Anytime air conditioning system is discharged, a new receiver/dryer must be installed. 1. Remove cap screws to remove access cover to air conditioning and heater assembly. 2. Recover air conditioning system. See Recover R134a System. (Group 1830.)

CED,OUTX547,182 –19–09FEB05–1/4

3. Disconnect (1, 2, 4—6, 8 and 9). 4. Remove cap screw (3) on both sides.

–UN–03NOV98

5. Remove eight cap screws (7) and remove A/C and heater assembly.

–UN–05NOV98

T118219B

1—Receiver-Dryer Hose-to-Condenser 2—Receiver-Dryer Hose from Evaporator 3—Cap Screw (2 used) 4—Two Heater Hoses-to-Under the Seat Heater Core 5—A/C Harness Connector-to-Cab Harness Connector 6—Expansion Valve Hose-to-Compressor 7—Cap Screw (8 used) 8—A/C Blower Fans and Switch Connector 9—Low Pressure Switch Connector

T118220B

18 1830 14

Continued on next page

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CED,OUTX547,182 –19–09FEB05–2/4

750J, 850J Crawler 032806

PN=404

Heating and Air Conditioning 6. Disconnect lines and bracket from expansion valve (14). 18 1830 15

7. Remove two screw (12) and remove expansion valve –UN–03NOV98

8. Remove bracket (13). 9. Remove two cap screw and remove plate (10).

T118221B

10. Remove cover (11) and remove evaporator or heater core.

10—Plate 11—Evaporator/Heater Core Cover 12—Cap Screw (2 used) 13—Bracket 14—Expansion Valve

Continued on next page

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18-1830-15

CED,OUTX547,182 –19–09FEB05–3/4

750J, 850J Crawler 032806

PN=405

Heating and Air Conditioning 11. Install evaporator or heater core.

13. Connect (4—6, 8 and 9). Tighten cap screws (3 and 7). 14. Connect hoses (1 and 2).

T118221B

15. Install access cover and tighten cap screws.

–UN–03NOV98

12. Install (11, 10, 13, and 14). Tighten cap screws.

16. Install new receiver/dryer. 17. Apply refrigerant oil to new O-rings and immediately connect lines.

T118220B

–UN–03NOV98

19. Evacuate and charge the air conditioning system. See Evacuate R134a System and see Charge R134a System. (Group 1830.)

–UN–05NOV98

18. Add oil. See R134a Component Oil Charge. (Group 1830.)

T118219B

18 1830 16

CED,OUTX547,182 –19–09FEB05–4/4

TM2261 (10FEB06)

18-1830-16

750J, 850J Crawler 032806

PN=406

Heating and Air Conditioning

Expansion Valve Remove and Install 18 1830 17

NOTE: Anytime air conditioning system is discharged, a new receiver-dryer must be installed. –UN–20MAY04

1. Open access cover.

T200241A

2. Recover the air conditioning system. See Recover R134a System. (Group 1830.) 3. Disconnect hoses (1 and 3) and remove cap screw and bracket (2). 4. Remove two screws on expansion valve and remove valve.

1—Expansion Valve Hose-to-Compressor 2—Cap Screw and Bracket 3—Expansion Valve Hose-to-Receiver/Dryer

5. Install valve, bracket and connect hoses. 6. Install new receiver-dryer. See Receiver-Dryer Remove and Install. (Group 1830.) 7. Apply refrigerant oil to new O-rings and immediately connect lines. 8. Add oil. See R134a Component Oil Charge. (Group 1830.) 9. Evacuate and charge the air conditioning system. See Evacuate R134a System and see Charge R134a System. (Group 1830.)

CED,TX03399,5065 –19–09FEB05–1/1

TM2261 (10FEB06)

18-1830-17

750J, 850J Crawler 032806

PN=407

Heating and Air Conditioning

A/C Freeze Switch Remove and Install 1. Disconnect connector (1).

–UN–16NOV98

2. Remove sensor (2) from evaporator. 3. Remove cap screws (3).

T118417B

1—Connector 2—Sensor 3—Cap Screw (2 used)

CED,TX03399,5071 –19–09FEB05–1/1

Upper Cab Heater Blower Motor and Heater Blower Resistor Remove and Install 1. Remove A/C and heater access cover. –UN–16NOV98

2. Remove blower motor cover (for blower motor only). 3. Disconnect blower motor connectors (3). Remove cap screws (1 and 2).

T118407B

18 1830 18

4. Remove blower motor. 5. Disconnect leads (5) and cap screw (4) to remove heater resistor. 6. Install new resistor and connect leads and install cap screw (4).

1—Cap Screw (4 used) 2—Cap Screw 3—Blower Motor Connector (2 used) 4—Resistor Cap Screw 5—Resistor Wire Lead (3 used)

7. Install blower motor and connect connectors. 8. Install covers.

CED,TX03399,5066 –19–09FEB05–1/1

TM2261 (10FEB06)

18-1830-18

750J, 850J Crawler 032806

PN=408

Heating and Air Conditioning

18 1830 19

TM2261 (10FEB06)

18-1830-19

750J, 850J Crawler 032806

PN=409

Heating and Air Conditioning

Cab Upper Heater Disassemble and Assemble

T117712

–UN–15DEC98

18 1830 20

Continued on next page

TM2261 (10FEB06)

18-1830-20

CED,TX03399,5025 –19–09FEB05–1/2

750J, 850J Crawler 032806

PN=410

Heating and Air Conditioning 1—Top Cover 2—Cap Screw (24 used) 3—Evaporator Core 4—Heater Core 5—Cap Screw (10 used) 6—Bracket 7—Grommet (2 used) 8—Gasket Kit 9—Switch Knob (2 used)

10—Nut (2 used) 11—Rotary Switch 12—Heater Switch 13—Heater Control Switch 14—Recirculation Filter 15—Fresh Air Filter 16—Main Housing 17—Cap Screw (4 used) 18—Grommet

19—Mount Plate 20—O-Ring 21—Cap Screw (2 used) 22—Thermal Expansion Valve 23—O-Ring 24—Plate 25—Bracket 26—Freeze Control Switch

27—Blower Fan 28—Wiring Harness 29—Resistor 30—Motor Support Retainer 31—Motor Retainer 32—Bracket 33—A/C Back Cover 34—Upper Heater Assembly

18 1830 21

CED,TX03399,5025 –19–09FEB05–2/2

TM2261 (10FEB06)

18-1830-21

750J, 850J Crawler 032806

PN=411

Heating and Air Conditioning

Cab or ROPS Under Seat Heater Disassemble and Assemble

T117713

–UN–03DEC98

18 1830 22

Continued on next page

TM2261 (10FEB06)

18-1830-22

CED,TX03399,5024 –19–09FEB05–1/3

750J, 850J Crawler 032806

PN=412

Heating and Air Conditioning 1—Heater Base 2—Heater Assembly 3—Heater Tray 4—Gasket Kit

5—Blower Motor Bulkhead 6—Heater Core 7—Support 8—Wiring Harness (Not Shown) with Grommet

9—Backing Plate 10—Cap Screw (10 used) 11—Blower

1. Drain engine coolant. See Drain and Refill Capacities for amount. (Operator’s Manual.)

12—Cap Screw (2 used) 13—Switch 18 1830 23

3. For machines equipped with a toolbox, pull out drawer and remove cap screw holding toolbox in place. Remove toolbox.

2. Remove floor mat and floor access plate.

CED,TX03399,5024 –19–09FEB05–2/3

4. Remove four cap screws (A) from around seat box bottom.

7. On units equipped with rear screen or cab, tilt back of seat forward.

T116758B

6. Remove two cap screws from knee pad (E) on both sides of seat (if equipped).

–UN–03SEP98

5. Remove shoulder cap screws (C) from seat box under armrest (B) on both sides of seat.

8. Tilt seat up as far as possible with jack screw (D) located in left rear corner of seat box. 9. Disconnect blower wire connector and heater hoses.

–UN–21AUG98

10. Remove heater/blower assembly 11. Remove part as necessary.

T116757B

12. Assemble parts and lower seat. 13. Install floor access plate and floor mat. 14. Fill engine coolant. See Drain and Refill Capacities. (Operator’s Manual.)

T200435A

–UN–27MAY04

A—Cap Screws Around Seat Box Bottom (4 used) B—Armrest C—Shoulder Cap Screws (2 used) D—Jack Screw E—Knee Pad

CED,TX03399,5024 –19–09FEB05–3/3

TM2261 (10FEB06)

18-1830-23

750J, 850J Crawler 032806

PN=413

Heating and Air Conditioning

Receiver-Dryer Remove and Install NOTE: Anytime air conditioning system is discharged, a new receiver-dryer must be installed. –UN–02NOV98

1. Remove left hand side cover. 2. Recover the air conditioning system. See Recover R134a System. (Group 1830.)

T118142B

18 1830 24

3. Disconnect hoses (1 and 3) and remove four cap screws (2) and remove receiver-dryer. 4. Install new receiver-dryer, and bracket. Tighten cap screws.

1—Receiver/Dryer Hose-to-Condenser 2—Receiver/Dryer Hose-from-Evaporator 3—Receiver/Dryer Bracket Cap Screw (4 used)

5. Apply refrigerant oil to new O-rings and immediately connect lines. 6. Add oil. See R134a Component Oil Charge. (Group 1830.) 7. Evacuate and charge the air conditioning system. See Evacuate R134a System and see Charge R134a System. (Group 1830.)

CED,OUTX547,181 –19–09FEB05–1/1

TM2261 (10FEB06)

18-1830-24

750J, 850J Crawler 032806

PN=414

Heating and Air Conditioning

Condenser Remove and Install 18 1830 25

NOTE: Anytime air conditioning system is discharged, a new receiver-dryer must be installed. –UN–02NOV98

If servicing the condenser fans do not disconnect condenser hoses. Remove condenser and lay to the side.

T118149B

1. Remove bottom cover. 2. Recover the air conditioning system. See Recover R134a System. (Group 1830.) 3. Disconnect hoses (1 and 3) and remove six cap screws (2) and remove condenser.

1—From Receiver-Dryer-to-Condenser Hose 2—Cap Screw (6 used) 3—Condenser-to-Compressor Hose

4. Install condenser. Tighten cap screws. 5. Connect lines (1 and 3). 6. Install a new receiver-dryer. See Receiver-Dryer Remove and Install. (Group 1830.) 7. Apply refrigerant oil to new O-rings connect lines. 8. Add compressor oil. See R134a Component Oil Charge. (Group 1830.) 9. Evacuate and charge the air conditioning system. See Evacuate R134a System and see Charge R134a System. (Group 1830.)

CED,OUTX547,183 –19–09FEB05–1/1

TM2261 (10FEB06)

18-1830-25

750J, 850J Crawler 032806

PN=415

Heating and Air Conditioning

Compressor Remove and Install

T117702

–UN–22OCT98

18 1830 26

1—Compressor 2—Spring Pin (2 used) 3—Bracket 4—Support

5—Spacer 6—Sleeve 7—Pulley 8—Cap Screw

9—Washer (6 used) 10—Cap Screw 11—Cap Screw (3 used) 12—Nut (3 used)

1. Remove refrigerant from the system. See Recover R134a System. (Group 1830.)

13—Washer (2 used) 14—Cap Screw (2 used) 15—Cap Screw

4. Remove four cap screws and compressor. 5. Repair or replace compressor. See Compressor Disassemble and Assemble. (Group 1830.)

2. Loosen belt adjuster and remove belt. 3. Disconnect wiring lead, suction and discharge lines.

Continued on next page

TM2261 (10FEB06)

18-1830-26

CED,TX03399,5020 –19–09FEB05–1/2

750J, 850J Crawler 032806

PN=416

Heating and Air Conditioning 6. Install compressor and tighten cap screws.

8. Install belt.

Air Conditioning Compressor Remove and Install—Specification Compressor-to-Bracket Cap Screws—Torque ...................................................................... 35 N•m 26 lb-ft Support Bracket-to-Engine Block Cap Screw—Torque .................................................... 120 N•m 89 lb-ft Compressor Bracket to Engine Block Cap Screws—Torque .................................................... 70 N•m 52 lb-ft Idler pulley-to-fan drive cap screw—Torque......................................................................... 50 N•m 37 lb-ft

9. Install a new receiver/dryer. 10. Evacuate and charge the air conditioning system. See Evacuate R134a System and see Charge R134a System. (Group 1830.) IMPORTANT: When turning air conditioning on for the first time, set the engine rpm at slow idle to avoid possible high pressure discharge of extra refrigerant oil that is in all new compressors.

7. Connect suction and discharge lines and wiring lead.

CED,TX03399,5020 –19–09FEB05–2/2

TM2261 (10FEB06)

18-1830-27

750J, 850J Crawler 032806

PN=417

18 1830 27

Heating and Air Conditioning

Compressor Clutch Disassemble and Assemble

T114965

–UN–29APR98

RW21157

–UN–24JUN92

18 1830 28

A—JDG747 Compressor Clutch Spanner B—Clutch Shaft Bolt

C—Clutch Hub D—Pulley Snap Ring

E—Pulley F—Clutch Coil Snap Ring

1. Mount compressor on D01006AA Bench Mounted Holding Fixture or DFRW20 Compressor Holding Fixture using two 6 in. x 1/4 in. eye bolts with nuts as illustrated.

2. Remove dust cover.

Continued on next page

TM2261 (10FEB06)

G—Clutch Coil H—Shims

18-1830-28

TX,18,RB761 –19–09FEB05–1/2

750J, 850J Crawler 032806

PN=418

Heating and Air Conditioning 3. Hold the clutch hub using JDG747 Compressor Clutch Spanner (A) and remove the clutch shaft bolt (B).

8. Install the clutch coil and new snap ring with flat side of the snap ring down. Connect the clutch coil lead wire.

4. Remove the clutch hub (C). Remove the shims (H) from the clutch hub and save for installation.

9. Install the pulley and new snap ring with the flat side of the snap ring down. Apply grease to the shims (H) and install to the clutch hub.

5. Remove and discard snap ring (D). Remove the pulley (E) using a plastic hammer or JDG220 Puller, JDG748 Jaws and JDG771 Forcing Screw. 6. Disconnect the clutch coil lead wire. Remove and discard the snap ring (F) and remove the clutch coil (G).

10. Install clutch hub and shaft bolt and tighten. Specification Compressor Hub Retaining Nut—Torque ............................................................................ 14 N•m 124 lb-in.

NOTE: The bearing in the pulley is not serviceable. 7. Check pulley bearing operation. Replace pulley and bearing as required.

TX,18,RB761 –19–09FEB05–2/2

TM2261 (10FEB06)

18-1830-29

750J, 850J Crawler 032806

PN=419

18 1830 29

Heating and Air Conditioning

Clutch Hub Clearance Check NOTE: The clutch coil is not polarity sensitive. 1. Check pulley-to-clutch hub clearance using a dial indicator. Mount the gauge to the pulley as illustrated and connect a set of jumper wires from the compressor to a 12V battery. 2. Rotate the pulley and check clearance in three equally spaced locations around the clutch hub. Add or remove shims to obtain specified clearance. Specification Air Conditioning Clutch Hub-to-Pulley—Clearance ................................................. 0.35—0.65 mm 0.014—0.026 in.

Specification Air Conditioning Clutch Shaft Bolt—Torque ................................................................................. 14 N•m 124 lb-in.

–UN–24JUN92

3. Tighten clutch shaft bolt to specification after correct clearance is obtained.

RW21159

18 1830 30

TX,18,RB762 –19–09FEB05–1/1

TM2261 (10FEB06)

18-1830-30

750J, 850J Crawler 032806

PN=420

Heating and Air Conditioning

Compressor Manifold Inspect 18 1830 31

1. Remove cap screws (A) and the manifold (B). 2. Remove and discard seal (C). Inspect porting surfaces. 3. Lubricate and install a new seal (C). 4. Install manifold and tighten cap screws.

–UN–24JUN92

Specification Manifold Through Bolt—Torque ..................................................... 26 N•m 19 lb-ft

RW21160

A—Manifold Cap Screw B—Manifold C—Manifold Seal

TX,18,RB763 –19–09FEB05–1/1

TM2261 (10FEB06)

18-1830-31

750J, 850J Crawler 032806

PN=421

Heating and Air Conditioning

Compressor Disassemble and Assemble

RW21161

–UN–24JUN92

18 1830 32

A—Rear Pins B—Rear Housing C—Rear Gasket D—Rear Discharge Reed Valve E—Rear Valve Plate F—Rear Suction Reed Valve

G—Rear O-Ring H—Front O-Ring I—Front Suction Reed Valve J—Front Valve Plate K—Front Discharge Reed Valve

L—Front Gasket M—Snap Ring N—Lip Seal O—Washer P—Through Bolt

Continued on next page

TM2261 (10FEB06)

18-1830-32

Q—Felt Holder R—Felt S—Front Housing T—Front Pins

TX,18,RB764 –19–09FEB05–1/3

750J, 850J Crawler 032806

PN=422

Heating and Air Conditioning 1. Clean the compressor using solvent before disassembly. Mount compressor on holding fixture and remove clutch. See Compressor Clutch Disassemble and Assemble. (Group 1830.)

18 1830 33

IMPORTANT: When removing front and rear housing, be careful not to damage the sealing surfaces. 2. Disassemble the compressor as illustrated and discard the O-rings, gaskets, lip seal, snap ring, and through bolt washers. Replace parts from service kits. –UN–24JUN92

NOTE: The valve plates, reed valves, cylinders, and cylinder housings are not serviceable. Some cylinder scuffing (light scratches) is normal.

RW21162

3. Inspect the valves for an even wear pattern and the cylinders for scoring or excessive wear. Replace compressor as required. 4. Remove the shaft seal snap ring (M). Turn the housing over and remove the felt holder (Q) and felt (R) from the front housing (S). 5. Remove the shaft lip seal (N) from the front housing (S) using a small tool with 5/8 in. OD. 6. Wash all parts in clean solvent and dry before assembly.

–UN–24JUN92

IMPORTANT: Lubricate O-rings, gaskets, and lip seal using only TY22025 (R134a) refrigerant oil during assembly. Other oils could damage the compressor.

RW21163

7. Apply R134a oil to the bore of the front housing and install new lip seal (N) to the bottom of the bore using a socket. Install new snap ring (M) flat side down. IMPORTANT: Bushing spacer (U) must be in position before assembling the compressor. C—Rear Gasket D—Rear Discharge Reed Valve E—Rear Valve Plate F—Rear Suction Reed Valve U—Pump Body

8. Install pins (A) and new O-ring (G) in the rear cylinder.

Continued on next page

TM2261 (10FEB06)

18-1830-33

TX,18,RB764 –19–09FEB05–2/3

750J, 850J Crawler 032806

PN=423

Heating and Air Conditioning NOTE: The rear valve plate is marked with an “R” and is installed face up. 18 1830 34

9. Install parts (F—D) over the pins on the rear cylinder. 10. Install a new gasket (C) flat side down and the rear housing (B) on the rear cylinder. Mount the compressor onto the holding fixture. 11. Install pins (T) and new O-ring (H) in the front cylinder.

NOTE: The front valve plate is marked with an “F” and is installed face up. 12. Install parts (I—K) over the pins on the front cylinder. 13. Install a new gasket (L) flat side down. Put JDG746 lip seal protector on the shaft and lubricate with R134a oil. 14. Install the front housing (S) on the front cylinder and remove the lip seal protectors. Install through bolts (P) and new washers (O). 15. Partially tighten the through bolts and then tighten to specification. Specification Air Conditioning Compressor Through Bolt—Torque ................................................................... 26 N•m 230 lb-in.

16. Install the felt (R) and felt holder (Q) using the clutch hub. 17. Install the pulley-clutch hub and check clearance. See Clutch Hub Clearance Check. (Group 1830.)

TX,18,RB764 –19–09FEB05–3/3

TM2261 (10FEB06)

18-1830-34

750J, 850J Crawler 032806

PN=424

Section 19

Sheet Metal Contents Page

Group 1910—Hood and Engine Enclosures Hood Remove and Install . . . . . . . . . . . . . . .19-1910-2 Engine Side Shields Remove and Install . . . .19-1910-4 Hood Support Remove and Install. . . . . . . . .19-1910-5

TM2261 (10FEB06)

19-1

750J, 850J Crawler 032806

PN=1

Contents

TM2261 (10FEB06)

19-2

750J, 850J Crawler 032806

PN=2

Group 1910

Hood and Engine Enclosures

19 1910 1

TM2261 (10FEB06)

19-1910-1

750J, 850J Crawler 032806

PN=427

Hood and Engine Enclosures

Hood Remove and Install

T209535

–UN–15MAR05

19 1910 2

T209535 Hood Continued on next page

TM2261 (10FEB06)

19-1910-2

TX,1910,SS2510 –19–01JUL05–1/2

750J, 850J Crawler 032806

PN=428

Hood and Engine Enclosures 1—Hood 2—Hinge

4—Cap Screw (4 used) 5—Cap Screw (9 used)

6—Washer (9 used) 7—Washer (4 used)

8—Service Door 9—Grille Housing Cover

2. Install hood and grille housing cover.

CAUTION: Prevent possible injury from heavy hood. Use an appropriate lifting device. 1. Remove hood (1) and grille housing cover (9).

19 1910 3

Specification Hood—Weight............................................................................. 73 kg 160 lb

TX,1910,SS2510 –19–01JUL05–2/2

TM2261 (10FEB06)

19-1910-3

750J, 850J Crawler 032806

PN=429

Hood and Engine Enclosures

Engine Side Shields Remove and Install

T209552

–UN–15MAR05

19 1910 4

T209552 Engine Side Shields 1—Grommet (2 used) 2—Washer (14 used) 3—Washer (8 used) 4—Cap Screw (14 used)

5—Guide (8 used) 6—Washer (4 used) 7—Cap Screw (4 used) 8—Lock Nut (4 used)

9—Left Hand Side Shield 10—Right Hand Side Shield 11—Nut 12—Door Latch

CAUTION: Prevent possible crushing injury from heavy engine side shields. Use appropriate lifting device.

13—Latch 14—Hinge 15—Rivet (4 used) 16—Washer

2. Install engine side shields.

1. Remove engine side shields. Specification Engine Side Shields—Weight..................................................... 27 kg 65 lb

BR81691,0000012 –19–11MAR05–1/1

TM2261 (10FEB06)

19-1910-4

750J, 850J Crawler 032806

PN=430

Hood and Engine Enclosures

Hood Support Remove and Install 1. Remove hood. See Hood Remove and Install. (Group 1910.) 2. Remove engine side shields. See Engine Side Shields Remove and Install. (Group 1910.) 19 1910 5

3. Tilt cab/ROPS. See Cab or ROPS Tilting Procedure. (Operator’s Manual.)

Continued on next page

TM2261 (10FEB06)

19-1910-5

TX,1910,SS2511 –19–01JUL05–1/2

750J, 850J Crawler 032806

PN=431

Hood and Engine Enclosures 4. Remove starting aid (4) from hood support (2). 5. Remove air cleaner (3) from hood support. 6. Remove ECU (1) from hood support. CAUTION: Prevent possible crushing injury from heavy hood support. Use an appropriate lifting device when removing and installing. 7. Remove hardware (6 and 7) and hood support (2).

–UN–28JUN05

Specification Hood Support—Weight ..................................................................... 34 kg 75 lb

T212503A

8. Install hood support (2) using mounting hardware (6 and 7). 9. Install ECU (1). 10. Install air cleaner (3). 11. Install starting aid (4). 2

12. Lower cab/ROPS. See Cab or ROPS Tilting Procedure. (Operator’s Manual.) 13. Install engine side shields. See Engine Side Shields Remove and Install. (Group 1910.)

1—Engine Control Unit (ECU) 2—Hood Support 3—Air Cleaner 4—Start Aid 6—Cap Screw (6 used) 7—Washer (6 used)

–UN–06JUL05

14. Install hood. See Hood Remove and Install. (Group 1910.)

6 7

T212504

19 1910 6

TX,1910,SS2511 –19–01JUL05–2/2

TM2261 (10FEB06)

19-1910-6

750J, 850J Crawler 032806

PN=432

Section 20

Safety, Convenience and Miscellaneous Contents Page

Group 2004—Horn and Warning Devices Remove and Install Reverse Alarm . . . . . . . .20-2004-1 Adjust Reverse Warning Alarm Volume. . . . .20-2004-1 20

TM2261 (10FEB06)

20-1

750J, 850J Crawler 032806

PN=1

Contents

TM2261 (10FEB06)

20-2

750J, 850J Crawler 032806

PN=2

Group 2004

Horn and Warning Devices Remove and Install Reverse Alarm 1. Remove rear access panel (A).

–UN–19JUN95

2. Disconnect wiring leads to alarm. 3. Remove alarm (B).

T8507AI

A—Rear Access Panel B—Alarm

TX,9025,BS516 –19–23APR96–1/1

20 2004 1

Adjust Reverse Warning Alarm Volume IMPORTANT: The reverse warning alarm is set on low volume at the factory. It may be necessary to adjust the volume to meet local regulations.

NOTE: Alarm removed from machine for clarity of photograph. 1. To change alarm to high volume, remove nuts from terminals (B and C). 2. Attach shorting bar (A) to terminals (B and C).

T8429AX

–UN–02MAR95

A—Shorting Bar B—Terminal C—Terminal

TX,9025,BS515 –19–23APR96–1/1

TM2261 (10FEB06)

20-2004-1

750J, 850J Crawler 032806

PN=435

Horn and Warning Devices

20 2004 2

TM2261 (10FEB06)

20-2004-2

750J, 850J Crawler 032806

PN=436

Section 32

Bulldozer Contents Page

Group 3201—Blade Cutting Edges and End Bits Remove and Install. . . . . . . . . . . . . . . . . . . . . . . . . . . . .32-3201-1 Blade Remove and Install . . . . . . . . . . . . . . .32-3201-2 Group 3240—Frames Outside Dozer Push Beams Remove and Install. . . . . . . . . . . . . . . . . . . . . . . . . . . . .32-3240-2 C-Frame Remove and Install. . . . . . . . . . . . .32-3240-3 32

Group 3260—Hydraulic System Hydraulic Pump Remove and Install . . . . . . .32-3260-1 Hydraulic Pump Disassemble and Assemble. . . . . . . . . . . . . . . . . . . . . . . . . .32-3260-3 Hydraulic Pump Control Valve Disassemble and Assemble . . . . . . . . . . . . . . . . . . . . . .32-3260-4 Hydraulic Reservoir Remove and Install . . . .32-3260-5 Hydraulic Reservoir Cleanout Cover Remove and Install . . . . . . . . . . . . . . . . . . . . . . . . .32-3260-9 Hydraulic Control Valve Remove and Install. . . . . . . . . . . . . . . . . . . . . . . . . . . .32-3260-13 Hydraulic Control Valve Disassemble and Assemble. . . . . . . . . . . . . . . . . . . . . . . . .32-3260-14 Pilot Control Valve Remove and Install . . . .32-3260-17 Pilot Control Valve Disassemble and Assemble . . . . . . . . . . . . . . . . . . . . . . . .32-3260-19 Quick-Drop Valve Remove and Install . . . . .32-3260-21 Power Angle Tilt (PAT) Cylinder Remove and Install . . . . . . . . . . . . . . . . . . . . . . . .32-3260-22 Angle Cylinder (PAT) Remove and Install. . . . . . . . . . . . . . . . . . . . . . . . . . . .32-3260-22 Hydraulic Cylinder Repair . . . . . . . . . . . . . .32-3260-23

TM2261 (10FEB06)

32-1

750J, 850J Crawler 032806

PN=1

Contents

TM2261 (10FEB06)

32-2

750J, 850J Crawler 032806

PN=2

Group 3201

Blade Cutting Edges and End Bits Remove and Install

31 29 29 3 29 5

T212231

–UN–23JUN05

29 Cutting Edges and End Bits

3—Cutting Edge (2 used) 5—Cutting Edge

6—Washer (28 used) 7—Nut (28 used)

29—Cap Screw (28 used) 30—End Bit

1. Block frame securely with cutting edge above ground level. CAUTION: Prevent possible crushing injury from heavy cutting edges. Use an appropriate lifting device to remove and install cutting edges. 2. Remove cutting edges (3 and 5) and end bits (30 and 31).

31—End Bit

Specification Cutting Edge (5)—Weight........................................................... 41 kg 90 lb Cutting Edge (3)—Weight........................................................... 32 kg 70 lb

3. Inspect parts and replace as necessary. 4. Install cutting edges (3 and 5) and end bits (30 and 31).

TX,3201,SS2516 –19–11JUL95–1/1

TM2261 (10FEB06)

32-3201-1

750J, 850J Crawler 032806

PN=439

32 3201 1

Blade

Blade Remove and Install NOTE: This procedure is written using a Power Angle Tilt (PAT) machine. 1. Lower blade. 2. Relieve hydraulic system pressure.

Continued on next page

CED,TX14826,12131 –19–06JUL05–1/3

32 3201 2

TM2261 (10FEB06)

32-3201-2

750J, 850J Crawler 032806

PN=440

Blade

32 3201 3

TM2261 (10FEB06)

32-3201-3

750J, 850J Crawler 032806

PN=441

Blade

T212340

–UN–30JUN05

32 3201 4

T212340 Blade—PAT Machine Shown

Continued on next page

TM2261 (10FEB06)

32-3201-4

CED,TX14826,12131 –19–06JUL05–2/3

750J, 850J Crawler 032806

PN=442

Blade 3—Cutting Edge (2 used) 4—Pin 5—Cutting Edge 6—Washer (28 used) 7—Nut (28 used)

8—Half Shell Bearings (2 used) 11—Pin (3 used) 12—Plate (4 used) 16—Bushing (2 used)

17—Screw (4 used) 21—Socket 22—Shim (8 used) 24—Cap Screw (6 used) 25—Washer (6 used)

3. Connect hoist chain to blade lifting points (32).

26—Lubrication Fitting 29—Cap Screw (28 used) 30—End Bit 31—End Bit

7. Install cylinders to blade using cylinder pins (4 and 11).

4. Remove pivot ball cap screws (24) and half shell bearings (8). 5. Remove cylinder pins (4 and 11) to separate blade from cylinders.

8. Install pivot ball cap screws (24) and half shell bearings (8). 9. Disconnect hoist chains from blade lifting points (32).

CAUTION: Prevent possible crushing injury from heavy dozer blade. Use an appropriate lifting device to remove and install. 6. Remove blade.

32 3201 5

Specification Blade—Approximate Weight ................................................... 1360 kg 3000 lb

CED,TX14826,12131 –19–06JUL05–3/3

TM2261 (10FEB06)

32-3201-5

750J, 850J Crawler 032806

PN=443

Blade

32 3201 6

TM2261 (10FEB06)

32-3201-6

750J, 850J Crawler 032806

PN=444

Group 3240

Frames

32 3240 1

TM2261 (10FEB06)

32-3240-1

750J, 850J Crawler 032806

PN=445

Frames

Outside Dozer Push Beams Remove and Install

T206032

–UN–14JAN05

32 3240 2

Push Beams and Pitch Jack Continued on next page

TM2261 (10FEB06)

32-3240-2

TX,3240,SS2521 –19–08JUL05–1/2

750J, 850J Crawler 032806

PN=446

Frames 1—Cap Screw (4 used) 2—Nut (8 used) 3—Cap Screw (6 used) 4—Cap Screw (2 used) 5—Cap Screw (2 used) 6—Cap Screw (20 used) 7—Washer (36 used) 8—Pitch Jack Rod 9—Pitch Jack Rod

10—Pitch Jack Turnbuckle 11—Lubrication Fitting (3 used) 12—Left Push Beam 13—Self-Aligning Bushing (2 used) 14—Trunnion Seat Cap (2 used)

15—Ring (4 used) 16—Pin Fastener 17—Pivot 18—Snap Ring (2 used) 19—Self-Aligning Bushing 20—Trunnion (2 used) 21—Blade-to-Push Beam Link 22—Lock Nut (4 used)

23—Pin Fastener (2 used) 24—Plate (2 used) 25—Bushing (4 used) 26—Cap (2 used) 27—Bushing (2 used) 28—Plate (4 used) 29—Plate (20 used) 30—Right Push Beam

Item

Measurement

Specification

Push Beam

Approximate Weight

680 kg 1500 lb

Push Beam Trunnion

Approximate Weight

70 kg 155 lb

TX,3240,SS2521 –19–08JUL05–2/2

C-Frame Remove and Install NOTE: C-Frame must be supported with blocks during procedure. 1. Remove blade. Perform Outside Dozer Blade Remove and Install. (Group 3201.)

Continued on next page

TM2261 (10FEB06)

32-3240-3

BR81691,0000019 –19–11JUL05–1/3

750J, 850J Crawler 032806

PN=447

32 3240 3

Frames

T205979

–UN–14JAN05

32 3240 4

C-Frame

Continued on next page

TM2261 (10FEB06)

32-3240-4

BR81691,0000019 –19–11JUL05–2/3

750J, 850J Crawler 032806

PN=448

Frames 1—Lock Nut M8 (2 used) 2—Cap Screw M20 x 45 (4 used) 3—Cap Screw M20 x 110 (4 used) 4—Cap Screw M8 x 100 (2 used) 5—Cap Screw M12 x 16 (2 used)

6—Washer (4 used) 7—Frame 8—Pivot Ball 9—Pitch Link Mount 10—Step 11—Step 12—Pitch Strut Assembly

13—Bushing (2 used) 14—Snap Ring (4 used) 15—Lubrication Fitting (2 used) 16—Quick Lock Pin (2 used) 17—Washer (4 used) 18—Strap (2 used)

2. Remove lift cylinder rod end pins (19) using a slide hammer.

19—Pin (4 used) 20—Pin (2 used) 21—Plate (2 used) 22—Pin Fastener (2 used) 23—Pin Fastener (4 used) 24—Pin

6. Install C-frame. 7. Install C-Frame pins (22) and cap screws (2).

3. Disconnect hydraulic hoses from tee fittings on C-Frame and from tilt cylinder.

8. Connect hydraulic hoses to tee fittings on C-Frame and to tilt cylinder.

4. Remove cap screws (2) and C-Frame pins (22). 9. Install lift cylinder rod end pins (19). CAUTION: Prevent possible crushing injury from heavy C-frame. Use an appropriate lifting device to remove and install C-frame.

10. Install blade. Perform Blade Remove and Install. (Group 3201.)

32 3240 5

5. Remove C-frame. Specification C-Frame Without Blade— Approximate Weight ................................................................. 770 kg 1700 lb

BR81691,0000019 –19–11JUL05–3/3

TM2261 (10FEB06)

32-3240-5

750J, 850J Crawler 032806

PN=449

Frames

32 3240 6

TM2261 (10FEB06)

32-3240-6

750J, 850J Crawler 032806

PN=450

Group 3260

Hydraulic System Hydraulic Pump Remove and Install

109 200 201

129 199

32 3260 1

131 129

130

132

–UN–20NOV04

131

T202385

104

T202385 104—Hydraulic Pump 109—Pressure Reducing Valve 129—Control Valve-to-Pressure Reducing Valve Hose

130—Hydraulic Reservoir-to-Hydraulic Pump Inlet Hose 131—Load Sense Hose 132—Hydraulic Pump-to-Control Valve Inlet Hose

1. Lower all equipment to ground.

199—Hydraulic Pump Case Drain Hose 200—Control Valve-to-Hydraulic Filter Hose

201—Pressure Reducing Valve-to-Hydraulic Reservoir Return Hose

3. Turn battery disconnect switch to OFF.

2. Relieve all hydraulic pressure in system.

Continued on next page

TM2261 (10FEB06)

32-3260-1

TX,3260,SS2326 –19–13JUL05–1/2

750J, 850J Crawler 032806

PN=451

Hydraulic System 4. Tilt cab/ROPS. See Cab or ROPS Tilting Procedure. (Operator’s Manual.)

hydraulic pump. See DFT1243 Lifting Bracket Extension. See DF1065 Final Drive and Pump Adapter Bracket. See DFT1167 Spacer. See DFT1063 Pump Lifting Bracket. (Group 9900.)

5. Drain hydraulic reservoir. Specification Hydraulic Reservoir—Capacity ................................................ 105.6 L 27.9 gal

Specification Hydraulic Pump—Weight............................................................ 41 kg 90 lb

6. Label all hoses connected to hydraulic pump.

9. Install hydraulic pump with O-ring to rear hydrostatic pump using cap screws.

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. 32 3260 2

7. Disconnect hoses (130, 131, 132, and 199). Cap and plug all openings. CAUTION: Prevent possible crushing injury from hydraulic pump. Use an appropriate lifting device. 8. Install lifting strap around hydraulic pump. Connect strap to the end of DFT1243, DFT1065, DFT1167, and DFT1063. Remove cap screws along with

10. Connect all hydraulic hoses (130, 131, 132, and 199). 11. Fill reservoir to specification. Specification Hydraulic Reservoir—Capacity ................................................ 105.6 L 27.9 gal

12. Fill hydraulic pump with oil to avoid air pockets in system. 13. Start engine and check for leaks. 14. Tilt cab/ROPS. See Cab or ROPS Tilting Procedure. (Operator’s Manual.)

TX,3260,SS2326 –19–13JUL05–2/2

TM2261 (10FEB06)

32-3260-2

750J, 850J Crawler 032806

PN=452

Hydraulic System

Hydraulic Pump Disassemble and Assemble

T209628

–UN–17MAR05

32 3260 3

Hydraulic Pump 1—Rotating Group 2—Control Piston 3—Piston Rod 4—Hydraulic Pump Case 6—Inlet/Outlet End Cap 7—Swashplate 8—Pump Drive Shaft

9—Plug 10—Spring 12—Spacer 15—Tapered Roller Bearing 16—Bearing 17—Bearing

CAUTION: Prevent possible crushing injury from heavy hydraulic pump. 1. Mount pump on DO1006AA Bench Mounted Holding Fixture.

18—Bearing 20—Seal 21—O-Ring 22—O-Ring 24—O-Ring 25—Snap-Ring

27—Cap Screw 29—Stop Ring 31—Plug 33—Cylinder Pin 34—Plug 37—Set Screw

2. Remove cap screws (27) and end cap (6). 3. Replace parts as necessary. See parts catalog to find serviceable parts. 4. Install end cap (6) using cap screws (27).

Specification Hydraulic Pump—Approximate Weight ......................................................................................... 41 kg 90 lb

TX,3260,SS2327 –19–17MAR05–1/1

TM2261 (10FEB06)

32-3260-3

750J, 850J Crawler 032806

PN=453

Hydraulic System

Hydraulic Pump Control Valve Disassemble and Assemble

IMPORTANT: When removing adjusting screws and O-rings make note to retain current settings. 1. Remove complete adjustment screw assemblies by removing fittings (4 & 23) with all adjusting parts in place. Replace O-ring (5 & 21). Install adjustment assemblies in housing. Tighten in housing (14) port.

3 23 4 5

2. Remove adjustment covers (1) for load sense and high pressure cut off screws (3).

3. Remove lock nuts (22) and O-rings (2) being careful not to lose current settings. Replace O-rings.

17 8 16

4. Install lock nuts, O-rings and adjustment covers.

5. Install control on hydraulic pump housing. 15

1—Cap (adjustment screw) 2—O-rings (4 used) 3—Adjustment Screw (2 used) 4—Fitting 5—O-Ring 6—Spring 7—Spring 8—Guide 9—Spool—Load Sense 10—Plug 11—Plug 12—Cap Screw (4 used) 13—Plug (2 used) 14—Control Housing 15—Spool—High Pressure Cut-Off 16—Guide 17—Spring 18—Spring 19—Spacer 20—Spacer 21—O-Ring 22—Hex Nut (2 used) 23—Fitting

–UN–23JUN05

6. Perform Pump Load Sense Differential and System Pressure Test and Adjustment. (Group 9025-25.)

T211883

32 3260 4

NOTE: Pump control is serviced as complete assembly or a seal kit only.

Pump Control Exploded View

BR81691,000001C –19–13JUL05–1/1

TM2261 (10FEB06)

32-3260-4

750J, 850J Crawler 032806

PN=454

Hydraulic System

Hydraulic Reservoir Remove and Install

109 200 201

129 199

32 3260 5

131 129

130

132

–UN–20NOV04

131

T202385

104

T202385 Hydraulic Reservoir 104—Hydraulic Pump 109—Pressure Reducing Valve 129—Control Valve-to-Pressure Reducing Valve Hose

130—Hydraulic Reservoir-to-Hydraulic Pump Inlet Hose 131—Load Sense Hose 132—Hydraulic Pump-to-Control Valve Inlet Hose

1. Lower all equipment to the ground.

199—Hydraulic Pump Case Drain Hose 200—Control Valve-to-Hydraulic Filter Hose

2. Relieve all hydraulic system pressure.

Continued on next page

TM2261 (10FEB06)

201—Pressure Reducing Valve-to-Hydraulic Reservoir Return Hose

32-3260-5

TX,3260,SS2328 –19–11JUL95–1/4

750J, 850J Crawler 032806

PN=455

Hydraulic System 3. Turn battery disconnect switch to OFF.

6. Remove right rear service door.

4. Tilt cab/ROPS. See Cab or ROPS Tilting Procedure. (Operator’s Manual.)

7. Disconnect hydraulic hose (200) from hydraulic filter assembly.

5. Drain hydraulic reservoir.

8. Disconnect hydraulic hoses (130, 199, and 201.)

Specification Hydraulic Reservoir—Capacity ................................................ 105.6 L 27.9 gal

Continued on next page

TX,3260,SS2328 –19–11JUL95–2/4

32 3260 6

TM2261 (10FEB06)

32-3260-6

750J, 850J Crawler 032806

PN=456

Hydraulic System

CAUTION: Prevent possible crushing injury from heavy rear fender. Use an appropriate lifting device. –UN–04MAR05

9. Remove rear fender (2).

T209325A

Specification Rear Fender—Weight........................................................................ 30 kg 65 lb

10. Remove right rear fender (1). Rear Fenders

11. Disconnect wiring eyelets from backup alarm.

1—Right Rear Fender 2—Rear Fender 3—Fuel Tank Guard

CAUTION: Prevent possible crushing injury from heavy fuel tank guard. Use an appropriate lifting device.

32 3260 7

12. Remove fuel tank guard (3). Specification Fuel Tank Guard—Weight................................................................. 32 kg 70 lb

13. Remove reservoir mounting cap screws. CAUTION: Prevent possible crushing injury from heavy component. Use an appropriate lifting device. 14. Remove hydraulic reservoir. Specification Hydraulic Reservoir—Weight .......................................................... 131 kg 288 lb

15. Install hydraulic reservoir on mounting pads and loosely install hardware. Align right side of hydraulic reservoir with right side of frame. Tighten cap screws.

Continued on next page

TM2261 (10FEB06)

32-3260-7

TX,3260,SS2328 –19–11JUL95–3/4

750J, 850J Crawler 032806

PN=457

Hydraulic System

CAUTION: Prevent possible crushing injury from heavy fuel tank guard. Use an appropriate lifting device. 16. Install fuel tank guard (3). Specification Fuel Tank Guard—Weight................................................................. 32 kg 70 lb

17. Connect wiring eyelets to backup alarm. 18. Install right rear fender (1). CAUTION: Prevent possible crushing injury from heavy rear fender. Use an appropriate lifting device. 32 3260 8

19. Install rear fender (2). Specification Rear Fender—Weight........................................................................ 30 kg 65 lb

20. Connect hydraulic hoses (130, 199, and 201.) 21. Connect hydraulic hose (200) to hydraulic filter assembly. 22. Install right rear service door. 23. Fill hydraulic reservoir to specification. Specification Hydraulic Reservoir—Capacity....................................................... 105.6 L 27.9 gal

24. Lower cab/ROPS. See Cab or ROPS Tilting Procedure. (Operator’s Manual.) 25. Start engine and check for leaks. Repair as necessary.

TX,3260,SS2328 –19–11JUL95–4/4

TM2261 (10FEB06)

32-3260-8

750J, 850J Crawler 032806

PN=458

Hydraulic System

Hydraulic Reservoir Cleanout Cover Remove and Install 1. Drain reservoir. Specification 750J and 850J Hydraulic Reservoir—Capacity ....................................................................... 105.6 L 27.9 gal

2. Remove components as necessary to adequately access cleanout cover.

Continued on next page

TM2261 (10FEB06)

32-3260-9

BT40170,000000B –19–27JUN05–1/5

750J, 850J Crawler 032806

PN=459

32 3260 9

Hydraulic System IMPORTANT: Prevent fluid contamination. Remove paint and debris from sealing edge of cleanout cover prior to removal.

–UN–02FEB04

3. Remove paint from sealing edge of hydraulic reservoir cleanout cover (3).

T197423A

NOTE: Do not fully remove cap screw (2) from inner plate. 4. Loosen cap screw (2) enough to remove cleanout cover assembly. Hydraulic Reservoir Cleanout Cover

IMPORTANT: Avoid fluid contamination. Paint may be chipped if cleanout cover drops into reservoir. Clean all debris from reservoir before installing cleanout cover. 32 3260 10

1—Hydraulic Reservoir 2—Cap Screw 3—Hydraulic Reservoir Cleanout Cover

5. Inspect gasket and cover plates for any cuts or loose material that could lead to contamination. Repair or replace parts as necessary. IMPORTANT: Avoid fluid contamination. Do not allow paint or debris to enter reservoir. Thoroughly clean if debris enters reservoir. 6. Inspect and remove paint build-up and debris from reservoir exterior wall. Inspect locator tabs in reservoir to verify that they are perpendicular to reservoir wall.

NOTE: Cap screw should turn into weld nut without resistance. If resistance is felt, inspect weld nut for debris in threads and clean as necessary.

Continued on next page

TM2261 (10FEB06)

32-3260-10

BT40170,000000B –19–27JUN05–2/5

750J, 850J Crawler 032806

PN=460

Hydraulic System IMPORTANT: Avoid possible fluid leak. Verify O-ring is installed under head of cap screw before assembly.

NOTE: To ease installation, do not thread cap screw all the way into weld nut. Orient as shown. 7. Loosely assemble cleanout cover with gasket and inner plate.

T198245B

–UN–02MAR04

4—Inner Plate Tabs

BT40170,000000B –19–27JUN05–3/5

IMPORTANT: Inner plate must seat flush against reservoir wall. Damage will result to locator tabs (5 and 6) if inner plate is installed incorrectly. –UN–02MAR04

NOTE: Install inner plate with tabs (4) facing towards top of reservoir. Inner plate must be located between upper (5) and lower (6) locator tabs.

T198238B

8. Install cleanout cover assembly starting with one corner of inner plate upper tabs. Rest one tab of inner plate on locator tab (5) and rotate inner plate around until entirely inside reservoir. Pull back on cap screw to seat inner plate against reservoir wall between locator tabs (5 and 6).

4—Inner Plate Tab (2 used) 5—Upper Locator Tab (2 used) 6—Lower Locator Tab (2 used) 7—Inner Plate

Continued on next page

TM2261 (10FEB06)

32-3260-11

BT40170,000000B –19–27JUN05–4/5

750J, 850J Crawler 032806

PN=461

32 3260 11

Hydraulic System 9. Hand tighten cap screw (2) while prying out on gasket and outer plate as shown to ensure that inner plate stays seated between locator tabs (5 and 6). IMPORTANT: Do not use impact gun to tighten cap screw. Damage will result to cleanout cover assembly. 10. Tighten cap screw to specification. Specification Hydraulic Reservoir Cleanout Cover Cap Screw—Torque ............................................................ 47 N•m 35 lb-ft

11. Paint affected areas using TY6522 spray paint. 12. Install components removed to access cleanout cover. –UN–02MAR04

13. Fill reservoir. Specification 750J and 850J Hydraulic Reservoir—Capacity ....................................................................... 105.6 L 27.9 gal

T198239B

32 3260 12

2—Cap Screw 5—Upper Locator Tab (2 used) 6—Lower Locator Tab (2 used)

BT40170,000000B –19–27JUN05–5/5

TM2261 (10FEB06)

32-3260-12

750J, 850J Crawler 032806

PN=462

Hydraulic System

Hydraulic Control Valve Remove and Install 1. Lower all equipment to the ground.

–UN–03MAR05

2. Relieve all hydraulic pressure in system. 3. Turn battery disconnect switch to OFF.

T208751A

4. Drain oil from hydraulic reservoir or pull a vacuum pump on reservoir. Specification Hydraulic Reservoir—Capacity....................................................... 105.6 L 27.9 gal

Hydraulic Control Valve

5. Tilt cab/ROPS. See Cab or ROPS Tilting Procedure. (Operator’s Manual.) 6. Label all control valve hoses. 32 3260 13

7. Disconnect all control valve hoses. Cap and plug all hoses. 8. Properly support control valve and remove mounting cap screws. 9. Remove control valve mounting cap screws. CAUTION: Prevent possible crushing injury from heavy control valve. Use an appropriate lifting device. 10. Remove control valve using a hoist and strap. Specification Hydraulic Control Valve—Weight ...................................................... 39 kg 85 lb

11. Install control valve with mounting cap screws. 12. Connect all control valve hoses. 13. Fill hydraulic reservoir to specification or remove vacuum. Specification Hydraulic Reservoir—Capacity....................................................... 105.6 L 27.9 gal

14. Start engine and check for leaks.

Continued on next page

TM2261 (10FEB06)

32-3260-13

TX,3260,SS2338 –19–14JUL05–1/2

750J, 850J Crawler 032806

PN=463

Hydraulic System 15. Lower cab/ROPS. See Cab or ROPS Tilting Procedure. (Operator’s Manual.)

TX,3260,SS2338 –19–14JUL05–2/2

Hydraulic Control Valve Disassemble and Assemble

12 14

32 3260 14

7 3 6 4

–UN–18MAR05

5 10 9

T209668

11 8 Control Valve Inlet, Outlet, and Tie Rods 1—Nut (2 used) 2—Tie Rod (2 used) 3—Tie Rod 4—Nut (4 used)

5—Inlet Valve 6—O-Ring 7—Outlet Valve 8—Fitting Plug

1. Remove nuts (4) and tie rods (2) as shown.

9—O-Ring 10—Snap-Ring 11—Spring

2. Separate valve sections.

Continued on next page

TM2261 (10FEB06)

12—System Relief Valve 13—O-Ring 14—Seal Kit

32-3260-14

TX,3260,SS2342 –19–13JUL05–1/3

750J, 850J Crawler 032806

PN=464

Hydraulic System

32 3260 15

TM2261 (10FEB06)

32-3260-15

750J, 850J Crawler 032806

PN=465

Hydraulic System

T208323

–UN–28FEB05

32 3260 16

Hydraulic Control Valve

Continued on next page

TM2261 (10FEB06)

32-3260-16

TX,3260,SS2342 –19–13JUL05–2/3

750J, 850J Crawler 032806

PN=466

Hydraulic System 1—Pressure Relief Valve 2—Plug 3—Screw 4—Valve Cover 5—Spool 6—O-Ring

7—Disk 8—O-Ring 9—O-Ring 10—Retainer 11—Retainer 12—Spring

13—Screw 14—Valve Cover 15—Screw 16—Housing 17—Poppet

3. Disassemble parts (1—22). 4. Assemble parts (1—22). 5. Assemble valve stacks together with tie rods and nuts.

18—Spring 19—Seal 20—O-Ring 21—Backup Ring 22—O-Ring

Specification Control Valve Tie Rod and Nut (7/16 in.)—Torque.................................................................... 65 N•m 48 lb-ft Control Valve Tie Rod and Nut (1/2 in.)—Torque.................................................................... 100 N•m 74 lb-ft

TX,3260,SS2342 –19–13JUL05–3/3

Pilot Control Valve Remove and Install 1. Lower all equipment to ground. 2. Relieve hydraulic system pressure. 3. Disconnect pilot controller hydraulic hoses using STC special tool. 4. Disconnect all electrical connections from pilot controller.

Continued on next page

TM2261 (10FEB06)

32-3260-17

BR81691,0000018 –19–15JUN05–1/2

750J, 850J Crawler 032806

PN=467

32 3260 17

Hydraulic System 5. Remove cap screws (4) and plate (11) with pilot controller.

NOTE: Fittings (8 and 10) must be removed to separate pilot controller from plate (11). Fitting (8) is different from other fittings, mark location before removing.

35 29

6. Remove fittings (8 and 10) from pilot controller.

7. Assemble plate (11) and pilot controller. 8. Install fittings (8 and 10) to pilot controller. 9. Install pilot controller with plate (11) using cap screws (4). 36 10. Connect all electrical connectors to pilot controller. 27

11. Connect all hydraulic hoses to pilot controller.

28 12. Operate machine and verify all functions work correctly. 2—O-Ring 3—Flange Nut 4—Cap Screw 8—STC Adapter Fitting 9—Hydraulic Control Lever 10—STC Adapter Fitting 11—Plate 24—Plate 25—Pilot Enable Switch 26—Nut 27—Nut 28—Cap Screw 29—Cap Screw 30—Washer 31—Pilot Controller 32—Plate 35—Nut 36—Tie Bolt 37—Boot 38—Seal 49—Screw 52—Adapter

30 32 4 4

38 4 11

–UN–21JUN05

T212073

32 3260 18

8 Pilot Controller—PAT Machine Shown

BR81691,0000018 –19–15JUN05–2/2

TM2261 (10FEB06)

32-3260-18

750J, 850J Crawler 032806

PN=468

Hydraulic System

Pilot Control Valve Disassemble and Assemble

Perform Pressure Reducing Valve Pressure Test and Adjustment. (Group 9025-25.) 1. Perform Pilot Control Valve Remove and Install. (Group 3260.)

Continued on next page

BR81691,0000017 –19–07JUL05–1/2

32 3260 19

TM2261 (10FEB06)

32-3260-19

750J, 850J Crawler 032806

PN=469

Hydraulic System 2. Disassemble and assemble parts as shown.

35 29

36 27 28 30 32 4 4

38 4 11

–UN–21JUN05

T212073

32 3260 20

3—Flange Nut (4 used) 4—Screw (8 used) 8—Adapter (5 used) 9—Lever 10—Adapter (5 used) 11—Plate 17—Bolt 18—Check Valve 19—Seal Kit 20—Valve (2 used) 21—Hydraulic Pressure Valve 22—Fitting plug 23—Fitting Plug 24—Plate (2 used) 25—Rocker Switch 26—Nut (4 used) 27—Nut 28—Cap Screw (4 used) 29—Screw (2 used) 30—Washer (8 used) 31—Hydraulic Pilot Control Valve 32—Plate 35—Nut (2 used) 36—Stud 37—Boot 38—Seal 49—Screw (2 used) 52—Adapter

8 Pilot Control Lever—PAT Machine Shown

BR81691,0000017 –19–07JUL05–2/2

TM2261 (10FEB06)

32-3260-20

750J, 850J Crawler 032806

PN=470

Hydraulic System

Quick-Drop Valve Remove and Install NOTE: Quick-drop valve is only used on outside dozer (OSD) machines. 1. Lower blade to the ground.

–UN–07JUN05

4. Disconnect hydraulic hoses (1—4). Cap and plug all openings.

T211967A

3. Remove front hood cover.

Quick-Drop Valve

5. Disconnect quick-drop valve wiring harness (5). 6. Remove quick-drop valve.

–UN–07JUN05

7. Install quick-drop valve. 8. Connect hydraulic hoses (1—4).

T211969A

9. Install front hood cover. 1—Hydraulic Hose 2—Hydraulic Hose 3—Hydraulic Hose 4—Hydraulic Hose 5—Quick-Drop Valve Wiring Harness

Quick-Drop Valve Wiring Harness

TX,3260,SS2491 –19–13JUL05–1/1

TM2261 (10FEB06)

32-3260-21

750J, 850J Crawler 032806

PN=471

32 3260 21

Hydraulic System

Power Angle Tilt (PAT) Cylinder Remove and Install 1. Lower all equipment to the ground. –UN–08JUL05

2. Relieve hydraulic system pressure.

T212727A

CAUTION: Prevent possible crushing injury from heavy cylinders. Use an appropriate lifting device to remove and install. 3. Remove and install cylinders.

–UN–08JUL05

Specification Lift Cylinder—PAT Machines— Approximate Weight .......................................................................... 50 kg 110 lb Tilt Cylinder-PAT Machines— Approximate Weight .......................................................................... 61 kg 135 lb

1—Lift Cylinder (2 used) 3—Tilt Cylinder

T212729A

32 3260 22

Lift Cylinder—PAT Machines

Tilt Cylinder-PAT Machines BR81691,000001D –19–07JUL05–1/1

Angle Cylinder (PAT) Remove and Install NOTE: Front of machine must be raised with blade down for access to angle cylinder head end pins. 1. Relieve hydraulic system pressure. 2. Remove hose guard on angle cylinder. 3. Disconnect hydraulic hoses from angle cylinder.

Continued on next page

TM2261 (10FEB06)

32-3260-22

CED,TX14826,12132 –19–20JUN05–1/2

750J, 850J Crawler 032806

PN=472

Hydraulic System 4. Remove angle cylinder rod end pin.

–UN–21JUN05

CAUTION: Prevent possible crushing injury from heavy angle cylinder. Use an appropriate lifting device. 5. Remove angle cylinder head end pin.

T212348A

Specification Angle Cylinder—Approximate Weight................................................................................................ 84 kg 185 lb

Angle Cylinder Pin

6. Remove angle cylinder.

1—Angle Cylinder Head End Pin

7. Install angle cylinder. 8. Install angle cylinder head end pin. 32 3260 23

9. Install angle cylinder rod end pin. 10. Connect hydraulic hoses to angle cylinder. 11. Install hose guard on angle cylinder.

CED,TX14826,12132 –19–20JUN05–2/2

Hydraulic Cylinder Repair NOTE: Blade lift and tilt are 120 series hydraulic cylinders. Blade angle are 125 series hydraulic cylinders. For more information on 120 series hydraulic cylinders, see Disassemble Cylinder or Assemble Cylinder. (TM-H120A.) For more information on 125 series hydraulic cylinders, see Disassemble Cylinder or Assemble Cylinder. (TM-H125A.)

BR81691,000001B –19–05JUL05–1/1

TM2261 (10FEB06)

32-3260-23

750J, 850J Crawler 032806

PN=473

Hydraulic System

32 3260 24

TM2261 (10FEB06)

32-3260-24

750J, 850J Crawler 032806

PN=474

Section 9900

Dealer Fabricated Tools Contents Page

Group 0999—Dealer Fabricated Tools DF1065 Final Drive and Pump Adapter Bracket . . . . . . . . . . . . . . . . . . . . . . . . . 9900-0999-1 DFT1041 Track Nut Removal Tool . . . . . . 9900-0999-2 DFT1063 Final Drive Lift Bracket . . . . . . . 9900-0999-3 DFT1132 Hydrostatic Motor Removal and Installation Tool . . . . . . . . . . . . . . . . . . . 9900-0999-4 DFT1137 Hydrostatic Motor Removal and Installation Tool . . . . . . . . . . . . . . . . . . . 9900-0999-5 DFT1167 Final Drive Lifting Bracket Adapter Spacer . . . . . . . . . . . . . . . . . . . . . . . . . . 9900-0999-6 DFT1243 Lifting Bracket Extension . . . . . . 9900-0999-7 DFT1250 Lifting Bracket . . . . . . . . . . . . . . 9900-0999-8 DFT1260 Final Drive Lifting Fixture . . . . . 9900-0999-10 DFT1261 Rolling Torque Measurement Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . 9900-0999-11

TM2261 (10FEB06)

9900-1

9900

750J, 850J Crawler 032806

PN=1

Contents

9900

TM2261 (10FEB06)

9900-2

750J, 850J Crawler 032806

PN=2

Group 0999

Dealer Fabricated Tools

T100422

–19–29FEB96

DF1065 Final Drive and Pump Adapter Bracket

Adapter used with DF1063 to remove or install final drive and hydraulic pump.

• 1/2 in. 1020 steel plate (B) 3 x 4.5 in. • 2 x 3 rectangular tube 13 in. long

Material required:

CED,OUO1065,1019 –19–29AUG00–1/1

TM2261 (10FEB06)

9900-0999-1

750J, 850J Crawler 032806

PN=477

9900 0999 1

Dealer Fabricated Tools

–19–20MAR89

DFT1041 Track Nut Removal Tool

T6690AH

9900 0999 2

Track Nut Removal Tool is used to remove and install track shoe nuts.

TX14826,0003243 –19–14DEC01–1/1

TM2261 (10FEB06)

9900-0999-2

750J, 850J Crawler 032806

PN=478

Dealer Fabricated Tools

DFT1063 Final Drive Lift Bracket

T8360AM

–19–10JAN95

9900 0999 3

Tool used to remove and install final drives. Material required:

• 1—1/2 in. x 3 in. Square Tube • 1/2 in. 1020 Steel • 3/8 in. x 1—1/2 in. Cap Screw with Nut (4 used)

CED,TX03399,5076 –19–24NOV98–1/1

TM2261 (10FEB06)

9900-0999-3

750J, 850J Crawler 032806

PN=479

Dealer Fabricated Tools

–UN–10JUL95

DFT1132 Hydrostatic Motor Removal and Installation Tool

T8366AC

9900 0999 4

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 with DFT1137 to remove and install hydrostatic motors from rear of machine.

E—Pipe F—Weld

G—Pipe

• 1 in. piece heavy wall steel pipe 8 ft. x 6 in. long • Weld (E) to (G)

Material required:

TX,9900,YY1166 –19–13JUL95–1/1

TM2261 (10FEB06)

9900-0999-4

750J, 850J Crawler 032806

PN=480

Dealer Fabricated Tools

T8499BB

–19–10JUL95

DFT1137 Hydrostatic Motor Removal and Installation Tool

This tool is used with DFT1132 to remove and install hydrostatic motors from rear of machine.

• 750J—1/2 in. x 9 in. cap screws (2 used) • 850J—1/2 in. x 10 in. cap screws (2 used)

Material required:

Install and tighten eyebolt in bracket. Trim any excess eyebolt material so it is even with bottom surface of bracket.

• 1-1/2 in. x 3/4 in. x 12 in. long steel bars (2 used) • M12 x 1.75 eyebolt

TX,9900,YY1200 –19–13JUL05–1/1

TM2261 (10FEB06)

9900-0999-5

750J, 850J Crawler 032806

PN=481

9900 0999 5

Dealer Fabricated Tools

–UN–01DEC98

DFT1167 Final Drive Lifting Bracket Adapter Spacer

T118674

9900 0999 6

To be used with DFT1166 Final Drive Lifting Bracket Adapter when installing DFT1063 Final Drive lifting Bracket.

Material: 1/2 in. 1020 Steel Plate

CED,TX03399,5085 –19–30NOV98–1/1

TM2261 (10FEB06)

9900-0999-6

750J, 850J Crawler 032806

PN=482

Dealer Fabricated Tools

DFT1243 Lifting Bracket Extension

3 1

4 –UN–20JUN05

T212193

T212193 1—38.1 mm x 63.5 mm x 6.4 mm (1 1/2 in. x 2 1/2 in. x 1/4 in. wall) rectangular steel tubing

2—JT01748 Lifting Bracket 3—910 mm (35.8 in.)

4—190 mm (7.5 in.) 5—100 mm (3.94 in.)

6—22 mm (0.866 in.) diameter 7—31.8 mm (1.25 in.)

TE14778,00000DC –19–22JUN05–1/1

TM2261 (10FEB06)

9900-0999-7

750J, 850J Crawler 032806

PN=483

9900 0999 7

Dealer Fabricated Tools

DFT1250 Lifting Bracket

T202517

–UN–01DEC04

9900 0999 8

Continued on next page

TM2261 (10FEB06)

9900-0999-8

OUT3035,00004FB –XX–29NOV04–1/2

750J, 850J Crawler 032806

PN=484

Dealer Fabricated Tools Lifting bracket is used to remove and install final drives and other heavy components with limited access.

• 50 x 50 mm (2 x 2 in.) 1020 Steel Bar Stock • 20 x 50 mm (0.75 x 2 in.) 1020 Steel Plate • 7018 Electrodes for welding

Material required: OUT3035,00004FB –XX–29NOV04–2/2

9900 0999 9

TM2261 (10FEB06)

9900-0999-9

750J, 850J Crawler 032806

PN=485

Dealer Fabricated Tools

DFT1260 Final Drive Lifting Fixture

T211502

–UN–26MAY05

9900 0999 10

1—6 mm (0.25 in.) Fillet Weld (8 places) 2—242 mm (9.52 in.) 3—6.35 mm (0.25 in.) Stock 4—50 mm (1.97 in.) 5—12.7 mm (0.5 in.) 6—294.6 mm (11.6 in.) 8—21.6 mm (0.85 in.)

9—50 mm (1.97 in.) 11—22 mm (0.866 in.) Drill Three Holes 12—127 mm (5.0 in.) Stock 13—63.5 mm (2.5 in.) 15—100 mm (3.94 in.) 16—394.3 mm (15.53 in.) 17—342 mm (13.46 in.)

18—196.9 mm (7.75 in.) 19—88.9 mm (3.5 in.) 20—127 mm (5.0 in.) Stock 21—19 mm (0.75 in.) 22—25.4 mm (1.0 in.) 23—17.5 mm (0.69 in.) Drill (4 places) 24—19 mm (0.75 in.)

25—19 mm (0.75 in.) Stock 27—50.8 mm (2.0 in.) 28—50.8 mm (2.0 in.) Stock 29—609.6 mm (24 in.) Radius, Back Side Only 30—12.7 mm (0.5 in.) 31—45° 32—101.6 mm (4.0 in.)

TE14778,00000DA –19–13JUN05–1/1

TM2261 (10FEB06)

9900-0999-10

750J, 850J Crawler 032806

PN=486

Dealer Fabricated Tools

DFT1261 Rolling Torque Measurement Tool 1 2 8

3 4

T211904

–UN–20JUN05

T211904 1—627 mm (24.7 in.) (minimum) 2—570 mm (22.4 in.)

3—10 mm (3/8 in.) flat steel bar 4—285 mm (11.2 in.)

5—13 mm (0.51 in.) diameter 6—M12 (0.47 in.) cap screw, washer, and nut

7—269 mm (10.59 in.) 8—538 mm (21.18 in.)

TE14778,00000DB –19–22JUN05–1/1

TM2261 (10FEB06)

9900-0999-11

750J, 850J Crawler 032806

PN=487

9900 0999 11

Dealer Fabricated Tools

9900 0999 12

TM2261 (10FEB06)

9900-0999-12

750J, 850J Crawler 032806

PN=488

Index Page

A A/C freeze switch Remove and install . . . . . . . . . . . . . . . .18-1830-18 Adjust track sag . . . . . . . . . . . . . . . . . . . .01-0130-62 Air conditioning Cleaning procedures . . . . . . . . . . . . . . .18-1830-10 Clutch hub clearance . . . . . . . . . . . . . .18-1830-30 Compressor clutch . . . . . . . . . . . . . . . .18-1830-28 Leak testing . . . . . . . . . . . . . . . . . . . . . .18-1830-4 Air conditioning compressor Remove and install . . . . . . . . . . . . . . . .18-1830-26 Angle cylinder Disassemble and assemble . . . . . . . . .32-3260-23 Remove and install . . . . . . . . . . . . . . . .32-3260-22 Attachments Adding Safely . . . . . . . . . . . . . . . . . . . . . .00-01-10 Operating Safely . . . . . . . . . . . . . . . . . . . .00-01-10

B Backup alarm, adjust . . . . . . . . . . . . . . . . .20-2004-1 Battery Explosions, prevent. . . . . . . . . . . . . . . . . . .00-01-4 Blade Remove and install . . . . . . . . . . . . . . . . .32-3201-2 Blade edges and end bits Remove and install . . . . . . . . . . . . . . . . .32-3201-1 Bleed procedure Hand pump bleed procedure. . . . . . . . . .18-1810-3 Bottom guard, front Remove and install . . . . . . . . . . . . . . . . .17-1746-1 Brake Disassemble and assemble . . . . . . . . . .11-1160-1 Brake pedal Disassemble and assemble . . . . . . . . . .05-0515-2 Remove and install . . . . . . . . . . . . . . . . .05-0515-1 Bushing Bushing outside diameter for lubricated track chain inspection . . . . . . . . . . . . . . . . . . . . .01-0130-38

C C-Frame Remove and install . . . . . . . . . . . . . . . . .32-3240-3 Cab under seat heater Diassemble and assemble . . . . . . . . . .18-1830-22 Cab upper heater Disassemble and assemble . . . . . . . . .18-1830-20 TM2261 (10FEB06)

Page

Cab/ROPS Remove and install . . . . . . . . . . . . . . . . .18-1800-1 Carrier roller Disassemble and assemble . . . . . . . . . .01-0130-7 Leakage test . . . . . . . . . . . . . . . . . . . . .01-0130-11 Remove and install . . . . . . . . . . . . . . . . .01-0130-5 Wear Inspection . . . . . . . . . . . . . . . . . . .01-0130-5 Chain, lubricated track Remove and install . . . . . . . . . . . . . . . .01-0130-41 Charge air cooler Remove and install . . . . . . . . . . . . . . . . .05-0510-4 Charge pump Disassemble and assemble . . . . . . . . . .03-0360-9 Chemical Products Handling . . . . . . . . . . . . . . . . . . . . . . . . . . .00-01-5 Cleanout cover Remove and install . . . . . . . . . . . . . . . . .32-3260-9 Clutch hub clearance . . . . . . . . . . . . . . . .18-1830-30 Compressor Disassemble and assemble . . . . . . . . .18-1830-32 Disassemble and assemble clutch . . . .18-1830-28 Oil charge check . . . . . . . . . . . . . . . . . . .18-1830-1 Oil removal . . . . . . . . . . . . . . . . . . . . . . .18-1830-2 Remove and install . . . . . . . . . . . . . . . .18-1830-26 Condenser Remove and install . . . . . . . . . . . . . . . .18-1830-25 Control valve, pump Disassemble and assemble . . . . . . . . . .32-3260-4 Cooling package Remove and install . . . . . . . . . . . . . . . . .05-0510-4 Counterweight, front Remove and install . . . . . . . .17-1749-2, 17-1749-4 Cover, cleanout Hydraulic reservoir . . . . . . . . . . . . . . . . .32-3260-9 Crossbar Disassemble and assemble . . . . . . . . .01-0130-36 Crossbar lube Remove and install . . . . . . . . . . . . . . . .01-0130-30 Cutting edges and end bits Remove and install . . . . . . . . . . . . . . . . .32-3201-1 Cylinder, angle Remove and install . . . . . . . . . . . . . . . .32-3260-22 Cylinder, PAT Remove and install . . . . . . . . . . . . . . . .32-3260-22 Cylinder, track adjuster Disassemble and assemble . . . . . . . . .01-0130-75 Cylinder, track adjuster and recoil spring Remove and install . . . . . . . . . . . . . . . .01-0130-64

D Dampener drive Remove and install . . . . . . . . . . . . . . . . .07-0752-1

Index-1

750J, 850J Crawler 032806

PN=1

Indx 1

Index

Page

Dealer fabricated tool DFT1132 hydrostatic motor removal . . . . . . . . . . . . . . . . . . . . . . 9900-0999-4 DFT1137 hydrostatic motor removal . . . . . . . . . . . . . . . . . . . . . . 9900-0999-5 DFT1243 lifting bracket extension . . . . 9900-0999-7 DFT1250 lifting bracket . . . . . . . . . . . . 9900-0999-8 Decelerator pedal Disassemble and assemble . . . . . . . . . .05-0515-2 Remove and install . . . . . . . . . . . . . . . . .05-0515-1 DFT1041 Track Nut Removal Tool . . . . . 9900-0999-2 DFT1260 Final drive lifting fixture . . . . . . . . . . . 9900-0999-10 Dozer control valve Disassemble and assemble . . . . . . . . .32-3260-14 Drawbar, rigid Remove and install . . . . . . . . . . . . . . . . .15-1511-4 Drawbar, rigid, extended Remove and install . . . . . . . . . . . . . . . . .15-1511-2

Fan shroud Remove and install . . . . . . . . . . . . . . . . .05-0510-1 Final drive Remove and install . . . . . . . . . . . . . . . . .02-0201-1 Final drive lift bracket . . . . . . . . . . . . . . . 9900-0999-3 Final drive lifting fixture DFT1260. . . . . . . . . . . . . . . . . . . . . . 9900-0999-10 Fires, prevent . . . . . . . . . . . . . . . . . . . . . . . . .00-01-4 Fluids, high pressure Avoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . .00-01-3 Flywheel Remove and install . . . . . . . . . . . . . . . .04-0400-13 FNR Disassemble and assemble . . . . . . . . . .03-0315-2 Remove and install . . . . . . . . . . . . . . . . .03-0315-1 Frame, C Remove and install . . . . . . . . . . . . . . . . .32-3240-3 Frame, track Remove . . . . . . . . . . . . . . . . . . . . . . . .01-0130-77 Front bottom guard Remove and install . . . . . . . . . . . . . . . . .17-1746-1 Front idler Disassemble and assemble . . . . . . . . .01-0130-93 Remove . . . . . . . . . . . . . . . . . . . . . . . .01-0130-85 Test for oil leakage . . . . . . . . . . . . . . . 01-0130-104 Vertical movement adjustment . . . . . . 01-0130-102 Fuel tank Remove and install . . . . . . . . . . . . . . . . .05-0560-1 Fumes, exhaust Beware . . . . . . . . . . . . . . . . . . . . . . . . . . . .00-01-4

Indx 2

Edges, cutting Remove and install . . . . . . . . . . . . . . . . .32-3201-1 Electrical Welding procedure . . . . . . . . . . . . . . . . .17-1740-1 Emergencies Prepare for . . . . . . . . . . . . . . . . . . . . . . . . .00-01-5 End bits Remove and install . . . . . . . . . . . . . . . . .32-3201-1 Engine Remove and Install . . . . . . . . . . . . . . . . .04-0400-1 Engine mounts Remove and install . . . . . . . . . . . . . . . .04-0400-16 Engine side shields Remove and install . . . . . . . . . . . . . . . . .19-1910-4 Equipment, Protective Wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .00-01-2 Evaporator Remove and install . . . . . . . . . . . . . . . .18-1830-14 Expansion valve Remove and install . . . . . . . . . . . . . . . .18-1830-17

F Fan Remove and install . . . . . . . . . . . . . . . . .05-0510-1 Fan guards Remove and install . . . . . . . . . . . . . . . . .05-0510-1 TM2261 (10FEB06)

G Grouser Track show grouser wear inspection . . .01-0130-27 Guard, bottom front Remove and install . . . . . . . . . . . . . . . . .17-1746-1

H Hand pump bleed procedure . . . . . . . . . . .18-1810-3 Handholds Use correctly. . . . . . . . . . . . . . . . . . . . . . . .00-01-6 Heater core, upper Remove and install . . . . . . . . . . . . . . . .18-1830-14 HIC valve Hydraulic intregrated circuit (HIC) valve disassemble and assemble . . . . . . . .03-0360-46 Hydraulic intregrated circuit (HIC) valve remove and install . . . . . . . . . . . . . . . . . . . . .03-0360-44

Index-2

750J, 850J Crawler 032806

PN=2

Index

Page

Hood Remove and install . . . . . . . . . . . . . . . . .19-1910-2 Hood support Remove and install . . . . . . . . . . . . . . . . .19-1910-5 Hydraulic Fittings, 30&deg; cone seat. . . . . . . . . . . . .00-03-5 Fittings, 37&deg; flare . . . . . . . . . . . . . . . . .00-03-5 Hydraulic control lever Disassemble and assemble . . . . . . . . .32-3260-19 Remove and install . . . . . . . . . . . . . . . .32-3260-17 Hydraulic control valve Disassemble and assemble . . . . . . . . .32-3260-14 Remove and install . . . . . . . . . . . . . . . .32-3260-13 Hydraulic cylinder repair Disassemble and assemble . . . . . . . . .32-3260-23 Hydraulic fan motor Remove and install . . . . . . . . . . . . . . . .03-0360-51 Hydraulic fan pump Remove and install . . . . . . . . . . . . . . . .03-0360-55 Hydraulic fan reversing valve Disassemble and assemble . . . . . . . . .03-0360-58 Remove and install . . . . . . . . . . . . . . . .03-0360-56 Hydraulic fitting Flared connections . . . . . . . . . . . . . . . . . .00-03-10 Non-restricted banjo (adjustable). . . . . . . .00-03-21 O-ring boss with shoulder . . . . . . . . . . . . .00-03-23 Hydraulic intregrated circuit (HIC) valve Disassemble and assemble . . . . . . . . .03-0360-46 Remove and install . . . . . . . . . . . . . . . .03-0360-44 Hydraulic motor Hydraulic fan motor remove and install. . . . . . . . . . . . . . . . . . . . . . . . .03-0360-51 Hydraulic fan pump remove and install. . . . . . . . . . . . . . . . . . . . . . . . .03-0360-55 Hydraulic fan reversing valve disassemble and assemble . . . . . . . . . . . . . . . . . . . . . .03-0360-58 Hydraulic fan reversing valve remove and install. . . . . . . . . . . . . . . . . . . . . . . . .03-0360-56 Hydraulic pump Disassemble and assemble . . . . . . . . . .32-3260-3 Remove and install . . . . . . . . . . . . . . . . .32-3260-1 Hydraulic pump control valve Disassemble and assemble . . . . . . . . . .32-3260-4 Hydraulic reservoir cleanout cover Remove and install . . . . . . . . . . . . . . . . .32-3260-9 Hydrostatic motor Assemble . . . . . . . . . . . . . . . . . . . . . . .03-0360-32 Disassemble . . . . . . . . . . . . . . . . . . . . .03-0360-27 Hydrostatic motors Remove and install . . . . . . . . . . . . . . . . .03-0300-8 Hydrostatic pump Assemble . . . . . . . . . . . . . . . . . . . . . . .03-0360-17 Disassemble . . . . . . . . . . . . . . . . . . . . . .03-0360-2

Hydrostatic pumps Remove and install . . . . . . . . . . . . . . . . .03-0300-1 Hydrostatic reservoir Remove and Install . . . . . . . . . . . . . . . .03-0360-48 Hydrostatic system Hydraulic fan motor remove and install. . . . . . . . . . . . . . . . . . . . . . . . .03-0360-51 Hydraulic fan pump remove and install. . . . . . . . . . . . . . . . . . . . . . . . .03-0360-55 Hydraulic fan reversing valve disassemble and assemble . . . . . . . . . . . . . . . . . . . . . .03-0360-58 Hydraulic fan reversing valve remove and install. . . . . . . . . . . . . . . . . . . . . . . . .03-0360-56 Hydrostatic System Hydraulic intregrated circuit (HIC) valve disassemble and assemble . . . . . . . .03-0360-46 Remove and Install . . . . . . . . . . . . . . . .03-0360-44

TM2261 (10FEB06)

I Idler, front Disassemble and assemble . . . . . . . . .01-0130-93 Measure wear . . . . . . . . . . . . . . . . . . . .01-0130-85 Remove . . . . . . . . . . . . . . . . . . . . . . . .01-0130-85 Test for oil leakage . . . . . . . . . . . . . . . 01-0130-104 Vertical movement adjustment . . . . . . 01-0130-102 Inch bolt and cap screw Torque value. . . . . . . . . . . . . . . . . . . . . . . .00-03-4 Inch series four bolt flange fitting Service recommendation, torque value for high pressure . . . . . . . . . . . . . . . . . . . . . . . .00-03-20 Inner final drive housing Disassemble and assemble . . . . . . . . .02-0250-20 Remove and install . . . . . . . . . . . . . . . .02-0250-17 Inspection Bushing outside diameter for lubricated track chain . . . . . . . . . . . . . . . . . . . . . . . . .01-0130-38 Carrier roller wear . . . . . . . . . . . . . . . . . .01-0130-5 Track link height . . . . . . . . . . . . . . . . . .01-0130-37 Track shoe grouser wear . . . . . . . . . . .01-0130-27

L Leakage test Carrier roller . . . . . . . . . . . . . . . . . . . . .01-0130-11 Lift cylinder Disassemble and assemble . . . . . . . . .32-3260-23 Loop Flushing Valve Assemble . . . . . . . . . . . . . . . . . . . . . . .03-0360-32 Disassemble . . . . . . . . . . . . . . . . . . . . .03-0360-27

Index-3

750J, 850J Crawler 032806

PN=3

Indx 3

Index

Page

Lubricated track chain Assemble and not relubricate . . . . . . . .01-0130-55 Assemble to lubricate . . . . . . . . . . . . . .01-0130-48 Assemble to turn bushings . . . . . . . . . .01-0130-48 Disassemble and assemble . . . . . . . . .01-0130-55 Disassemble and not relubricate . . . . . .01-0130-55 Disassemble to lubricate . . . . . . . . . . . .01-0130-45 Disassemble to turn bushing . . . . . . . . .01-0130-45 Remove and install . . . . . . . . . . . . . . . .01-0130-41

O-ring seal, metric 24° Service recommendation. . . . . . . . . . . . . .00-03-26 Oil Cooler Remove and install . . . . . . . . . . . . . . . . .05-0510-4 Oil pan Remove and install . . . . . . . . . . . . . . . .04-0400-11 Operating Charge Relief Valve Assemble . . . . . . . . . . . . . . . . . . . . . . .03-0360-32 Disassemble . . . . . . . . . . . . . . . . . . . . .03-0360-27 Install . . . . . . . . . . . . . . . . . . . . . . . . . .03-0360-32 Remove . . . . . . . . . . . . . . . . . . . . . . . .03-0360-27 Operation Qualification . . . . . . . . . . . . . . . . . .00-01-2 Operator’s Seat Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . .00-01-6 Outside dozer pushbeam Remove and install . . . . . . . . . . . . . . . . .32-3240-2

Indx 4

Machine modifications Avoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . .00-01-2 Machine, inspect . . . . . . . . . . . . . . . . . . . . . .00-01-3 Measure front idler wear. . . . . . . . . . . . . .01-0130-85 Measure track pitch . . . . . . . . . . . . . . . . .01-0130-40 Metal face seals Inspect . . . . . . . . . . . . . . . . . . . . . . . . .01-0130-10 Metric bolt and cap screw Torque value. . . . . . . . . . . . . . . . . . . . . . . .00-03-1 Motor Hydraulic fan motor remove and install. . . . . . . . . . . . . . . . . . . . . . . . .03-0360-51 Hydraulic fan pump remove and install. . . . . . . . . . . . . . . . . . . . . . . . .03-0360-55 Motor Shift Solenoid Valve Assemble . . . . . . . . . . . . . . . . . . . . . . .03-0360-32 Disassemble . . . . . . . . . . . . . . . . . . . . .03-0360-27 Install . . . . . . . . . . . . . . . . . . . . . . . . . .03-0360-32 Remove . . . . . . . . . . . . . . . . . . . . . . . .03-0360-27 Muffler Remove and install . . . . . . . . . . . . . . . . .05-0530-1 Multi-function valve Assemble and disassemble. . . . . . . . . .03-0360-16 Remove and install . . . . . . . . . . . . . . . .03-0360-15

O O-ring boss fitting in aluminum housing—excavators Torque value, service recommendation. . . .00-03-8 O-ring boss fittings . . . . . . . . . . . . . . . . . . . . .00-03-6 O-ring face seal fitting Inch hex nut and stud end for high pressure torque values . . . . . . . . . . . . . . . . . . . . . . . . . .00-03-12 Metric hex nut and stud end for high pressure torque values. . . . . . . . . . . . . . . . . . . . .00-03-16 Metric hex nut and stud end for standard pressure torque values. . . . . . . . . . . . . . . . . . . . .00-03-14 TM2261 (10FEB06)

P Park brake Disassemble and assemble . . . . . . . . . .11-1160-1 Remove and install . . . . . . . . . . . . . . . . .11-1100-1 Park lock linkage Disassemble and assemble . . . . . . . . . .11-1115-3 Remove and install . . . . . . . . . . . . . . . . .11-1115-2 Parts, moving Stay clear . . . . . . . . . . . . . . . . . . . . . . . . . .00-01-3 PAT cylinder Remove and install . . . . . . . . . . . . . . . .32-3260-22 PAT six way blade Remove and install . . . . . . . . . . . . . . . . .32-3201-2 Pilot control valve Disassemble and assemble . . . . . . . . .32-3260-19 Remove and install . . . . . . . . . . . . . . . .32-3260-17 Pivot shaft Remove and install . . . . . . . . . . . . . . . .01-0130-30 Planet carrier Disassemble and assemble . . . . . . . . . .02-0250-4 Remove and install . . . . . . . . . . . . . . . . .02-0250-1 Planet housing Disassemble and assemble . . . . . . . . .02-0250-14 Remove and install . . . . . . . . . . . . . . . .02-0250-12 Pump Hand pump bleed procedure. . . . . . . . . .18-1810-3 Pump control valve Disassemble and assemble . . . . . . . . . .32-3260-4 Pump displacement control valve (PDCV) Disassemble and assemble . . . . . . . . .03-0360-14 Pump, hydraulic Remove and install . . . . . . . . . . . . . . . . .32-3260-1

Index-4

750J, 850J Crawler 032806

PN=4

Index

Page

Push beam, Outside Dozer Remove and install . . . . . . . . . . . . . . . . .32-3240-2

ROPS under seat heater Disassemble and assemble . . . . . . . . .18-1830-22 R134a Component oil charge . . . . . . . . . . . . . . .18-1830-3 R134a system Charge . . . . . . . . . . . . . . . . . . . . . . . . . .18-1830-9 Evacuate. . . . . . . . . . . . . . . . . . . . . . . . .18-1830-7 Flush. . . . . . . . . . . . . . . . . . . . . . . . . . .18-1830-12 Purge . . . . . . . . . . . . . . . . . . . . . . . . . .18-1830-11 Recover . . . . . . . . . . . . . . . . . . . . . . . . .18-1830-6

Q Quick-drop valve Remove and install . . . . . . . . . . . . . . . .32-3260-21

R Radiator Remove and install . . . . . . . . . . . . . . . . .05-0510-4 Receiver-dryer Remove and install . . . . . . . . . . . . . . . .18-1830-24 Recoil spring and track adjuster cylinder Remove and install . . . . . . . . . . . . . . . .01-0130-64 Recoil spring, track adjuster Assemble . . . . . . . . . . . . . . . . . . . . . . .01-0130-71 Disassemble . . . . . . . . . . . . . . . . . . . . .01-0130-65 Disassemble and assemble . . . . . . . . .01-0130-65 Recovery/charging station Installation procedure . . . . . . . . . . . . . . .18-1830-5 Refrigerant R134a caution . . . . . . . . . . . . .18-1830-1 Remove and install Pivot shaft. . . . . . . . . . . . . . . . . . . . . . .01-0130-30 Track shoe . . . . . . . . . . . . . . . . . . . . . .01-0130-28 Reservoir cover Remove and install . . . . . . . . . . . . . . . . .32-3260-9 Reservoir, hydraulic Remove and install . . . . . . . . . . . . . . . . .32-3260-5 Reverse alarm, Remove and install . . . . . . . . . . . . . . . . .20-2004-1 Reverse warning alarm, adjust . . . . . . . . . .20-2004-1 Ring gear and hub Disassemble and assemble . . . . . . . . .02-0250-11 Remove and Install . . . . . . . . . . . . . . . . .02-0250-7 Ripper Remove and install . . . . . . . . . . . . . . . . .15-1540-2 Rock guard Remove and install . . . . . . . . . . . . . . . . .01-0130-1 Roller, carrier Disassemble and assemble . . . . . . . . . .01-0130-7 Remove and install . . . . . . . . . . . . . . . . .01-0130-5 Roller, track Disassemble and assemble . . . . . . . . .01-0130-16 Remove and install . . . . . . . . . . . . . . . .01-0130-14 Test for oil leakage . . . . . . . . . . . . . . . .01-0130-26 Wear inspection . . . . . . . . . . . . . . . . . .01-0130-12 ROPS or cab Remove and install . . . . . . . . . . . . . . . . .18-1800-1 TM2261 (10FEB06)

S Safety Add cab guarding for special uses . . . . . . .00-01-6 Avoid backover accidents . . . . . . . . . . . . . .00-01-9 Avoid machine tip over . . . . . . . . . . . . . . . .00-01-9 Avoid work site hazards . . . . . . . . . . . . . . .00-01-8 Drive metal pins safely . . . . . . . . . . . . . . .00-01-12 Information, recognize. . . . . . . . . . . . . . . . .00-01-1 Instructions, follow . . . . . . . . . . . . . . . . . . .00-01-1 Keep riders off machine . . . . . . . . . . . . . . .00-01-8 Make welding repairs safely . . . . . . . . . . .00-01-12 Park and preapre for service safely. . . . . .00-01-10 Prevent unintended machine movement . . .00-01-7 Seals, metal face Inspect . . . . . . . . . . . . . . . . . . . . . . . . .01-0130-10 Seat Disassemble and assemble . . . . . . . . . .18-1821-1 Seat belt Use and maintain . . . . . . . . . . . . . . . . . . . .00-01-7 Service recommendation Inch series four bolt flange fitting for high pressure . . . . . . . . . . . . . . . . . . . . . . . .00-03-20 O-ring boss fitting in aluminum housing— excavators . . . . . . . . . . . . . . . . . . . . . . . .00-03-8 O-ring face seal fittings with inch hex nut and stud end for high pressure. . . . . . . . . . .00-03-12 O-ring face seal fittings with metric hex nut and stud end for high pressure. . . . . . . . . . .00-03-16 O-ring face seal fittings with metric hex nut and stud end for standard pressure . . . . . . .00-03-14 O-ring seal, metric 24° . . . . . . . . . . . . . . .00-03-26 Side shields Remove and install . . . . . . . . . . . . . . . . .19-1910-4 Single lever control Disassemble and assemble . . . . . . . . . .03-0315-2 Remove and install . . . . . . . . . . . . . . . . .03-0315-1 Six way blade Remove and install . . . . . . . . . . . . . . . . .32-3201-2

Index-5

750J, 850J Crawler 032806

PN=5

Indx 5

Index

Page

Spring, recoil and track adjuster cylinder Remove and install . . . . . . . . . . . . . . . .01-0130-64 Spring, track adjuster recoil Disassemble and assemble . . . . . . . . .01-0130-65 Sprocket guard Remove and install . . . . . . . . . . . . . . . . .01-0130-1 Sprocket segment Remove and install . . . . . . . . . . . . . . . 01-0130-105 Starting aid assembly Remove and install . . . . . . . . . . . . . . . . .05-0505-1 Starting machine Operator’s seat . . . . . . . . . . . . . . . . . . . . . .00-01-6 Steps Use correctly. . . . . . . . . . . . . . . . . . . . . . . .00-01-6 Switch, A/C freeze Removel and install. . . . . . . . . . . . . . . .18-1830-18

O-ring face seal fittings with metric hex nut and stud end for high pressure. . . . . . . . . . .00-03-16 O-ring face seal fittings with metric hex nut and stud end for standard pressure . . . . . . .00-03-14 O-ring seal, metric 24° . . . . . . . . . . . . . . .00-03-26 Unified inch bolt and cap screw . . . . . . . . .00-03-4 30&deg; cone seat hydraulic fittings . . . . . .00-03-5 37&deg; flare hydraulic fittings . . . . . . . . . .00-03-5 Track adjuster cylinder Disassemble and assemble . . . . . . . . .01-0130-75 Track adjuster cylinder and recoil spring Remove and install . . . . . . . . . . . . . . . .01-0130-64 Track adjuster cylinder recoil spring Assemble . . . . . . . . . . . . . . . . . . . . . . .01-0130-71 Track adjuster recoil spring Disassemble . . . . . . . . . . . . . . . . . . . . .01-0130-65 Disassemble and assemble . . . . . . . . .01-0130-65 Track chain bushing Bushing outside diameter for lubricated track chain inspection . . . . . . . . . . . . . . . . . . . . .01-0130-38 Track chain, lubricated Remove and install . . . . . . . . . . . . . . . .01-0130-41 Track frame Remove . . . . . . . . . . . . . . . . . . . . . . . .01-0130-77 Track guide Remove and install . . . . . . . . . . . . . . . . .01-0130-1 Track guides and rock guards Remove and install . . . . . . . . . . . . . . . . .01-0130-1 Track link bushing Bushing outside diameter for lubricated track chain inspection . . . . . . . . . . . . . . . . . . . . .01-0130-38 Track link height Inspection . . . . . . . . . . . . . . . . . . . . . . .01-0130-37 Track roller Disassemble and Assemble . . . . . . . . .01-0130-16 Remove and install . . . . . . . . . . . . . . . .01-0130-14 Test for oil leakage . . . . . . . . . . . . . . . .01-0130-26 Wear inspection . . . . . . . . . . . . . . . . . .01-0130-12 Track sag Adjust . . . . . . . . . . . . . . . . . . . . . . . . . .01-0130-62 Track sag adjustment . . . . . . . . . . . . . . . .01-0130-62 Track shoe Remove and install . . . . . . . . . . . . . . . .01-0130-28 Track shoe grouser wear Inspection . . . . . . . . . . . . . . . . . . . . . . .01-0130-27 Transmission bottom guard . . . . . . . . . . . .17-1746-1 Transmission control lever (TCL) Disassemble and assemble . . . . . . . . . .03-0315-2 Remove and install . . . . . . . . . . . . . . . . .03-0315-1

Indx 6

TCL Disassemble and assemble . . . . . . . . . .03-0315-2 Remove and install . . . . . . . . . . . . . . . . .03-0315-1 Test Hand pump bleed procedure. . . . . . . . . .18-1810-3 Tilt cylinder Disassemble and assemble . . . . . . . . .32-3260-23 Tool, dealer fabricated DFT1243 lifting bracket extension . . . . 9900-0999-7 DFT1250 lifting bracket . . . . . . . . . . . . 9900-0999-8 Tools, dealer fabricated DFT1132 hydrostatic motor removal . . . . . . . . . . . . . . . . . . . . . . 9900-0999-4 DFT1137 hydrostatic motor removal . . . . . . . . . . . . . . . . . . . . . . 9900-0999-5 Torque value Flared connections . . . . . . . . . . . . . . . . . .00-03-10 Flat face O-ring seal fitting . . . . . . . . . . . .00-03-11 Inch SAE four bolt flange fitting. . . . . . . . .00-03-19 Inch series four bolt flange fitting for high pressure . . . . . . . . . . . . . . . . . . . . . . . .00-03-20 Metric bolt and cap screw . . . . . . . . . . . . . .00-03-1 Metric cap screw. . . . . . . . . . . . . . . . . . . . .00-03-2 Metric four bolt flange fitting . . . . . . . . . . .00-03-18 Non-restricted banjo fittings. . . . . . . . . . . .00-03-21 O-Ring boss fitting . . . . . . . . . . . . . . . . . . .00-03-6 O-ring boss fitting in aluminum housing— excavators . . . . . . . . . . . . . . . . . . . . . . . .00-03-8 O-ring boss fittings with shoulder . . . . . . .00-03-23 O-ring face seal fittings with inch hex nut and stud end for high pressure. . . . . . . . . . .00-03-12 TM2261 (10FEB06)

U Upper heater core Remove and install . . . . . . . . . . . . . . . .18-1830-14

Index-6

750J, 850J Crawler 032806

PN=6

Index

Page

V Valve Hydraulic fan reversing valve disassemble and assemble . . . . . . . . . . . . . . . . . . . . . .03-0360-58 Hydraulic fan reversing valve remove and install. . . . . . . . . . . . . . . . . . . . . . . . .03-0360-56 Hydraulic intregrated circuit (HIC) valve disassemble and assemble . . . . . . . .03-0360-46 Hydraulic intregrated circuit (HIC) valve remove and install . . . . . . . . . . . . . . . . . . . . .03-0360-44 Valve, control dozer disassemble and assemble . . . . . . . . . .32-3260-14 Valve, hydraulic control Remove and install . . . . . . . . . . . . . . . .32-3260-13 Valve, pilot control Disassemble and assemble . . . . . . . . .32-3260-19 Remove and install . . . . . . . . . . . . . . . .32-3260-17 Valve, quick-drop Remove and install . . . . . . . . . . . . . . . .32-3260-21

W Waste Dispose of properly . . . . . . . . . . . . . . . . . . .00-01-5 Welding procedure . . . . . . . . . . . . . . . . . . .17-1740-1 Window Remove and install . . . . . . . . . . . . . . . . .18-1810-1

TM2261 (10FEB06)

Index-7

Indx 7

750J, 850J Crawler 032806

PN=7

Index

Indx 8

TM2261 (10FEB06)

Index-8

750J, 850J Crawler 032806

PN=8