PDF DOWNLOAD John Deere Dump Trucks 370E 410E 460E Repair Technical Manual TM12408 -

370E, 410E, and 460E Articulated Dump Truck Repair

REPAIR TECHNICAL MANUAL iT4/S3B models 370E, 410E, 460E (SN. E634583-668586) TM12408 27 DEC 15 (ENGLISH)

For complete service information also see: 370E, 410E, and 460E Articulated Dump Truck Diagnostic

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John Deere Construction and Forestry Pinted by Belgreen

TM12408-REPAIR TECHNICAL MANUAL

(g) by Belgreen v2.5

Table of contents FOREWORD MANUAL IDENTIFICATION—READ THIS FIRST! Section 00 - GENERAL INFORMATION Group 0001 - Safety Section 01 - WHEELS Group 0100 - Removal and Installation Section 02 - AXLES AND SUSPENSION SYSTEMS Group 0200 - Removal and Installation Group 0225 - Input Drive Shafts and U-Joints Group 0242 - Axle Mounting Parts Group 0250 - Axle Shaft, Bearings, and Reduction Gears Group 0260 - Hydraulic System Section 03 - TRANSMISSION Group 0300 - Removal and Installation Group 0325 - Input Drive Shafts and U-Joints Group 0350 - Gear, Shafts, and Power Shift Clutches Group 0360 - Hydraulic System Section 04 - ENGINE Group 0400 - Removal and Installation Section 05 - ENGINE AUXILIARY SYSTEM Group 0505 - Cold Weather Starting Aids Group 0510 - Cooling Systems Group 0520 - Intake System Group 0530 - External Exhaust Systems Group 0560 - External Fuel Supply Systems Section 07 - DAMPER DRIVE Group 0752 - Elements Section 09 - STEERING SYSTEM Group 0930 - Secondary Steering Group 0960 - Hydraulic System Section 10 - SERVICE BRAKES Group 1011 - Active Elements Group 1060 - Hydraulic System Section 11 - PARK BRAKE Group 1111 - Active Elements Group 1160 - Hydraulic System Section 17 - FRAME OR SUPPORTING STRUCTURE Group 1740 - Frame Installation Section 18 - OPERATOR′S STATION Group 1810 - Operator Enclosure Group 1821 - Seat and Seat Belt Group 1830 - Heating and Air Conditioning Section 19 - SHEET METAL AND STYLING Group 1910 - Hood or Engine Enclosure Group 1927 - Fenders Section 21 - MAIN HYDRAULIC SYSTEM Group 2160 - Hydraulic System Section 35 - HAULAGE DEVICE Group 3540 - Frames Group 3560 - Hydraulic System Section 99 - DEALER FABRICATED TOOLS Group 9900 - Dealer Fabricated Tools <- Go to Global Table of contents

TM12408-REPAIR TECHNICAL MANUAL

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TM12408-REPAIR TECHNICAL MANUAL

TM12408-REPAIR TECHNICAL MANUAL

(g) by Belgreen v2.5

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. CAUTION: This is the safety-alert symbol. When you see this symbol on the machine or in this manual, be alert to the potential for personal injury. Technical manuals are divided in two parts: repair and operation and tests. Repair sections tell how to repair the components. Operation and tests sections help you identify the majority of routine failures quickly. Information is organized in groups for the various components requiring service instruction. At the beginning of each group are summary listings of all applicable essential tools, service equipment and tools, other materials needed to do the job, service parts kits, specifications, wear tolerances, and torque values. Technical Manuals are concise guides for specific machines. They are on-the-job guides containing only the vital information needed for diagnosis, analysis, testing, and repair. Fundamental service information is available from other sources covering basic theory of operation, fundamentals of troubleshooting, general maintenance, and basic type of failures and their causes.

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TM12408-REPAIR TECHNICAL MANUAL

TM12408-REPAIR TECHNICAL MANUAL

(g) by Belgreen v2.5

Manual Identification—READ THIS FIRST! IMPORTANT: Use only supporting manuals designated for your specific machine. If incorrect manual is chosen, improper service may occur. Verify product identification number (PIN) when choosing the correct manual. Choosing the Correct Supporting Manuals John Deere articulated dump trucks are available in different machine configurations based on the various markets into which they are sold. Different supporting manuals exist for different machine configurations. When necessary, product identification numbers are listed on the front covers of articulated dump truck manuals. These numbers are used to identify the correct supporting manual for your machine. Product Identification Number

PIN Plate Location

PIN Plate LEGEND: 1 PIN Plate 2 17 Character PIN The product identification number (PIN) plate (1) is located on the left-side of equipment frame under operator′s station. Each machine has a 17 character PIN (2) shown on PIN plate.

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TM12408-REPAIR TECHNICAL MANUAL

GENERAL INFORMATION

(g) by Belgreen v2.0

PIN Identification PIN Identification 3

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3—World Code —Identifies location where machine is manufactured. 4—Machine Model Identifier —Identifies model number. 5—Option Code —Identifies which major machine option is equipped. This digit will change from one machine to another. 6—Check Letter —This is a random character assigned by the factory. This is not used in machine identification. 7—Manufacturing Year Code —Identifies year of machine manufacture. 8—Engine Emission Code —Represents engine emission certification. 9—Machine Serial Number The PIN identifies the producing factory, machine model number, machine option, year of manufacture, engine emission level, and machine serial number. The following is an example for a 370E Interim Tier 4/Stage IIIB machine:

PIN Identification 1DW370EX_ _E123456 1DW ..........

World Code (manufacturing location) 1DW ..........

Davenport Works

1T0 ..........

Dubuque Works

370E ..........

Machine Model Identifier

X ..........

Machine Option Code X ..........

Base Machine

T ..........

Truck

_ ..........

Check Letter (variable)

_ ..........

Manufacturing Year Code (variable) C ..........

2012

D ..........

2013

E ..........

2014

F ..........

2015

G ..........

2016

E ..........

Engine Emission Code C ..........

Tier 2/Stage II

D ..........

Tier 3/Stage IIIA

E ..........

Interim Tier 4/Stage IIIB

F ..........

Tier 4

123456 ..........

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Machine Serial Number

Section 00 page 2

TM12408-REPAIR TECHNICAL MANUAL

TM12408-REPAIR TECHNICAL MANUAL

(g) by Belgreen v2.5

Section 00 - GENERAL INFORMATION Table of contents Group 0001 - Safety ................................................................................................................................. 1 Safety and Operator Convenience Features ......................................................................................... 1 Recognize Safety Information ............................................................................................................... 1 Follow Safety Instructions ..................................................................................................................... 2 Operate Only If Qualified ...................................................................................................................... 3 Wear Protective Equipment .................................................................................................................. 4 Avoid Unauthorized Machine Modifications .......................................................................................... 4 Inspect Machine ................................................................................................................................... 4 Stay Clear of Moving Parts ................................................................................................................... 5 Avoid High-Pressure Fluids ................................................................................................................... 5 Avoid High-Pressure Oils ...................................................................................................................... 6 Work In Ventilated Area ........................................................................................................................ 6 Prevent Fires ........................................................................................................................................ 7 Prevent Battery Explosions ................................................................................................................... 8 Handle Chemical Products Safely ......................................................................................................... 8 Decommissioning: Proper Recycling and Disposal of Fluids and Components ..................................... 8 Exhaust Filter Ash Handling and Disposal ............................................................................................ 9 Prepare for Emergencies ...................................................................................................................... 9 Clean Debris from Machine ................................................................................................................ 10 Use Steps and Handholds Correctly ................................................................................................... 10 Start Only From Operator′s Seat ......................................................................................................... 11 Use and Maintain Seat Belt ................................................................................................................ 11 Prevent Unintended Machine Movement ............................................................................................ 11 Avoid Work Site Hazards .................................................................................................................... 12 Keep Riders Off Machine .................................................................................................................... 13 Avoid Backover Accidents .................................................................................................................. 14 Avoid Machine Tip Over ...................................................................................................................... 14 Operating on Slopes ........................................................................................................................... 15 Operating or Traveling On Public Roads ............................................................................................. 15 Inspect and Maintain ROPS ................................................................................................................. 15 Add and Operate Attachments Safely ................................................................................................ 16 Prepare Machine for Maintenance ...................................................................................................... 17 Park and Prepare for Service Safely ................................................................................................... 17 Service Cooling System Safely ........................................................................................................... 18 Remove Paint Before Welding or Heating ........................................................................................... 19 Make Welding Repairs Safely ............................................................................................................. 19 Drive Metal Pins Safely ....................................................................................................................... 20 Service Tires Safely ............................................................................................................................ 21 Clean Exhaust Filter Safely ................................................................................................................. 21

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TM12408-REPAIR TECHNICAL MANUAL

Section 00 - GENERAL INFORMATION

Group 0001: Safety

Group 0001 - Safety Safety and Operator Convenience Features

Safety Features Please remember, the operator is the key to preventing accidents. 1. ROPS/FOPS Cab Protection. Structures designed to help protect the operator are certified to ISO, SAE, and OSHA. Enclosures also deflect sun and rain. 2. Cab with Heater/Defroster. Cab ventilation system circulates both outside and inside air through a filter for a clean working environment. Built-in defroster vents direct air flow for effective window defogging/deicing. 3. Dump Body Service Lock. A mechanical lock is provided for working on or around this machine with the dump body raised. 4. Stop/Backup Lights. Highly visible lights are standard equipment. 5. Backup Alarm. Alerts bystanders when reverse travel direction is selected by the operator. 6. Independent Parking Brake. Is mechanically engaged and hydraulically released. It engages whenever the engine stop switch is turned on or the park brake switch is activated. 7. Articulation Locking Bar. A self-storing mechanical lock is provided for transport or service. 8. Secondary Steering. Ground driven, continuously in operation. Secondary steering indicator light will light when active. 9. Horn. Standard horn is useful when driving or when signaling co-workers. 10. Halogen Lights and Turn Signals. High-intensity halogen drive/work lights and high-visibility turn signals are standard equipment. 11. Engine Fan Guard. A fan guard on both fan doors helps prevent contact with rotating fan blades. 12. Bypass Start Protection. Shielding over the starter terminals helps prevent dangerous bypass starting. 13. Transmission Retarder. Engages whenever the truck is in motion and the operator lets up on the accelerator. 14. Seat Belt Retractors. Help keep belts clean and convenient to use. 15. Mirrors. Large exterior mirrors on both sides offer the operator a view of activity behind the machine. 16. Large Windshield Wiper with Washer. Extra long wiper cleans large windshield area.

Recognize Safety Information

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Section 00 page 1

TM12408-REPAIR TECHNICAL MANUAL

Section 00 - GENERAL INFORMATION

Group 0001: Safety

Safety alert Symbols

Safety Alert Symbols 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. Follow the precautions and safe operating practices highlighted by this symbol. A signal word — DANGER, WARNING, or CAUTION — is used with the safety alert symbol. DANGER identifies the most serious hazards. On your machine, DANGER signs are red in color, WARNING signs are orange, and CAUTION signs are yellow. DANGER and WARNING signs are located near specific hazards. General precautions are on CAUTION labels.

Follow Safety Instructions

Safety Messages Carefully read all safety messages in this manual and on your machine safety signs. Keep safety signs in good condition. Replace missing or damaged safety signs. Use this operator’s manual for correct safety sign placement. Be sure that new equipment components and repair parts include the current safety signs. Replacement safety signs are available from your John Deere dealer. There can be additional safety information contained on parts and components sourced from suppliers that is not reproduced in this operator′s manual. Learn how to operate the machine and how to use controls properly. Do not let anyone operate without instruction. <- Go to Section TOC

Section 00 page 2

TM12408-REPAIR TECHNICAL MANUAL

Section 00 - GENERAL INFORMATION

Group 0001: Safety

Keep your machine in proper working condition. Unauthorized modifications to the machine could impair the function or safety and affect machine life. If you do not understand any part of this manual and need assistance, contact your John Deere dealer.

Operate Only If Qualified Do not operate this machine unless the operator′s manual has been read carefully, and you have been qualified by supervised training and instruction. Operator should be familiar with the job site and surroundings before operating. Try all controls and machine functions with the machine in an open area before starting to work. Know and observe all safety rules that may apply to every work situation and work site.

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Section 00 page 3

TM12408-REPAIR TECHNICAL MANUAL

Section 00 - GENERAL INFORMATION

Group 0001: Safety

Wear Protective Equipment

Protective Clothing Guard against injury from flying pieces or metal or debris; wear goggles or safety glasses. Wear close fitting clothing and safety equipment appropriate to the job. Operating equipment safely requires the full attention of the operator. Do not wear radio or music headphones while operating machine. Prolonged exposure to loud noise can cause impairment or loss of hearing. Wear suitable hearing protection such as earmuffs or earplugs to protect against objectionable or uncomfortable loud noises. Radio or music headphones are not suitable to use for hearing protection.

Avoid Unauthorized Machine Modifications John Deere recommends using only genuine John Deere replacement parts to ensure machine performance. Never substitute genuine John Deere parts with alternate parts not intended for the application as these can create hazardous situations or hazardous performance. Non-John Deere parts, or any damage or malfunctions resulting from their use, are not covered by any John Deere warranty. Modifications of this machine, or addition of unapproved products or attachments, may affect machine stability or reliability, and may create a hazard for the operator or others near the machine. The installer of any modification which may affect the electronic controls of this machine is responsible for establishing that the modification does not adversely affect the machine or its performance. Always contact an authorized dealer before making machine modifications that change the intended use, weight or balance of the machine, or that alter machine controls, performance, or reliability.

Inspect Machine

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Section 00 page 4

TM12408-REPAIR TECHNICAL MANUAL

Section 00 - GENERAL INFORMATION

Group 0001: Safety

Inspect Machine Inspect machine carefully each day by walking around it before starting. Keep all guards and shields in good condition and properly installed. Fix damage and replace worn or broken parts immediately. Pay special attention to hydraulic hoses and electrical wiring.

Stay Clear of Moving Parts

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

Avoid High-Pressure Fluids

High Pressure Inspect hydraulic hoses periodically – at least once per year – for leakage, kinking, cuts, cracks, abrasion, blisters, corrosion, exposed wire braid or any other signs of wear or damage. Replace worn or damaged hose assemblies immediately with John Deere approved replacement parts. <- Go to Section TOC

Section 00 page 5

TM12408-REPAIR TECHNICAL MANUAL

Section 00 - GENERAL INFORMATION

Group 0001: Safety

Escaping fluid under pressure can penetrate the skin causing serious injury. Avoid the hazard by relieving pressure before disconnecting hydraulic or other lines. Tighten all connections before applying pressure. Search for leaks with a piece of cardboard. Protect hands and body from high-pressure fluids. If an accident occurs, see a doctor immediately. Any fluid injected into the skin must be surgically removed within a few hours or gangrene may result. Doctors unfamiliar with this type of injury should reference a knowledgeable medical source. Such information is available in English from Deere & Company Medical Department in Moline, Illinois, U.S.A., by calling 1-800-822-8262 or +1 309-748-5636.

Avoid High-Pressure Oils

Avoid High Pressure Oils

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

Work In Ventilated Area

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Section 00 page 6

TM12408-REPAIR TECHNICAL MANUAL

Section 00 - GENERAL INFORMATION

Group 0001: Safety

Engine exhaust fumes Engine exhaust fumes can cause sickness or death. If it is necessary to run an engine in an enclosed area, remove the exhaust fumes from the area with an exhaust pipe extension. If you do not have an exhaust pipe extension, open the doors and get outside air into the area.

Prevent Fires

Handle Fuel Safely

Clean Machine Regularly

Carry A Fire Extinguisher Handle Fuel Safely: Store flammable fluids away from fire hazards. Never refuel machine while smoking or when near sparks or flame. Clean Machine Regularly: Keep trash, debris, grease and oil from accumulating in engine compartment, around fuel lines, hydraulic lines, exhaust components, and electrical wiring. Never store oily rags or flammable materials inside a machine compartment. <- Go to Section TOC

Section 00 page 7

TM12408-REPAIR TECHNICAL MANUAL

Section 00 - GENERAL INFORMATION

Group 0001: Safety

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

Prevent Battery Explosions

Battery Explosions Keep sparks, lighted matches, and open flame away from the top of battery. Battery gas can explode. Never check battery charge by placing a metal object across the posts. Use a volt-meter or hydrometer. Do not charge a frozen battery; it may explode. Warm battery to 16°C (60°F).

Handle Chemical Products Safely

Material Safety Data Sheet Direct exposure to hazardous chemicals can cause serious injury. Potentially hazardous chemicals used with John Deere equipment include such items as lubricants, coolants, paints, and adhesives. A Material Safety Data Sheet (MSDS) provides specific details on chemical products: physical and health hazards, safety procedures, and emergency response techniques. Check the MSDS before you start any job using a hazardous chemical. That way you will know exactly what the risks are and how to do the job safely. Then follow procedures and recommended equipment. (See your John Deere dealer for MSDS’s on chemical products used with John Deere equipment.)

Decommissioning: Proper Recycling and Disposal of Fluids and Components

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Section 00 page 8

TM12408-REPAIR TECHNICAL MANUAL

Section 00 - GENERAL INFORMATION

Group 0001: Safety

Recycle Waste Safety and environmental stewardship measures must be taken into account when decommissioning a machine and/or component. These measures include the following: Use appropriate tools and personal protective equipment such as clothing, gloves, face shields or glasses, during the removal or handling of objects and materials. Follow instructions for specialized components. Release stored energy by lowering suspended machine elements, relaxing springs, disconnecting the battery or other electrical power, and releasing pressure in hydraulic components, accumulators, and other similar systems. Minimize exposure to components which may have residue from agricultural chemicals, such as fertilizers and pesticides. Handle and dispose of these components appropriately. Carefully drain engines, fuel tanks, radiators, hydraulic cylinders, reservoirs, and lines before recycling components. Use leak-proof containers when draining fluids. Do not use food or beverage containers. Do not pour waste fluids onto the ground, down a drain, or into any water source. Observe all national, state, and local laws, regulations, or ordinances governing the handling or disposal of waste fluids (example: oil, fuel, coolant, brake fluid); filters; batteries; and, other substances or parts. Burning of flammable fluids or components in other than specially designed incinerators may be prohibited by law and could result in exposure to harmful fumes or ashes. Service and dispose of air conditioning systems appropriately. Government regulations may require a certified service center to recover and recycle air conditioning refrigerants which could damage the atmosphere if allowed to escape. Evaluate recycling options for tires, metal, plastic, glass, rubber, and electronic components which may be recyclable, in part or completely. Contact your local environmental or recycling center, or your John Deere dealer for information on the proper way to recycle or dispose of waste.

Exhaust Filter Ash Handling and Disposal CAUTION: Under federal, state, and local laws or regulations, exhaust filter ash can be classified as a hazardous waste. Hazardous waste must be disposed of in accordance with all applicable federal, state, and local laws or regulations governing hazardous waste disposal. Only a qualified service provider should remove ash from the exhaust filter. Personal protective equipment and clothing, maintained in a sanitary and reliable condition, should be used when handling and cleaning exhaust filter. See your authorized dealer for exhaust filter ash handling and disposal.

Prepare for Emergencies

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Section 00 page 9

TM12408-REPAIR TECHNICAL MANUAL

Section 00 - GENERAL INFORMATION

Group 0001: Safety

First Aid Kit Be prepared if a fire starts. Keep a first aid kit and fire extinguisher handy. Keep emergency numbers for doctors, ambulance service, hospital, and fire department near your telephone.

Clean Debris from Machine

Clean Debris From Machine Keep engine compartment, radiator, batteries, hydraulic lines, exhaust components, fuel tank, and operator′s station clean and free of debris. Clean any oil spills or fuel spills on machine surfaces. Temperature in engine compartment could go up immediately after engine is stopped. BE ON GUARD FOR FIRES DURING THIS PERIOD. Open access door(s) to cool the engine faster, and clean engine compartment.

Use Steps and Handholds Correctly

Use Handholds And Steps <- Go to Section TOC

Section 00 page 10

TM12408-REPAIR TECHNICAL MANUAL

Section 00 - GENERAL INFORMATION

Group 0001: Safety

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. 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.

Start Only From Operator′s Seat

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

Use and Maintain Seat Belt

Use and Maintain Seat Belt 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 that 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.

Prevent Unintended Machine Movement

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Section 00 page 11

TM12408-REPAIR TECHNICAL MANUAL

Section 00 - GENERAL INFORMATION

Group 0001: Safety

25-Button Sealed Switch Module (SSM) Park Function LEGEND: 1 2 3

Engine Stop Switch Park Brake Switch Neutral Selection Switch

Be careful not to accidentally actuate controls when coworkers are present. Ensure dump body is lowered during work interruptions. Push neutral selection switch (3) to engage neutral gear, push park brake switch (2) to engage park brake, and push engine stop switch (1) to stop engine before allowing anyone to approach the machine. Follow these same precautions before standing up, leaving the operator’s seat, or exiting the machine.

Avoid Work Site Hazards

Contact with Overhead Wires

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Section 00 page 12

TM12408-REPAIR TECHNICAL MANUAL

Section 00 - GENERAL INFORMATION

Group 0001: Safety

Operate Only on Solid Footing Avoid contact with gas lines, buried cables and water lines. Call utility line location services to identify all underground utilities before starting work. Prepare work site properly. Avoid operating near structures or objects that could fall onto the machine. Clear away debris that could move unexpectedly if run over. Avoid boom or attachment contact with overhead obstacles or overhead electrical lines. Never move machine closer than 3 m (10 ft) plus twice the line insulator length to overhead wires. Keep bystanders clear at all times. Keep bystanders away from raised booms, attachments, and unsupported loads. Avoid swinging or raising booms, attachments, or loads over or near personnel. Use barricades or a signal person to keep vehicles and pedestrians away. Use a signal person if moving machine in congested areas or where visibility is restricted. Always keep signal person in view. Coordinate hand signals before starting machine. Operate only on solid footing with strength sufficient to support machine. Be especially alert working near embankments or excavations. Avoid working under over-hanging embankments or stockpiles that could collapse under or on machine. Reduce machine speed when operating with tool on or near ground when obstacles may be hidden (e.g., during snow removal or clearing mud, dirt, etc.). At high speeds hitting obstacles (rocks, uneven concrete or manholes) can cause a sudden stop. Always wear your seat belt.

Keep Riders Off Machine

Keep Riders Off Machine Use seat belt at all times. Only allow operator on machine except when necessary for instruction or short periods of observation. Riders are subject to injury. They may fall from machine, be caught between machine parts, or be struck by foreign objects. They also may obstruct operator’s view or impair his ability to operate machine safely. <- Go to Section TOC

Section 00 page 13

TM12408-REPAIR TECHNICAL MANUAL

Section 00 - GENERAL INFORMATION

Group 0001: Safety

Use the instructional seat only to accommodate trainers or persons needing to observe machine operation for short periods.

Avoid Backover Accidents

Avoid Backover Accidents Before moving machine, be sure that all persons are clear of machine path. Turn around and look directly for best visibility. Use mirrors to assist in checking all around machine. Keep windows and mirrors clean, adjusted, and in good repair. Be certain reverse warning alarm is working properly. Use a signal person when backing if view is obstructed or when in close quarters. Keep signal person in view at all times. Use prearranged hand signals to communicate. Do not rely on the rear camera and radar object detection systems to determine if personnel are behind the machine. The system has limitations due to maintenance practices, environmental conditions, and operating range.

Avoid Machine Tip Over

Use Seat Belt

Avoid Machine Tip Over Use seat belt at all times. Do not jump if the machine tips. You will be unlikely to jump clear and the machine may crush you. Use extra care when bin (dump body) is raised. Machine stability is greatly reduced when bin (dump body) is raised. Drive slowly. Avoid sharp turns and uneven ground. <- Go to Section TOC

Section 00 page 14

TM12408-REPAIR TECHNICAL MANUAL

Section 00 - GENERAL INFORMATION

Group 0001: Safety

Be careful on slopes and soft, rocky, or frozen ground. Traction and stability are reduced by slopes and adverse terrain. Avoid piles of dirt and banks or excavations that may cave in and cause the machine to tip or fall. Do not overload the machine. Oversize loads reduce machine stability, increase tire flex, and erode travel surfaces. Braking capability and brake life are also reduced. If machine tips, carefully inspect brake and hydraulic lines, electrical wiring, and machine structure before operating.

Operating on Slopes

Operating on Slopes Avoid side slope travel whenever possible. Check service brake condition frequently when operating on slopes. Select low gear speed before starting down slope. The maximum slope you can operate on will be limited by ground conditions and the load being handled. Use the transmission retarder, exhaust brake, and service brakes to control speed. Sudden brake application with a loaded bin (dump body) could cause loss of machine control.

Operating or Traveling On Public Roads

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

Inspect and Maintain ROPS A damaged rollover protective structure (ROPS) should be replaced, not reused. The protection offered by ROPS could be impaired if ROPS is subjected to structural damage, is involved in an overturn incident, or is in any way altered by welding, bending, drilling, or cutting. <- Go to Section TOC

Section 00 page 15

TM12408-REPAIR TECHNICAL MANUAL

Section 00 - GENERAL INFORMATION

Group 0001: Safety

If ROPS was loosened or removed for any reason, inspect it carefully before operating the machine again. To maintain the ROPS: Replace missing hardware using correct grade hardware. Check hardware torque. Check isolation mounts for damage, looseness, or wear; replace them if necessary. Check ROPS for cracks or physical damage.

Add and Operate Attachments Safely Always verify compatibility of attachments by contacting your authorized dealer. Adding unapproved attachments could affect machine stability or reliability and could 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.

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Section 00 page 16

TM12408-REPAIR TECHNICAL MANUAL

Section 00 - GENERAL INFORMATION

Group 0001: Safety

Prepare Machine for Maintenance Before performing maintenance on machine: [1] - Unload dump body. [2] - Wash machine. [3] - Park machine on firm, level ground. Steer machine to straighten frames. [4] - Install articulation locking bar. See Install Articulation Locking Bar. (Section 3-2.) [5] - Fully lower dump body, unless specifically instructed otherwise in a maintenance procedure. If dump body must be raised, install dump body support rod. See Install Dump Body Locking Bar. (Section 3-2.) [6] - Fully lower the strut lowering system. [7] - Stop engine and engage park brake. [8] - Attach a DO NOT OPERATE sign to steering wheel. [9] - Relieve hydraulic pressure: a. Turn steering wheel back and forth three times. b. If dump body is fully lowered, hydraulic pressure is automatically relieved. If dump body is raised and dump body support rod is installed, move dump body control lever forward and rearward three times to ensure that the weight of the dump body is securely settled onto the dump body support rod. [10] CAUTION: Avoid serious injury or death from being crushed by machine moving unexpectedly. To prevent rollaway, install wheel chocks on one axle. Install wheel chocks to ensure that machine cannot move backward or forward during service. [11] CAUTION: Prevent injury when working with hot equipment and fluids. Hot equipment and fluids can cause burns to unprotected skin. Wear personal protective equipment.

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. Allow time for the engine and all fluids to cool, unless specifically instructed otherwise in a maintenance procedure. →NOTE: The air conditioning system is charged with gas under pressure. Air conditioning service should be performed only by a qualified technician with proper equipment. (See your authorized dealer.)

Park and Prepare for Service Safely <- Go to Section TOC

Section 00 page 17

TM12408-REPAIR TECHNICAL MANUAL

Section 00 - GENERAL INFORMATION

Group 0001: Safety

Do Not Operate Tag

Support Machine Properly Warn others of service work. Always park and prepare your machine for service or repair properly. Park machine on a level surface. Lower bin (dump body) unless raised position is required for service. Engage park brake. Stop engine. Lower struts completely. Attach a “Do Not Operate” tag in an obvious place in the operator′s station. Install the articulation lock bar. Install service locks if bin (dump body) or cab is raised for service. Securely support machine before working under it. Install wheel chocks to ensure that machine cannot move backward or forward during service. Understand service procedures before beginning repairs. Keep service area clean and dry. Use two people whenever the engine must be running for service work.

Service Cooling System Safely

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Section 00 page 18

TM12408-REPAIR TECHNICAL MANUAL

Section 00 - GENERAL INFORMATION

Group 0001: Safety

Cooling System Explosive release of fluids from pressurized cooling system can cause serious burns. Do not service radiator through the radiator cap. Only fill through the surge tank filler cap. Shut off engine. Only remove surge tank filler cap when cool enough to touch with bare hands. Slowly loosen cap to relieve pressure before removing completely.

Remove Paint Before Welding or Heating

Toxic Fumes Avoid potentially toxic fumes and dust. Hazardous fumes can be generated when paint is heated by welding, soldering, or using a torch. Remove paint before heating: Remove paint a minimum of 100 mm (4 in.) from area to be affected by heating. If paint cannot be removed, wear an approved respirator before heating or welding. If you sand or grind paint, avoid breathing the dust. Wear an approved respirator. If you use solvent or paint stripper, remove stripper with soap and water before welding. Remove solvent or paint stripper containers and other flammable material from area. Allow fumes to disperse at least 15 minutes before welding or heating. Do not use a chlorinated solvent in areas where welding will take place. Do all work in an area that is well ventilated to carry toxic fumes and dust away. Dispose of paint and solvent properly.

Make Welding Repairs Safely

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Section 00 page 19

TM12408-REPAIR TECHNICAL MANUAL

Section 00 - GENERAL INFORMATION

Group 0001: Safety

Heating Near Pressurized Fluid Lines IMPORTANT: Disable electrical power before welding. Turn off main battery switch and disconnect positive (+) and negative (-) battery cables. Do not weld or apply heat on any part of a reservoir or tank that has contained oil or fuel. Heat from welding and cutting can cause oil, fuel, or cleaning solution to create gases which are explosive, flammable, or toxic. Avoid welding or heating near pressurized fluid lines. Flammable spray may result and cause severe burns if pressurized lines malfunction as a result of heating. Do not let heat go beyond work area to nearby pressurized lines. Remove paint properly. Do not inhale paint dust or fumes. Use a qualified welding technician for structural repairs. Make sure there is good ventilation. Wear eye protection and protective equipment when welding.

Drive Metal Pins Safely

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

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Section 00 page 20

TM12408-REPAIR TECHNICAL MANUAL

Section 00 - GENERAL INFORMATION

Group 0001: Safety

Service Tires Safely

Explosive Tire and Rim Parts Explosive separation of a tire and rim parts can cause serious injury or death. Do not attempt to mount a tire unless you have the proper equipment and experience to perform the job. Always maintain the correct tire pressure. Do not inflate the tires above the recommended pressure. Never weld or heat a wheel and tire assembly. The heat can cause an increase in air pressure resulting in a tire explosion. Welding can structurally weaken or deform the wheel. When inflating tires, use a clip-on chuck and extension hose long enough to allow you to stand to one side and NOT in front of or over the tire assembly. Use a safety cage if available. Check wheels for low pressure, cuts, bubbles, damaged rims or missing lug bolts and nuts.

Clean Exhaust Filter Safely

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Section 00 page 21

TM12408-REPAIR TECHNICAL MANUAL

Section 00 - GENERAL INFORMATION

Group 0001: Safety

Fire Safety

Hand Over Flame

Moving Parts

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Section 00 page 22

TM12408-REPAIR TECHNICAL MANUAL

WHEELS

(g) by Belgreen v2.0

Stop During exhaust filter cleaning operations, the engine may run at elevated idle and hot temperatures for an extended period of time. Exhaust gases and exhaust filter components reach temperatures hot enough to burn people, or ignite or melt common materials. Keep machine away from people, animals, or structures which may be susceptible to harm or damage from hot exhaust gases or components. Avoid potential fire or explosion hazards from flammable materials and vapors near the exhaust. Keep exhaust outlet away from people and anything that can melt, burn, or explode. Closely monitor machine and surrounding area for smoldering debris during and after exhaust filter cleaning. Adding fuel while an engine is running can create a fire or explosion hazard. Always stop engine before refueling machine and clean up any spilled fuel. Always make sure that engine is stopped while hauling machine on a truck or trailer. Contact with exhaust components while still hot can result in serious personal injury. Avoid contact with these components until cooled to safe temperatures. If service procedure requires engine to be running: Only engage power-driven parts required by service procedure Ensure that other people are clear of operator station and machine Keep hands, feet, and clothing away from power-driven parts. Always disable movement (neutral), set the parking brake or mechanism and disconnect power to attachments or tools before leaving the operator’s station. Shut off engine and remove key (if equipped) before leaving the machine unattended.

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Section 01 page 23

TM12408-REPAIR TECHNICAL MANUAL

TM12408-REPAIR TECHNICAL MANUAL

(g) by Belgreen v2.5

Section 01 - WHEELS Table of contents Group 0100 - Removal and Installation ................................................................................................ 1 Wheel Remove and Install .................................................................................................................... 1 Tire Remove and Install ........................................................................................................................ 3

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TM12408-REPAIR TECHNICAL MANUAL

Section 01 - WHEELS

Group 0100: Removal and Installation

Group 0100 - Removal and Installation Wheel Remove and Install Specifications SPECIFICATIONS 370E Articulated Dump Truck Weight

30 112 kg 66 386 lb.

410E Articulated Dump Truck Weight

31 450 kg 69 335 lb.

460E Articulated Dump Truck Weight

31 822 kg 70 155 lb.

Tire and Rim Weight (approximate)

771 kg 1700 lb.

Wheel Cap Screw Torque

675 N·m 500 lb.-ft.

Service Equipment and Tools SERVICE EQUIPMENT AND TOOLS JT07372 Heavy Duty Wheel Chock 18-t (20-ton) Service Jack D01182AA 18-t (20-ton) Floor Stand JT05726 Wheel and Axle Lift

[1] →NOTE: It is necessary to establish each tire′s pressure sensor information after performing tire maintenance involving rotating the tires and wheels on the machine or after replacing a tire pressure sensor. If a tire is mounted or dismounted, this procedure may also be necessary. A special tool is required to complete this procedure. See TPM—Programming Sensors with SmartWave® Advanced Maintenance Tool . (Group 9015-20.) →NOTE: If the sensor identification number is known, the number can be entered manually using the monitor display unit (MDU) and the 25-button sealed switch module (SSM) (OC3). See TPM—Programming Using Sensor Identification Numbers . (Group 9015-20.) If the sensor identification number is not known, the sensor can be programmed using the JDG10928 SmartWave ™ Advanced Maintenance Tool. See TPM—Programming Sensors with SmartWave® Advanced Maintenance Tool . (Group 9015-20.) Park the machine on firm, level ground. [2] - Prepare Machine for Maintenance . (Group 0001.) [3] CAUTION: Prevent possible injury from unexpected machine movement. Install wheel chocks at front and rear of at least one other wheel when raising a wheel off the ground. Install heavy duty wheel chocks under one or more of the wheels not being removed. Heavy Duty Wheel Chock JT07372 Used to block the wheels during repair to prevent machine movement. [4] -

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Section 01 page 1

TM12408-REPAIR TECHNICAL MANUAL

Section 01 - WHEELS

Group 0100: Removal and Installation

LEGEND: 1 Cap Screw and Washer (32 used)

Cap Screw and Washer Loosen cap screws (1) one full turn. [5] CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device. Item

Measurement

Specification

370E Articulated Dump Truck

Weight

30 112 kg 66 386 lb.

410E Articulated Dump Truck

Weight

31 450 kg 69 335 lb.

460E Articulated Dump Truck

Weight

31 822 kg 70 155 lb.

Raise wheel being removed off the floor using a (20-ton) service jack under axle housing. Support axle housing with a 18-t (20ton) floor stand. 18-t (20-ton) Service Jack Used under an axle housing to raise wheel being removed off the floor. 18-t (20-ton) Floor Stand D01182AA To support axle housing when removing a wheel. [6] -

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Section 01 page 2

TM12408-REPAIR TECHNICAL MANUAL

Section 01 - WHEELS

Group 0100: Removal and Installation

LEGEND: 2

Wheel Lift

Wheel Lift Attach wheel lift (2) to wheel. Secure tire with safety chain. Item

Measurement

Specification

Tire and Rim

Weight (approximate)

771 kg 1700 lb.

Wheel and Axle Lift JT05726 To remove and install a wheel on the machine. [7] - Remove cap screws and washers. Remove wheel. [8] - Clean cap screw threads with solvent and wipe until dry. Clean mating surfaces of cap screws, washers, rim, and hub. [9] IMPORTANT: Check tire diameter before installing wheel. Difference in tire diameter must be within 2% across axles and between axles. Excessive differences in tire rollout will cause drive train malfunctions. IMPORTANT: Check torque on cap screws after 5 hours. Tighten as necessary. Check torque every 50 hours thereafter. Install wheel. Install washers and cap screws. Tighten cap screws to specification in a crisscross pattern. Item

Measurement

Specification

Wheel Cap Screw

Torque

675 N·m 500 lb.-ft.

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

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Section 01 page 3

TM12408-REPAIR TECHNICAL MANUAL

Section 01 - WHEELS

Group 0100: Removal and Installation

IMPORTANT: Avoid tire pressure sensor damage on machines equipped with the tire pressure monitoring (TPM) system. When removing tire from rim, always follow these instructions, along with the instructions in TPM—Tire Pressure Sensor Remove and Install. (Group 9015-20.) IMPORTANT: Avoid damage to tire pressure monitoring (TPM) system, if equipped. TPM sensor may not function if liquids are present inside tire. Do not expose TPM sensor to liquids (rust inhibitors, calcium chloride, etc.).

Explosive Single Piece Rim and Tire

Explosive Multi-Piece Rim and Tire <- Go to Section TOC

Section 01 page 4

TM12408-REPAIR TECHNICAL MANUAL

AXLES AND SUSPENSION SYSTEMS

(g) by Belgreen v2.0

Always maintain the correct tire pressure. Do not inflate the tires above the recommended pressure. Never weld or heat a wheel and tire assembly, as heating can increase air pressure and result in tire explosion. Welding can also structurally weaken or deform the wheel. For initial inflation, always use a clip-on chuck and extension hose long enough to allow you to stand to one side and NOT in front of, or over, the tire assembly. Inflate in a safety cage if available. Use safety chains, cables, or equivalent restraining devices during inflation. CAUTION: Stand clear when using a cable or chain sling. These devices can snap and lash out, causing serious injury or death. Check tire and wheel assemblies for low pressure, cuts, bubbles, damaged rim components, or missing lug bolts and nuts. Check that the tire size exactly matches the rim size. Improperly-sized tires may not perform as intended. Wheels may contain multi-piece rim components. Inspect all rim components and replace those that are cracked, worn, damaged, or severely rusted. Use only rim components designed to work with one another. Do not combine rim components from different rim types or rim manufacturers. Incorrectly assembled or mismatched rim components can fly apart with explosive force.

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Section 02 page 5

TM12408-REPAIR TECHNICAL MANUAL

TM12408-REPAIR TECHNICAL MANUAL

(g) by Belgreen v2.5

Section 02 - AXLES AND SUSPENSION SYSTEMS Table of contents Group 0200 - Removal and Installation ................................................................................................ 1 TeamMate V 1500 Series Axle .............................................................................................................. 1 Front Axle Remove and Install .............................................................................................................. 2 Middle or Rear Axle Remove and Install ............................................................................................... 8 Group 0225 - Input Drive Shafts and U-Joints ................................................................................... 13 Transmission-to-Front Axle Drive Shaft or Transmission-to-Oscillation Joint Drive Shaft Remove and Install ........................................................................................................................................... 13 Oscillation Joint Drive Shaft Remove and Install ................................................................................. 16 Park Brake-to-Middle Axle Drive Shaft Remove and Install ................................................................ 20 Middle Axle-to-Rear Axle Drive Shaft Remove and Install .................................................................. 22 Group 0242 - Axle Mounting Parts ...................................................................................................... 24 Front Suspension Strut Remove and Install ........................................................................................ 24 Front Suspension Accumulator Remove and Install ............................................................................ 25 Axle Links and Stabilizers Remove and Install .................................................................................... 26 Axle Link, Stabilizer, and Strut Bushing Replace ................................................................................ 28 Front Axle Pivot Disassemble and Assemble ...................................................................................... 30 Walking Beam Remove and Install ..................................................................................................... 35 Walking Beam Bushing Remove and Install ....................................................................................... 40 Middle and Rear Axle Rubber Mount Remove and Install ................................................................... 42 Strain Gauge Remove and Install ....................................................................................................... 44 Group 0250 - Axle Shaft, Bearings, and Reduction Gears ............................................................... 51 TeamMate V 1500 Series Axle ............................................................................................................ 51 Group 0260 - Hydraulic System ........................................................................................................... 52 Front Axle Pump Remove and Install .................................................................................................. 52 Rear Axle Pump Remove and Install ................................................................................................... 52 Front Axle Cooling Manifold Remove and Install ................................................................................. 54 Middle Axle Cooling Manifold Remove and Install .............................................................................. 56 Rear Axle Cooling Manifold Remove and Install ................................................................................. 58 Comfort Ride Control Valve Remove and Install ................................................................................. 60 Strut Accumulator Remove and Install ............................................................................................... 62

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TM12408-REPAIR TECHNICAL MANUAL

Section 02 - AXLES AND SUSPENSION SYSTEMS

Group 0200: Removal and Installation

Group 0200 - Removal and Installation TeamMate V 1500 Series Axle This machine uses John Deere TeamMate ™ V axles. To identify the model of axle, see Axle Identification . (CTM115319.) For repair on John Deere TeamMate V axles, see the following: TeamMate V 1500 Series Axle Rebuild Stand . (CTM115319.) Yoke List . (CTM115319.) Input Shaft Assembly List . (CTM115319.) Output Shaft Assembly List . (CTM115319.) Input Housing with Drop Assembly List . (CTM115319.) Final Drive Assembly List . (CTM115319.) Brake Group List . (CTM115319.) Differential Gear Case List . (CTM115319.) Differential Lock Assembly List . (CTM115319.)

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Section 02 page 1

TM12408-REPAIR TECHNICAL MANUAL

Section 02 - AXLES AND SUSPENSION SYSTEMS

Group 0200: Removal and Installation

Front Axle Remove and Install Specifications SPECIFICATIONS 370E Operating Weight (approximate)

30 782 kg 67 862 lb.

410E Operating Weight (approximate)

31 853 kg 70 224 lb.

460E Operating Weight (approximate)

32 216 kg 71 024 lb.

Panhard Link and Panhard Link Mounting Bracket Weight (approximate)

96 kg 211 lb.

Axle Weight (approximate)

1630 kg 3594 lb.

A-Frame Mounting Cap Screw Torque

920 N·m 679 lb.-ft.

Panhard Link Mounting Bracket Cap Screw Torque

920 N·m 679 lb.-ft.

Service Equipment and Tools SERVICE EQUIPMENT AND TOOLS JT07372 Heavy Duty Wheel Chock

[1] - Park and prepare machine for service safely. See Prepare Machine for Maintenance . (Group 0001.) [2] - Install JT07372 Heavy Duty Wheel Chocks in front and behind middle and rear wheels. Heavy Duty Wheel Chock JT07372 Used to block the wheels during repair to prevent machine movement. [3] CAUTION: Prevent possible crushing injury from heavy component. Weight may increase significantly due to buildup of mud or debris. Remove debris before proceeding with task. Use appropriate lifting device. Raise front of machine and install floor stands underneath front frame. Item

Measurement

Specification

370E Operating Weight

Weight (approximate)

30 782 kg 67 862 lb.

410E Operating Weight

Weight (approximate)

460E Operating Weight

Weight (approximate)

31 853 kg 70 224 lb. 32 216 kg 71 024 lb.

[4] CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device. Remove front fenders. See Fender Remove and Install . (Group 1910.) [5] - Disconnect drive shaft at front axle. See Transmission-to-Front Axle Drive Shaft or Transmission-to-Oscillation Joint Drive Shaft Remove and Install . (Group 0225.) <- Go to Section TOC

Section 02 page 2

TM12408-REPAIR TECHNICAL MANUAL

Section 02 - AXLES AND SUSPENSION SYSTEMS

Group 0200: Removal and Installation

[6] - Remove front wheels. See Wheel Remove and Install . (Group 0110.) [7] - Support axle using appropriate lifting device. [8] - Remove lower mounting bolts at front struts. See Front Suspension Strut Remove and Install . (Group 0242.) [9] - Tag and disconnect hoses (1—5). Close all openings using caps and plugs. LEGEND: 1 Axle-to-Axle Filter Supply Hose 2 Brake Hose 3 Axle Filter-to-Axle Return Hose 4 Axle Coolant Pump-to-Axle Hose 5 Breather Hose

Hydraulic Hoses [10] CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device. LEGEND: 6 Cap Screw (9 used) 7 Panhard Link Mounting Bracket 8 Panhard Link

Panhard Link Mounting Bracket Support panhard link (8) and panhard link mounting bracket (7) with appropriate lifting device. Item

Measurement

Specification

Panhard Link and Panhard Link Mounting Bracket

Weight (approximate)

96 kg 211 lb.

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Section 02 page 3

TM12408-REPAIR TECHNICAL MANUAL

Section 02 - AXLES AND SUSPENSION SYSTEMS

Group 0200: Removal and Installation

[11] - Remove cap screws (6). Secure panhard link and panhard link mounting bracket in position. [12] LEGEND: 9 10

Front Axle A-Frame

A-Frame Lower front axle (9) onto support stands until A-frame (10) support beams are horizontal. [13] -

Axle Mounting Cap Screws LEGEND: <- Go to Section TOC

Section 02 page 4

TM12408-REPAIR TECHNICAL MANUAL

Section 02 - AXLES AND SUSPENSION SYSTEMS

Group 0200: Removal and Installation

11 Mounting Hole (7 used) 12 A-Frame Mounting Cap Screw (7 used) 14 A-Frame 15 Front Axle Remove mounting cap screws (12) from the mounting holes (11). [14] CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device. Lower axle (15) to the ground. Item

Measurement

Specification

Axle

Weight (approximate)

1630 kg 3594 lb.

[15] - Repair or replace axle components as necessary. See TeamMate™ V 1500 Series Axle . (Group 0200.) [16] CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device.

Axle Mounting Cap Screws LEGEND: <- Go to Section TOC

Section 02 page 5

TM12408-REPAIR TECHNICAL MANUAL

Section 02 - AXLES AND SUSPENSION SYSTEMS

Group 0200: Removal and Installation

11 Mounting Hole (7 used) 12 A-Frame Mounting Cap Screw (7 used) 14 A-Frame 15 Front Axle Raise the front axle (15) to the mounting surface on the A-frame (14). Apply clean oil to cap screws (12). Install cap screws and tighten to specification. Item

Measurement

Specification

A-Frame Mounting Cap Screw

Torque

920 N·m 679 lb.-ft.

[17] CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device. LEGEND: 6 Cap Screw (9 used) 7 Panhard Link Mounting Bracket 8 Panhard Link

Panhard Link Mounting Bracket Raise the front axle and A-frame assembly to line up the panhard link mounting bracket (7) location. [18] - Apply clean oil to remaining cap screws (6). Install cap screws and tighten to specification. Item

Measurement

Specification

Panhard Link Mounting Bracket Cap Screw

Torque

920 N·m 679 lb.-ft.

[19] -

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Section 02 page 6

TM12408-REPAIR TECHNICAL MANUAL

Section 02 - AXLES AND SUSPENSION SYSTEMS

Group 0200: Removal and Installation

LEGEND: 1 Axle-to-Axle Filter Supply Hose 2 Brake Hose 3 Axle Filter-to-Axle Return Hose 4 Axle Coolant Pump-to-Axle Hose 5 Breather Hose

Hydraulic Hoses Connect hoses (1—5). [20] - Install lower mounting bolts at front struts. See Front Suspension Strut Remove and Install . (Group 0242.) [21] - Install front wheels. Wheel Remove and Install . (Group 0110.) [22] - Connect drive shaft. See Transmission-to-Front Axle Drive Shaft or Transmission-to-Oscillation Joint Drive Shaft Remove and Install . (Group 0225.) [23] - Install front fenders. See Fender Remove and Install . (Group 1910.) [24] - Bleed service brake. See Bleed Service Brake . (Group 1060.)

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Section 02 page 7

TM12408-REPAIR TECHNICAL MANUAL

Section 02 - AXLES AND SUSPENSION SYSTEMS

Group 0200: Removal and Installation

Middle or Rear Axle Remove and Install Specifications SPECIFICATIONS 370E Operating Weight (approximate)

30 782 kg 67 862 lb.

410E Operating Weight (approximate)

31 853 kg 70 224 lb.

460E Operating Weight (approximate)

32 216 kg 71 024 lb.

Rear Axle Weight (approximate)

1630 kg 3594 lb.

Middle Axle Weight (approximate)

1643 kg 3623 lb.

Panhard Link and Panhard Link Mounting Bracket Weight (approximate)

96 kg 211 lb.

Mounting Block Cap Screw Torque

620 N·m 457 ft. lb.

Panhard Link Mounting Bracket Cap Screw Torque

920 N·m 679 lb.-ft.

Service Equipment and Tools SERVICE EQUIPMENT AND TOOLS JT07372 Heavy Duty Wheel Chock

[1] - Park and prepare machine for service safely. See Prepare Machine for Maintenance . (Group 0001.) [2] - Install JT07372 Heavy Duty Wheel Chocks in front and behind both front tires. Heavy Duty Wheel Chock JT07372 Used to block the wheels during repair to prevent machine movement. [3] CAUTION: Prevent possible crushing injury from heavy component. Weight may increase significantly due to buildup of mud or debris. Remove debris before proceeding with task. Use appropriate lifting device. Raise rear of machine and install floor stands underneath rear frame as shown.

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Section 02 page 8

TM12408-REPAIR TECHNICAL MANUAL

Section 02 - AXLES AND SUSPENSION SYSTEMS

Group 0200: Removal and Installation

Support Rear Frame Item

Measurement

Specification

370E Operating Weight

Weight (approximate)

30 782 kg

410E Operating Weight

Weight (approximate)

67 862 lb. 31 853 kg 70 224 lb. 460E Operating Weight

Weight (approximate)

32 216 kg 71 024 lb.

[4] - Disconnect drive shaft at axle to be removed. See Park Brake-to-Middle Axle Drive Shaft Remove and Install or see Middle Axle-to-Rear Axle Drive Shaft Remove and Install . (Group 0225.) [5] CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device. Remove wheels at axle to be removed. See Wheel Remove and Install . (Group 0110.) [6] - Support axle using appropriate lifting device and stands. [7] →NOTE: Rear axle shown, middle axle procedure similar.

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Section 02 page 9

TM12408-REPAIR TECHNICAL MANUAL

Section 02 - AXLES AND SUSPENSION SYSTEMS

Group 0200: Removal and Installation

LEGEND: 1 Axle-to-Filter Hose 2 Filter-to-Axle Return Hose 3 Axle-to-Pump Hose 4 Axle Breather Hose 5 Cap Screw (2 used) 6 Upper Suspension Link

Axle Hoses Tag and disconnect hoses (1—4). Close all openings using caps and plugs. [8] - Secure upper suspension link (6) in attached position. Remove cap screws (5). [9] CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device. LEGEND: 7 Panhard Link Mounting Bracket 8 Cap Screw (9 used) 9 Panhard Link 10 Rear Axle 11 Cap Screw (8 used) 12 Lower Suspension Link (2 used) 13 Cap Screw (8 used)

Rear Axle Secure panhard link (9) and panhard link mounting bracket (7) in attached position. Remove cap screws (8). [10] - See Axle Link, Stabilizer, and Strut Bushing Replace . (Group 0242.) Remove cap screws (11) from both lower suspension links (12). Remove lower suspension links. [11] - Remove mounting block cap screws (13). [12] - Using appropriate lifting device, lower rear axle (10) to the ground. Item

Measurement

Specification

Rear Axle

Weight (approximate)

1630 kg 3594 lb.

Middle Axle

Weight (approximate)

1643 kg 3623 lb.

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Section 02 page 10

TM12408-REPAIR TECHNICAL MANUAL

Section 02 - AXLES AND SUSPENSION SYSTEMS

Group 0200: Removal and Installation

[13] - Repair or replace axle components as necessary. See TeamMate™ V 1500 Series Axle . (Group 0200.) [14] CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device. LEGEND: 7 Panhard Link Mounting Bracket 8 Cap Screw (9 used) 9 Panhard Link 10 Rear Axle 11 Cap Screw (8 used) 12 Lower Suspension Link (2 used) 13 Cap Screw (8 used)

Rear Axle Using appropriate lifting device, lift rear axle (10) into machine. [15] - Install mounting block cap screws (13). Tighten to specification. Item

Measurement

Specification

Mounting Block Cap Screw

Torque

620 N·m 457 ft. lb.

[16] - Install lower suspension links (12) using cap screws (11). See Axle Links and Stabilizers Remove and Install . (Group 0242.) [17] - Apply clean oil to cap screws (8). Secure panhard link mounting bracket (7) with cap screws. Tighten to specification Item

Measurement

Specification

Panhard Link Mounting Bracket Cap Screw

Torque

920 N·m 679 lb.-ft.

. [18] LEGEND: 1 Axle-to-Filter Hose 2 Filter-to-Axle Return Hose 3 Axle-to-Pump Hose 4 Axle Breather Hose 5 Cap Screw (2 used) 6 Upper Suspension Link

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Section 02 page 11

TM12408-REPAIR TECHNICAL MANUAL

Section 02 - AXLES AND SUSPENSION SYSTEMS

Group 0225: Input Drive Shafts and U-Joints

Axle Hoses Connect hoses (1—4). [19] - Secure upper suspension link (6) with cap screws (5). [20] - Install wheels. See Wheel Remove and Install . (Group 0110.) [21] - Connect drive shaft. See Park Brake-to-Middle Axle Drive Shaft Remove and Install or see Middle Axle-to-Rear Axle Drive Shaft Remove and Install . (Group 0225.) [22] - Lower machine to the ground. [23] - Bleed service brake. See Bleed Service Brake . (Group 1060.)

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Section 02 page 12

TM12408-REPAIR TECHNICAL MANUAL

Section 02 - AXLES AND SUSPENSION SYSTEMS

Group 0225: Input Drive Shafts and U-Joints

Group 0225 - Input Drive Shafts and U-Joints Transmission-to-Front Axle Drive Shaft or Transmission-to-Oscillation Joint Drive Shaft Remove and Install Specifications SPECIFICATIONS Transmission-to-Front Axle Drive Shaft Weight (approximate)

24 kg 52 lb.

Transmission-to-Oscillation Joint Drive Shaft Weight (approximate)

41 kg 89 lb.

Transmission-to-Oscillation Joint Drive Shaft Mounting Cap Screw Torque

140 N·m 103 lb.-ft.

Transmission-to-Front Axle Drive Shaft Mounting Cap Screw Torque

140 N·m 103 lb.-ft.

Service Equipment and Tools SERVICE EQUIPMENT AND TOOLS JT07372 Heavy Duty Wheel Chock

[1] - Park and prepare machine for maintenance safely. Prepare Machine for Maintenance . (Group 0001.) [2] - Install JT07372 Heavy Duty Wheel Chocks in front of and behind middle and rear wheels. Heavy Duty Wheel Chock JT07372 Used to block the wheels during repair to prevent machine movement. [3] LEGEND: 1 Cap Screw (8 used) 2 End Cap (4 used) 3 Transmission-to-Front Axle Drive Shaft

Transmission-to-Front Axle Drive Shaft Remove cap screws (1) and end caps (2). [4] CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device. Remove transmission-to-front axle drive shaft. <- Go to Section TOC

Section 02 page 13

TM12408-REPAIR TECHNICAL MANUAL

Section 02 - AXLES AND SUSPENSION SYSTEMS

Group 0225: Input Drive Shafts and U-Joints

Item

Measurement

Specification

Transmission-to-Front Axle Drive Shaft

Weight (approximate)

24 kg 52 lb.

[5] LEGEND: 4 Cap Screw (8 used) 5 End Cap (4 used) 6 Transmission-to-Oscillation Joint Drive Shaft

Transmission-to-Oscillation Joint Drive Shaft Remove cap screws (4) and end caps (5). [6] CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device. Remove transmission-to-oscillation joint drive shaft (6). Item

Measurement

Specification

Transmission-to-Oscillation Joint Drive Shaft

Weight (approximate)

41 kg 89 lb.

[7] IMPORTANT: Avoid damage to drive shaft during installation. Assemble drive shaft so universal joints are fully seated in yokes. Install transmission-to-oscillation drive shaft, secure with end caps and cap screws. Item

Measurement

Specification

Transmission-to-Oscillation Joint Drive Shaft Mounting Cap Screw

Torque

140 N·m 103 lb.-ft.

[8] IMPORTANT: Avoid damage to drive shaft during installation. Assemble drive shaft so universal joints are fully seated in yokes. Install transmission-to-front axle drive shaft, secure with end caps and cap screws. Item

Measurement

Specification

Transmission-to-Front Axle Drive Shaft Mounting Cap Screw

Torque

140 N·m

<- Go to Section TOC

Section 02 page 14

TM12408-REPAIR TECHNICAL MANUAL

Section 02 - AXLES AND SUSPENSION SYSTEMS

Group 0225: Input Drive Shafts and U-Joints

Item

Measurement

Specification 103 lb.-ft.

<- Go to Section TOC

Section 02 page 15

TM12408-REPAIR TECHNICAL MANUAL

Section 02 - AXLES AND SUSPENSION SYSTEMS

Group 0225: Input Drive Shafts and U-Joints

Oscillation Joint Drive Shaft Remove and Install Specifications SPECIFICATIONS 40 kg 88 lb.

Oscillation Joint Drive Shaft Weight (approximate)

Service Equipment and Tools SERVICE EQUIPMENT AND TOOLS 12 x 1.75 Cap Screw DFT1187 Bearing Driver

[1] - Park and prepare machine for service safely. See Prepare Machine for Maintenance . (Group 0001.) [2] - Disconnect transmission-to-oscillation joint drive shaft at oscillation joint. See Transmission-to-Front Axle Drive Shaft or Transmission-to-Oscillation Joint Drive Shaft Remove and Install . (Group 0225.) [3] - Remove cap screw (1) and front yoke (2). LEGEND: 1 Cap Screw 2 Front Yoke 3 Lube Fitting 4 Cap Screw (4 used) 5 12 x 1.75 Cap Screw (2 used) 6 Front Bearing Cover

Front Yoke

Front Bearing Cover [4] - Remove lube fitting (3) and bracket. [5] - Remove cap screws (4). [6] - Install 12 x 1.75 cap screws (5) and tighten in sequence to remove front bearing cover (6). Cap Screw 12 x 1.75 Remove front bearing cover <- Go to Section TOC

Section 02 page 16

TM12408-REPAIR TECHNICAL MANUAL

Section 02 - AXLES AND SUSPENSION SYSTEMS

Group 0225: Input Drive Shafts and U-Joints

[7] - Disconnect park brake-to-middle axle drive shaft at the park brake. See Park Brake-to-Middle Axle Drive Shaft Remove and Install . (Group 0225.) [8] - Remove park brake caliper. See Park Brake Caliper Remove and Install . (Group 1111.) [9] - Remove park brake disk. See Park Brake Disk Remove and Install . (Group 1111.) [10] LEGEND: 7 8 9 10 11

Cap Screw Rear Yoke Remote Grease Fitting Cap Screw (8 used) Rear Bearing Cover

Rear Yoke

Rear Bearing Cover Remove cap screw (7) and rear yoke (8). [11] - Remove remote grease fitting (9). [12] - Remove cap screws (10) and rear bearing cover (11). [13] CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device. Item

Measurement

Specification

Oscillation Joint Drive Shaft

Weight (approximate)

40 kg 88 lb.

Remove the oscillation joint shaft rearward from the housing. [14] -

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Section 02 page 17

TM12408-REPAIR TECHNICAL MANUAL

Section 02 - AXLES AND SUSPENSION SYSTEMS

Group 0225: Input Drive Shafts and U-Joints

Oscillation Joint Drive Shaft LEGEND: 11 Rear Bearing Cover 12 Bearing (2 used) 13 Snap Ring 14 Drive Shaft Remove snap ring (13) and rear bearing cover (11). [15] - Remove bearings (12) from drive shaft (14). [16] - Inspect and replace parts as necessary. [17] - Install bearings (12) onto drive shaft. [18] - Install rear bearing cover to drive shaft and secure with snap ring. [19] CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device. Install drive shaft (14) and secure with cap screws (15). Item

Measurement

Specification

Oscillation Joint Drive Shaft

Weight (approximate)

40 kg 88 lb.

LEGEND: 14 15 16

<- Go to Section TOC

Section 02 page 18

Drive Shaft Cap Screw (8 used) Remote Grease Fitting

TM12408-REPAIR TECHNICAL MANUAL

Section 02 - AXLES AND SUSPENSION SYSTEMS

Group 0225: Input Drive Shafts and U-Joints

Drive Shaft Installation [20] - Install remote grease fitting (16). [21] LEGEND: 17 18

Rear Yoke Cap Screw

Rear Yoke Install rear yoke (17) and secure with cap screw (18). Tighten cap screw to specification. Item

Measurement

Specification

Rear Yoke Cap Screw

Torque

435 N·m 320 lb.-ft.

[22] - Install park brake disk. See Park Brake Disk Remove and Install . (Group 1111). [23] - Install park brake caliper. See Park Brake Caliper Remove and Install . (Group 1111). [24] - Connect park brake-to-middle axle drive shaft at the park brake. See Park Brake-to-Middle Axle Drive Shaft Remove and Install . (Group 0225.) [25] LEGEND: 19 20 21 22 23

Front Bearing Cover Cap Screw (4 used) Front Yoke Cap Screw Remote Grease Fitting

Front Yoke Install front bearing cover (19) and secure with cap screws (20). [26] - Install the front yoke (21) and install cap screw (22). [27] - Install the remote grease fitting (23). [28] - Install the transmission-to-oscillation joint at the oscillation joint. See Transmission-to-Front Axle Drive Shaft or Transmission-to-Oscillation Joint Drive Shaft Remove and Install . (Group 0225). [29] - Grease the oscillation joint shaft. Lubricate Articulation Joint, Oscillation Joint, and Through Drive Bearing . (Operator’s Manual.)

<- Go to Section TOC

Section 02 page 19

TM12408-REPAIR TECHNICAL MANUAL

Section 02 - AXLES AND SUSPENSION SYSTEMS

Group 0225: Input Drive Shafts and U-Joints

Park Brake-to-Middle Axle Drive Shaft Remove and Install Specifications SPECIFICATIONS Park Brake-to-Middle Axle Drive Shaft Weight (approximate)

60 kg 133 lb.

Park Brake-to-Middle Axle Drive Shaft Mounting Cap Screw Torque

140 N·m 103 lb.-ft.

Service Equipment and Tools SERVICE EQUIPMENT AND TOOLS JT07372 Heavy Duty Wheel Chock

[1] - Park and prepare machine for service safely. See Prepare Machine for Maintenance . (Group 0001.) [2] - Install JT07372 Heavy Duty Wheel Chocks in front of and behind middle and rear wheels. Heavy Duty Wheel Chock JT07372 Used to block the wheels during repair to prevent machine movement. [3] LEGEND: 1 Front Cap Screw (4 used) 2 Drive Shaft Assembly 3 Rear Cap Screw (4 used) 4 Universal Joint (2 used)

Park Brake-to-Middle Axle Drive Shaft Remove front cap screws (1) and secure drive shaft assembly (2). [4] CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device. Remove rear cap screws (3) and remove drive shaft with appropriate lifting device. Item

Measurement

Specification

Park Brake-to-Middle Axle Drive Shaft

Weight (approximate)

60 kg 133 lb.

[5] - Inspect drive shaft and universal joints (4). Replace parts as necessary. [6] IMPORTANT: Avoid damage to drive shaft during installation. Assemble drive shaft so universal joints are fully seated in yokes.

<- Go to Section TOC

Section 02 page 20

TM12408-REPAIR TECHNICAL MANUAL

Section 02 - AXLES AND SUSPENSION SYSTEMS

Group 0225: Input Drive Shafts and U-Joints

Install drive shaft and cap screws. Torque cap screws to specification. Item

Measurement

Specification

Park Brake-to-Middle Axle Drive Shaft Mounting Cap Screw

Torque

140 N·m 103 lb.-ft.

<- Go to Section TOC

Section 02 page 21

TM12408-REPAIR TECHNICAL MANUAL

Section 02 - AXLES AND SUSPENSION SYSTEMS

Group 0225: Input Drive Shafts and U-Joints

Middle Axle-to-Rear Axle Drive Shaft Remove and Install Specifications SPECIFICATIONS Middle Axle-to-Rear Axle Drive Shaft Weight (approximate)

180 kg 396 lb.

Middle Axle-to-Rear Axle Drive Shaft Mounting Cap Screw Torque

140 N·m 103 lb.-ft.

Service Equipment and Tools SERVICE EQUIPMENT AND TOOLS JT07372 Heavy Duty Wheel Chock

[1] - Park and prepare machine for service safely. See Prepare Machine for Maintenance . (Group 0001.) [2] - Install JT07372 Heavy Duty Wheel Chocks in front of and behind middle and rear wheels. Heavy Duty Wheel Chock JT07372 Used to block the wheels during repair to prevent machine movement. [3] LEGEND: 1 Front Cap Screw (4 used) 2 Drive Shaft Assembly 3 Rear Cap Screw (4 used) 4 Universal Joint (2 used)

Middle Axle-to-Rear Axle Drive Shaft Remove and Install Remove front cap screws (1) and secure drive shaft assembly (2). [4] CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device. Remove rear cap screws (3) and remove drive shaft with appropriate lifting device. Item

Measurement

Specification

Middle Axle-to-Rear Axle Drive Shaft

Weight (approximate)

180 kg 396 lb.

[5] - Inspect drive shaft and universal joints (4). Replace parts as necessary. [6] -

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Section 02 page 22

TM12408-REPAIR TECHNICAL MANUAL

Section 02 - AXLES AND SUSPENSION SYSTEMS

Group 0242: Axle Mounting Parts

IMPORTANT: Avoid damage to drive shaft during installation. Assemble drive shaft so universal joints are fulled seated in yokes. Install drive shaft and cap screws. Torque cap screws to specification. Item

Measurement

Specification

Middle Axle-to-Rear Axle Drive Shaft Mounting Cap Screw

Torque

140 N·m 103 lb.-ft.

<- Go to Section TOC

Section 02 page 23

TM12408-REPAIR TECHNICAL MANUAL

Section 02 - AXLES AND SUSPENSION SYSTEMS

Group 0242: Axle Mounting Parts

Group 0242 - Axle Mounting Parts Front Suspension Strut Remove and Install Specifications SPECIFICATIONS Strut Weight (approximate)

88 kg 194 lb.

Mounting Cap Screw Torque

1200 N·m 885 lb.-ft.

[1] - Park and prepare machine for service safely. See Prepare Machine for Maintenance . (Group 0001.) [2] - Remove fender. See Fender Remove and Install . (Group 1910.) [3] - Fully lower front suspension struts. [4] LEGEND: 1 Mounting Cap Screw (4 used) 2 Nut (4 used) 3 Strut-to-Manifold Hose 4 Strut Linkage 5 Strut 6 Strut-to-Accumulator Hose

Suspension Strut Tag and disconnect strut-to-manifold hose (3) and strut-to-accumulator hose (6). Close all openings using caps and plugs. [5] - Disconnect strut linkage (4). [6] CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device. Secure strut (5) with appropriate lifting device. Item

Measurement

Specification

Strut

Weight (approximate)

88 kg 194 lb.

. [7] - Secure nuts (2) and remove mounting cap screws (1). [8] - Using appropriate lifting device, remove strut. [9] - Repair or replace strut as necessary.

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Section 02 page 24

TM12408-REPAIR TECHNICAL MANUAL

Section 02 - AXLES AND SUSPENSION SYSTEMS

Group 0242: Axle Mounting Parts

[10] - Using appropriate lifting device, install strut. [11] - Install mounting cap screws and nuts. Tighten to specification. Item

Measurement

Specification

Mounting Cap Screw

Torque

1200 N·m 885 lb.-ft.

[12] - Connect strut linkage. [13] - Connect strut-to-manifold hose and strut to accumulator hose. [14] - Install fender. See Fender Remove and Install . (Group 1910.)

Front Suspension Accumulator Remove and Install See Strut Accumulator Remove and Install . (Group 0260.)

<- Go to Section TOC

Section 02 page 25

TM12408-REPAIR TECHNICAL MANUAL

Section 02 - AXLES AND SUSPENSION SYSTEMS

Group 0242: Axle Mounting Parts

Axle Links and Stabilizers Remove and Install Specifications SPECIFICATIONS Upper and Lower Axle Link Weight (approximate)

60 kg 132 lb.

Axle Panhard Link Weight (approximate)

80 kg 176 lb.

Service Equipment and Tools SERVICE EQUIPMENT AND TOOLS JT07372 Heavy Duty Wheel Chock

Axle Link and Stabilizers LEGEND: 1 2 3 4 5 6

Middle Axle Upper Link Rear Axle Upper Link Middle Axle Lower Link (2 used) Rear Axle Lower Link (2 used) Middle Axle Panhard Link Rear Axle Panhard Link

[1] - Park and prepare machine for service safely. See Prepare Machine for Maintenance . (Group 0001.) [2] CAUTION: Prevent possible injury from unexpected machine movement. Install wheel chocks at front and rear of one or more tires. Install JT07372 Heavy Duty Wheel Chocks in front of and behind one or more wheels. Heavy Duty Wheel Chock JT07372 <- Go to Section TOC

Section 02 page 26

TM12408-REPAIR TECHNICAL MANUAL

Section 02 - AXLES AND SUSPENSION SYSTEMS

Group 0242: Axle Mounting Parts

Used to block the wheels during repair to prevent machine movement. [3] CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device.

Front Panhard Link LEGEND: 7 Front Axle Panhard Link Remove cap screw, nut, and mounting components as necessary. Item

Measurement

Specification

Upper and Lower Axle Link

Weight (approximate)

60 kg 132 lb.

Axle Panhard Link

Weight (approximate)

80 kg 176 lb.

[4] - Inspect parts and replace as necessary. [5] - Replace bushings, if necessary. See Axle Link, Stabilizer, and Strut Bushing Replace . (Group 0242.) [6] - Install mounting components, cap screws and nuts.

<- Go to Section TOC

Section 02 page 27

TM12408-REPAIR TECHNICAL MANUAL

Section 02 - AXLES AND SUSPENSION SYSTEMS

Group 0242: Axle Mounting Parts

Axle Link, Stabilizer, and Strut Bushing Replace Service Equipment and Tools SERVICE EQUIPMENT AND TOOLS DFT1196 Bushing Driver

[1] - Park and prepare machine for service safely. See Prepare Machine for Maintenance . (Group 0001.) [2] - Remove axle link, panhard link, or strut to be repaired. See Axle Links and Stabilizers Remove and Install or see Front Suspension Strut Remove and Install . (Group 0242.) [3] - To remove bushings use DFT1196 Bushing Driver. [4] - Apply a suitable assembly lubricant (if required) to outside diameter of bushing and inside diameter of link or strut eye. [5] - Bushings need to be pressed into bores within 2 degrees as illustrated. [6] -

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Section 02 page 28

TM12408-REPAIR TECHNICAL MANUAL

Section 02 - AXLES AND SUSPENSION SYSTEMS

Group 0242: Axle Mounting Parts

Bushing Angles LEGEND: 1 Front Axle Strut 2 Axle End 3 Frame End 4 Top Axle Link 5 Bottom Axle Link 6 Front Panhard Link 7 Middle Panhard Link 8 Rear Panhard Link Ensure proper bore alignment by holding bore in line with press ram. [7] -

DFT1196 In Use Install bushings using DFT1196 Bushing Driver. Press bushings into bore until centered. Bushing Driver DFT1196 Install bushings

<- Go to Section TOC

Section 02 page 29

TM12408-REPAIR TECHNICAL MANUAL

Section 02 - AXLES AND SUSPENSION SYSTEMS

Group 0242: Axle Mounting Parts

Front Axle Pivot Disassemble and Assemble Specifications SPECIFICATIONS A-Frame Arm Weight (approximate)

85 kg 187 lb.

A-Frame Pivot Weight (approximate)

70 kg 154 lb.

A-Frame Pivot Cap Screw Torque

2130 N·m 1571 lb.-ft.

A-Frame Arm Mounting Cap Screw Torque

1070 N·m 789 lb.-ft.

Service Equipment and Tools SERVICE EQUIPMENT AND TOOLS JT07372 Heavy Duty Wheel Chock DFT1200 Bushing Driver

[1] - Park and prepare machine for service safely. See Prepare Machine for Maintenance . (Group 0001). [2] - Install wheel chocks in front and behind both front tires to avoid axle shift. Heavy Duty Wheel Chock JT07372 Used to block the wheels during repair to prevent machine movement. [3] LEGEND: 1 Cap Screw (8 used) 2 Cap Screw (8 used) 3 A-Frame Arm (2 used)

A-Frame Arm Loosen cap screws (1) and cap screws (2) at one of the A-frame arms (3). [4] CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device. Remove cap screws at the opposing A-frame arm and remove A-frame arm. Item

Measurement

Specification

A-Frame Arm

Weight (approximate)

85 kg 187 lb.

[5] -

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Section 02 page 30

TM12408-REPAIR TECHNICAL MANUAL

Section 02 - AXLES AND SUSPENSION SYSTEMS

Group 0242: Axle Mounting Parts

CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device. Remove remaining A-frame arm where original cap screws were loosened. Item

Measurement

Specification

A-Frame Arm

Weight (approximate)

85 kg 187 lb.

[6] LEGEND: 4 5 6

A-Frame Pivot Nut Cap Screw

A-Frame Pivot Secure nut (5) and remove cap screw (6). [7] CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device. Remove A-frame pivot (4). Item

Measurement

Specification

A-Frame Pivot

Weight (approximate)

70 kg 154 lb.

[8] -

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Section 02 page 31

TM12408-REPAIR TECHNICAL MANUAL

Section 02 - AXLES AND SUSPENSION SYSTEMS

Group 0242: Axle Mounting Parts

Axle Pivot Bushing LEGEND: 7 8 Remove pin (7) from bushing (8).

Pin Bushing

[9] - Remove bushing from A-frame pivot. [10] - Repair or replace parts as necessary. [11] -

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Section 02 page 32

TM12408-REPAIR TECHNICAL MANUAL

Section 02 - AXLES AND SUSPENSION SYSTEMS

Group 0242: Axle Mounting Parts

Pivot Bushing Align Press bushing into A-frame pivot using DFT1200 Bushing Driver . Verify protruding edge of bushing matches opposing side. Bushing Driver DFT1200 Install bushings in pivot. [12] - Press pin into the bushing. [13] CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device. LEGEND: 9 10 11

A-Frame Pivot Nut Cap Screw

A-Frame Pivot Install A-frame pivot (9) into mounting location. Item

Measurement

Specification

A-Frame Pivot

Weight (approximate)

70 kg

<- Go to Section TOC

Section 02 page 33

TM12408-REPAIR TECHNICAL MANUAL

Section 02 - AXLES AND SUSPENSION SYSTEMS Item

Group 0242: Axle Mounting Parts

Measurement

Specification 154 lb.

[14] - Install cap screw (11) and nut (10), torque to specification. Item

Measurement

Specification

A-Frame Pivot Cap Screw

Torque

2130 N·m 1570 lb.-ft.

[15] CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device. LEGEND: 11 12 13

A-Frame Arm (2 used) Cap Screw (4 used) Cap Screw (4 used

A-Frame Arm Install A-frame arms (11) and cap screws (12—13), leave cap screws loose during installation. Item

Measurement

Specification

A-Frame Arm

Weight (approximate)

85 kg 187 lb.

[16] - After both A-frame arms and all cap screws are installed, torque cap screws to specification. Item

Measurement

Specification

A-Frame Arm Mounting Cap Screw

Torque

1070 N·m 789 lb.-ft.

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Section 02 page 34

TM12408-REPAIR TECHNICAL MANUAL

Section 02 - AXLES AND SUSPENSION SYSTEMS

Group 0242: Axle Mounting Parts

Walking Beam Remove and Install

Walking Beam Removal LEGEND: 1 2 3 4 5 6 7 8 9 10 11 X28

Suspension Block (2 used) Washer (8 used) Nut (8 used) Pivot Inner Bushing Walking Beam Outer Bushing Tapered Plug Bushing (3 used) Washer (3 used) Cap Screw (3 used) Right Strain Gauge 4-Pin Connector

Specifications SPECIFICATIONS 370E Operating Weight (approximate)

30 782 kg 67 862 lb.

410E Operating Weight (approximate)

31 853 kg 70 224 lb.

460E Operating Weight (approximate)

32 216 kg 71 024 lb.

Middle Axle Weight (approximate)

1643 kg 3623 lb.

Rear Axle Weight (approximate)

1630 kg 3594 lb.

Walking Beam Weight (approximate)

196 kg 432 lb.

Walking Beam Taper Plug Cap Screw Torque

1830 N·m 1350 lb.-ft.

Suspension Block Nut Torque

530 N·m 390 lb.-ft.

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Section 02 page 35

TM12408-REPAIR TECHNICAL MANUAL

Section 02 - AXLES AND SUSPENSION SYSTEMS

Group 0242: Axle Mounting Parts

Service Equipment and Tools SERVICE EQUIPMENT AND TOOLS JT07372 Heavy Duty Wheel Chock DFT1199 Bushing Pusher

[1] - Park and prepare machine for service safely. See Prepare Machine for Maintenance . (Group 0001.) [2] CAUTION: Prevent possible injury from unexpected machine movement. Install wheel chocks at front and rear of one or more wheels. Install JT07372 Heavy Duty Wheel Chocks in front of and behind front tires. Heavy Duty Wheel Chock JT07372 Used to block the wheels during repair to prevent machine movement. [3] - Remove rear wheels. See Wheel Remove and Install . (Group 0100.) [4] CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device. Using appropriate lifting device, raise rear of machine. Support rear frame of machine with suitable floor stands. Item

Measurement

Specification

370E Operating Weight

Weight (approximate)

30 782 kg 67 862 lb.

410E Operating Weight

Weight (approximate)

31 853 kg 70 224 lb.

460E Operating Weight

Weight (approximate)

32 216 kg 71 024 lb.

Support Rear Frame <- Go to Section TOC

Section 02 page 36

TM12408-REPAIR TECHNICAL MANUAL

Section 02 - AXLES AND SUSPENSION SYSTEMS

Group 0242: Axle Mounting Parts

[5] CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device. Attach lifting devices to middle and rear axles. Item

Measurement

Specification

Middle Axle

Weight (approximate)

1643 kg 3623 lb.

Rear Axle

Weight (approximate)

1630 kg 3594 lb.

[6] - Raise rear axles and support with suitable floor stands. [7] - Disconnect right strain gauge 4-pin connector (X28). See Rear Frame Harness (W12) Component Location . (Group 9015-10.) [8] - Remove nuts (3) from rear suspension blocks (1). [9] CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device. Lower middle and rear axles approximately 2.5 cm (1 in.) from walking beam (6) with lifting devices. Support middle and rear axles with suitable floors stands. [10] CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device. Support walking beam with a suitable lifting device. Item

Measurement

Specification

Walking Beam

Weight (approximate)

196 kg 432 lb.

[11] - Remove cap screws (11) from tapered plug (8) and pivot (4). [12] -

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Section 02 page 37

TM12408-REPAIR TECHNICAL MANUAL

Section 02 - AXLES AND SUSPENSION SYSTEMS

Group 0242: Axle Mounting Parts

LEGEND: 12 Single, Centered, Jack Screw Location

Bushing Driver Insert DFT1199 Bushing Pusher in single, centered, jack screw location (12) in tapered plug. Turn bushing pusher clockwise until tapered plug comes off. Bushing Pusher DFT1199 Remove walking beam from frame [13] - Remove walking beam. [14] - Remove outer bushing (7), pivot (4), and inner bushing (5). See Walking Beam Bushing Remove and Install . (Group 0242.) [15] - Replace parts as necessary. [16] - Install inner bushing, pivot, and outer bushing. See Walking Beam Bushing Remove and Install . (Group 0242.) [17] - Install tapered plug. Secure with cap screws (11). [18] CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device. Install walking beam on machine. Item

Measurement

Specification

Walking Beam

Weight (approximate)

196 kg 432 lb.

[19] - Tighten cap screws (11) to specification. Item

Measurement

Specification

Walking Beam Taper Plug Cap Screw

Torque

1830 N·m 1350 lb.-ft.

[20] CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device. <- Go to Section TOC

Section 02 page 38

TM12408-REPAIR TECHNICAL MANUAL

Section 02 - AXLES AND SUSPENSION SYSTEMS

Group 0242: Axle Mounting Parts

Raise axles to walking beam. [21] - Install walking beam to suspension block. Install nuts and tighten to specification. Item

Measurement

Specification

Suspension Block Nut

Torque

530 N·m 390 lb.-ft.

[22] - Connect strain gauge 4-pin connector. See Rear Frame Harness (W12) Component Location . (Group 9015-10.) [23] - Install wheels. See Wheel Remove and Install . (Group 0100.)

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Section 02 page 39

TM12408-REPAIR TECHNICAL MANUAL

Section 02 - AXLES AND SUSPENSION SYSTEMS

Group 0242: Axle Mounting Parts

Walking Beam Bushing Remove and Install Specifications SPECIFICATIONS 3.175 mm 0.125 in.

Bushing Installation Distance (below bushing bore)

Service Equipment and Tools SERVICE EQUIPMENT AND TOOLS DFT1200 Bushing Driver

Other Material OTHER MATERIAL TY24811 U.S. Never-Seez Lubricant

Walking Beam Bushings LEGEND: 1

Bushing (2 used)

[1] - Park and prepare machine for service safely. See Prepare Machine for Maintenance . (Group 0001.) [2] - Remove walking beam from machine. See Walking Beam Remove and Install . (Group 0242.) [3] - Remove bushings (1) by cutting with a hand-held grinder or cutting torch. [4] - Press new bushings into bores using DFT1200 Bushing Driver. Press bushings below edge of bore according to specifications. Bushing Driver <- Go to Section TOC

Section 02 page 40

TM12408-REPAIR TECHNICAL MANUAL

Section 02 - AXLES AND SUSPENSION SYSTEMS

Group 0242: Axle Mounting Parts

DFT1200 Install bushings in walking beam Item

Measurement

Specification

Bushing Installation

Distance (below bushing bore)

3.175 mm 0.125 in.

[5] - Apply TY24811 Never-Seez Lubricant to walking beam pivot shaft and bushing. Number

Name

Use

• TY24811 (us)

Never-Seez Lubricant

Apply to cap screws and mounting area of walking beam.

[6] - Install walking beam. See Walking Beam Remove and Install . (Group 0242.)

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Section 02 page 41

TM12408-REPAIR TECHNICAL MANUAL

Section 02 - AXLES AND SUSPENSION SYSTEMS

Group 0242: Axle Mounting Parts

Middle and Rear Axle Rubber Mount Remove and Install Specifications SPECIFICATIONS 370E Operating Weight (approximate)

30 782 kg 67 862 lb.

410E Operating Weight (approximate)

31 853 kg 70 224 lb.

460E Operating Weight (approximate)

32 216 kg 71 024 lb.

[1] - Park and prepare machine for service safely. See Prepare Machine for Maintenance . (Group 0001.) [2] LEGEND: 1 Nut (4 used) 2 Upper Cap Screw (4 used) 3 Lower Cap Screw (4 used) 4 Rubber Mount

Rear Suspension Rubber Mount Secure nuts (1) and remove upper cap screws (2). [3] CAUTION: Prevent possible crushing injury from heavy component. Weight may increase significantly due to buildup of mud or debris. Remove debris before proceeding with task. Use appropriate lifting device.

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Section 02 page 42

TM12408-REPAIR TECHNICAL MANUAL

Section 02 - AXLES AND SUSPENSION SYSTEMS

Group 0242: Axle Mounting Parts

Support Rear Frame Raise rear of machine and install floor stands underneath rear frame. Item

Measurement

Specification

370E Operating Weight

Weight (approximate)

30 782 kg 67 862 lb.

410E Operating Weight

Weight (approximate)

31 853 kg 70 224 lb.

460E Operating Weight

Weight (approximate)

32 216 kg 71 024 lb.

[4] - Remove lower cap screws (3). [5] - Remove rubber mount (4). [6] - Install or replace rubber mount [7] - Install lower cap screws. [8] CAUTION: Prevent possible crushing injury from heavy component. Weight may increase significantly due to buildup of mud or debris. Remove debris before proceeding with task. Use appropriate lifting device. Lower rear of machine onto rubber mount. Install upper cap screws and nuts finger tight. [9] - Fully lower machine into rubber mount. Tighten upper cap screws and nuts.

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Section 02 page 43

TM12408-REPAIR TECHNICAL MANUAL

Section 02 - AXLES AND SUSPENSION SYSTEMS

Group 0242: Axle Mounting Parts

Strain Gauge Remove and Install Specifications SPECIFICATIONS 370E Operating Weight (approximate)

30 782 kg 67 862 lb

410E Operating Weight (approximate)

31 853 kg 70 224 lb

460E Operating Weight (approximate)

32 216 kg 71 024 lb 15 N·m 138 lb·in

Cover Cap Screw Torque

Essential Tools ESSENTIAL TOOLS DFT1353 Strain Gauge Alignment Tool JT07372 Heavy Duty Wheel Chocks

Other Material OTHER MATERIAL M-Bond 200 Adhesive M-Coat B Nitrile Rubber Coating

[1] →NOTE: For the OBW video, refer to the E-Series_ADT_OBW Video contained in Service ADVISOR ™ under the training material folder. →NOTE: Circuit board needs to be replaced when replacing strain gauge. →NOTE: For improved accuracy, calibration of on board weighing (OBW) system is recommended after replacing strain gauge. To calibrate OBW system, See On Board Weighing (OBW) Calibration . (Group 9015-20.)

Rear Frame Park and prepare machine for service safely. See Prepare Machine for Maintenance . (Group 0001.)

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Section 02 page 44

TM12408-REPAIR TECHNICAL MANUAL

Section 02 - AXLES AND SUSPENSION SYSTEMS

Group 0242: Axle Mounting Parts

[2] CAUTION: Prevent possible injury from unexpected machine movement. Install wheel chocks at front and rear of one or more wheels. Install JT07372 Heavy Duty Wheel Chocks in front of and behind front tires. [3] CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device. Using appropriate lifting device, raise rear of machine. Support rear frame of machine with suitable floor stands. Item

Measurement

Specification

370E Operating Weight

Weight (approximate)

30 782 kg 67 862 lb

410E Operating Weight

Weight (approximate)

460E Operating Weight

Weight (approximate)

31 853 kg 70 224 lb 32 216 kg 71 024 lb

[4] - Remove rear wheels. See Wheel Remove and Install . (Group 0110.) [5] - Disconnect strain gauge 4-pin connector. See Rear Frame Harness (W12) Component Location . (Group 9015-10.) [6] -

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Section 02 page 45

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Section 02 - AXLES AND SUSPENSION SYSTEMS

Group 0242: Axle Mounting Parts

Strain Gauge LEGEND: 1 Strain Gauge Cover 2 Cap Screw (4 used) Remove cap screws (2) and strain gauge cover (1). [7] LEGEND: 3 4 5 6 7 8 9

Walking Beam Strain Gauge Circuit Board Brown Wire Black Wire Yellow Wire Gray Wire

Circuit Board and Strain Gauge Remove wiring harness wires (6—9). [8] - Remove circuit board (5) and strain gauge (4) from walking beam (3) by grinding them off.

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Section 02 page 46

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Section 02 - AXLES AND SUSPENSION SYSTEMS

Group 0242: Axle Mounting Parts

IMPORTANT: Prevent premature strain gauge malfunction. Absolute cleanliness is essential when installing new strain gauge. Walking beam must be clean of all traces of rust, paint, or debris. a. Verify that surface of walking beam has no surface defects, such as porosity. Replace walking beam if any defects are present. b. Use grinder with 120 grit flapper wheel to remove all traces of rust, paint, and debris. Polish walking beam with 180 grit followed with 240 grit flapper wheel. c. Use 600 grit Scotch-Brite ™ pad to polish area where strain gauge will be installed. d. Clean area with acetone and a clean white rag until no more material is picked up by rag. [9] -

DFT1353 Strain Gauge Alignment Tool LEGEND: 10 DFT1353 Strain Gauge Alignment Tool Using DFT1353 Strain Gauge Alignment Tool (10). Mark location for strain gauge. See DFT1353 Strain Gauge Alignment Tool . (Group 9900.) Strain Gauge Alignment Tool DFT1353 Tool is used to mark location for strain gauge. [10] →NOTE: The catalyst comes with the M-Bond 200 adhesive. Apply the catalyst prior to applying M-Bond 200 adhesive to back side of circuit board. Allow adhesive to dry completely. Number

Name

Use

M-Bond 200 Adhesive

Used to bond circuit board to walking beam.

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Section 02 page 47

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Section 02 - AXLES AND SUSPENSION SYSTEMS

Group 0242: Axle Mounting Parts

[11] IMPORTANT: Prevent premature strain gauge malfunction. Absolute cleanliness is essential when working with the strain gauge. Do not touch strain gauge with hands. Prepare strain gauge. a. Clean a piece of glass with acetone. b. Using tweezers, remove new strain gauge by leads from package and set on piece of clean glass. c. Tape strain gauge to glass with top side against tape. d. Carefully peel back one end of tape until bottom side of strain gauge is completely exposed. e. Apply the catalyst prior to applying M-Bond 200 adhesive to back side of strain gauge. Allow adhesive to dry completely before continuing. [12] - Install strain gauge. a. Clean location for strain gauge with acetone. IMPORTANT: Prevent premature strain gauge malfunction. Strain gauge will not operate if installed improperly. Align strain gauge properly. Strain gauge must be lined up when installing on walking beam. Remove tape and strain gauge from glass. Tape strain gauge to marked location on walking beam. One set of strain gauge leads will be parallel with edge of walking beam, and the other set of strain gauge leads will be perpendicular to edge of walking beam. c. Carefully peel back one end of tape until bottom side of strain gauge is completely exposed. d. Apply the catalyst prior to applying M-Bond 200 adhesive to back side of strain gauge. Allow adhesive to dry completely. Do not apply adhesive to walking beam. e. Tape strain gauge back on walking beam. IMPORTANT: Prevent strain gauge damage. Solid devices may cause damage to the strain gauge. Use a hand or other soft device to hold pressure on strain gauge. →NOTE: When adhesive completely dries, the area around strain gauge will appear cloudy. Cover strain gauge with a piece of teflon plastic. Apply pressure to strain gauge for 1 minute using a hand or other soft device. Carefully remove and discard teflon plastic. Allow adhesive to completely dry. IMPORTANT: Prevent strain gauge damage. Strain gauge and strain gauge leads are very brittle. Remove tape carefully to prevent tearing strain gauge or strain gauge leads. →NOTE: Strain gauge leads must be lifted completely off walking beam to avoid a short to ground. Remove tape carefully from walking beam and strain gauge. Gently lift the strain gauge leads using tweezers.

[13] IMPORTANT: Prevent circuit board damage. Solid devices may cause damage to the circuit board. Use a hand or other soft device to hold pressure on circuit board. Apply the catalyst prior to applying M-Bond 200 adhesive to back side of the circuit board. Install circuit board. Apply pressure to circuit board for 1 minute using a hand or other soft device. <- Go to Section TOC

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Section 02 - AXLES AND SUSPENSION SYSTEMS

Group 0242: Axle Mounting Parts

[14] LEGEND: 3 Walking Beam 4 Strain Gauge 5 Circuit Board 6 Brown Wire 7 Black Wire 8 Yellow Wire 9 Gray Wire 11 Wiring Harness Circuit Board Pad (4 used) 12 Strain Gage Circuit Board Pad A 13 Strain Gage Circuit Board Pad B 14 Strain Gage Circuit Board Pad C 15 Strain Gage Circuit Board Pad D

Circuit Board

Circuit Board and Strain Gauge Tin circuit board pads (11—15). [15] - Solder strain gauge leads from strain gauge (4) to circuit board (5). Trim excess wire. [16] - Install wiring harness. a. Install wiring harness through walking beam. b. Strip wiring harness wires (6—9). c. Tin wiring harness wires. d. Solder wiring harness wires to circuit board. [17] - Using an ohm meter, strain gauge wires for resistances. Strain gage circuit board pads A and B, should read approximately 120 ohms. Strain gage circuit board pads C and D, should read approximately 120 ohms. Strain gage circuit board pads A and D, should read approximately 240 ohms. [18] - Using an ohm meter, test harness wires for resistances. Gray wire to all other wires, should read no continuity. Yellow wire and brown wire, should read approximately 120 ohms. Yellow wire and black wire, should read approximately 120 ohms. Black wire and brown wire, should read approximately 240 ohms. [19] - Verify wiring at DEUTSCH ™ connector. <- Go to Section TOC

Section 02 page 49

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Section 02 - AXLES AND SUSPENSION SYSTEMS

Group 0250: Axle Shaft, Bearings, and Reduction Gears

Pin 1 should be a yellow wire. Pin 2 should be a brown wire. Pin 3 should be a black wire. Pin 4 should be a gray wire. [20] - Cover surface of strain gauge and circuit board with a M-Coat B Nitrile Rubber Coating. Allow a minimum of 1 hour to air dry. Number

Name

Use

M-Coat B Nitrile Rubber Coating

Seals wiring and circuit board.

[21] IMPORTANT: Prevent strain gage damage, excessive silicon sealant will create additional pressure on strain gage, resulting in damage to strain gage. Apply silicon sealant. [22] - Apply silicon sealant to bottom circumference of strain gauge cover. [23] - Install strain gauge cover and cap screws. Tighten cap screws to specification. Item

Measurement

Specification

Cover Cap Screw

Torque

15 N·m 138 lb·in

[24] - Connect strain gauge 4-pin connector (X27 or X28). See Rear Frame Harness (W12) Component Location . (Group 9015-10.) [25] - Install rear wheels. See Wheel Remove and Install . (Group 0110.) [26] - Calibrate on board weighing (OBW) system. See On Board Weighing (OBW) Calibration . (Group 9015-20.)

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TM12408-REPAIR TECHNICAL MANUAL

Section 02 - AXLES AND SUSPENSION SYSTEMS

Group 0260: Hydraulic System

Group 0250 - Axle Shaft, Bearings, and Reduction Gears TeamMate V 1500 Series Axle This machine uses John Deere TeamMate ™ V axles. To identify the model of axle, see Axle Identification . (CTM115319.) For repair on John Deere TeamMate V axles, see the following: TeamMate V 1500 Series Axle Rebuild Stand . (CTM115319.) Yoke List . (CTM115319.) Input Shaft Assembly List . (CTM115319.) Output Shaft Assembly List . (CTM115319.) Input Housing with Drop Assembly List . (CTM115319.) Final Drive Assembly List . (CTM115319.) Brake Group List . (CTM115319.) Differential Gear Case List . (CTM115319.) Differential Lock Assembly List . (CTM115319.)

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TM12408-REPAIR TECHNICAL MANUAL

Section 02 - AXLES AND SUSPENSION SYSTEMS

Group 0260: Hydraulic System

Group 0260 - Hydraulic System Front Axle Pump Remove and Install [1] - Park and prepare machine for service safely. Prepare Machine for Maintenance . (Group 0001.) [2] - Turn battery disconnect switch to the OFF position. See Battery Disconnect Switch and Battery Circuit Breakers . (Operator’s Manual.) [3] - Open hood and left side fan door. [4] LEGEND: 1 Hydraulic Line (2 used) 2 Cap Screw (2 used) 3 Front Axle Pump

Front Axle Pump Install identification tags disconnect hydraulic lines (1). Close all openings using caps and plugs. [5] - Remove cap screws (2) and remove front axle pump (3). [6] - Repair or replace front axle pump. [7] - Install front axle pump, secure cap screws, and connect hydraulic lines. [8] - Close left side fan door and hood. [9] - Turn battery disconnect switch to the ON position. See Battery Disconnect Switch and Battery Circuit Breakers . (Operator’s Manual.) [10] CAUTION: Escaping fluid under pressure can penetrate the skin causing serious injury. Avoid the hazard by relieving pressure before disconnecting hydraulic or other lines. Tighten all connections before applying pressure. Search for leaks with a piece of cardboard. Protect hands and body from high pressure fluids. If an accident occurs, see a doctor immediately. Any fluid injected into the skin must be surgically removed within a few hours or gangrene may result. Doctors unfamiliar with this type of injury should reference a knowledgeable medical source. Such information is available from Deere & Company Medical Department in Moline, Illinois, U.S.A. Start machine and check for leaks.

Rear Axle Pump Remove and Install [1] - Park and prepare machine for service safely. Prepare Machine for Maintenance . (Group 0001.) [2] - Turn battery disconnect switch to the OFF position. See Battery Disconnect Switch and Battery Circuit Breakers . (Operator’s Manual.) [3] <- Go to Section TOC

Section 02 page 52

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Section 02 - AXLES AND SUSPENSION SYSTEMS

Group 0260: Hydraulic System

LEGEND: 1 Hydraulic Line (7 used) 2 Cap Screw (4 used) 3 Rear Axle Pump

Rear Axle Pump Install identification tags and disconnect hydraulic lines (1). Close all openings using caps and plugs. [4] - Remove cap screws (2) and remove rear axle pump (3). [5] - Repair or replace rear axle pump. [6] - Install rear axle pump, secure cap screws, and connect hydraulic lines. [7] - Turn battery disconnect switch to the ON position. See Battery Disconnect Switch and Battery Circuit Breakers . (Operator’s Manual.) [8] CAUTION: Escaping fluid under pressure can penetrate the skin causing serious injury. Avoid the hazard by relieving pressure before disconnecting hydraulic or other lines. Tighten all connections before applying pressure. Search for leaks with a piece of cardboard. Protect hands and body from high pressure fluids. If an accident occurs, see a doctor immediately. Any fluid injected into the skin must be surgically removed within a few hours or gangrene may result. Doctors unfamiliar with this type of injury should reference a knowledgeable medical source. Such information is available from Deere & Company Medical Department in Moline, Illinois, U.S.A. Start machine and check for leaks.

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TM12408-REPAIR TECHNICAL MANUAL

Section 02 - AXLES AND SUSPENSION SYSTEMS

Group 0260: Hydraulic System

Front Axle Cooling Manifold Remove and Install [1] - Park and prepare machine for service safely. Prepare Machine for Maintenance . (Group 0001.) [2] - Turn battery disconnect switch to the OFF position. See Battery Disconnect Switch and Battery Circuit Breakers . (Operator’s Manual.) [3] - Open front service door. [4] LEGEND: 1 Hydraulic Line (5 used) 5 Drain Line (S.N. 668587— ) B58 Front Axle Differential Lock Pressure Sensor B61 Front Axle Temperature Sensor B64 Front Axle Pressure Sensor B67 Front Axle Filter Restriction Switch Y52 Front Axle Differential Lock Apply Solenoid Front Axle Differential Lock Pressure Regulation Y55 Solenoid

Hydraulic Lines and Connectors Install identification tags and disconnect hydraulic lines (1). Close all openings using caps and plugs. [5] - For machines with (S.N. 668587— ): Disconnect drain line (5) and close it using cap and plug. [6] - Disconnect front axle differential lock pressure sensor (B58). [7] - Disconnect front axle temperature sensor (B61). [8] - Disconnect front axle pressure sensor (B64). [9] - Disconnect front axle filter restriction switch (B67). [10] - Disconnect front axle differential lock apply solenoid (Y52). [11] - Disconnect front axle differential lock pressure regulation solenoid (Y55). [12] -

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Section 02 page 54

TM12408-REPAIR TECHNICAL MANUAL

Section 02 - AXLES AND SUSPENSION SYSTEMS

Group 0260: Hydraulic System

LEGEND: 2 Front Axle Cooling Manifold 3 Nut (3 used) 4 Cap Screw (3 used)

Front Axle Cooling Manifold Secure nuts (3) and remove cap screws (4). [13] - Remove front axle cooling manifold (2). [14] - Repair or replace front axle cooling manifold as necessary. [15] - Install front axle cooling manifold. Secure with cap screws and nuts. [16] - Connect sensors, solenoids, and switches at front axle cooling manifold. [17] - Connect hydraulic lines. [18] - Close front service door. [19] - Turn battery disconnect switch to the ON position. See Battery Disconnect Switch and Battery Circuit Breakers . (Operator’s Manual.) [20] CAUTION: Escaping fluid under pressure can penetrate the skin causing serious injury. Avoid the hazard by relieving pressure before disconnecting hydraulic or other lines. Tighten all connections before applying pressure. Search for leaks with a piece of cardboard. Protect hands and body from high-pressure fluids. If an accident occurs, see a doctor immediately. Any fluid injected into the skin must be surgically removed within a few hours or gangrene may result. Doctors unfamiliar with this type of injury should reference a knowledgeable medical source. Such information is available from Deere & Company Medical Department in Moline, Illinois, U.S.A. Start machine and check for leaks.

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Section 02 page 55

TM12408-REPAIR TECHNICAL MANUAL

Section 02 - AXLES AND SUSPENSION SYSTEMS

Group 0260: Hydraulic System

Middle Axle Cooling Manifold Remove and Install [1] - Park and prepare machine for service safely. Prepare Machine for Maintenance . (Group 0001.) [2] - Turn battery disconnect switch to the OFF position. See Battery Disconnect Switch and Battery Circuit Breakers . (Operator’s Manual.) [3] - Install identification tags and disconnect hydraulic lines (1). Close all openings using caps and plugs. LEGEND: 1 Hydraulic Line (5 used) 5 Drain Line (S.N. 668587— ) B59 Middle Axle Differential Lock Pressure Sensor B62 Middle Axle Temperature Sensor B65 Middle Axle Pressure Sensor B68 Middle Axle Filter Restriction Switch Y53 Middle Axle Differential Lock Apply Solenoid Middle Axle Differential Lock Pressure Regulating Y56 Solenoid

Hydraulic Lines and Connectors [4] - For machines with (S.N. 668587— ): Disconnect drain line (5) and close it by cap and plug. [5] - Disconnect middle axle differential lock pressure sensor (B59). [6] - Disconnect middle axle temperature sensor (B62). [7] - Disconnect middle axle pressure sensor (B65). [8] - Disconnect middle axle filter restriction switch (B68). [9] - Disconnect middle axle differential lock apply solenoid (Y53). [10] - Disconnect middle axle differential lock pressure regulating solenoid (Y56). [11] LEGEND: 2 Middle Axle Cooling Manifold 3 Cap Screw (3 used) 4 Nut (3 used)

Middle Axle Cooling Manifold Secure nuts (4) and remove cap screws (3). [12] - Remove middle axle cooling manifold (2). <- Go to Section TOC

Section 02 page 56

TM12408-REPAIR TECHNICAL MANUAL

Section 02 - AXLES AND SUSPENSION SYSTEMS

Group 0260: Hydraulic System

[13] - Repair or replace middle axle cooling manifold as necessary. [14] - Install middle axle cooling manifold. Secure with cap screws and nuts. [15] - Connect sensors, solenoids, and switches at middle axle cooling manifold. [16] - Connect hydraulic lines. [17] - Turn battery disconnect switch to the ON position. See Battery Disconnect Switch and Battery Circuit Breakers . (Operator’s Manual.) [18] CAUTION: Escaping fluid under pressure can penetrate the skin causing serious injury. Avoid the hazard by relieving pressure before disconnecting hydraulic or other lines. Tighten all connections before applying pressure. Search for leaks with a piece of cardboard. Protect hands and body from high-pressure fluids. If an accident occurs, see a doctor immediately. Any fluid injected into the skin must be surgically removed within a few hours or gangrene may result. Doctors unfamiliar with this type of injury should reference a knowledgeable medical source. Such information is available from Deere & Company Medical Department in Moline, Illinois, U.S.A. Start machine and check for leaks.

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Section 02 page 57

TM12408-REPAIR TECHNICAL MANUAL

Section 02 - AXLES AND SUSPENSION SYSTEMS

Group 0260: Hydraulic System

Rear Axle Cooling Manifold Remove and Install [1] - Park and prepare machine for service safely. Prepare Machine for Maintenance . (Group 0001.) [2] - Turn battery disconnect switch to the OFF position. See Battery Disconnect Switch and Battery Circuit Breakers . (Operator’s Manual.) [3] - Install identification tags and disconnect hydraulic lines (1). Close all openings using caps and plugs. LEGEND: 1 Hydraulic Line (3 used) 5 Drain Line (S.N. 668587— ) B65 Rear Axle Pressure Sensor B60 Rear Axle Differential Lock Pressure Sensor B63 Rear Axle Temperature Sensor B69 Rear Axle Filter Restriction Switch Y54 Rear Axle Differential Lock Apply Solenoid Rear Axle Differential Lock Pressure Regulating Y57 Solenoid

Hydraulic Lines and Connectors [4] - For machines with (S.N. 668587— ): Disconnect drain line (5) and close it using cap and plug. [5] - Disconnect rear axle pressure sensor (B55). [6] - Disconnect rear axle differential lock pressure sensor (B60). [7] - Disconnect rear axle temperature sensor (B63). [8] - Disconnect rear axle filter restriction switch (B69). [9] - Disconnect rear axle differential lock apply solenoid (Y54). [10] - Disconnect rear axle differential lock pressure regulation solenoid (Y57). [11] LEGEND: 2 Rear Axle Cooling Manifold 3 Cap Screw (3 used) 4 Nut (3 used)

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Section 02 page 58

TM12408-REPAIR TECHNICAL MANUAL

Section 02 - AXLES AND SUSPENSION SYSTEMS

Group 0260: Hydraulic System

Rear Axle Cooling Manifold Secure nuts (4) and remove cap screws (3). [12] - Remove rear axle cooling manifold (2). [13] - Repair or replace rear axle cooling manifold as necessary. [14] - Install rear axle cooling manifold. Secure with cap screws and nuts. [15] - Connect sensors, solenoids, and switches at rear axle cooling manifold. [16] - Connect hydraulic lines. [17] - Close front service door. [18] - Turn battery disconnect switch to the ON position. See Battery Disconnect Switch and Battery Circuit Breakers . (Operator’s Manual.) [19] CAUTION: Escaping fluid under pressure can penetrate the skin causing serious injury. Avoid the hazard by relieving pressure before disconnecting hydraulic or other lines. Tighten all connections before applying pressure. Search for leaks with a piece of cardboard. Protect hands and body from high-pressure fluids. If an accident occurs, see a doctor immediately. Any fluid injected into the skin must be surgically removed within a few hours or gangrene may result. Doctors unfamiliar with this type of injury should reference a knowledgeable medical source. Such information is available from Deere & Company Medical Department in Moline, Illinois, U.S.A. Start machine and check for leaks.

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Section 02 page 59

TM12408-REPAIR TECHNICAL MANUAL

Section 02 - AXLES AND SUSPENSION SYSTEMS

Group 0260: Hydraulic System

Comfort Ride Control Valve Remove and Install [1] - Park and prepare machine for service safely. Prepare Machine for Maintenance . (Group 0001.) [2] - Turn battery disconnect switch to the OFF position. See Battery Disconnect Switch and Battery Circuit Breakers . (Operator’s Manual.) [3] - Raise cab. See Tilt Cab . (Operator’s Manual.) [4] LEGEND: 1 Hydraulic Line (5 used) 2 Mounting Cap Screw (2 used) 3 Comfort Ride Control Valve Y38 Right Strut Up Solenoid Y39 Right Strut Down Solenoid Y40 Left Strut Up Solenoid Y41 Left Strut Down Solenoid

Comfort Ride Control Valve Install identification tags and disconnect hydraulic lines (1). Close all openings using caps and plugs. [5] - Disconnect right strut up and down solenoids (Y38 and Y39). [6] - Disconnect left strut up and down solenoids (Y40 and Y41). [7] - Remove mounting cap screws (2). [8] - Remove comfort ride control valve (3). [9] - Repair or replace comfort ride control valve as necessary. [10] - Install comfort ride control valve and secure with cap screws. [11] - Connect left strut up and down solenoids. [12] - Connect right strut up and down solenoids. [13] - Lower cab. See Tilt Cab . (Operator’s Manual.) [14] - Turn battery disconnect switch to the ON position. See Battery Disconnect Switch and Battery Circuit Breakers . (Operator’s Manual.) [15] -

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Section 02 page 60

TM12408-REPAIR TECHNICAL MANUAL

Section 02 - AXLES AND SUSPENSION SYSTEMS

Group 0260: Hydraulic System

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

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Section 02 - AXLES AND SUSPENSION SYSTEMS

Group 0260: Hydraulic System

Strut Accumulator Remove and Install [1] - Park and prepare machine for service. See Park and Prepare for Service Safely . (Group 9000-01.) [2] - Remove fender. See Fender Remove and Install . (Group 1927.) [3] →NOTE: Strut lowering switch is located in the engine service compartment. Open front grille. [4] 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.

→NOTE: Front struts will automatically rise to operating height when the machine is driven faster than 3 km/h (2 mph).

Strut Lowering Switch Location LEGEND: 5 <- Go to Section TOC

Strut Lowering Switch Section 02 page 62

TM12408-REPAIR TECHNICAL MANUAL

Section 02 - AXLES AND SUSPENSION SYSTEMS

Group 0260: Hydraulic System

Push and hold strut lowering switch (5) until front of machine is fully lowered. Hold an additional 10 seconds to ensure accumulator is fully depleted. [5] - Turn battery disconnect switch to OFF position. [6] -

Strut Accumulator (right strut accumulator shown) LEGEND: 1 Clamp (2 used) 2 Cap Screw (4 used) 3 Strut Accumulator 4 Hydraulic Line 5 Elbow Adapter Fitting Disconnect hydraulic line (4) from elbow adapter fitting (5). Remove elbow adapter fitting from strut accumulator (3). Close all openings using caps and plugs. [7] →NOTE: Accumulator (original equipment) is not serviceable except for recharging. Replacement accumulator is shipped flat and precharged in the field. Remove strut accumulator. [8] IMPORTANT: Only dry nitrogen should be used to charge accumulator. Do not use compressed air or any combustible gas as these will cause oxidation and condensation in the accumulator.

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Section 02 page 63

TM12408-REPAIR TECHNICAL MANUAL

TRANSMISSION

(g) by Belgreen v2.0

Charge strut accumulator with dry nitrogen. See Strut Accumulator Pressure Test and Charge Procedure . (Group 9020-25.) [9] - Install elbow adapter fitting. Connect hydraulic line. [10] - Turn battery disconnect switch to ON position. [11] - Install fender. See Fender Remove and Install . (Group 1927.)

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Section 03 page 64

TM12408-REPAIR TECHNICAL MANUAL

TM12408-REPAIR TECHNICAL MANUAL

(g) by Belgreen v2.5

Section 03 - TRANSMISSION Table of contents Group 0300 - Removal and Installation ................................................................................................ 1 Transmission Remove and Install ......................................................................................................... 1 Transmission Alignment ..................................................................................................................... 14 Front Transmission Mount Washer Installation ................................................................................... 18 Group 0325 - Input Drive Shafts and U-Joints ................................................................................... 20 Engine-to-Transmission Drive Shaft Remove and Install .................................................................... 20 Group 0350 - Gear, Shafts, and Power Shift Clutches ..................................................................... 22 Transmission Disassemble ................................................................................................................. 22 Transmission Assemble ...................................................................................................................... 38 Transmission Clutch (F) Hi/Lo Planetary Disassemble and Assemble ................................................. 55 Transmission Clutch (E) Disassemble and Assemble .......................................................................... 74 Transmission Clutch (R) Disassemble and Assemble .......................................................................... 93 Transmission Clutch (B) Disassemble and Assemble ........................................................................ 106 Transmission Clutch (V) Disassemble and Assemble ........................................................................ 121 Transmission Clutch (C) Disassemble and Assemble ........................................................................ 135 Transmission Clutch (D) Disassemble and Assemble ....................................................................... 149 Transmission Clutch (A) Disassemble and Assemble ........................................................................ 163 Transmission Clutch (G) Inter-Axle Differential Lock (IDL) Disassemble and Assemble .................... 176 Transmission Speed Sensors Remove and Install ............................................................................. 193 Transmission Clutch (F) Hi/Lo Planetary Remove and Install ............................................................ 196 Group 0360 - Hydraulic System ......................................................................................................... 202 Transmission Oil Cooler Thermal Bypass Valve Remove and Install ................................................. 202 Transmission Control Valve Remove and Install ............................................................................... 203 Torque Converter Remove and Install .............................................................................................. 204 Clutch Control Valve Remove and Install .......................................................................................... 204 Retarder Control Valve Remove and Install ...................................................................................... 204 Oil Pump Remove and Install ............................................................................................................ 204 Transmission Retarder Remove and Install ...................................................................................... 205 Transmission Control Valve Disassemble and Assemble .................................................................. 221 Clutch Control Valve Disassemble and Assemble ............................................................................. 225 Retarder Control Valve Disassemble and Assemble ......................................................................... 230 Oil Pump Disassemble and Assemble ............................................................................................... 234 Transmission Retarder Disassemble and Assemble ......................................................................... 236

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TM12408-REPAIR TECHNICAL MANUAL

Section 03 - TRANSMISSION

Group 0300: Removal and Installation

Group 0300 - Removal and Installation Transmission Remove and Install Specifications SPECIFICATIONS Transmission Weight (approximate)

1415 kg 3120 lb.

Transmission Weight (approximate)

1415 kg 3120 lb.

Side Mounting Cap Screw Torque

620 N·m 458 lb.-ft.

Front Mounting Cap Screw Torque

1070 N·m 789 lb.-ft.

Rear Mounting Cap Screw Torque

1070 N·m 789 lb.-ft.

[1] →NOTE: Transmission calibration must be performed after servicing the transmission. See Electronic Clutch Calibration . (Group 9020-25.) See Prepare Machine for Maintenance . (Group 0001.) [2] - Turn battery disconnect switch to the OFF position. See Battery Disconnect Switch and Battery Circuit Breakers . (Operator’s Manual.) [3] - Remove cab. See Cab Remove and Install . (Group 1810.) [4] LEGEND: 1 Left Side Steering Cylinder Hydraulic Line (2 used) 2 Cap Screw (2 used) 3 Bracket

Top of Transmission Disconnect left side steering cylinder hydraulic lines (1). Close all openings using caps and plugs. [5] - Remove cap screws (2) and set bracket (3) aside from transmission, leaving hydraulic lines attached. [6] - Remove hydraulic reservoir. See Hydraulic Reservoir Remove and Install . (Group 2160.) [7] -

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Section 03 page 1

TM12408-REPAIR TECHNICAL MANUAL

Section 03 - TRANSMISSION

Group 0300: Removal and Installation

LEGEND: R7 Hydraulic Harness CAN 1 Termination Resistor Hydraulic Harness-to-Hydraulic Tank Harness 6-Pin X5 Connector Hydraulic Harness-to-Transmission Control Harness 2X19 Pin Connector Hydraulic Harness Transmission Control Unit (TCU) X70 Connector

Electrical Connectors Install identification tags and disconnect hydraulic harness-to-transmission control harness 2-pin connector (X19) and hydraulic harness transmission control unit (TCU) connector (X70). See Hydraulic Harness (W9) Component Location . (Group 9015.) [8] LEGEND: Hydraulic System Manifold-to-Secondary Steering Pump 4 Hose Secondary Steering Pump-to-Hydraulic System Manifold 5 Hose 6 Secondary Steering Pump

Secondary Steering Pump Lines (S.N. —664888)

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Section 03 page 2

TM12408-REPAIR TECHNICAL MANUAL

Section 03 - TRANSMISSION

Group 0300: Removal and Installation

Secondary Steering Pump Lines (S.N. 664889— ) Install identification tags and disconnect hydraulic hoses (4 and 5) from secondary steering pump (6). Close all openings using caps and plugs. [9] - Disconnect engine-to-transmission drive shaft at transmission. See Engine-to-Transmission Drive Shaft Remove and Install . (Group 0325.) [10] - Disconnect drive shaft from transmission-to-axle at transmission. See Transmission-to-Front Axle Drive Shaft or Transmission-to-Oscillation Joint Drive Shaft Remove and Install . (Group 0225.) [11] LEGEND: 7 Hydraulic Pump-to-Secondary Steering Pump Line 8 Hydraulic Pump-to-Attenuator Line 9 Hydraulic Pump-to-Hydraulic Control Valve Line 10 Mounting Cap Screw (2 used) 11 Transmission Fill Tube Bracket

Hydraulic Lines Install identification tags and disconnect hydraulic lines (7—9) from main hydraulic pump. Close all openings using caps and plugs. [12] - Remove mounting cap screws (10) from transmission fill tube bracket (11) and set aside. [13] -

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Section 03 page 3

TM12408-REPAIR TECHNICAL MANUAL

Section 03 - TRANSMISSION

Group 0300: Removal and Installation

LEGEND: 12 Transmission Fast Fill Hose (if equipped) 13 Transmission Oil Quick Service Port (if equipped)

Transmission Oil Quick Service (if equipped) Disconnect transmission fast fill hose (12) at transmission oil quick service port (13) if equipped. Close all openings using caps and plugs. [14] LEGEND: Transmission Filter Housing-to-Transmission Return 14 Hose Transmission Filter Housing-to-Transmission Bypass 15 Hose 16 Transmission Dipstick 17 Transmission-to-Filter Housing Supply Hose

Transmission Lines Install identification tags and disconnect transmission filter housing-to-transmission return hose (14) at transmission. Close all openings using caps and plugs. [15] - Install identification tags and disconnect transmission filter housing-to-transmission bypass hose (15) at transmission. Close all openings using caps and plugs. [16] - Remove transmission dipstick (16). Close all openings using caps and plugs. [17] - Install identification tags and disconnect transmission-to-filter housing supply hose (17) at transmission. Close all openings using caps and plugs. [18] -

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Section 03 page 4

TM12408-REPAIR TECHNICAL MANUAL

Section 03 - TRANSMISSION

Group 0300: Removal and Installation

LEGEND: 18 Attenuator 19 Attenuator Clamp (2 used) 20 Transmission-to-Transmission Oil Cooler Supply Hose 21 Transmission Oil Cooler-to-Transmission Return Hose

Transmission Lines Remove attenuator clamps (19) from attenuator (18), move attenuator away from transmission. [19] - Install identification tags and disconnect transmission-to-transmission oil cooler supply hose (20) at transmission. Close all opening using caps and plugs. [20] - Install identification tags and disconnect transmission oil cooler-to-transmission return hose (21) at transmission. Close all openings using caps and plugs. [21] CAUTION: Prevent crushing injury from heavy component. Use appropriate lifting device.

<- Go to Section TOC

Section 03 page 5

TM12408-REPAIR TECHNICAL MANUAL

Section 03 - TRANSMISSION

Group 0300: Removal and Installation

Support Transmission LEGEND: 22 Lifting Eye (3 used) Attach appropriate lifting device to transmission lifting eyes (22). Item

Measurement

Specification

Transmission

Weight (approximate)

1415 kg 3120 lb.

[22] -

<- Go to Section TOC

Section 03 page 6

TM12408-REPAIR TECHNICAL MANUAL

Section 03 - TRANSMISSION

Group 0300: Removal and Installation

Transmission Mounts LEGEND: 23 Rear Mounting Cap Screw (2 used) 24 Side Mounting Cap Screw (8 used) 25 Washer (8 used) 26 Front Transmission Mount (2 used) 27 Transmission Mounting Bracket (2 used) Loosen rear mounting cap screws (23) on transmission mounting brackets (27). [23] - Remove side mounting cap screws (24) and washers (25). [24] - Remove front transmission mounts (26). [25] - Remove transmission from machine. [26] CAUTION: D001003AA Repair Stand is rated for 907 kg (2000 lb). Prevent crushing injury from heavy component. Remove transmission components before mounting transmission to repair stand. Support transmission on floor using blocks. [27] - Repair or replace transmission as necessary. See Transmission Disassemble and see Transmission Assemble . (Group 0350.) [28] -

<- Go to Section TOC

Section 03 page 7

TM12408-REPAIR TECHNICAL MANUAL

Section 03 - TRANSMISSION

Group 0300: Removal and Installation

CAUTION: Prevent crushing injury from heavy component. Use appropriate lifting device. Install transmission to machine using appropriate lifting device. Item

Measurement

Specification

Transmission

Weight (approximate)

1415 kg 3120 lb.

[29] IMPORTANT: Use caution when installing transmission into mounting location. Note solenoid and harness locations to prevent damage due to close tolerances during mounting.

Transmission Mounts LEGEND: 28 Rear Mounting Cap Screw (2 used) 29 Side Mounting Cap Screw (8 used) 30 Washer (8 used) 31 Transmission Mounting Bracket (2 used) 32 Front Transmission Mount (2 used) Install side mounting cap screws and washers (29 and 30) to transmission mounting brackets (31). Tighten to specification. Item

Measurement

Specification

Side Mounting Cap Screw

Torque

620 N·m 458 lb.-ft.

<- Go to Section TOC

Section 03 page 8

TM12408-REPAIR TECHNICAL MANUAL

Section 03 - TRANSMISSION

Group 0300: Removal and Installation

[30] - Install front transmission mounts (32) and tighten to specification. Item

Measurement

Specification

Front Mounting Cap Screw

Torque

1070 N·m 789 lb.-ft.

[31] - Tighten rear mounting cap screws (28) to specification. Item

Measurement

Specification

Rear Mounting Cap Screw

Torque

1070 N·m 789 lb.-ft.

[32] LEGEND: 33 Attenuator 34 Attenuator Clamp (2 used) 35 Transmission-to-Transmission Oil Cooler Supply Hose 36 Transmission Oil Cooler-to-Transmission Return Hose

Transmission Lines Install attenuator (33) and attenuator clamps (34). [33] - Connect transmission oil cooler-to-transmission return hose (36) and connect transmission-to-transmission oil cooler supply hose (35). [34] LEGEND: Transmission Filter Housing-to-Transmission Return 37 Hose Transmission Filter Housing-to-Transmission Bypass 38 Hose 39 Transmission Dipstick 40 Transmission-to-Filter Housing Supply Hose

Transmission Lines Connect transmission-to-transmission filter housing supply hose (40), transmission filter housing-to-transmission bypass hose (38), and transmission filter housing-to-transmission return hose (37). <- Go to Section TOC

Section 03 page 9

TM12408-REPAIR TECHNICAL MANUAL

Section 03 - TRANSMISSION

Group 0300: Removal and Installation

[35] - Install transmission dipstick (39). [36] LEGEND: 41 Transmission Fast Fill Hose (if equipped) 42 Transmission Oil Quick Service Port (if equipped)

Transmission Oil Quick Service (if equipped) Connect transmission fast fill hose (41) at transmission oil quick service port (42) if equipped. [37] LEGEND: 43 Hydraulic Pump-to-Secondary Steering Pump Line 44 Hydraulic Pump-to-Attenuator Line 45 Hydraulic Pump-to-Hydraulic Control Valve Line 46 Mounting Cap Screw (2 used) 47 Transmission Fill Tube Bracket

Hydraulic Lines Connect main hydraulic pump lines (43—45). [38] - Install transmission fill tube bracket (47) and cap screws (46). [39] -

<- Go to Section TOC

Section 03 page 10

TM12408-REPAIR TECHNICAL MANUAL

Section 03 - TRANSMISSION

Group 0300: Removal and Installation

LEGEND: Hydraulic System Manifold-to-Secondary Steering Pump 48 Hose Secondary Steering Pump-to-Hydraulic System Manifold 49 Hose 50 Secondary Steering Pump

Secondary Steering Pump Lines (S.N. —664888)

Secondary Steering Pump Lines (S.N. 664889— ) Connect secondary steering pump hoses (48 and 49) to secondary steering pump (50). [40] - Connect drive shafts from transmission to axles at transmission. See Transmission-to-Front Axle Drive Shaft or Transmission-to-Oscillation Joint Drive Shaft Remove and Install . (Group 0225.) [41] - Connect engine-to-transmission drive shaft at transmission. See Engine-to-Transmission Drive Shaft Remove and Install . (Group 0325.) [42] -

<- Go to Section TOC

Section 03 page 11

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Section 03 - TRANSMISSION

Group 0300: Removal and Installation

LEGEND: R7 Hydraulic Harness CAN 1 Termination Resistor Hydraulic Harness-to-Hydraulic Tank Harness 6-pin X5 Connector Hydraulic Harness-to-Transmission Control Harness 2X19 pin Connector Hydraulic Harness Transmission Control Unit (TCU) X70 Connector

Electrical Connectors Connect hydraulic harness-to-transmission control harness 2-pin connector (X19) and hydraulic harness transmission control unit (TCU) connector (X70). See Hydraulic Harness (W9) Component Location . (Group 9015.) [43] - Install hydraulic reservoir. See Hydraulic Reservoir Remove and Install . (Group 2160.) [44] LEGEND: 51 Left Side Steering Cylinder Hydraulic Line (2 used) 52 Cap Screw (2 used) 53 Bracket

Top of Transmission Install bracket (53) and cap screws (52). [45] - Connect left side steering cylinder hydraulic lines (51). [46] - Install cab. See Cab Remove and Install . (Group 1810.) [47] →NOTE: Transmission calibration must be performed after servicing the transmission. See Electronic Clutch Calibration . (Group 9020-25.) Turn battery disconnect switch to the ON position. See Battery Disconnect Switch and Battery Circuit Breakers . (Operator’s Manual.) [48] - Start machine and allow hydraulic oil to reach operating temperature. See Warming Hydraulic System . (Operator′s Manual.) [49] -

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Section 03 page 12

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Section 03 - TRANSMISSION

Group 0300: Removal and Installation

CAUTION: Escaping fluid under pressure can penetrate the skin causing serious injury. Avoid the hazard by relieving pressure before disconnecting hydraulic or other lines. Tighten all connections before applying pressure. Search for leaks with a piece of cardboard. Protect hands and body from high pressure fluids. If an accident occurs, see a doctor immediately. Any fluid injected into the skin must be surgically removed within a few hours or gangrene may result. Doctors unfamiliar with this type of injury should reference a knowledgeable medical source. Such information is available from Deere & Company Medical Department in Moline, Illinois, U.S.A. Check for hydraulic leaks. [50] - Stop machine and check hydraulic oil level. See Check Hydraulic Oil Level . (Operator′s Manual.)

<- Go to Section TOC

Section 03 page 13

TM12408-REPAIR TECHNICAL MANUAL

Section 03 - TRANSMISSION

Group 0300: Removal and Installation

Transmission Alignment Specifications SPECIFICATIONS Transmission Alignment Measurement Angle

90° +/- 0.5°

Transmission Adjustment Cap Screw Torque

350 N·m 255 lb.-ft.

[1] - Park and prepare machine for service safely. See Prepare Machine for Maintenance . (Group 0001.) [2] - Tilt cab. See Tilt Cab . (Operator’s Manual.) [3] - Open grille. [4] IMPORTANT: Prevent improper transmission alignment measurement. Harmonic balancer has a decal that is painted over. Ensure digital protractor is not positioned over this decal. LEGEND: 1 Digital Protractor 2 Harmonic Balancer 3 Transmission Top Cover

Harmonic Balancer

Transmission Top Cover Position digital protractor (1) against front face of harmonic balancer (2) and set to zero. [5] -

<- Go to Section TOC

Section 03 page 14

TM12408-REPAIR TECHNICAL MANUAL

Section 03 - TRANSMISSION

Group 0300: Removal and Installation

IMPORTANT: Prevent improper transmission alignment measurement. Transmission top cover must be free of debris for proper angle measurement. Remove any debris particles before measuring angle. Position digital protractor on transmission top cover (3) to acquire measurement. Item

Measurement

Specification

Transmission Alignment Measurement

Angle

90° +/- 0.5°

[6] - If measurement is outside specification continue with Transmission Alignment. [7] IMPORTANT: Prevent damage to transmission housing. Transmission component is heavy and should not be directly contacted by metal at an acute point. Position a sturdy wooden block (5) or other means between jack and transmission housing to disperse weight. LEGEND: 4 5 6

Jack Wooden Block Cap Screw (4 used)

Transmission Support

Front Transmission Mount Position jack (4) under transmission housing as shown. [8] - Loosen transmission adjustment cap screws (6) and use jack to raise or lower transmission until alignment is to specification. Item

Measurement

Specification

Transmission Alignment Measurement

Angle

90° +/- 0.5°

[9] - If transmission alignment is achieved, continue with Transmission Alignment. <- Go to Section TOC

Section 03 page 15

TM12408-REPAIR TECHNICAL MANUAL

Section 03 - TRANSMISSION

Group 0300: Removal and Installation

[10] - If transmission alignment cannot be achieved, see Front Transmission Mount Washer Installation . (Group 0300.) [11] LEGEND: 4 5 6

Jack Wooden Block Cap Screw (4 used)

Front Transmission Mount

Transmission Support Tighten transmission adjustment cap screws (6) to specification. Item

Measurement

Specification

Transmission Adjustment Cap Screw

Torque

350 N·m 255 lb.-ft.

[12] - Lower jack (4) until it is not supporting transmission. [13] -

<- Go to Section TOC

Section 03 page 16

TM12408-REPAIR TECHNICAL MANUAL

Section 03 - TRANSMISSION

Group 0300: Removal and Installation

LEGEND: 1 Digital Protractor 2 Harmonic Balancer 3 Transmission Top Cover

Harmonic Balancer

Transmission Top Cover Measure transmission alignment to ensure specification. Repeat alignment procedure as necessary until transmission alignment is within specification. Item

Measurement

Specification

Transmission Alignment Measurement

Angle

90° +/- 0.5°

[14] - Lower cab. See Tilt Cab . (Operator’s Manual.) [15] - Close grille.

<- Go to Section TOC

Section 03 page 17

TM12408-REPAIR TECHNICAL MANUAL

Section 03 - TRANSMISSION

Group 0300: Removal and Installation

Front Transmission Mount Washer Installation Specifications SPECIFICATIONS 1070 N·m 789 lb.-ft.

Front Transmission Mount Cap Screw Torque

[1] LEGEND: 7 Cap Screw (2 used) 8 Front Transmission Mount 9 T260782 Washer (2 used) 10 Isolator (2 used) 11 Frame Cross Plate 12 Lock Washer (2 used) 13 Nut (2 used)

Front Transmission Mount

Washer Installation Remove nuts (13), lock washers (12), and cap screws (7) from front transmission mount (8). [2] IMPORTANT: Prevent damage to transmission housing. Transmission component is heavy and should not be directly contacted by metal at an acute point. Position a sturdy wooden block (5) or other means between jack and transmission housing to disperse weight.

<- Go to Section TOC

Section 03 page 18

TM12408-REPAIR TECHNICAL MANUAL

Section 03 - TRANSMISSION

Group 0325: Input Drive Shafts and U-Joints

LEGEND: 4 5

Jack Wooden Block

Transmission Support Position jack (4) under transmission housing as shown. [3] →NOTE: Only one washer per side will be installed to achieve transmission alignment. Raise transmission until washers (9) can be installed between isolators (10) and frame cross plate (11). [4] - Lower transmission and install front transmission mount to frame cross plate with cap screws, lock washers, and nuts. Tighten cap screws to specification. Item

Measurement

Specification

Front Transmission Mount Cap Screw

Torque

1070 N·m 789 lb.-ft.

[5] - To verify transmission alignment See Transmission Alignment . (Group 0300.)

<- Go to Section TOC

Section 03 page 19

TM12408-REPAIR TECHNICAL MANUAL

Section 03 - TRANSMISSION

Group 0325: Input Drive Shafts and U-Joints

Group 0325 - Input Drive Shafts and U-Joints Engine-to-Transmission Drive Shaft Remove and Install Specifications SPECIFICATIONS Drive Shaft Weight (approximate)

52 kg 113 lb

Drive Shaft Cap Screw Torque

140 N·m 103 lb.-ft.

Other Material OTHER MATERIAL PM38657 U.S. High Flex Form-In-Place Gasket Maker PM38628 Canadian High Flex Form-In-Place Gasket Maker 17430 Loctite ™ High Flex Form-In-Place Gasket Maker

[1] - See Prepare Machine for Maintenance . (Group 0001.) [2] - Turn battery disconnect switch to the OFF position. [3] - Tilt Cab . (Operator’s Manual.) [4] LEGEND: 1

Cap Screw (4 used)

Cap Screws Remove cap screws (1). [5] LEGEND: 2 Cap Screw with Nut (2 used) 3 Guard 4 Cap Screw (4 used) 5 Drive Shaft

Drive Shaft Remove cap screws with nuts (2). Remove guard (3). [6] <- Go to Section TOC

Section 03 page 20

TM12408-REPAIR TECHNICAL MANUAL

Section 03 - TRANSMISSION

Group 0350: Gear, Shafts, and Power Shift Clutches

CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device. Remove cap screws (4). Remove drive shaft (5). Item

Measurement

Specification

Drive Shaft

Weight (approximate)

52 kg 113 lb

[7] - Repair or replace drive shaft as required. [8] IMPORTANT: Assemble drive shaft so yokes on ends of the shaft are aligned. If yokes are not aligned, severe vibration and machine damage may result. Install drive shaft to transmission. Apply PM38657 High Flex Form-In-Place Gasket Maker to cap screws. Install cap screws and tighten to specification. Number

Name

Use

• PM38657 (us) • PM38628 (canadian) • 17430 Loctite ™ (loctite)

High Flex Form-In-Place Gasket Maker

Apply to cap screws.

Item

Measurement

Specification

Drive Shaft Universal Joint Cap Screw

Torque

140 N˙m 103 lb-ft

[9] IMPORTANT: Assemble drive shaft so yokes on ends of the shaft are aligned. If yokes are not aligned, severe vibration and machine damage may result. Install drive shaft to engine. Apply PM38657 High Flex Form-In-Place Gasket Maker to cap screws. Install cap screws and tighten to specification. Number

Name

Use

• PM38657 (us) • PM38628 (canadian) • 17430 Loctite ™ (loctite)

High Flex Form-In-Place Gasket Maker

Apply to cap screws.

Item

Measurement

Specification

Drive Shaft Universal Joint Cap Screw

Torque

140 N˙m 103 lb-ft

[10] - Install guard with cap screws and nuts. [11] - Return cab to original position. [12] - Turn battery disconnect switch to the ON position.

<- Go to Section TOC

Section 03 page 21

TM12408-REPAIR TECHNICAL MANUAL

Section 03 - TRANSMISSION

Group 0350: Gear, Shafts, and Power Shift Clutches

Group 0350 - Gear, Shafts, and Power Shift Clutches Transmission Disassemble Specifications SPECIFICATIONS Transmission Weight (approximate)

862 kg 1900 lb.

Differential Clutch (G) Weight

91 kg 200 lb.

Mounting Device 1 and Hook Weight

86 kg 190 lb.

Mounting Device 1 with Clutches Weight

408 kg 900 lb.

Transmission Cover Weight

181 kg 400 lb.

Essential Tools ESSENTIAL TOOLS JDG11545 Transmission Bracket JDG11563 Rapid Grip JDG11568 Pressure Piece JDG11555 Reduction JDG11560 Reassembly Aid JDG11558 Mounting Device 1 JDG11557 Hook JDG11559 Mounting Device 2 JDG11554 Basic Unit

Service Equipment and Tools SERVICE EQUIPMENT AND TOOLS D001003AA Repair Stand

[1] - Remove transmission. See Transmission Remove and Install . (Group 0300.) [2] CAUTION: D001003AA Repair Stand is rated for 907 kg (2000 lb.). Prevent crushing injury from heavy component. Follow steps to remove transmission components before mounting transmission to repair stand. Support transmission on floor using blocks. [3] - Remove transmission control valve. See Transmission Control Valve Remove and Install . (Group 0360.) [4] -

<- Go to Section TOC

Section 03 page 22

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Section 03 - TRANSMISSION

Group 0350: Gear, Shafts, and Power Shift Clutches

LEGEND: 1 2 3

Cap Screw (4 used) Cover O-Ring

Cover Remove cap screws (1), cover (2), and O-ring (3). [5] LEGEND: 4 Cap Screw (8 used) 5 PTO Shaft/Flange Assembly 6 Cap Screw (2 used) 7 Washer 8 Yoke

PTO Shaft Flange Remove cap screws (4) and use levers to remove PTO shaft/flange assembly (5). [6] - Remove cap screws (6), washer (7), and yoke (8). [7] - Remove transmission clutch (F). See Transmission Clutch (F) Hi/Lo Planetary Remove and Install . (Group 0350.) [8] - Remove transmission speed sensors. See Transmission Speed Sensors Remove and Install . (Group 0350.) [9] - Remove transmission retarder. See Transmission Retarder Remove and Install . (Group 0360.) [10] - Drill holes into D001003AA Repair Stand to mount JDG11545 Transmission Brackets. Repair Stand D001003AA Supports and Rotates Transmission Transmission Bracket JDG11545 Mounts Transmission to Repair Stand [11] - Mount JDG11545 Transmission Brackets to D001003AA Repair Stand. [12] -

<- Go to Section TOC

Section 03 page 23

TM12408-REPAIR TECHNICAL MANUAL

Section 03 - TRANSMISSION

Group 0350: Gear, Shafts, and Power Shift Clutches

CAUTION: Prevent crushing injury from heavy component. Use appropriate lifting device. Mount transmission to brackets in stand. Item

Measurement

Specification

Transmission

Weight (approximate)

862 kg 1900 lb.

[13] - Remove washer and cup springs from input shaft of (V) clutch. [14] - Remove flange bushing, snap ring and O-ring from input shaft of (V) clutch. [15] LEGEND: 9 Cap Screw (43 used) 10 Hidden Cap Screw (3 used)

Housing

Cap Screw Remove cap screws (9) and hidden cap screws (10). [16] →NOTE: Remove pins using a slide hammer with threaded M6 x 1.0 attachment.

<- Go to Section TOC

Section 03 page 24

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Section 03 - TRANSMISSION

Group 0350: Gear, Shafts, and Power Shift Clutches

LEGEND: 11

Pin (2 used)

Pins Remove pins (11). [17] CAUTION: Prevent crushing injury from heavy component. Use appropriate lifting device. →NOTE: Use fully threaded M10 jack screws of appropriate length. LEGEND: 12

Jack Screw (2 used)

Cover Evenly separate housing using jack screws (12). Remove cover. Item

Measurement

Specification

Transmission Cover

Weight

181 kg 400 lb.

[18] -

<- Go to Section TOC

Section 03 page 25

TM12408-REPAIR TECHNICAL MANUAL

Section 03 - TRANSMISSION

Group 0350: Gear, Shafts, and Power Shift Clutches

LEGEND: 13 14 15 16 17

Cap Screw (2 used) Bracket Cap Screw Clip Wire Harness

LEGEND: 18 19

Cap Screw (19 used) Pipe (9 used)

LEGEND: 20 21

Cap Screw (2 used) Suction Tube

Wire Harness Remove cap screws (13) and bracket (14). [19] - Remove cap screw (15) and clip (16). [20] - Remove wire harness (17). [21] -

Piping Remove cap screws (18) and pipes (19). [22] -

Suction Tube Remove cap screws (20) and suction tube (21). [23] <- Go to Section TOC

Section 03 page 26

TM12408-REPAIR TECHNICAL MANUAL

Section 03 - TRANSMISSION

Group 0350: Gear, Shafts, and Power Shift Clutches

→NOTE: Use an appropriate length of 1-7/8 in. round stock between the pressure piece and the jack screw of the basic unit. LEGEND: 22 23

JDG11568 Pressure Piece JDG11563 Rapid Grip

Tooling Set JDG11568 Pressure Piece (22) to boss in transmission cover, install JDG11563 Rapid Grip (23) to the outer race of bearing, thread JDG11555 Reduction onto the rapid grip. Use an appropriate length of 1-7/8 in. round stock between the pressure piece and the jack screw of the basic unit. Thread basic unit onto the reduction. Rotate jack screw against round stock and pressure piece to remove bearing. Rapid Grip JDG11563 Bearing Removal Pressure Piece JDG11568 Press Tool Reduction JDG11555 Tool Adapter Basic Unit JDG11554 Applies Pressure [24] LEGEND: 24

Bearing Race (7 used)

Bearing Races Remove bearing races (24). [25] -

<- Go to Section TOC

Section 03 page 27

TM12408-REPAIR TECHNICAL MANUAL

Section 03 - TRANSMISSION

Group 0350: Gear, Shafts, and Power Shift Clutches

LEGEND: 25 26

Retaining Ring Bearing

LEGEND: 27

Plug with O-Ring (5 used)

Bearing Remove retaining ring (25). Drive out bearing (26). [26] -

Plugs Remove plugs with O-rings (27). [27] →NOTE: Use a helper when removing input shaft (30). →NOTE: When removing and installing input shaft (30), make sure snap ring (29) end gap (31) is accessible in opening (28). LEGEND: 28 29 30 31

Opening (4 used) Snap Ring Input Shaft End Gap

Shaft Removal <- Go to Section TOC

Section 03 page 28

TM12408-REPAIR TECHNICAL MANUAL

Section 03 - TRANSMISSION

Group 0350: Gear, Shafts, and Power Shift Clutches

Top View Use appropriate pry tool in openings (28) to compress snap ring (29) into groove around circumference of input shaft (30). When snap ring is properly compressed, lift input shaft straight up to remove. [28] LEGEND: 32 33 34

O-Ring O-Ring Snap Ring

LEGEND: 35

Screen Sheet

Input Shaft Remove O-rings (32 and 33). Remove snap ring (34). [29] -

Screen Sheet Remove screen sheet (35). [30] -

<- Go to Section TOC

Section 03 page 29

TM12408-REPAIR TECHNICAL MANUAL

Section 03 - TRANSMISSION

Group 0350: Gear, Shafts, and Power Shift Clutches

CAUTION: Prevent crushing injury from heavy component. Use appropriate lifting device. →NOTE: Applying strikes to the shaft from below while lifting the clutch, will aid in clutch removal. LEGEND: 36

Differential Clutch (G)

Differential Clutch (G) Remove differential clutch (G) (36). Item

Measurement

Specification

Differential Clutch (G)

Weight

91 kg 200 lb.

[31] CAUTION: Use proper tooling when removing clutches. Attempting clutch removal without required tooling can cause personal injury and machine damage. LEGEND: 37 38 39 40 41 42 43

Clutch (R) Clutch (B) Clutch (V) Clutch (D) Clutch (E) Clutch (A) Clutch (C)

Clutch Arrangement Identify clutches (37—43). [32] -

<- Go to Section TOC

Section 03 page 30

TM12408-REPAIR TECHNICAL MANUAL

Section 03 - TRANSMISSION

Group 0350: Gear, Shafts, and Power Shift Clutches

CAUTION: Prevent crushing injury from heavy component. Use appropriate lifting device. →NOTE: Bar stock, threaded rods, knurled nuts, and locating pins required for use with JDG11558 Mounting Device 1 are included with purchased tool. LEGEND: 44 45 46

Reassembly Aid Mounting Device 1 Hook

Tooling Install reassembly aid (44) to transmission clutch (E). Mount hook (46) to mounting device 1 (45). Align and lower mounting device 1 to transmission clutches. Reassembly Aid JDG11560 Clutch Holder Mounting Device 1 JDG11558 Holds Clutches for Removal Hook JDG11557 Lifts Mounting Device 1 Item

Measurement

Specification

Mounting Device 1 and Hook

Weight

86 kg 190 lb.

[33] LEGEND: 47

Knurled Nut (6 used)

JDG11558 Mounting Device 1 <- Go to Section TOC

Section 03 page 31

TM12408-REPAIR TECHNICAL MANUAL

Section 03 - TRANSMISSION

Group 0350: Gear, Shafts, and Power Shift Clutches

Fasten clutches (R, A, B, C, D, and E) to JDG11558 Mounting Device 1 using knurled nuts (47). Mounting Device 1 JDG11558 Holds Clutches for Removal [34] LEGEND: 48 49

Threaded Rod Knurled Nut

Clutch (V) Use threaded rod (48) and knurled nut (49) to fasten clutch (V) to JDG11558 Mounting Device 1. Mounting Device 1 JDG11558 Holds Clutches for Removal [35] CAUTION: Prevent crushing injury from heavy component. Use appropriate lifting device. LEGEND: 50 JDG11559 Mounting Device 2

JDG11559 Mounting Device 2 Set JDG11559 Mounting Device 2 (50) onto working surface. Lift JDG11558 Mounting Device 1 with clutches into JDG11559 Mounting Device 2. Mounting Device 1 JDG11558 Holds Clutches for Removal Mounting Device 2 JDG11559 <- Go to Section TOC

Section 03 page 32

TM12408-REPAIR TECHNICAL MANUAL

Section 03 - TRANSMISSION

Group 0350: Gear, Shafts, and Power Shift Clutches

Holds Clutches Item

Measurement

Specification

Mounting Device 1 with Clutches

Weight

408 kg 900 lb.

[36] LEGEND: 51 JDG11558 Mounting Device 1

JDG11558 Mounting Device 1 Removal Remove knurled nuts. Remove JDG11558 mounting device 1 (51). [37] - Remove and install transmission clutches from JDG11559 mounting device 2 as required for inspection, cleaning, and repair. [38] LEGEND: 52

JDG11563 Rapid Grip

JDG11563 Rapid Grip Set JDG11568 Pressure Piece to boss in transmission, install JDG11563 Rapid Grip (52) to the outer race of bearing, thread JDG11555 Reduction over the pressure piece and onto the rapid grip. Thread JDG11554 Basic Unit onto the reduction. Rapid Grip JDG11563 Bearing Removal Pressure Piece JDG11568 Press Tool Reduction JDG11555 Tool Adapter Basic Unit <- Go to Section TOC

Section 03 page 33

TM12408-REPAIR TECHNICAL MANUAL

Section 03 - TRANSMISSION

Group 0350: Gear, Shafts, and Power Shift Clutches

JDG11554 Applies Pressure [39] - Use an appropriate length of 1-7/8 in. round stock between the pressure piece and the jack screw of the basic unit. Rotate jack screw against round stock and pressure piece to remove bearing. [40] LEGEND: 53

Screen Sheet

LEGEND: 54

Retaining Ring

LEGEND: 55 56

Puller Needle Sleeve

Screen Sheet Remove screen sheet (53). [41] -

Retaing Ring Remove retaining ring (54). [42] -

Needle Sleeve <- Go to Section TOC

Section 03 page 34

TM12408-REPAIR TECHNICAL MANUAL

Section 03 - TRANSMISSION

Group 0350: Gear, Shafts, and Power Shift Clutches

Using an appropriate puller (55) remove needle sleeve (56). [43] LEGEND: 57 Outer Bearing Race (6 used)

Outer Bearing Races Remove outer bearing races (57). [44] LEGEND: 58

Retaining Ring

Retaining Ring Expand retaining ring (58) until it clears groove in the ball bearing. Drive shaft out with slight hits until the groove passes the retaining ring. [45] LEGEND: 59

Gear

Steering Pump Drive Gear Use assembly lever to remove gear (59). [46] <- Go to Section TOC

Section 03 page 35

TM12408-REPAIR TECHNICAL MANUAL

Section 03 - TRANSMISSION

Group 0350: Gear, Shafts, and Power Shift Clutches

LEGEND: 60 61

Retaining Ring Bearing

LEGEND: 62 63

Cap Screw (3 used) Cable Tie (6 used)

LEGEND: 64

Wire Harness

Gear Remove retaining ring (60) and bearing (61). [47] -

Wire Harness Remove cap screws (62) and cable ties (63). [48] -

Wire Harness Remove wire harness (64). [49] -

<- Go to Section TOC

Section 03 page 36

TM12408-REPAIR TECHNICAL MANUAL

Section 03 - TRANSMISSION

Group 0350: Gear, Shafts, and Power Shift Clutches

LEGEND: 65

Cap Screw (18 used)

Pipes Remove cap screws (65) and all pipes. [50] →NOTE: Transmission calibration must be performed after servicing the transmission. See Electronic Clutch Calibration . (Group 9020-25.) Clean, inspect, repair or replace transmission parts as required.

<- Go to Section TOC

Section 03 page 37

TM12408-REPAIR TECHNICAL MANUAL

Section 03 - TRANSMISSION

Group 0350: Gear, Shafts, and Power Shift Clutches

Transmission Assemble Specifications SPECIFICATIONS Pipe Mounting Cap Screw Torque

23 N·m 17 lb.-ft.

Bearing Temperature

120°C 248°F

Differential Clutch (G) Weight

91 kg 200 lb

Plugs with O-Rings Torque

25 N·m 19 lb.-ft.

Transmission Cover Cap Screw Torque

50 N·m 37 lb.-ft.

Mounting Device 1 and Hook Weight

86 kg 190 lb.

Mounting Device 1 with Clutches Weight

408 kg 900 lb.

Transmission Cover Weight

181 kg 400 lb.

Essential Tools ESSENTIAL TOOLS JDG11559 Mounting Device 2 JDG11560 Reassembly Aid JDG11558 Mounting Device 1 JDG11557 Hook JDG11568 Pressure Piece JDG11572 Slip Bushing JDG11431 Installer JDG11434 Installer

[1] →NOTE: Transmission calibration must be performed after servicing the transmission. See Electronic Clutch Calibration . (Group 9020-25.) LEGEND: 1

O-Ring (18 used)

O-Rings Replace and grease O-rings (1). [2] - Install pipes using cap screws and tighten to specification. Item

Measurement

Specification

Pipe Mounting Cap Screw

Torque

23 N·m

<- Go to Section TOC

Section 03 page 38

TM12408-REPAIR TECHNICAL MANUAL

Section 03 - TRANSMISSION Item

Group 0350: Gear, Shafts, and Power Shift Clutches Measurement

Specification 17 lb.-ft.

[3] IMPORTANT: Use quality cable ties when fastening wire harness. Failure to use cable ties resistant to heat and lubricants may result in machine damage. LEGEND: 2 3 4

Wire Harness Cap Screw (3 used) Cable Tie (6 used)

LEGEND: 5 6 7

Retaining Ring Ball Bearing Inner Race

Wire Harness Install wire harness (2) using cap screws (3) and cable ties (4). [4] -

Retaining Ring Expand retaining ring (5) and press ball bearing (6) until retaining ring closes into groove of ball bearing. [5] - Heat inner race (7) to specification. Item

Measurement

Specification

Bearing Temperature

Temperature

120°C 248°F

[6] -

<- Go to Section TOC

Section 03 page 39

TM12408-REPAIR TECHNICAL MANUAL

Section 03 - TRANSMISSION

Group 0350: Gear, Shafts, and Power Shift Clutches

LEGEND: 8

Gear

Steering Pump Drive Gear Install gear (8) until it seats and contact is made. [7] LEGEND: 9 10

Retaining Ring Groove

LEGEND: 11 12

Bearing Retaining Ring

Retaining Ring Install retaining ring (9) to groove (10). [8] -

Bearing Install bearing (11) and secure with retaining ring (12). [9] -

<- Go to Section TOC

Section 03 page 40

TM12408-REPAIR TECHNICAL MANUAL

Section 03 - TRANSMISSION

Group 0350: Gear, Shafts, and Power Shift Clutches

LEGEND: 13 Bearing Outer Race (6 used)

Bearing Outer Races Install bearing outer races (13). [10] IMPORTANT: Exact position of needle bearing (15) is obtained only when using JDG11568 Pressure Piece (14). Use JDG11568 Pressure Piece to install needle bearing or machine damage can occur. LEGEND: 14 15

JDG11568 Pressure Piece Needle Bearing

LEGEND: 16

Retaining Ring

JDG11568 Pressure Piece Install needle bearing (15) using JDG11568 Pressure Piece (14). Pressure Piece JDG11568 Assembly Aid [11] -

Retaining Ring <- Go to Section TOC

Section 03 page 41

TM12408-REPAIR TECHNICAL MANUAL

Section 03 - TRANSMISSION

Group 0350: Gear, Shafts, and Power Shift Clutches

Install retaining ring (16). [12] LEGEND: 17

Screen Sheet

LEGEND: 18

Bearing Inner Race

Screen Sheet Install screen sheet (17). [13] -

Bearing Inner Race Heat bearing inner race (18) to specification. Item

Measurement

Specification

Bearing Temperature

Temperature

120°C 248°F

[14] →NOTE: Press bearing (19) into position until contact is made. LEGEND: 19

Bearing

Bearing Installation Install bearing (19). <- Go to Section TOC

Section 03 page 42

TM12408-REPAIR TECHNICAL MANUAL

Section 03 - TRANSMISSION

Group 0350: Gear, Shafts, and Power Shift Clutches

[15] CAUTION: It is not possible to remove or install single clutch assemblies. Use proper tooling when removing and installing clutches. Attempting clutch removal or installation without required tooling can cause personal and machine damage.

CAUTION: Prevent crushing injury from heavy component. Use appropriate lifting device. LEGEND: 20 21 22 23 24 25 26

Clutch (C) Clutch (A) Clutch (V) Clutch (R) Clutch (B) Clutch (D) Clutch (E)

Clutch Arrangement Install clutches (20—26) to JDG11559 Mounting Device 2. Slide all clutches to their innermost position in the mounting device. Mounting Device 2 JDG11559 Holds Clutches [16] - Install JDG11560 Reassembly Aid to transmission clutch (E) (26). Reassembly Aid JDG11560 Clutch Holder [17] CAUTION: Prevent crushing injury from heavy component. Use appropriate lifting device. →NOTE: Bar stock, threaded rods, knurled nuts, and locating pins required for use with mounting device 1 are included with purchased tool JDG11558.

<- Go to Section TOC

Section 03 page 43

TM12408-REPAIR TECHNICAL MANUAL

Section 03 - TRANSMISSION

Group 0350: Gear, Shafts, and Power Shift Clutches

LEGEND: 27 JDG11558 Mounting Device 1 28 JDG11557 Hook

JDG11558 Mounting Device 1 Mounting Device 1 JDG11558 Holds Clutches Hook JDG11557 Lifts Mounting Device 1 Item

Measurement

Specification

Mounting Device 1 and Hook

Weight

86 kg 190 lb.

Using an appropriate lifting device mount JDG11557 Hook (28) to JDG11558 Mounting Device 1 (27). Align and lower mounting device 1 to transmission clutches. [18] - Fasten clutches to JDG11558 Mounting Device 1. Mounting Device 1 JDG11558 Holds Clutches [19] CAUTION: Prevent crushing injury from heavy component. Use appropriate lifting device. →NOTE: Use locating pins (29) to aid in installation alignment. LEGEND: 29

Locating Pin (4 used)

Clutch Installation Using an appropriate lifting device, install clutches to transmission housing. <- Go to Section TOC

Section 03 page 44

TM12408-REPAIR TECHNICAL MANUAL

Section 03 - TRANSMISSION

Group 0350: Gear, Shafts, and Power Shift Clutches

Item

Measurement

Specification

Mounting Device 1 with Clutches

Weight

408 kg 900 lb.

[20] - Remove special tool fastenings and JDG11558 Mounting Device 1. [21] LEGEND: 30

JDG11560 Reassembly Aid

Transmission Clutch (E) Remove JDG11560 Reassembly Aid (30) from transmission clutch (E). Reassembly Aid JDG11560 Clutch Holder [22] LEGEND: 31

Bearing Inner Race

Bearing Inner Race Heat bearing inner bearing race (31) to specification. Item

Measurement

Specification

Bearing Temperature

Temperature

120°C 248°F

[23] CAUTION: Prevent crushing injury from heavy component. Use appropriate lifting device.

<- Go to Section TOC

Section 03 page 45

TM12408-REPAIR TECHNICAL MANUAL

Section 03 - TRANSMISSION

Group 0350: Gear, Shafts, and Power Shift Clutches

CAUTION: Transmission clutch (G) output gear (32) must mesh with emergency steering pump input gear (33). Failure to align transmission clutch (G) output gear with emergency steering pump input gear while installing transmission clutch (G) (34) may result in machine and/or personal damage. LEGEND: 32 Transmission Clutch (G) Output Gear 33 Emergency Steering Pump Input Gear 34 Transmission Clutch (G)

Gear Alignment

Transmission Clutch (G) Install transmission clutch (G) (34). Item

Measurement

Specification

Differential Clutch (G)

Weight

91 kg 200 lb

[24] LEGEND: 35 36 37 38

Retaining Ring O-Ring O-Ring Input Shaft

Input Shaft Verify retaining ring (35) is installed. Install and grease O-rings (36 and 37) to input shaft (38). [25] <- Go to Section TOC

Section 03 page 46

TM12408-REPAIR TECHNICAL MANUAL

Section 03 - TRANSMISSION

Group 0350: Gear, Shafts, and Power Shift Clutches

LEGEND: 39 40 41 42 43

Retaining Ring End Gap Retaining Ring Opening (4 used) JDG11572 Slip Bushing Input Shaft

Retaining Ring End Gap

Slip Bushing Install retaining ring (40) to input shaft (43). Align input shaft and retaining ring end gap (39) to opening (41) of transmission clutch (V). Note position of input shaft in relation to opening in transmission clutch (V). Lift input shaft and install JDG11572 Slip Bushing (42) with the tapered bore toward input shaft. Slip Bushing JDG11572 Aids Input Shaft Installation [26] - Push down on input shaft to collapse retaining ring in bore of slip bushing. Push down and rotate input shaft slightly to engage splines. Complete installation by pushing input shaft into splines until retaining ring makes contact in groove. Remove JDG11572 Slip Bushing and verify position of retaining ring end gap. [27] LEGEND: 44

Screen Sheet

Screen Sheet Install screen sheet (44). [28] -

<- Go to Section TOC

Section 03 page 47

TM12408-REPAIR TECHNICAL MANUAL

Section 03 - TRANSMISSION

Group 0350: Gear, Shafts, and Power Shift Clutches

LEGEND: 45

Bearing Inner Race

Bearing Inner Race Heat bearing inner race (45) to specification. Item

Measurement

Specification

Bearing Temperature

Temperature

120°C 248°F

[29] LEGEND: 46 47

Bearing Bearing Outer Race (6 used)

LEGEND: 48 49

O-Ring Suction Tube

Transmission Cover Install bearing (46). Grease and install bearing outer races (47). [30] -

Suction Tube Grease and install O-ring (48) to suction tube (49). [31] -

<- Go to Section TOC

Section 03 page 48

TM12408-REPAIR TECHNICAL MANUAL

Section 03 - TRANSMISSION

Group 0350: Gear, Shafts, and Power Shift Clutches

LEGEND: 50 51

Suction Tube Cap Screw (2 used)

Suction Tube Install Install suction tube (50) using cap screws (51). Tighten to specification. Item

Measurement

Specification

Pipe Mounting Cap Screw

Torque

23 N·m 17 lb.-ft.

[32] LEGEND: 52 53

O-Ring (2 used) Pipe

LEGEND: 54 55

Pipe Cap Screw (2 used)

Pipe Grease and install O-rings (52) to pipe (53). [33] -

Transmission Cover Install pipe (54) using cap screws (55). Tighten to specification. Item

Measurement

Specification

Pipe Mounting Cap Screw

Torque

23 N·m 17 lb.-ft.

[34] -

<- Go to Section TOC

Section 03 page 49

TM12408-REPAIR TECHNICAL MANUAL

Section 03 - TRANSMISSION

Group 0350: Gear, Shafts, and Power Shift Clutches

→NOTE: Route wiring harness so speed sensor and bracket are accessible through the opening for the transmission control valve. For more information see Transmission Speed Sensors Remove and Install . (Group 0350.) LEGEND: 56 57 58 59 60

Wire Harness Plate Cap Screw (2 used) Clip Cap Screw

Wire Harness Install wire harness (56) to plate (57) and fasten with cap screws (58). Tighten to specification. Fasten wire harness to case using clip (59) and cap screw (60). Use cable ties as required to secure wire harness. Item

Measurement

Specification

Cap Screw

Torque

23 N·m 17 lb.-ft.

[35] LEGEND: 61

Plug with O-Ring (5 used)

Plugs with O-Rings Install plugs with O-rings (61), tighten to specification. Item

Measurement

Specification

Plugs with O-rings

Torque

25 N·m 19 lb.-ft.

[36] -

<- Go to Section TOC

Section 03 page 50

TM12408-REPAIR TECHNICAL MANUAL

Section 03 - TRANSMISSION

Group 0350: Gear, Shafts, and Power Shift Clutches

LEGEND: 62 63

Bearing Retaining Ring

Bearing Using appropriate tooling, install bearing (62) and secure with retaining ring (63). [37] CAUTION: Prevent crushing injury from heavy component. Use appropriate lifting device. IMPORTANT: When lowering transmission cover (66) to transmission (67) verify proper alignment of screen sheets. Failure to verify the alignment of the screen sheets may result in machine damage.

Cover Assembly LEGEND: 64 Alignment Tool (2 used) 65 O-Ring (2 used) 66 Transmission Cover 67 Transmission Install alignment tools (64) to transmission (67). Install O-rings (65). Align transmission cover (66) and lower to transmission (67). Item

Measurement

Specification

Transmission Cover

Weight

181 kg 400 lb.

[38] -

<- Go to Section TOC

Section 03 page 51

TM12408-REPAIR TECHNICAL MANUAL

Section 03 - TRANSMISSION

Group 0350: Gear, Shafts, and Power Shift Clutches

LEGEND: 68 69

Pin (2 used) Cap Screw (43 used)

Assembly Install pins (68) and cap screws (69). Tighten cap screws to specification. Item

Measurement

Specification

Transmission Cover Cap Screw

Torque

50 N·m 37 lb.-ft.

[39] LEGEND: 70

Cap Screw (3 used)

Hidden Cap Screws Install cap screws (70) and tighten to specification. Item

Measurement

Specification

Transmission Cover Cap Screw

Torque

50 N·m 37 lb.-ft.

[40] LEGEND: 71 72

JDG11431 Installer Seal

Shaft Seal (output to front axle) Prior to installation, fill area between sealing lip and dust lip with grease. Apply 99% isopropyl alcohol to outer diameter (rubber coated) of seal (72). <- Go to Section TOC

Section 03 page 52

TM12408-REPAIR TECHNICAL MANUAL

Section 03 - TRANSMISSION

Group 0350: Gear, Shafts, and Power Shift Clutches

[41] - Use JDG11431 Installer (71) to install seal (72) with sealing lip towards the transmission oil sump. Seal Installer JDG11431 Shaft seal Installation [42] LEGEND: 78 79 80

Yoke With O-ring Washer Cap Screw (2 used)

Yoke (output to front axle) Press screen onto yoke. Install cap screws (80), washer (79), and yoke with O-ring (78). Tighten cap screws to specification. Item

Measurement

Specification

Cap Screw

Torque

70 N·m 52 lb.-ft.

[43] LEGEND: 73 74

JDG11434 Installer Seal

Shaft Seal (output to rear axle) Prior to installation, fill area between sealing lip and dust lip with grease. Apply Loctite ™ 574 on outer diameter of seal (74). Use JDG11434 Installer (73) to install seal (74) with sealing lip towards the transmission oil sump. Seal Installer JDG11434 Shaft seal Installation [44] - Press screen onto yoke. [45] -

<- Go to Section TOC

Section 03 page 53

TM12408-REPAIR TECHNICAL MANUAL

Section 03 - TRANSMISSION

Group 0350: Gear, Shafts, and Power Shift Clutches

LEGEND: 75 76 77

Yoke With O-ring Cap Screw (2 used) Washer

Yoke (output to rear axle) Install cap screws (76), washer (77), and yoke with O-ring (75). Tighten cap screws to specification. Item

Measurement

Specification

Cap Screw

Torque

120 N·m 88 lb.-ft.

→NOTE: Transmission calibration must be performed after servicing the transmission. See Electronic Clutch Calibration . (Group 9020-25.)

<- Go to Section TOC

Section 03 page 54

TM12408-REPAIR TECHNICAL MANUAL

Section 03 - TRANSMISSION

Group 0350: Gear, Shafts, and Power Shift Clutches

Transmission Clutch (F) Hi/Lo Planetary Disassemble and Assemble Specifications SPECIFICATIONS Clutch (F) Weight

70 kg 155 lb.

Planetary Carrier Weight

45 kg 100 lb.

Slotted Pin Length

5 mm 0.2 in.

Bearing Temperature

120°C 248°F

Essential Tools ESSENTIAL TOOLS JDG11565 Eye Bolt JDG11571 Assembly Aid

[1] LEGEND: 1

O-Ring

LEGEND: 2

Pin (2 used)

O-Ring Remove O-ring (1). [2] -

Pins Remove pins (2) flush from cover. [3] -

<- Go to Section TOC

Section 03 page 55

TM12408-REPAIR TECHNICAL MANUAL

Section 03 - TRANSMISSION

Group 0350: Gear, Shafts, and Power Shift Clutches

CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device. LEGEND: 3 JDG11565 Eye Bolt 4 Planetary Carrier with Ring Gear 5 Cover

JDG11565 Eye Bolt Install JDG11565 Eye Bolt (3) and remove planetary carrier with ring gear (4) from cover (5). Eyebolt JDG11565 Clutch (F) Removal Item

Measurement

Specification

Clutch (F)

Weight

70 kg 155 lb.

[4] LEGEND: 6 7

Snap Ring Bearing

Snap Ring Remove eye bolt and place planetary carrier with ring gear, shaft side down. Remove snap ring (6) and using an appropriate puller, remove bearing (7). [5] -

<- Go to Section TOC

Section 03 page 56

TM12408-REPAIR TECHNICAL MANUAL

Section 03 - TRANSMISSION

Group 0350: Gear, Shafts, and Power Shift Clutches

LEGEND: 8 9

Retaining Ring Thrust Ring

Thrust Ring Remove retaining ring (8) and thrust ring (9). [6] CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device. LEGEND: 10

Planetary Carrier

Planetary Carrier Removal Install JDG11565 Eye Bolt and remove planetary carrier (10) from ring gear. Eyebolt JDG11565 Clutch (F) Removal Item

Measurement

Specification

Planetary Carrier

Weight

45 kg 100 lb.

[7] -

<- Go to Section TOC

Section 03 page 57

TM12408-REPAIR TECHNICAL MANUAL

Section 03 - TRANSMISSION

Group 0350: Gear, Shafts, and Power Shift Clutches

LEGEND: 11 12

Thrust Ring Retaining Ring

LEGEND: 13 14

Pin (3 used) Bearing

Ring Gear Remove thrust ring (11) and retaining ring (12) from ring gear. [8] -

Pins Remove pins (13) and remove bearing (14) from planetary carrier. [9] LEGEND: 15

Slotted Pin (5 used)

Pin Installation Drive slotted pins (15) into the planetary pins until they contact the planetary carrier housing. [10] -

<- Go to Section TOC

Section 03 page 58

TM12408-REPAIR TECHNICAL MANUAL

Section 03 - TRANSMISSION

Group 0350: Gear, Shafts, and Power Shift Clutches

LEGEND: 16

Planetary Pin (5 used)

LEGEND: 15 16

Slotted Pin (5 used) Planetary Pin (5 used)

Planetary Carrier Drive planetary pins (16) out of planetary carrier. [11] -

Planetary Pins Once the planetary pins (16) are removed, remove the slotted pins (15). [12] LEGEND: 19

Planet Gear (5 used)

Planetary Carrier Remove planet gears (19) from planetary carrier. [13] -

<- Go to Section TOC

Section 03 page 59

TM12408-REPAIR TECHNICAL MANUAL

Section 03 - TRANSMISSION

Group 0350: Gear, Shafts, and Power Shift Clutches

LEGEND: 20 21

Roller (28 used) Washer (15 used)

LEGEND: 22

Sun Gear

Planet Gear Remove rollers (20) and washers (21) from planet gears. [14] -

Sun Gear Remove sun gear (22) from planetary carrier. [15] LEGEND: 23

Rectangular Ring

Rectangular Ring Remove rectangular ring (23) from sun gear. [16] -

<- Go to Section TOC

Section 03 page 60

TM12408-REPAIR TECHNICAL MANUAL

Section 03 - TRANSMISSION

Group 0350: Gear, Shafts, and Power Shift Clutches

LEGEND: 24

Driving Pin (3 used)

LEGEND: 25 26

Pressure Ring (2 used) Driving Pin (3 used)

Driving Pins Using a magnet, remove driving pins (24). [17] -

Pressure Rings Using a magnet, remove pressure rings (25) and remaining driving pins (26). [18] LEGEND: 27

Bearing

Planetary Carrier Remove bearing (27). [19] -

<- Go to Section TOC

Section 03 page 61

TM12408-REPAIR TECHNICAL MANUAL

Section 03 - TRANSMISSION

Group 0350: Gear, Shafts, and Power Shift Clutches

LEGEND: 28 29 30

Retaining Ring End Shim Disc Set

Clutch Pack Remove retaining ring (28), end shim (29) and disc set (30) from cover. [20] LEGEND: 31

JDG11571 Assembly Aid

JDG11571 Assembly Aid

Preload Cup Spring Set Use JDG11571 assembly aid (31) to preload cup spring. Assembly Aid JDG11571 Assembly Aid [21] -

<- Go to Section TOC

Section 03 page 62

TM12408-REPAIR TECHNICAL MANUAL

Section 03 - TRANSMISSION

Group 0350: Gear, Shafts, and Power Shift Clutches

LEGEND: 32 33

Guide Ring Cup Spring

Cup Spring With the cup spring pre-loaded, remove the guide ring (32). Remove tooling and remove cup spring (33). [22] LEGEND: 34

Pressure Port

Piston Removal Apply compressed air to pressure port (34) to remove piston. [23] IMPORTANT: Do not reuse O-rings and tension pins. Replace all O-rings and tension pins with new parts or machine damage could occur. LEGEND: 35 36

O-Ring O-Ring

O-Rings Remove O-rings (35, 36) from piston. Clean and inspect all parts. Repair or replace parts as required. <- Go to Section TOC

Section 03 page 63

TM12408-REPAIR TECHNICAL MANUAL

Section 03 - TRANSMISSION

Group 0350: Gear, Shafts, and Power Shift Clutches

[24] LEGEND: 37

Bearing

Planetary Carrier Using a press, install bearing (37). [25] LEGEND: 38 39 40

Drive Pin (3 used) Pressure Ring (2 used) Driving Pin (3 used)

Pressure Ring Position

Pressure Rings

<- Go to Section TOC

Section 03 page 64

TM12408-REPAIR TECHNICAL MANUAL

Section 03 - TRANSMISSION

Group 0350: Gear, Shafts, and Power Shift Clutches

Driving Pins Install drive pins (38), pressure rings (39), and driving pins (40). [26] LEGEND: 43

Rectangular Ring

LEGEND: 44 45

Sun Gear Planetary Carrier

Rectangular Ring Grease and install rectangular ring (43) to sun gear. [27] -

Sun Gear Install sun gear (44) to planetary carrier (45). [28] -

<- Go to Section TOC

Section 03 page 65

TM12408-REPAIR TECHNICAL MANUAL

Section 03 - TRANSMISSION

Group 0350: Gear, Shafts, and Power Shift Clutches

LEGEND: 41 42

Washer (15 used) Roller (28 used)

LEGEND: 46 47

Pressure Ring (2 used) Planet Gear (5 used)

Planet Gear Grease and preassemble washers (41) and rollers (42). [29] -

Planetary Carrier Verify correct pressure ring (46) location. Install planet gears (47) into the planetary carrier. [30] →NOTE: Install planet gears and pins one at a time. LEGEND: 47 49

Planet Gear (5 used) Planetary Pin (5 used)

Planetary Carrier Install planet gears (47) and planetary pins (49). Align planetary pin holes with holes in the planetary carrier. [31] -

<- Go to Section TOC

Section 03 page 66

TM12408-REPAIR TECHNICAL MANUAL

Section 03 - TRANSMISSION

Group 0350: Gear, Shafts, and Power Shift Clutches

LEGEND: 49 51 52

Planetary Pin (5 used) Slotted Pin (5 used) Planetary Carrier

Pin Installation Fasten planetary pins (49) with slotted pins (51). Drive pins flush with planetary carrier (52). [32] LEGEND: 53

Bearing

Bearing Heat bearing (53) to specification. Item

Measurement

Specification

Bearing

Temperature

120°C 248°F

[33] LEGEND: 54 55

Bearing Pin (3 used)

Pins

<- Go to Section TOC

Section 03 page 67

TM12408-REPAIR TECHNICAL MANUAL

Section 03 - TRANSMISSION

Group 0350: Gear, Shafts, and Power Shift Clutches

Pin Dimension Install bearing (54) and pins (55) to dimension. Item

Measurement

Specification

Slotted Pin

Length

5 mm 0.2 in.

[34] LEGEND: 56 57

Retaining Ring Thrust ring

LEGEND: 3 59 60

JDG11565 Eye Bolt Planetary Carrier Ring Gear

Ring Gear Install retaining ring (56) and thrust ring (57). [35] -

Gear Installation Install JDG11565 Eye Bolt (3). Lift planetary carrier (59) and install to ring gear (60). [36] -

<- Go to Section TOC

Section 03 page 68

TM12408-REPAIR TECHNICAL MANUAL

Section 03 - TRANSMISSION

Group 0350: Gear, Shafts, and Power Shift Clutches

LEGEND: 61 62

Thrust Ring Retaining Ring

LEGEND: 63 64

Bearing Snap Ring

LEGEND: 65 66

O-Ring O-Ring

Thrust Ring Install thrust ring (61) and retaining ring (62). [37] -

Snap Ring Install bearing (63) and snap ring (64). [38] -

O-Rings Install O-rings (65, 66) to piston. [39] -

<- Go to Section TOC

Section 03 page 69

TM12408-REPAIR TECHNICAL MANUAL

Section 03 - TRANSMISSION

Group 0350: Gear, Shafts, and Power Shift Clutches

LEGEND: 67 31

Piston JDG11571 Assembly Aid

JDG11571 Assembly Aid Install piston (67). Press into place with JDG11571 Assembly Aid (31). Assembly Aid JDG11571 Assembly Aid [40] LEGEND: 69 70

Cup Spring Guide Ring

LEGEND: 31

JDG11571 Assembly Aid

Cup Spring Position cup spring (69) and guide ring (70). [41] -

JDG11571 Assembly Aid Position JDG11571 Assembly Aid (31). Assembly Aid JDG11571 Assembly Aid <- Go to Section TOC

Section 03 page 70

TM12408-REPAIR TECHNICAL MANUAL

Section 03 - TRANSMISSION

Group 0350: Gear, Shafts, and Power Shift Clutches

[42] →NOTE: Check seating of the guide ring upon completion of the cup spring installation. LEGEND: 31 73 74

JDG11571 Assembly Aid Guide Ring Cup Spring

JDG11571 Assembly Aid

Assembly Press JDG11571 Assembly Aid (31) and install guide ring (73). Verify position of parts (73, 74). Assembly Aid JDG11571 Assembly Aid [43] LEGEND: 75

Bearing

Bearing Heat inner race of bearing (75) to specification.. Item

Measurement

Specification

Bearing

Temperature

120°C

<- Go to Section TOC

Section 03 page 71

TM12408-REPAIR TECHNICAL MANUAL

Section 03 - TRANSMISSION Item

Group 0350: Gear, Shafts, and Power Shift Clutches Measurement

Specification 248°F

[44] LEGEND: 3 JDG11565 Eye Bolt 4 Planetary Carrier with Ring Gear 5 Cover

JDG11565 Eye Bolt Install planetary carrier with ring gear (4) to cover (5) by using JDG11565 Eye Bolt (3). [45] IMPORTANT: Start assembly with an outer clutch disc (79), with coated side of clutch disc facing piston.

Clutch Discs (370E) LEGEND: 78 Planetary Drive 79 Outer Disc (10 used) 80 Inner Disc (10 used) Machines of (370E): Assemble inner and outer discs (80, 79) to planetary drive (78). [46] -

<- Go to Section TOC

Section 03 page 72

TM12408-REPAIR TECHNICAL MANUAL

Section 03 - TRANSMISSION

Group 0350: Gear, Shafts, and Power Shift Clutches

Clutch Discs (410E, 460E) LEGEND: 78 Planetary Drive 79 Outer Disc (10 used) 80 Inner Disc (10 used) Machines of (410E, 460E): Assemble inner and outer discs (80, 79) to planetary drive (78). [47] →NOTE: Closing and opening of clutch must be clearly audible. LEGEND: 81 82 83 84

End Shim Retaining Ring O-Ring Bore

Transmission Clutch Install end shim (81), retaining ring (82) and O-ring (83). Check closing and opening of clutch by introducing compressed air to bore (84).

<- Go to Section TOC

Section 03 page 73

TM12408-REPAIR TECHNICAL MANUAL

Section 03 - TRANSMISSION

Group 0350: Gear, Shafts, and Power Shift Clutches

Transmission Clutch (E) Disassemble and Assemble Specifications SPECIFICATIONS Ring Gear Temperature

120°C 248°F

Carrier Cap Screw Torque

34 N·m 25 lb.-ft.

Disc Carrier Temperature

120°C 248° F

Bearing Temperature

120°C 248° F

Idler Temperature

120°C 248° F

Transmission Clutch (E) Weight

95 kg 210 lb.

Essential Tools ESSENTIAL TOOLS JDG11560 Assembly Aid JDG11563 Rapid Grip JDG11554 Basic Unit JDG11556 Rapid Grip JDG11570 Assembly Fixture JDG11559 Nesting Plate

[1] CAUTION: Prevent crushing injury from heavy component. Use appropriate lifting device.

Item

Measurement

Specification

Transmission Clutch (E)

Weight

95 kg 210 lb.

Remove transmission clutch (E) from mounting device. [2] LEGEND: 1 JDG11560 Assembly Aid

JDG11560 Assembly Aid Remove JDG11560 Assembly Aid (1). Reassembly Aid JDG11560 <- Go to Section TOC

Section 03 page 74

TM12408-REPAIR TECHNICAL MANUAL

Section 03 - TRANSMISSION

Group 0350: Gear, Shafts, and Power Shift Clutches

Clutch Holder [3] LEGEND: 2 3

Outer Disc Carrier Inner Disc Carrier

LEGEND: 4 5

Bearing Outer Race Washer

LEGEND: 6

Retaining Ring

Disc Carrier Removal Separate outer disc carrier (2) from inner disc carrier (3). [4] -

Inner Disc Carrier Remove bearing outer race (4) and washer (5). [5] -

Retaining Ring Remove retaining ring (6). [6] <- Go to Section TOC

Section 03 page 75

TM12408-REPAIR TECHNICAL MANUAL

Section 03 - TRANSMISSION

Group 0350: Gear, Shafts, and Power Shift Clutches

LEGEND: 65

Bearing

LEGEND: 7 8

Driver Needle Sleeve

Bearing Remove bearing (65). [7] -

Needle Sleeve Use driver (7) to remove needle sleeve (8) from bore of disc carrier. [8] →NOTE: Use an appropriate length of 1 7/8 in. round stock between the pressure piece and the jack screw of the basic unit. LEGEND: 9

JDG11563 Rapid Grip

JDG11563 Rapid Grip Install appropriate size pressure piece before installing JDG11563 Rapid Grip (9) to the outer race of bearing on inner disc carrier. Rapid Grip <- Go to Section TOC

Section 03 page 76

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Section 03 - TRANSMISSION

Group 0350: Gear, Shafts, and Power Shift Clutches

JDG11563 Bearing Removal Basic Unit JDG11554 Applies Pressure [9] - Thread JDG11554 Basic Unit onto the reduction. Use an appropriate length of 1 7/8 in. round stock between the pressure piece and the jack screw of the basic unit. Rotate jack screw against round stock and pressure piece to remove bearing. [10] →NOTE: Inner disc carrier removal is only required when involved parts are damaged. LEGEND: 10 11 12

Retaining Ring Carrier Idler

Carrier Removal Remove retaining ring (10). Press the carrier (11) out of the idler (12) using a hydraulic press. [11] LEGEND: 13

Rectangular Ring (2 used)

Rectangular Rings Remove rectangular rings (13). [12] →NOTE: Use an appropriate length of 1 7/8 in. round stock between the pressure piece and the jack screw of the basic unit.

<- Go to Section TOC

Section 03 page 77

TM12408-REPAIR TECHNICAL MANUAL

Section 03 - TRANSMISSION

Group 0350: Gear, Shafts, and Power Shift Clutches

LEGEND: 14 15

JDG11556 Rapid Grip Outer Disc Carrier

JDG11556 Rapid Grip Install appropriate size pressure piece before installing JDG11556 Rapid Grip (14) to the outer race of bearing on outer disc carrier (15). Thread JDG11554 Basic Unit onto the rapid grip. Rapid Grip JDG11556 Bearing Removal Basic Unit JDG11554 Applies Pressure [13] - Use an appropriate length of 1 7/8 in. round stock between the pressure piece and the jack screw of the basic unit. Rotate jack screw against round stock and pressure piece to remove bearing. [14] →NOTE: Prevent damaging parts, pay attention to the shaft (16) and bearing (17) while shaft is being removed. LEGEND: 16 17

Shaft Bearing

Shaft Using a hydraulic press, remove shaft (16) from outer disc carrier through bearing (17). [15] →NOTE: Ring gear removal is only required when involved parts are damaged.

<- Go to Section TOC

Section 03 page 78

TM12408-REPAIR TECHNICAL MANUAL

Section 03 - TRANSMISSION

Group 0350: Gear, Shafts, and Power Shift Clutches

LEGEND: 18 19

Cap Screw (8 used) Washer

LEGEND: 20 21 22

Pressure Piece Puller Ring Gear

Outer Disc Carrier Remove cap screws (18) and washer (19). [16] -

Puller Using an appropriate pressure piece (20) and puller (21), remove ring gear (22). [17] LEGEND: 23

Retaining Ring

Retaining Ring Remove retaining ring (23). [18] -

<- Go to Section TOC

Section 03 page 79

TM12408-REPAIR TECHNICAL MANUAL

Section 03 - TRANSMISSION

Group 0350: Gear, Shafts, and Power Shift Clutches

LEGEND: 24 25

End Shim (2 used) Disc Set

LEGEND: 26 27

JDG11570 Assembly Fixture Retaining Ring

Clutch Pack Remove end shims (24) and disc set (25). [19] -

JDG11570 Assembly Fixture Preload cup springs with hydraulic press and JDG11570 Assembly Fixture (26). Remove retaining ring (27). JDG11570 Assembly Fixture JDG11570 Preload Cup Springs [20] LEGEND: 28 29

Baffle Plate Cup Spring Set

Baffle Plate and Cup Spring Set Remove baffle plate (28) and cup spring set (29).

<- Go to Section TOC

Section 03 page 80

TM12408-REPAIR TECHNICAL MANUAL

Section 03 - TRANSMISSION

Group 0350: Gear, Shafts, and Power Shift Clutches

[21] LEGEND: 28 39

Baffle Plate O-Ring

LEGEND: 30

Piston

Baffle Plate Remove O-ring (39) from baffle (28). [22] -

Piston Apply compressed air and remove piston (30). [23] LEGEND: 31 32 33

O-Ring O-Ring O-Ring

O-Rings Remove O-rings (31—33) from piston. Clean and inspect piston and bore. Repair or replace parts as required. [24] -

<- Go to Section TOC

Section 03 page 81

TM12408-REPAIR TECHNICAL MANUAL

Section 03 - TRANSMISSION

Group 0350: Gear, Shafts, and Power Shift Clutches

LEGEND: 31 32 33

O-Ring O-Ring O-Ring

O-Rings Grease and install O-rings (31—33) to piston. [25] LEGEND: 26 38

JDG11570 Assembly Fixture Disc Carrier

JDG11570 Assembly Fixture Use JDG11570 Assembly Fixture (26) with a press, and install piston until it bottoms in the disc carrier (38). [26] LEGEND: 28 39

Baffle Plate O-Ring

Baffle Plate Grease and install O-ring (39) to baffle plate (28). [27] -

<- Go to Section TOC

Section 03 page 82

TM12408-REPAIR TECHNICAL MANUAL

Section 03 - TRANSMISSION

Group 0350: Gear, Shafts, and Power Shift Clutches

LEGEND: 28 29

Baffle Plate Cup Spring Set

LEGEND: 26 27

JDG11570 Assembly Fixture Retaining Ring

Baffle Plate and Cup Spring Set Install cup spring set (29) and baffle plate (28). [28] -

JDG11570 Assembly Fixture

Cross Section Use JDG11570 Assembly Fixture (26) to preload baffle and cup spring set, and install retaining ring (27). Assembly Fixture JDG11570 Preload Cup Springs [29] -

<- Go to Section TOC

Section 03 page 83

TM12408-REPAIR TECHNICAL MANUAL

Section 03 - TRANSMISSION

Group 0350: Gear, Shafts, and Power Shift Clutches

LEGEND: 45

End Shim

End Shim Install end shim (45). [30] IMPORTANT: Start assembly with an inner clutch disc (46), with coated side of clutch disc facing piston. LEGEND: 46 Inner Clutch Disc (10 used) 47 Outer Clutch Disc (10 used) 48 Disc Carrier

Clutch Discs (370E) Machines of (370E): Assemble inner and outer clutch discs (46, 47) to disc carrier (48). [31] LEGEND: 46 Inner Clutch Disc (12 used) 47 Outer Clutch Disc (12 used) 48 Disc Carrier

Clutch Discs (410E, 460E) <- Go to Section TOC

Section 03 page 84

TM12408-REPAIR TECHNICAL MANUAL

Section 03 - TRANSMISSION

Group 0350: Gear, Shafts, and Power Shift Clutches

Machines of (410E, 460E): Assemble inner and outer clutch discs (46, 47) to disc carrier (48). [32] LEGEND: 49 50

End Shim Retaining Ring

LEGEND: 51 52

Ring Gear Disc Carrier

End Shim Install end shim (49) and retaining ring (50). [33] -

Ring Gear Heat ring gear (51) and mount to disc carrier (52). Item

Measurement

Specification

Ring Gear

Temperature

120°C 248°F

[34] LEGEND: 18 19

Cap Screw (8 used) Washer

Outer Disc Carrier <- Go to Section TOC

Section 03 page 85

TM12408-REPAIR TECHNICAL MANUAL

Section 03 - TRANSMISSION

Group 0350: Gear, Shafts, and Power Shift Clutches

Install washer (19) and cap screws (18) to specification. Item

Measurement

Specification

Carrier Cap Screw

Torque

34 N·m 25 lb.-ft.

[35] LEGEND: 55

Outer Disc Carrier

Outer Disc Carrier Heat outer disc carrier (55) to specification. Item

Measurement

Specification

Disc Carrier

Temperature

120° C 248° F

[36] LEGEND: 56 57

Outer Disc Carrier Shaft

Shaft Install outer disc carrier (56) to shaft (57). [37] LEGEND: 58

<- Go to Section TOC

Section 03 page 86

Bearing

TM12408-REPAIR TECHNICAL MANUAL

Section 03 - TRANSMISSION

Group 0350: Gear, Shafts, and Power Shift Clutches

Bearing Heat inner race of bearing (58). Item

Measurement

Specification

Bearing

Temperature

120°C 248°F

[38] LEGEND: 59

Bearing

LEGEND: 60

Idler

Bearing Install bearing (59) to shaft. [39] -

Idler Heat internal teeth of idler (60). Item

Measurement

Specification

Idler

Temperature

120°C 248°F

[40] -

<- Go to Section TOC

Section 03 page 87

TM12408-REPAIR TECHNICAL MANUAL

Section 03 - TRANSMISSION

Group 0350: Gear, Shafts, and Power Shift Clutches

LEGEND: 61 62 63

Idler Carrier Retaining Ring

Carrier and Idler Assembly Install carrier (62) to the idler (61) and fasten with retaining ring (63). [41] LEGEND: 64

Bearing

Bearing Heat bearing (64) to specification. Item

Measurement

Specification

Bearing

Temperature

120°C 248°F

[42] LEGEND: 65

Bearing

Bearing Install bearing (65). [43] -

<- Go to Section TOC

Section 03 page 88

TM12408-REPAIR TECHNICAL MANUAL

Section 03 - TRANSMISSION

Group 0350: Gear, Shafts, and Power Shift Clutches

LEGEND: 66

Needle Sleeve

Needle Sleeve Install needle sleeve (66) using an appropriate driver. [44] LEGEND: 6

Retaining Ring

LEGEND: 4 5

Outer Bearing Race Washer

Retaining Ring Install retaining ring (6). [45] -

Inner Disc Carrier Install washer (5) and outer bearing race (4). [46] -

<- Go to Section TOC

Section 03 page 89

TM12408-REPAIR TECHNICAL MANUAL

Section 03 - TRANSMISSION

Group 0350: Gear, Shafts, and Power Shift Clutches

LEGEND: 70 71

Inner Disc Carrier Outer Disc Carrier

Assembly Assemble the inner disc carrier (70) to outer disc carrier (71) by rotating the two components together until the clutch discs have aligned and components are assembled. [47] LEGEND: 72

Bearing

Bearing Heat bearing (72) to specification. Item

Measurement

Specification

Bearing

Temperature

120°C 248°F

[48] LEGEND: 73 74

Bearing Rectangular Ring (2 used)

Assembly Install bearing (73) and rectangular rings (74). <- Go to Section TOC

Section 03 page 90

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Section 03 - TRANSMISSION

Group 0350: Gear, Shafts, and Power Shift Clutches

[49] →NOTE: Opening and closing of the clutch must be clearly audible. LEGEND: 75

Activation Port

LEGEND: 76 77

JDG11560 Assembly Aid Lift Eye

Activation Port Apply compressed air to activation port (75). [50] -

JDG11560 Assembly Aid Install JDG11560 Assembly Aid (76) and lift eye (77). Reassembly Aid JDG11560 Clutch Holder [51] CAUTION: Prevent crushing injury from heavy component. Use appropriate lifting device.

<- Go to Section TOC

Section 03 page 91

TM12408-REPAIR TECHNICAL MANUAL

Section 03 - TRANSMISSION

Group 0350: Gear, Shafts, and Power Shift Clutches

LEGEND: 78 79

Clutch (E) JDG11559 Nesting Plate

JDG11559 Nesting Plate Install clutch (E) (78) to JDG11559 Nesting Plate (79). Nesting Plate JDG11559 Clutch Holder Item

Measurement

Specification

Transmission Clutch (E)

Weight

95 kg 210 lb.

<- Go to Section TOC

Section 03 page 92

TM12408-REPAIR TECHNICAL MANUAL

Section 03 - TRANSMISSION

Group 0350: Gear, Shafts, and Power Shift Clutches

Transmission Clutch (R) Disassemble and Assemble Specifications SPECIFICATIONS Inner Clutch Teeth Temperature

120°C 248°F

Inner Bearing Race Temperature

120°C 248°F

Transmission Clutch (R) Weight

50 kg 110 lb.

Essential Tools ESSENTIAL TOOLS JDG11569 Assembly Fixture

[1] CAUTION: Prevent crushing injury from heavy component. Use appropriate lifting device.

Item

Measurement

Specification

Transmission Clutch (R)

Weight

50 kg 110 lb.

Remove transmission clutch (R) from mounting device. [2] LEGEND: 1 Rectangular Ring (2 used) 2 Bearing

Rectangular Rings Remove rectangular rings (1) and bearing (2). [3] →NOTE: Use a helper to compress the retaining ring while the gear is being pulled.

<- Go to Section TOC

Section 03 page 93

TM12408-REPAIR TECHNICAL MANUAL

Section 03 - TRANSMISSION

Group 0350: Gear, Shafts, and Power Shift Clutches

LEGEND: 3 4

Puller Gear

Retaining Ring Use flat tipped pry tools at the four installation openings to compress retaining ring into groove. With retaining ring compressed, use puller (3) to remove gear (4). [4] LEGEND: 5 Gear 6 Washer 7 Axial Bearing with Washer (2 washers used) 8 Retaining Ring

Single Parts While gear (5) is being removed from shaft, account for washer (6), axial bearing and washers (7), and retaining ring (8). [5] LEGEND: 9

Needle Bearing

Needle Cage Remove needle bearing (9). [6] -

<- Go to Section TOC

Section 03 page 94

TM12408-REPAIR TECHNICAL MANUAL

Section 03 - TRANSMISSION

Group 0350: Gear, Shafts, and Power Shift Clutches

LEGEND: 10 11

Washer (2 used) Bearing

Bearing and Washers Remove washers (10) and bearing (11). [7] - Remove bearing from other end of shaft. [8] LEGEND: 12 13

Puller Gear

Gear Use flat tipped pry tools at the four installation openings to compress retaining ring into groove. With retaining ring compressed, use puller (12) to remove gear (13). [9] LEGEND: 14 15

Gear Retaining Ring

Retaining Ring and Gear With gear (14) removed, remove retaining ring (15). [10] -

<- Go to Section TOC

Section 03 page 95

TM12408-REPAIR TECHNICAL MANUAL

Section 03 - TRANSMISSION

Group 0350: Gear, Shafts, and Power Shift Clutches

LEGEND: 16 17

Shaft Disc Carrier

LEGEND: 18

Retaining Ring

LEGEND: 19 20

End Shim (2 used) Disc Set

Disc Carrier Press shaft (16) from disc carrier (17). [11] -

Retaining Ring Remove retaining ring (18). [12] -

End Shims and Disc Set Remove end shims (19) and disc set (20). [13] -

<- Go to Section TOC

Section 03 page 96

TM12408-REPAIR TECHNICAL MANUAL

Section 03 - TRANSMISSION

Group 0350: Gear, Shafts, and Power Shift Clutches

LEGEND: 21 22

JDG11569 Assembly Fixture Retaining Ring

Disc Carrier Use JDG11569 Assembly Fixture (21) with appropriate press to preload cup springs. Remove retaining ring (22). Assembly Fixture JDG11569 Press Aid [14] LEGEND: 23 24

Baffle Plate Cup Spring Set

LEGEND: 25

Piston

Baffle Plate and Cup Spring Set Remove baffle plate (23) and cup spring set (24). [15] -

Piston Apply compressed air to remove piston (25). [16] -

<- Go to Section TOC

Section 03 page 97

TM12408-REPAIR TECHNICAL MANUAL

Section 03 - TRANSMISSION

Group 0350: Gear, Shafts, and Power Shift Clutches

LEGEND: 26 27 28

O-Ring O-Ring O-Ring

LEGEND: 29 30 31 32 33 34 35 36 37 38 39 40 41

O-Ring Piston End Shim Inner Clutch Disc (10 used) Outer Clutch Disc (10 used) End Shim Retaining Ring Cup Spring Set Baffle Plate Retaining Ring O-Ring O-Ring Disc Carrier

O-Rings Remove O-rings (26—28). [17] - Clean, inspect, repair, and replace parts as required. [18] -

Cross Section Install O-rings (29, 39 and 40) to piston (30). Install piston to disc carrier (41) using appropriate press. [19] LEGEND: 42 43

JDG11569 Assembly Fixture Retaining ring

Disc Carrier Install baffle plate and cup spring set. Preload using appropriate press and JDG11569 Assembly Fixture (42). Install retaining ring (43). Assembly Fixture JDG11569 Press Aid [20] -

<- Go to Section TOC

Section 03 page 98

TM12408-REPAIR TECHNICAL MANUAL

Section 03 - TRANSMISSION

Group 0350: Gear, Shafts, and Power Shift Clutches

LEGEND: 44

End Shim

End Shim Install end shim (44). [21] IMPORTANT: Avoid damage to clutch assembly, start assembly with an inner clutch disc (45), with coated side of clutch disc toward piston. LEGEND: 45 Inner Clutch Disc (10 used) 46 Outer Clutch Disc (10 used) 47 Disc Carrier

Disc Assembly Install inner and outer clutch discs (45 and 46) to disc carrier (47). [22] LEGEND: 48 49

End Shim Retaining Ring

End Shim Install end shim (48) and retaining ring (49). [23] -

<- Go to Section TOC

Section 03 page 99

TM12408-REPAIR TECHNICAL MANUAL

Section 03 - TRANSMISSION

Group 0350: Gear, Shafts, and Power Shift Clutches

LEGEND: 50

Inner Clutch Teeth

Disc Carrier Heat inner clutch teeth (50) to specification. Item

Measurement

Specification

Inner Clutch Teeth

Temperature

120°C 248°F

[24] LEGEND: 51 52

Disc Carrier Shaft

LEGEND: 53

Retaining Ring

Assembly Assemble disc carrier (51) to shaft (52). [25] -

Retaining Ring Install retaining ring (53). [26] -

<- Go to Section TOC

Section 03 page 100

TM12408-REPAIR TECHNICAL MANUAL

Section 03 - TRANSMISSION

Group 0350: Gear, Shafts, and Power Shift Clutches

LEGEND: 54

Inner Clutch Teeth

Gear Heat inner clutch teeth (54) to specification. Item

Measurement

Specification

Inner Clutch Teeth

Temperature

120°C 248°F

[27] LEGEND: 55 56

Gear Opening (4 used)

Retaining Ring Install gear (55). Verify retaining ring is seated in recesses of shaft and gear. Locate retaining ring end gap to an opening (56). [28] LEGEND: 57

Inner Bearing Race

Bearing Heat inner bearing race (57) to specification. Item

Measurement

Specification

Inner Bearing Race

Temperature

120°C 248°F

[29] -

<- Go to Section TOC

Section 03 page 101

TM12408-REPAIR TECHNICAL MANUAL

Section 03 - TRANSMISSION

Group 0350: Gear, Shafts, and Power Shift Clutches

LEGEND: 58

Bearing

LEGEND: 59 60 61

Running Disc Axial Bearing Washer

Bearing Installed Install bearing (58). [30] -

Bearing and Washers Install running disc (59). The chamfer on the running disc should face the axial bearing (60). Install axial bearing and washer (61). Oil parts when installed. [31] LEGEND: 62

Needle Bearing

Needle Bearing Install needle bearing (62). [32] -

<- Go to Section TOC

Section 03 page 102

TM12408-REPAIR TECHNICAL MANUAL

Section 03 - TRANSMISSION

Group 0350: Gear, Shafts, and Power Shift Clutches

LEGEND: 63

Idler Gear

Idler Gear Install idler gear (63). Rotate gear back and forth using the teeth to align the clutch discs. [33] LEGEND: 64 65 66

Retaining Ring Washer Bearing

Assembly Install retaining ring (64), washer (65), and bearing (66). Oil parts when installed. [34] LEGEND: 67 68 69 70

Washer Bearing Washer Groove

Installation Sequence Use grease to adhere washer (67) to bearing (68). Use an appropriate press to install washer (69). Retaining ring has to recess into groove (70) of washer. [35] -

<- Go to Section TOC

Section 03 page 103

TM12408-REPAIR TECHNICAL MANUAL

Section 03 - TRANSMISSION

Group 0350: Gear, Shafts, and Power Shift Clutches

LEGEND: 71

Opening (4 used)

Openings Verify retaining ring is seated in recesses of shaft and gear. Locate retaining ring end gap to an opening (71). [36] LEGEND: 72

Inner Bearing Race

Inner Bearing Race Heat inner bearing race (72) to specification. Item

Measurement

Specification

Inner Bearing Race

Temperature

120°C 248°F

[37] LEGEND: 73

Bearing

Bearing Install bearing (73). [38] -

<- Go to Section TOC

Section 03 page 104

TM12408-REPAIR TECHNICAL MANUAL

Section 03 - TRANSMISSION

Group 0350: Gear, Shafts, and Power Shift Clutches

LEGEND: 74

Rectangular Ring (2 used)

Rectangular Rings Install rectangular rings (74). [39] LEGEND: 75

Port

Actuation Port Verify opening and closing of clutch by applying compressed air to port (75).

<- Go to Section TOC

Section 03 page 105

TM12408-REPAIR TECHNICAL MANUAL

Section 03 - TRANSMISSION

Group 0350: Gear, Shafts, and Power Shift Clutches

Transmission Clutch (B) Disassemble and Assemble Specifications SPECIFICATIONS Inner Clutch Teeth Temperature

120°C 248°F

Inner Bearing Race Temperature

120°C 248°F

Transmission Clutch (B) Weight

50 kg 110 lb.

Essential Tools ESSENTIAL TOOLS JDG11569 Assembly Fixture

[1] CAUTION: Prevent crushing injury from heavy component. Use appropriate lifting device.

Item

Measurement

Specification

Transmission Clutch (B)

Weight

50 kg 110 lb.

Remove transmission clutch (B) from mounting device. [2] LEGEND: 1 Rectangular Ring (2 used) 2 Bearing

Rectangular Rings Remove rectangular rings (1) and bearing (2). [3] →NOTE: Use a helper to compress the retaining ring while the gear is being pulled.

<- Go to Section TOC

Section 03 page 106

TM12408-REPAIR TECHNICAL MANUAL

Section 03 - TRANSMISSION

Group 0350: Gear, Shafts, and Power Shift Clutches

LEGEND: 3 4

Puller Gear

Retaining Ring Use flat tipped pry tools at the four installation openings to compress retaining ring into groove. With retaining ring compressed, use puller (3) to remove gear (4). [4] LEGEND: 5

Retaining Ring

Retaining Ring Remove retaining ring (5). [5] LEGEND: 6 Axial Bearing with Washer (2 washers used) 7 Idler Gear 8 Needle Bearing 9 Washer 10 Bearing 11 Running Disc

Idler Gear Remove axial bearing with washers (6). Remove idler gear (7) and needle bearing (8). Remove washer (9), bearing (10), and running disc (11). [6] →NOTE: Use a helper to compress the retaining ring while the gear is being pulled.

<- Go to Section TOC

Section 03 page 107

TM12408-REPAIR TECHNICAL MANUAL

Section 03 - TRANSMISSION

Group 0350: Gear, Shafts, and Power Shift Clutches

LEGEND: 12 13

Puller Gear

Gear Use flat tipped pry tools at the four installation openings to compress retaining ring into groove. With retaining ring compressed, use puller (12) to remove gear (13). [7] LEGEND: 14

Retaining Ring

LEGEND: 15 16

Shaft Disc Carrier

Retaining Ring Remove retaining ring (14). [8] -

Shaft Press shaft (15) from disc carrier (16). [9] -

<- Go to Section TOC

Section 03 page 108

TM12408-REPAIR TECHNICAL MANUAL

Section 03 - TRANSMISSION

Group 0350: Gear, Shafts, and Power Shift Clutches

LEGEND: 17

Retaining Ring

LEGEND: 18 19

End Shim (2 used) Disc Set

LEGEND: 20 21

JDG11569 Assembly Fixture Retaining Ring

Retaining Ring Remove retaining ring (17). [10] -

End Shims and Disc Set Remove end shims (18) and disc set (19). [11] -

JDG11569 Assembly Fixture Use JDG11569 Assembly Fixture (20) with appropriate press to preload cup springs. Remove retaining ring (21). Assembly Fixture JDG11569 Press Aid [12] -

<- Go to Section TOC

Section 03 page 109

TM12408-REPAIR TECHNICAL MANUAL

Section 03 - TRANSMISSION

Group 0350: Gear, Shafts, and Power Shift Clutches

LEGEND: 22 23

Baffle Plate Cup Spring Set

LEGEND: 45 46

O-Ring Baffle Plate

LEGEND: 24

Piston

Baffle Plate and Cup Spring Set Remove baffle plate (22) and cup spring set (23). [13] -

Baffle Plate Remove O-ring (45) from baffle plate (46). [14] -

Piston Apply compressed air to remove piston (24). [15] -

<- Go to Section TOC

Section 03 page 110

TM12408-REPAIR TECHNICAL MANUAL

Section 03 - TRANSMISSION

Group 0350: Gear, Shafts, and Power Shift Clutches

LEGEND: 25 26 27

O-Ring O-Ring O-Ring

O-Rings Remove O-rings (25—27) from piston. Clean and inspect piston and bore. Repair or replace parts as required. [16] LEGEND: 41 42 43

O-Ring O-Ring O-Ring

O-Rings Grease and install O-rings (41—43) to piston. [17] LEGEND: 44

JDG11569 Assembly Fixture

JDG11569 Assembly Fixture Install piston to disc carrier, using JDG11569 Assembly Fixture (44) with an appropriate press. Assembly Fixture JDG11569 Press Aid [18] -

<- Go to Section TOC

Section 03 page 111

TM12408-REPAIR TECHNICAL MANUAL

Section 03 - TRANSMISSION

Group 0350: Gear, Shafts, and Power Shift Clutches

LEGEND: 45 46

O-Ring Baffle Plate

LEGEND: 46 47

Baffle Plate Cup Spring Set

LEGEND: 49 50

JDG11569 Assembly Fixture Retaining Ring

Baffle Plate Grease and install O-ring (45) to baffle plate (46). [19] -

Baffle Plate and Cup Spring Set Install cup spring set (47) and baffle plate (46). [20] -

JDG11569 Assembly Fixture Use JDG11569 Assembly Fixture (49) with appropriate press and install retaining ring (50). Assembly Fixture JDG11569 Press Aid [21] -

<- Go to Section TOC

Section 03 page 112

TM12408-REPAIR TECHNICAL MANUAL

Section 03 - TRANSMISSION

Group 0350: Gear, Shafts, and Power Shift Clutches

LEGEND: 51

End Shim

End Shim Install end shim (51). [22] IMPORTANT: Start assembly with an inner clutch disc (52), with coated side of clutch disc facing piston. LEGEND: 52 Inner Clutch Disc (8 used) 53 Outer Clutch Disc (8 used) 54 Disc Carrier

Disc Assembly (370E) Machines of (370E): Install inner and outer clutch discs (52, 53) to disc carrier (54). [23] LEGEND: 52 Inner Clutch Disc (10 used) 53 Outer Clutch Disc (10 used) 54 Disc Carrier

Disc Assembly (410E, 460E) Machines of (410E, 460E): Install inner and outer clutch discs (52, 53) to disc carrier (54). [24] -

<- Go to Section TOC

Section 03 page 113

TM12408-REPAIR TECHNICAL MANUAL

Section 03 - TRANSMISSION

Group 0350: Gear, Shafts, and Power Shift Clutches

LEGEND: 55 56

End shim Retaining Ring

LEGEND: 57

Inner Clutch Teeth

End Shim Install end shim (55) and retaining ring (56). [25] -

Inner Teeth Heat inner clutch teeth (57) to specification. Item

Measurement

Specification

Inner Clutch Teeth

Temperature

120°C 248°F

[26] LEGEND: 58 59

Disc Carrier Shaft

Assembly Install disc carrier (58) to shaft (59). [27] -

<- Go to Section TOC

Section 03 page 114

TM12408-REPAIR TECHNICAL MANUAL

Section 03 - TRANSMISSION

Group 0350: Gear, Shafts, and Power Shift Clutches

LEGEND: 60

Retaining Ring

LEGEND: 61

Inner Teeth

Retaining Ring Install retaining ring (60). [28] -

Internal Teeth Heat inner teeth (61) to specification. Item

Measurement

Specification

Inner Teeth

Temperature

120°C 248°F

[29] LEGEND: 62 63

Gear Opening (4 used)

Retaining Ring Install gear (62). Verify retaining ring is seated in recesses of shaft and gear. Locate retaining ring end gap to an opening (63). [30] -

<- Go to Section TOC

Section 03 page 115

TM12408-REPAIR TECHNICAL MANUAL

Section 03 - TRANSMISSION

Group 0350: Gear, Shafts, and Power Shift Clutches

LEGEND: 64

Inner Bearing Race

Bearing Heat inner bearing race (64) to specification. Item

Measurement

Specification

Inner Bearing Race

Temperature

120°C 248°F

[31] LEGEND: 65

Bearing

LEGEND: 66 67 68

Running Disc Axial Bearing Washer

Bearing Installed Install bearing (65). [32] -

Bearing and Washers Install running disc (66). The chamfer on the running disc should face the axial bearing (67). Install axial bearing and washer (68). Oil parts when installed. [33] -

<- Go to Section TOC

Section 03 page 116

TM12408-REPAIR TECHNICAL MANUAL

Section 03 - TRANSMISSION

Group 0350: Gear, Shafts, and Power Shift Clutches

LEGEND: 69

Needle Bearing

LEGEND: 70

Idler Gear

Needle Bearing Install needle bearing (69). [34] -

Idler Gear Install idler gear (70). Rotate gear back and forth using the gear teeth to align the clutch discs. [35] LEGEND: 71 72

Washer (2 used) Bearing

Bearing and Washers Install washers (71) and bearing (72). [36] -

<- Go to Section TOC

Section 03 page 117

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Section 03 - TRANSMISSION

Group 0350: Gear, Shafts, and Power Shift Clutches

LEGEND: 73

Retaining Ring

LEGEND: 74

Inner Teeth

Retaining Ring Install retaining ring (73). [37] -

Inner Teeth Heat inner teeth (74) to specification. Item

Measurement

Specification

Inner Teeth

Temperature

120°C 248°F

[38] LEGEND: 75 76

Gear Opening (4 used)

Openings Install gear (75). Verify retaining ring is seated in recesses of shaft and gear. Locate retaining ring end gap to an opening (76). [39] -

<- Go to Section TOC

Section 03 page 118

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Section 03 - TRANSMISSION

Group 0350: Gear, Shafts, and Power Shift Clutches

LEGEND: 77

Inner Bearing Race

Inner Bearing Race Heat inner bearing race (77) to specification. Item

Measurement

Specification

Inner Bearing Race

Temperature

120°C 248°F

[40] LEGEND: 78

Bearing

Bearing Install bearing (78). [41] LEGEND: 79

Rectangular Ring (2 used)

Rectangular Rings Install rectangular rings (79). [42] -

<- Go to Section TOC

Section 03 page 119

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Section 03 - TRANSMISSION

Group 0350: Gear, Shafts, and Power Shift Clutches

LEGEND: 80

Port

Transmission Clutch Verify opening and closing of clutch by applying compressed air to port (80).

<- Go to Section TOC

Section 03 page 120

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Section 03 - TRANSMISSION

Group 0350: Gear, Shafts, and Power Shift Clutches

Transmission Clutch (V) Disassemble and Assemble Specifications SPECIFICATIONS Idler Nut Torque

800 N·m 590 lb.-ft.

Component Assembly Temperature

120°C 248°F

Transmission Clutch (V) Weight

55 kg 120 lb.

Essential Tools ESSENTIAL TOOLS JDG11570 Assembly Fixture JDG11564 Latch JDG11553 Slotted Nut Wrench JDG11552 Wrench Insert JDG11566 Bearing Driver

[1] CAUTION: Prevent crushing injury from heavy component. Use appropriate lifting device.

Item

Measurement

Specification

Transmission Clutch (V)

Weight

55 kg 120 lb.

Remove transmission clutch (V) from mounting device. [2] LEGEND: 1

Rectangular Ring

Rectangular Ring Remove rectangular ring (1). [3] -

<- Go to Section TOC

Section 03 page 121

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Section 03 - TRANSMISSION

Group 0350: Gear, Shafts, and Power Shift Clutches

LEGEND: 2 3

Gear Bearing

LEGEND: 4 5

Clutch Shaft

Puller Use appropriate puller and remove gear (2) and bearing (3). [4] -

Clutch Remove clutch (4) from shaft (5). [5] LEGEND: 6

Retaining Ring

Retaining Ring Remove retaining ring (6). [6] -

<- Go to Section TOC

Section 03 page 122

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Section 03 - TRANSMISSION

Group 0350: Gear, Shafts, and Power Shift Clutches

LEGEND: 7 8

End Shim (2 used) Disc Set

End Shims and Disc Set Remove end shims (7) and disc set (8). [7] LEGEND: 9 JDG11570 Assembly Fixture 10 Retaining Ring

Retaining Ring Use JDG11570 Assembly Fixture (9) with appropriate press to preload baffle plate and cup spring set. Remove retaining ring (10). Assembly Fixture JDG11570 Press Aid [8] LEGEND: 11 12

Baffle Plate Cup Spring Set

Baffle Plate and Cup Spring Set Remove baffle plate (11) and cup spring set (12). [9] -

<- Go to Section TOC

Section 03 page 123

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Section 03 - TRANSMISSION

Group 0350: Gear, Shafts, and Power Shift Clutches

LEGEND: 13

Piston

Piston Apply compressed air and remove piston (13). [10] LEGEND: 14 15 16

O-Ring O-Ring O-Ring

O-Rings Remove O-rings (14—16). [11] LEGEND: 17 JDG11564 Latch 18 JDG11553 Slotted Nut Wrench 19 JDG11552 Wrench Insert 20 Nut

Disassembly Install JDG11564 Latch (17) to an appropriate vise. Mount clutch shaft to latch. Install JDG11553 Slotted Nut Wrench (18). Install JDG11552 Wrench Insert (19). Remove nut (20). Latch JDG11564 Holder Slotted Nut Wrench JDG11553 Slotted Nut Removal Wrench Insert <- Go to Section TOC

Section 03 page 124

TM12408-REPAIR TECHNICAL MANUAL

Section 03 - TRANSMISSION

Group 0350: Gear, Shafts, and Power Shift Clutches

JDG11552 Removal Aid [12] LEGEND: 21 22

Shaft Idler

Shaft Removal Use an appropriate press to remove shaft (21) from idler (22). [13] LEGEND: 23 24 25

Bearing Outer Bearing Race Idler

LEGEND: 26 27

Shaft Outer Bearing Race

Idler Remove bearing (23) and outer bearing race (24) from idler (25). [14] -

Bearing Removal Mount shaft (26) in appropriate press. Apply pressure to outer bearing race (27). [15] -

<- Go to Section TOC

Section 03 page 125

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Section 03 - TRANSMISSION

Group 0350: Gear, Shafts, and Power Shift Clutches

LEGEND: 28 29 30 31

Spacer Bushing Bearing Bearing Outer Bearing Race

Exploded View Remove spacer bushing (28), bearings (29 and 30), and outer bearing race (31). [16] LEGEND: 32

Plain Bearing

LEGEND: 33 34

JDG11566 Bearing Driver Plain Bearing

Plain Bearing Use an appropriate driver to remove plain bearing (32). [17] - Clean, inspect, repair, and replace parts as required. [18] -

Plain Bearing Install Use JDG11566 Bearing Driver (33) to install plain bearing (34). Bearing Driver JDG11566 Driver [19] -

<- Go to Section TOC

Section 03 page 126

TM12408-REPAIR TECHNICAL MANUAL

Section 03 - TRANSMISSION

Group 0350: Gear, Shafts, and Power Shift Clutches

LEGEND: 35

Inner Bearing Race (2 used)

Heat Bearing Heat inner bearing races (35) to specification. Item

Measurement

Specification

Bearing Temperature

Temperature

120°C 248°F

[20] LEGEND: 36 37 38 39

Outer Bearing Race Bearing Bearing Spacer Bushing

Assembly Install outer bearing race (36), bearings (37 and 38), and spacer bushing (39). [21] LEGEND: 40 41

Outer Bearing Race (2 used) Idler

Idler Install outer bearing races (40) to idler (41). [22] -

<- Go to Section TOC

Section 03 page 127

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Section 03 - TRANSMISSION

Group 0350: Gear, Shafts, and Power Shift Clutches

LEGEND: 42 43

Idler Shaft

Assembly Mount shaft (43) to JDG11564 Latch using appropriate vice. Install idler (42). Latch JDG11564 Holder [23] LEGEND: 44

Inner Bearing Race

Heat Bearing Heat inner bearing race (44) to specification. Item

Measurement

Specification

Bearing Temperature

Temperature

120°C 248°F

[24] LEGEND: 45

Bearing

Assembly Install bearing (45). [25] <- Go to Section TOC

Section 03 page 128

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Section 03 - TRANSMISSION

Group 0350: Gear, Shafts, and Power Shift Clutches

LEGEND: 46 47 48 49

Chamfer Nut JDG11553 Slotted Nut Wrench JDG11552 Wrench Insert

Exploded View Chamfer (46) must face down toward idler. Install nut (47), JDG11553 Slotted Nut Wrench (48), and JDG11552 Wrench Insert (49). Slotted Nut Wrench JDG11553 Slotted Nut Removal Wrench Insert JDG11552 Removal Aid [26] LEGEND: 50

Fitting

Tool Assembly Use appropriate socket and torque device to tighten fitting (50) to specification. Item

Measurement

Specification

Idler Nut

Torque

800 N·m 590 lb.-ft.

[27] - Remove special tools from idler. [28] -

<- Go to Section TOC

Section 03 page 129

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Section 03 - TRANSMISSION

Group 0350: Gear, Shafts, and Power Shift Clutches

LEGEND: 51 52 53

O-Ring O-Ring O-Ring

O-Rings Grease and install O-rings (51—53). [29] LEGEND: 54

JDG11570 Assembly Fixture

Piston Installation Install piston to idler. Use JDG11570 (54) and an appropriate press to seat piston into idler. Assembly Fixture JDG11570 Press Aid [30] LEGEND: 55 56

O-Ring Baffle Plate

Baffle Plate Grease and install O-ring (55) to baffle plate (56). [31] -

<- Go to Section TOC

Section 03 page 130

TM12408-REPAIR TECHNICAL MANUAL

Section 03 - TRANSMISSION

Group 0350: Gear, Shafts, and Power Shift Clutches

LEGEND: 57 58

Cup Spring Set Baffle Plate

LEGEND: 59 60

JDG11570 Assembly Fixture Retaining Ring

Cup Spring Set Install cup spring set (57) and baffle plate (58). [32] -

Retaining Ring Use appropriate press and JDG11570 Assembly Fixture (59) to preload baffle plate and cup spring set. Install retaining ring (60). Assembly Fixture JDG11570 Press Aid [33] LEGEND: 61

End Shim

End Shim Install end shim (61). [34] -

<- Go to Section TOC

Section 03 page 131

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Section 03 - TRANSMISSION

Group 0350: Gear, Shafts, and Power Shift Clutches

LEGEND: 62 Inner Clutch Disc (10 used) 63 Outer Clutch Disc (10 used) 64 Disc Carrier

Clutch Discs Oil and install clutch discs (62 and 63) to disc carrier (64). Start with an inner disc, coated side of discs always face down, toward piston. [35] LEGEND: 65 66

End Shim Retaining Ring

LEGEND: 67

Teeth

End Shim Install end shim (65) and retaining ring (66). [36] -

Disc Carrier Heat teeth (67) to specification. Item

Measurement

Specification

Teeth

Temperature

120°C 248°F

[37] -

<- Go to Section TOC

Section 03 page 132

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Section 03 - TRANSMISSION

Group 0350: Gear, Shafts, and Power Shift Clutches

LEGEND: 68

Disc Carrier

LEGEND: 69

Teeth

Disc Carrier Installation Install disc carrier (68). Rotate slightly to align teeth. [38] -

Gear Heat teeth (69) to specification. Item

Measurement

Specification

Teeth

Temperature

120°C 248°F

[39] LEGEND: 70

Gear

Gear Install gear (70). [40] -

<- Go to Section TOC

Section 03 page 133

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Section 03 - TRANSMISSION

Group 0350: Gear, Shafts, and Power Shift Clutches

LEGEND: 71

Inner Bearing Race

Inner Bearing Race Heat inner bearing race (71) to specification. Item

Measurement

Specification

Bearing

Temperature

120°C 248°F

[41] LEGEND: 72 73

Bearing Rectangluar Ring

LEGEND: 74

Port

Bearing Install bearing (72). Grease and install rectangular ring (73). [42] -

Port Apply compressed air to port (74) to verify clutch opening and closing.

<- Go to Section TOC

Section 03 page 134

TM12408-REPAIR TECHNICAL MANUAL

Section 03 - TRANSMISSION

Group 0350: Gear, Shafts, and Power Shift Clutches

Transmission Clutch (C) Disassemble and Assemble Specifications SPECIFICATIONS Inner Bearing Race Temperature

120°C 248°F

Transmission Clutch (D) Weight

45kg 100 lb.

Essential Tools ESSENTIAL TOOLS JDG11569 Assembly Fixture

[1] CAUTION: Prevent crushing injury from heavy component. Use appropriate lifting device.

Item

Measurement

Specification

Transmission Clutch (D)

Weight

45 kg 100 lb.

Remove transmission clutch (D) from mounting device. [2] LEGEND: 1 Rectangular Ring (2 used) 2 Bearing

Rectangular Rings Remove rectangular rings (1) and bearing (2). [3] →NOTE: Use a helper to compress the retaining ring while the gear is being pulled. LEGEND: 3 4

Puller Idler Gear

Retaining Ring <- Go to Section TOC

Section 03 page 135

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Section 03 - TRANSMISSION

Group 0350: Gear, Shafts, and Power Shift Clutches

Use flat-tipped pry tools at the four installation openings to compress retaining ring into groove. With retaining ring compressed, use puller (3) to remove idler gear (4). [4] LEGEND: 5 Idler Gear 6 Washer 7 Axial Bearing with Washer (2 washers used) 8 Retaining Ring

Single Parts While idler gear (5) is being removed from shaft, locate washer (6), axial bearing with washers (7), and retaining ring (8). [5] LEGEND: 9

Needle Bearing

LEGEND: 59 60 61

Running Disc Axial Bearing Washer

Needle Bearing Remove needle bearing (9). [6] -

Bearing and Washers Remove running disc (59) , axial bearing (60) and washer (61). [7] - Remove bearing from other end of shaft. [8] -

<- Go to Section TOC

Section 03 page 136

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Section 03 - TRANSMISSION

Group 0350: Gear, Shafts, and Power Shift Clutches

LEGEND: 12 13

Puller Gear

Gear Use flat-tipped pry tools at the four installation openings to compress retaining ring into groove. With retaining ring compressed, use puller (12) to remove gear (13). [9] LEGEND: 14 15

Gear Retaining Ring

LEGEND: 16 17

Shaft Disc Carrier

Retaining Ring and Gear With gear (14) removed, remove retaining ring (15). [10] -

Disc Carrier Press shaft (16) from disc carrier (17). [11] -

<- Go to Section TOC

Section 03 page 137

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Section 03 - TRANSMISSION

Group 0350: Gear, Shafts, and Power Shift Clutches

LEGEND: 18

Retaining Ring

LEGEND: 19 20

End Shim (2 used) Disc Set

LEGEND: 21 22

JDG11569 Assembly Fixture Retaining Ring

Retaining Ring Remove retaining ring (18). [12] -

End Shims and Disc Set Remove end shims (19) and disc set (20). [13] -

JDG11569 Assembly Fixture Use JDG11569 Assembly Fixture (21) with appropriate press to preload cup springs. Remove retaining ring (22). Assembly Fixture JDG11569 Press Aid [14] -

<- Go to Section TOC

Section 03 page 138

TM12408-REPAIR TECHNICAL MANUAL

Section 03 - TRANSMISSION

Group 0350: Gear, Shafts, and Power Shift Clutches

LEGEND: 23 24

Baffle Plate Cup Spring Set

LEGEND: 23 29

Baffle Plate O-Ring

LEGEND: 25

Piston

Baffle Plate and Cup Spring Set Remove baffle plate (23) and cup spring set (24). [15] -

Baffle Plate Remove O-ring (29) from baffle plate (23). [16] -

Piston Apply compressed air to remove piston (25). [17] -

<- Go to Section TOC

Section 03 page 139

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Section 03 - TRANSMISSION

Group 0350: Gear, Shafts, and Power Shift Clutches

LEGEND: 26 27 28

O-Ring O-Ring O-Ring

O-Rings Remove O-rings (26—28) from piston. Clean, inspect, repair, and replace parts as required. [18] LEGEND: 26 27 28

O-Ring O-Ring O-Ring

O-Rings Mount and grease O-rings (26—28) to piston. [19] LEGEND: 21

JDG11569 Assembly Fixture

JDG11569 Assembly Fixture Use JDG11569 Assembly Fixture (21) with a press and install piston until it bottoms disc carrier. [20] -

<- Go to Section TOC

Section 03 page 140

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Section 03 - TRANSMISSION

Group 0350: Gear, Shafts, and Power Shift Clutches

LEGEND: 23 29

Baffle Plate O-Ring

LEGEND: 23 24

Baffle Plate Cup Spring Set

LEGEND: 21 22

JDG11569 Assembly Fixture Retaining Ring

Baffle Plate Grease and install O-ring (29) to baffle plate (23). [21] -

Baffle Plate and Cup Spring Set Install baffle plate (23) and cup spring set (24). [22] -

JDG11569 Assembly Fixture Use JDG11569 Assembly Fixture (21) to preload baffle plate and cup spring set, and install retaining ring (22) [23] -

<- Go to Section TOC

Section 03 page 141

TM12408-REPAIR TECHNICAL MANUAL

Section 03 - TRANSMISSION

Group 0350: Gear, Shafts, and Power Shift Clutches

LEGEND: 19

End Shim

End Shim Install end shim (19). [24] IMPORTANT: Start assembly with an inner clutch disc (45), with coated side of clutch disc facing piston. LEGEND: 45 Inner Clutch Disc (8 used) 46 Outer Clutch Disc (8 used) 47 Disc Carrier

Disc Assembly (370E) Machines of (370E): Install inner and outer clutch discs (45, 46) to disc carrier (47). [25] LEGEND: 45 Inner Clutch Disc (10 used) 46 Outer Clutch Disc (10 used) 47 Disc Carrier

Disc Assembly (410E, 460E) Machines of (410E, 460E): Install inner and outer clutch discs (45, 46) to disc carrier (47). [26] -

<- Go to Section TOC

Section 03 page 142

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Section 03 - TRANSMISSION

Group 0350: Gear, Shafts, and Power Shift Clutches

LEGEND: 48 49

End Shim Retaining Ring

LEGEND: 50

Inner Clutch Teeth

End Shim Install end shim (48) and retaining ring (49). [27] -

Disc Carrier Heat inner clutch teeth (50) to specification. Item

Measurement

Specification

Inner Clutch Teeth

Temperature

120°C 248°F

[28] LEGEND: 51 52

Disc Carrier Shaft

Assembly Assemble disc carrier (51) to shaft (52). [29] -

<- Go to Section TOC

Section 03 page 143

TM12408-REPAIR TECHNICAL MANUAL

Section 03 - TRANSMISSION

Group 0350: Gear, Shafts, and Power Shift Clutches

LEGEND: 53

Retaining Ring

LEGEND: 54

Inner Teeth

Retaining Ring Install retaining ring (53). [30] -

Gear Heat inner teeth (54) to specification. Item

Measurement

Specification

Inner Teeth

Temperature

120°C 248°F

[31] LEGEND: 55 56

Gear Opening (4 used)

Retaining Ring Install gear (55). Verify retaining ring is seated in recesses of shaft and gear. Align retaining ring end gap with opening (56). [32] -

<- Go to Section TOC

Section 03 page 144

TM12408-REPAIR TECHNICAL MANUAL

Section 03 - TRANSMISSION

Group 0350: Gear, Shafts, and Power Shift Clutches

LEGEND: 57

Inner Bearing Race

Inner Bearing Race Heat inner bearing race (57) to specification. Item

Measurement

Specification

Inner Bearing Race

Temperature

120°C 248°F

[33] LEGEND: 58

Bearing

LEGEND: 59 60 61

Running Disc Axial Bearing Washer

Bearing Installed Install bearing (58). [34] -

Bearing and Washers Install running disc (59), with the chamfer on the running disc facing the axial bearing (60). Install axial bearing and washer (61). Oil parts when installed. [35] -

<- Go to Section TOC

Section 03 page 145

TM12408-REPAIR TECHNICAL MANUAL

Section 03 - TRANSMISSION

Group 0350: Gear, Shafts, and Power Shift Clutches

LEGEND: 62

Needle Bearing

LEGEND: 63

Idler Gear

Needle Bearing Install needle bearing (62). [36] -

Idler Gear Install idler gear (63). Rotate gear back and forth using the gear teeth to align the clutch discs. [37] LEGEND: 64 65 66

Retaining Ring Washer Bearing

Assembly Install retaining ring (64), washer (65), and bearing (66). Oil parts when installed. [38] -

<- Go to Section TOC

Section 03 page 146

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Section 03 - TRANSMISSION

Group 0350: Gear, Shafts, and Power Shift Clutches

LEGEND: 67 68 69 70

Washer Bearing Washer Groove

Installation Sequence Use grease to adhere washer (67) to bearing (68). Use an appropriate press to install washer (69). Retaining ring must be seated in groove (70) of washer. [39] LEGEND: 71

Opening (4 used)

Openings Verify retaining ring is seated in recesses of shaft and idler gear. Align retaining ring end gap with opening (71). [40] LEGEND: 72

Inner Bearing Race

Inner Bearing Race Heat inner bearing race (72) to specification. Item

Measurement

Specification

Inner Bearing Race

Temperature

120°C 248°F

[41] -

<- Go to Section TOC

Section 03 page 147

TM12408-REPAIR TECHNICAL MANUAL

Section 03 - TRANSMISSION

Group 0350: Gear, Shafts, and Power Shift Clutches

LEGEND: 73

Bearing

Bearing Install bearing (73). [42] LEGEND: 74

Rectangular Ring (2 used)

Rectangular Rings Install rectangular rings (74). [43] LEGEND: 75

Port

Transmission Clutch Verify opening and closing of clutch by applying compressed air to port (75).

<- Go to Section TOC

Section 03 page 148

TM12408-REPAIR TECHNICAL MANUAL

Section 03 - TRANSMISSION

Group 0350: Gear, Shafts, and Power Shift Clutches

Transmission Clutch (D) Disassemble and Assemble Specifications SPECIFICATIONS Inner Bearing Race Temperature

120°C 248°F

Transmission Clutch (D) Weight

50 kg 110 lb.

Essential Tools ESSENTIAL TOOLS JDG11569 Assembly Fixture

[1] CAUTION: Prevent crushing injury from heavy component. Use appropriate lifting device.

Item

Measurement

Specification

Transmission Clutch (D)

Weight

50 kg 110 lb.

Remove transmission clutch (D) from mounting device. [2] LEGEND: 1 Rectangular Ring (2 used) 2 Bearing

Rectangular Rings Remove rectangular rings (1) and bearing (2). [3] →NOTE: Use a helper to compress the retaining ring while the gear is being pulled. LEGEND: 3 4

Puller Idler Gear

Retaining Ring <- Go to Section TOC

Section 03 page 149

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Section 03 - TRANSMISSION

Group 0350: Gear, Shafts, and Power Shift Clutches

Use flat-tipped pry tools at the four installation openings to compress retaining ring into groove. With retaining ring compressed, use puller (3) to remove idler gear (4). [4] LEGEND: 5 Idler Gear 6 Washer 7 Axial Bearing with Washer (2 washers used) 8 Retaining Ring

Single Parts While idler gear (5) is being removed from shaft, locate washer (6), axial bearing with washers (7), and retaining ring (8). [5] LEGEND: 9

Needle Bearing

LEGEND: 59 60 61

Running Disc Axial Bearing Washer

Needle Bearing Remove needle bearing (9). [6] -

Bearing and Washers Remove running disc (59) , axial bearing (60) and washer (61). [7] - Remove bearing from other end of shaft. [8] -

<- Go to Section TOC

Section 03 page 150

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Section 03 - TRANSMISSION

Group 0350: Gear, Shafts, and Power Shift Clutches

LEGEND: 12 13

Puller Gear

Gear Use flat-tipped pry tools at the four installation openings to compress retaining ring into groove. With retaining ring compressed, use puller (12) to remove gear (13). [9] LEGEND: 14 15

Gear Retaining Ring

LEGEND: 16 17

Shaft Disc Carrier

Retaining Ring and Gear With gear (14) removed, remove retaining ring (15). [10] -

Disc Carrier Press shaft (16) from disc carrier (17). [11] -

<- Go to Section TOC

Section 03 page 151

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Section 03 - TRANSMISSION

Group 0350: Gear, Shafts, and Power Shift Clutches

LEGEND: 18

Retaining Ring

LEGEND: 19 20

End Shim (2 used) Disc Set

LEGEND: 21 22

JDG11569 Assembly Fixture Retaining Ring

Retaining Ring Remove retaining ring (18). [12] -

End Shims and Disc Set Remove end shims (19) and disc set (20). [13] -

JDG11569 Assembly Fixture Use JDG11569 Assembly Fixture (21) with appropriate press to preload cup springs. Remove retaining ring (22). Assembly Fixture JDG11569 Press Aid [14] -

<- Go to Section TOC

Section 03 page 152

TM12408-REPAIR TECHNICAL MANUAL

Section 03 - TRANSMISSION

Group 0350: Gear, Shafts, and Power Shift Clutches

LEGEND: 23 24

Baffle Plate Cup Spring Set

LEGEND: 23 29

Baffle Plate O-Ring

LEGEND: 25

Piston

Baffle Plate and Cup Spring Set Remove baffle plate (23) and cup spring set (24). [15] -

Baffle Plate Remove O-ring (29) from baffle plate (23). [16] -

Piston Apply compressed air to remove piston (25). [17] -

<- Go to Section TOC

Section 03 page 153

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Section 03 - TRANSMISSION

Group 0350: Gear, Shafts, and Power Shift Clutches

LEGEND: 26 27 28

O-Ring O-Ring O-Ring

O-Rings Remove O-rings (26—28) from piston.Clean, inspect, repair, and replace parts as required. [18] LEGEND: 26 27 28

O-Ring O-Ring O-Ring

O-Rings Mount and grease O-rings (26—28) to piston. [19] LEGEND: 21

JDG11569 Assembly Fixture

JDG11569 Assembly Fixture Use JDG11569 Assembly Fixture (21) with a press and install piston until it bottoms disc carrier. [20] -

<- Go to Section TOC

Section 03 page 154

TM12408-REPAIR TECHNICAL MANUAL

Section 03 - TRANSMISSION

Group 0350: Gear, Shafts, and Power Shift Clutches

LEGEND: 23 29

Baffle Plate O-Ring

LEGEND: 23 24

Baffle Plate Cup Spring Set

LEGEND: 21 22

JDG11569 Assembly Fixture Retaining Ring

Baffle Plate Grease and install O-ring (29) to baffle plate (23). [21] -

Baffle Plate and Cup Spring Set Install baffle plate (23) and cup spring set (24). [22] -

JDG11569 Assembly Fixture Use JDG11569 Assembly Fixture (21) to preload baffle plate and cup spring set, and install retaining ring (22) [23] -

<- Go to Section TOC

Section 03 page 155

TM12408-REPAIR TECHNICAL MANUAL

Section 03 - TRANSMISSION

Group 0350: Gear, Shafts, and Power Shift Clutches

LEGEND: 19

End Shim

End Shim Install end shim (19). [24] IMPORTANT: Start assembly with an inner clutch disc (45), with coated side of clutch disc facing piston. LEGEND: 45 Inner Clutch Disc (8 used) 46 Outer Clutch Disc (8 used) 47 Disc Carrier

Disc Assembly (370E) Machines of (370E): Install inner and outer clutch discs (45, 46) to disc carrier (47). [25] LEGEND: 45 Inner Clutch Disc (10 used) 46 Outer Clutch Disc (10 used) 47 Disc Carrier

Disc Assembly (410E, 460E) Machines of (410E, 460E): Install inner and outer clutch discs (45, 46) to disc carrier (47). [26] -

<- Go to Section TOC

Section 03 page 156

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Section 03 - TRANSMISSION

Group 0350: Gear, Shafts, and Power Shift Clutches

LEGEND: 48 49

End Shim Retaining Ring

LEGEND: 50

Inner Clutch Teeth

End Shim Install end shim (48) and retaining ring (49). [27] -

Disc Carrier Heat inner clutch teeth (50) to specification. Item

Measurement

Specification

Inner Clutch Teeth

Temperature

120°C 248°F

[28] LEGEND: 51 52

Disc Carrier Shaft

Assembly Assemble disc carrier (51) to shaft (52). [29] -

<- Go to Section TOC

Section 03 page 157

TM12408-REPAIR TECHNICAL MANUAL

Section 03 - TRANSMISSION

Group 0350: Gear, Shafts, and Power Shift Clutches

LEGEND: 53

Retaining Ring

LEGEND: 54

Inner Teeth

Retaining Ring Install retaining ring (53). [30] -

Gear Heat inner teeth (54) to specification. Item

Measurement

Specification

Inner Teeth

Temperature

120°C 248°F

[31] LEGEND: 55 56

Gear Opening (4 used)

Retaining Ring Install gear (55). Verify retaining ring is seated in recesses of shaft and gear. Align retaining ring end gap with opening (56). [32] -

<- Go to Section TOC

Section 03 page 158

TM12408-REPAIR TECHNICAL MANUAL

Section 03 - TRANSMISSION

Group 0350: Gear, Shafts, and Power Shift Clutches

LEGEND: 57

Inner Bearing Race

Inner Bearing Race Heat inner bearing race (57) to specification. Item

Measurement

Specification

Inner Bearing Race

Temperature

120°C 248°F

[33] LEGEND: 58

Bearing

LEGEND: 59 60 61

Running Disc Axial Bearing Washer

Bearing Installed Install bearing (58). [34] -

Bearing and Washers Install running disc (59), with the chamfer on the running disc facing the axial bearing (60). Install axial bearing and washer (61). Oil parts when installed. [35] -

<- Go to Section TOC

Section 03 page 159

TM12408-REPAIR TECHNICAL MANUAL

Section 03 - TRANSMISSION

Group 0350: Gear, Shafts, and Power Shift Clutches

LEGEND: 62

Needle Bearing

LEGEND: 63

Idler Gear

Needle Bearing Install needle bearing (62). [36] -

Idler Gear Install idler gear (63). Rotate gear back and forth using the gear teeth to align the clutch discs. [37] LEGEND: 64 65 66

Retaining Ring Washer Bearing

Assembly Install retaining ring (64), washer (65), and bearing (66). Oil parts when installed. [38] -

<- Go to Section TOC

Section 03 page 160

TM12408-REPAIR TECHNICAL MANUAL

Section 03 - TRANSMISSION

Group 0350: Gear, Shafts, and Power Shift Clutches

LEGEND: 67 68 69 70

Washer Bearing Washer Groove

Installation Sequence Use grease to adhere washer (67) to bearing (68). Use an appropriate press to install washer (69). Retaining ring must be seated in groove (70) of washer. [39] LEGEND: 71

Opening (4 used)

Openings Verify retaining ring is seated in recesses of shaft and idler gear. Align retaining ring end gap with opening (71). [40] LEGEND: 72

Inner Bearing Race

Inner Bearing Race Heat inner bearing race (72) to specification. Item

Measurement

Specification

Inner Bearing Race

Temperature

120°C 248°F

[41] -

<- Go to Section TOC

Section 03 page 161

TM12408-REPAIR TECHNICAL MANUAL

Section 03 - TRANSMISSION

Group 0350: Gear, Shafts, and Power Shift Clutches

LEGEND: 73

Bearing

Bearing Install bearing (73). [42] LEGEND: 74

Rectangular Ring (2 used)

Rectangular Rings Install rectangular rings (74). [43] LEGEND: 75

Port

Transmission Clutch Verify opening and closing of clutch by applying compressed air to port (75).

<- Go to Section TOC

Section 03 page 162

TM12408-REPAIR TECHNICAL MANUAL

Section 03 - TRANSMISSION

Group 0350: Gear, Shafts, and Power Shift Clutches

Transmission Clutch (A) Disassemble and Assemble Specifications SPECIFICATIONS Inner Clutch Teeth Temperature

120°C 248°F

Inner Gear Teeth Temperature

120°C 248°F

Inner Bearing Race Temperature

120°C 248°F

Transmission Clutch (A) Weight

50 kg 110 lb.

Essential Tools ESSENTIAL TOOLS JDG11569 Assembly Fixture

[1] CAUTION: Prevent crushing injury from heavy component. Use appropriate lifting device.

Item

Measurement

Specification

Transmission Clutch (A)

Weight

50 kg 110 lb.

Remove transmission clutch (A) from mounting device. [2] LEGEND: 1 Rectangular Ring (2 used) 2 Bearing

Rectangular Rings Remove rectangular rings (1) and bearing (2). [3] →NOTE: Use a helper to compress the retaining ring while the gear is being pulled.

<- Go to Section TOC

Section 03 page 163

TM12408-REPAIR TECHNICAL MANUAL

Section 03 - TRANSMISSION

Group 0350: Gear, Shafts, and Power Shift Clutches

LEGEND: 3 4

Puller Gear

Retaining Ring Use flat tipped pry tools at the four installation openings to compress retaining ring into groove. With retaining ring compressed, use puller (3) to remove gear (4). [4] LEGEND: 5 6

Gear Retaining Ring

Gear Once gear (5) is removed, remove retaining ring (6). [5] LEGEND: 7 Axial Bearing with Washer 8 Idler 9 Needle Bearing 10 Axial Bearing with Washers and Running Disc 11 Gear

Disassembly Remove axial bearing with washers (7) and idler (8). Remove needle bearing (9) and axial bearing with washers and running disc (10). Rotate shaft to position gear (11) on top. [6] -

<- Go to Section TOC

Section 03 page 164

TM12408-REPAIR TECHNICAL MANUAL

Section 03 - TRANSMISSION

Group 0350: Gear, Shafts, and Power Shift Clutches

LEGEND: 12 13

Puller Gear

Gear Use flat tipped pry tools at the four installation openings to compress retaining ring into groove. With retaining ring compressed, use puller (12) to remove gear (13). [7] LEGEND: 14 15

Gear Retaining Ring

LEGEND: 16 17

Shaft Disc Carrier

Retaining Ring and Gear With gear (14) removed, remove retaining ring (15). [8] -

Disc Carrier Press shaft (16) from disc carrier (17). [9] -

<- Go to Section TOC

Section 03 page 165

TM12408-REPAIR TECHNICAL MANUAL

Section 03 - TRANSMISSION

Group 0350: Gear, Shafts, and Power Shift Clutches

LEGEND: 18

Retaining Ring

LEGEND: 19 20

End Shim (2 used) Disc Set

LEGEND: 21 22

JDG11569 Assembly Fixture Retaining Ring

Retaining Ring Remove retaining ring (18). [10] -

End Shims and Disc Set Remove end shims (19) and disc set (20). [11] -

Disc Carrier Use JDG11569 Assembly Fixture (21) with appropriate press to preload cup springs. Remove retaining ring (22). Assembly Fixture JDG11569 Press Aid [12] -

<- Go to Section TOC

Section 03 page 166

TM12408-REPAIR TECHNICAL MANUAL

Section 03 - TRANSMISSION

Group 0350: Gear, Shafts, and Power Shift Clutches

LEGEND: 23 24

Baffle Plate Cup Spring Set

LEGEND: 25

Piston

Baffle Plate and Cup Spring Set Remove baffle plate (23) and cup spring set (24). [13] -

Piston Apply compressed air to remove piston (25). [14] LEGEND: 26 27 28

O-Ring O-Ring O-Ring

O-Rings Remove O-rings (26—28). [15] - Clean, inspect, repair, and replace parts as required. [16] -

<- Go to Section TOC

Section 03 page 167

TM12408-REPAIR TECHNICAL MANUAL

Section 03 - TRANSMISSION

Group 0350: Gear, Shafts, and Power Shift Clutches

LEGEND: 29 30 31 32 33 34 35 36 37 38 39 40 41

O-Ring Piston End Shim Inner Clutch Disc (10 used) Outer Clutch Disc (10 used) End Shim Retaining Ring Cup Spring Set Baffle Plate Retaining Ring O-Ring O-Ring Disc Carrier

Cross Section Install O-rings (29, 39 and 40) to piston (30). Install piston to disc carrier (41) using appropriate press. [17] LEGEND: 42 43

JDG11569 Assembly Fixture Retaining ring

Disc Carrier Install baffle plate and cup spring set. Preload using appropriate press and JDG11569 Assembly Fixture (42). Install retaining ring (43). Assembly Fixture JDG11569 Press Aid [18] LEGEND: 44

End Shim

End Shim Install end shim (44). [19] IMPORTANT: Avoid damage to clutch assembly, start assembly with an inner clutch disc (45), with coated side of clutch disc toward piston. <- Go to Section TOC

Section 03 page 168

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Section 03 - TRANSMISSION

Group 0350: Gear, Shafts, and Power Shift Clutches

LEGEND: 45 Inner Clutch Disc (10 used) 46 Outer Clutch Disc (10 used) 47 Disc Carrier

Disc Assembly Install inner and outer clutch discs (45 and 46) to disc carrier (47). [20] LEGEND: 48 49

End Shim Retaining Ring

LEGEND: 50

Inner Clutch Teeth

End Shim Install end shim (48) and retaining ring (49). [21] -

Disc Carrier Heat inner clutch teeth (50) to specification. Item

Measurement

Specification

Inner Clutch Teeth

Temperature

120°C 248°F

[22] -

<- Go to Section TOC

Section 03 page 169

TM12408-REPAIR TECHNICAL MANUAL

Section 03 - TRANSMISSION

Group 0350: Gear, Shafts, and Power Shift Clutches

LEGEND: 51 52

Disc Carrier Shaft

LEGEND: 53

Retaining Ring

LEGEND: 54

Inner Teeth

Assembly Assemble disc carrier (51) to shaft (52). [23] -

Retaining Ring Install retaining ring (53). [24] -

Gear Heat inner teeth (54) to specification. Item

Measurement

Specification

Gear Inner Teeth

Temperature

120°C 248°F

[25] -

<- Go to Section TOC

Section 03 page 170

TM12408-REPAIR TECHNICAL MANUAL

Section 03 - TRANSMISSION

Group 0350: Gear, Shafts, and Power Shift Clutches

LEGEND: 55 56

Gear Opening (4 used)

Retaining Ring Install gear (55). Verify retaining ring is seated in recesses of shaft and gear. Locate retaining ring end gap to an opening (56). [26] LEGEND: 57

Inner Bearing Race

Bearing Heat inner bearing race (57) to specification. Item

Measurement

Specification

Inner Bearing Race

Temperature

120°C 248°F

[27] LEGEND: 58

Bearing

Bearing Installed Install bearing (58). [28] -

<- Go to Section TOC

Section 03 page 171

TM12408-REPAIR TECHNICAL MANUAL

Section 03 - TRANSMISSION

Group 0350: Gear, Shafts, and Power Shift Clutches

LEGEND: 59 60 61

Running Disc Axial Bearing Washer

Bearing and Washers Install running disc (59). The chamfer on the running disc should face the axial bearing (60). Install axial bearing and washer (61). Oil parts when installed. [29] LEGEND: 62

Needle Bearing

LEGEND: 63

Idler Gear

Needle Bearing Install needle bearing (62). [30] -

Idler Gear Install idler gear (63). Rotate gear back and forth using the gear teeth to align the clutch discs. [31] -

<- Go to Section TOC

Section 03 page 172

TM12408-REPAIR TECHNICAL MANUAL

Section 03 - TRANSMISSION

Group 0350: Gear, Shafts, and Power Shift Clutches

LEGEND: 64 65

Washer (2 used) Bearing

LEGEND: 66

Retaining Ring

LEGEND: 67

Gear

Assembly Install washers (64) and bearing (65). Oil parts when installed. [32] -

Retaining Ring Install retaining ring (66). [33] -

Heat Gear Heat gear (67) to specification. Item

Measurement

Specification

Gear Inner Teeth

Temperature

120°C 248°F

[34] - Install gear (68), verify retaining ring (69) has seated into recess of gear.

<- Go to Section TOC

Section 03 page 173

TM12408-REPAIR TECHNICAL MANUAL

Section 03 - TRANSMISSION

Group 0350: Gear, Shafts, and Power Shift Clutches

Retaining Ring LEGEND: 68 69

Gear Retaining Ring

[35] LEGEND: 70

Inner Bearing Race

Heat Bearing Heat inner bearing race (70) to specification. Item

Measurement

Specification

Bearing Inner Race

Temperature

120°C 248°F

[36] LEGEND: 71

Bearing

Bearing Install bearing (71). [37] -

<- Go to Section TOC

Section 03 page 174

TM12408-REPAIR TECHNICAL MANUAL

Section 03 - TRANSMISSION

Group 0350: Gear, Shafts, and Power Shift Clutches

LEGEND: 72

Rectangular Ring (2 used)

Rectangular Rings Install rectangular rings (72). [38] LEGEND: 73

Port

Port Apply compressed air to port (73) to verify opening and closing of clutch.

<- Go to Section TOC

Section 03 page 175

TM12408-REPAIR TECHNICAL MANUAL

Section 03 - TRANSMISSION

Group 0350: Gear, Shafts, and Power Shift Clutches

Transmission Clutch (G) Inter-Axle Differential Lock (IDL) Disassemble and Assemble Specifications SPECIFICATIONS Carrier Temperature

120°C 248°F

Carrier Cap Screw Torque

120 N·m 89 lb.-ft.

Transmission Clutch (G) Weight

95 kg 210 lb.

Essential Tools ESSENTIAL TOOLS JDG10191 Assembly Aid JDG11567 Assembly Fixture JDG11568 Pressure Piece

[1] CAUTION: Prevent crushing injury from heavy component. Use appropriate lifting device.

Item

Measurement

Specification

Transmission Clutch (G)

Weight

95 kg 210 lb.

Remove transmission clutch (G) from mounting transmission. [2] →NOTE: Assembled parts are located with tension pins. Separate parts evenly during disassembly. LEGEND: 1 2 3

Cap Screw (12 used) Output Gear Planet Carrier

Inter-Axle Differential Lock (G)

<- Go to Section TOC

Section 03 page 176

TM12408-REPAIR TECHNICAL MANUAL

Section 03 - TRANSMISSION

Group 0350: Gear, Shafts, and Power Shift Clutches

Planet Carrier and Ring Gear Remove cap screws (1). Remove planet carrier (3), from output gear (2). [3] LEGEND: 4

Slotted Pin (4 used)

LEGEND: 5 6

Planet Carrier Ring Gear

Slotted Pins Remove slotted pins (4) only if damaged. [4] -

Planet Carrier Separate planet carrier (5) from ring gear (6). [5] -

<- Go to Section TOC

Section 03 page 177

TM12408-REPAIR TECHNICAL MANUAL

Section 03 - TRANSMISSION

Group 0350: Gear, Shafts, and Power Shift Clutches

LEGEND: 7

Slotted Pin (4 used)

LEGEND: 8

Planetary Pin (4 used)

LEGEND: 9

Planetary Gear (4 used)

Planet Carrier Remove slotted pins (7). [6] -

Planetary Pins Remove planetary pins (8). [7] -

Planetary Gear Remove planetary gears (9). [8] -

<- Go to Section TOC

Section 03 page 178

TM12408-REPAIR TECHNICAL MANUAL

Section 03 - TRANSMISSION

Group 0350: Gear, Shafts, and Power Shift Clutches

LEGEND: 10 11

Thrust Washer (8 used) Needle Bearing (8 used)

Planetary Gear Exploded View Remove thrust washers (10) and needle bearings (11). [9] →NOTE: Disassembly of the output shaft (12) is only required if the shaft is damaged. LEGEND: 12 13

Output Shaft Ring Gear

LEGEND: 14

Rectangular Ring (3 used)

Output Shaft Pull the output shaft (12) from the ring gear (13). [10] -

Rectangular Rings Remove rectangular rings (14). [11] -

<- Go to Section TOC

Section 03 page 179

TM12408-REPAIR TECHNICAL MANUAL

Section 03 - TRANSMISSION

Group 0350: Gear, Shafts, and Power Shift Clutches

LEGEND: 15

Retaining Ring

Retaining Ring Remove retaining ring (15). Separate the output gear from the ring gear. [12] LEGEND: 16

Snap Ring

LEGEND: 17

Needle Sleeve

Snap Ring Remove snap ring (16) from the bore of the shaft. [13] -

Needle Sleeve Use an appropriate puller and remove needle sleeve (17). [14] -

<- Go to Section TOC

Section 03 page 180

TM12408-REPAIR TECHNICAL MANUAL

Section 03 - TRANSMISSION

Group 0350: Gear, Shafts, and Power Shift Clutches

LEGEND: 18

L-Ring

Cup Springs Preload cup springs using JDG10191 Assembly Aid and remove L-ring (18) from the outside diameter of the shaft. Assembly Aid JDG10191 Applies Pressure [15] LEGEND: 19

Cup Spring (7 used)

Cup Spring Removal Remove cup springs (19). [16] LEGEND: 20

Piston

Piston Apply compressed air to hole in shaft to remove piston (20). [17] -

<- Go to Section TOC

Section 03 page 181

TM12408-REPAIR TECHNICAL MANUAL

Section 03 - TRANSMISSION

Group 0350: Gear, Shafts, and Power Shift Clutches

LEGEND: 21 22

O-Ring O-Ring

O-Rings Remove O-rings (21 and 22). [18] LEGEND: 23

Retaining Ring

LEGEND: 24 25

Disc Set End Shim

Retaining Ring Remove retaining ring (23). [19] -

Disc Set Remove disc set (24) and end shim (25). [20] -

<- Go to Section TOC

Section 03 page 182

TM12408-REPAIR TECHNICAL MANUAL

Section 03 - TRANSMISSION

Group 0350: Gear, Shafts, and Power Shift Clutches

LEGEND: 26

Retaining Ring

Retaining Ring Remove retaining ring (26). [21] - Clean and inspect parts. Repair or replace parts as required. [22] LEGEND: 27 28

Retaining Ring Ring Gear

LEGEND: 29

End Shim

Retaining Ring Install retaining ring (27) into lower groove of ring gear (28). [23] -

End Shim Install end shim (29). [24] →NOTE: Begin assembly with an inner clutch disc (30). The coated side of the clutch plate must face the end shim (29).

<- Go to Section TOC

Section 03 page 183

TM12408-REPAIR TECHNICAL MANUAL

Section 03 - TRANSMISSION

Group 0350: Gear, Shafts, and Power Shift Clutches

LEGEND: 30 Inner Clutch Disc (9 used) 31 Outter Clutch Disc (9 used) 32 Ring Gear

Clutch Discs Assemble inner and outer clutch discs (30 and 31) to ring gear (32). [25] LEGEND: 33

Retaining Ring

Retaining Ring

Cross Section Install retaining ring (33). [26] IMPORTANT: Check function of ball in drain port; ball must not be jammed in orifice (see bold arrow in graphic). If ball does not have free movement, machine will not operate properly.

<- Go to Section TOC

Section 03 page 184

TM12408-REPAIR TECHNICAL MANUAL

Section 03 - TRANSMISSION

Group 0350: Gear, Shafts, and Power Shift Clutches

LEGEND: 34 35

O-Ring O-Ring

LEGEND: 36

Piston

O-Rings Install O-rings (34 and 35). [27] -

Piston Position piston (36) on output shaft. [28] LEGEND: 37

JDG10191 Assembly Aid

JDG10191 Assembly Aid Use JDG10191 Assembly Aid (37) and a hand press to seat piston. Assembly Aid JDG10191 Applies Pressure [29] -

<- Go to Section TOC

Section 03 page 185

TM12408-REPAIR TECHNICAL MANUAL

Section 03 - TRANSMISSION

Group 0350: Gear, Shafts, and Power Shift Clutches

LEGEND: 38 39 40

Output Shaft Cup Spring (7 used) L-Ring

Cup Springs Install JDG11567 Assembly Fixture to output shaft (38). Slide cup springs (39) and L-ring (40) over assembly fixture. Assembly Fixture JDG11567 Assembly Aid [30] LEGEND: 41

JDG10191 Assembly Aid

JDG10191 Preload cup springs using JDG10191 Assembly Aid (41). Install L-ring. [31] →NOTE: JDG11568 Pressure Piece (43) is required to achieve proper location of needle sleeve (42). LEGEND: 42 43

Needle Sleeve JDG11568 Pressure Piece

Needle Sleeve Install needle sleeve using JDG11568 Pressure Piece. Pressure Piece <- Go to Section TOC

Section 03 page 186

TM12408-REPAIR TECHNICAL MANUAL

Section 03 - TRANSMISSION

Group 0350: Gear, Shafts, and Power Shift Clutches

JDG11568 Installation Aid [32] LEGEND: 44

Retaining Ring

LEGEND: 45 46

Output Shaft Ring Gear

LEGEND: 47

Retaining Ring

Retaining Ring Install retaining ring (44). [33] -

Output Shaft Assemble output shaft (45) into ring gear (46). [34] -

Retaining Ring Install retaining ring (47). [35] -

<- Go to Section TOC

Section 03 page 187

TM12408-REPAIR TECHNICAL MANUAL

Section 03 - TRANSMISSION

Group 0350: Gear, Shafts, and Power Shift Clutches

LEGEND: 48

Rectangular Ring (3 used)

O-Rings Install rectangular rings (48). [36] LEGEND: 49

Carrier

Carrier Heat inner teeth of carrier (49). Item

Measurement

Specification

Carrier

Temperature

120°C 248°F

[37] LEGEND: 50 51

Disc Carrier Sun Gear

Disc Carrier Assemble disc carrier (50) onto sun gear (51). [38] -

<- Go to Section TOC

Section 03 page 188

TM12408-REPAIR TECHNICAL MANUAL

Section 03 - TRANSMISSION

Group 0350: Gear, Shafts, and Power Shift Clutches

LEGEND: 52

Retaining Ring

LEGEND: 53

Output Shaft

Retaining Ring Install retaining ring (52). [39] -

Output Shaft Align clutch discs and install output shaft (53). [40] LEGEND: 54 Planetary Gear (4 used) 55 Thrust Washer (8 used) 56 Needle Bearing (8 used)

Planetary Gear Assemble planetary gears (54), using needle bearings (56) and thrust washers (55). [41] -

<- Go to Section TOC

Section 03 page 189

TM12408-REPAIR TECHNICAL MANUAL

Section 03 - TRANSMISSION

Group 0350: Gear, Shafts, and Power Shift Clutches

LEGEND: 57

Planetary Gear (4 used)

LEGEND: 58

Planetary Pin (4 used)

LEGEND: 59 60 61

Planetary Pin (4 used) Slotted Pin (4 used) Carrier

Planetary Carrier Install assembled planetary gears (57) to carrier. [42] -

Planetary Pins Align and install planetary pins (58). [43] -

Slotted Pins Fasten planetary pins (59) using slotted pins (60). Drive pins flush to carrier (61). [44] -

<- Go to Section TOC

Section 03 page 190

TM12408-REPAIR TECHNICAL MANUAL

Section 03 - TRANSMISSION

Group 0350: Gear, Shafts, and Power Shift Clutches

LEGEND: 62 63

Output Shaft with Ring Gear Output Gear

LEGEND: 64

Alignment Tooling

LEGEND: 65

Slotted Pin (4 used)

Output Shaft Install output shaft with ring gear (62) into the output gear (63). [45] →NOTE: Pay attention to hole alignment.

Alignment Tooling Install alignment tooling (64). Align planet carrier to ring gear. [46] -

Slotted Pins Remove alignment tooling and install slotted pins (65). [47] -

<- Go to Section TOC

Section 03 page 191

TM12408-REPAIR TECHNICAL MANUAL

Section 03 - TRANSMISSION

Group 0350: Gear, Shafts, and Power Shift Clutches

LEGEND: 66 67

Press Tooling Cap Screw (12 used)

Final Assembly Press planet carrier and ring gear with press tooling (66). Install cap screws (67) and torque to specification. Item

Measurement

Specification

Carrier Cap Screw

Torque

120 N·m 89 lb.-ft.

<- Go to Section TOC

Section 03 page 192

TM12408-REPAIR TECHNICAL MANUAL

Section 03 - TRANSMISSION

Group 0350: Gear, Shafts, and Power Shift Clutches

Transmission Speed Sensors Remove and Install [1] - Remove transmission control valve. See Transmission Control Valve Remove and Install . (Group 0360.) [2] LEGEND: 1 2 3

Cap Screw (4 used) Bracket Connector (2 used)

Transmission Control Valve Remove cap screws (1) and bracket (2). [3] - Remove connectors (3). [4] LEGEND: 4 Cap Screw (2 used) 5 Turbine Speed and Clutch (A) Speed Sensor (2 used)

Bracket Remove cap screws (4) and turbine speed and clutch (A) speed sensors (5). [5] - Install cap screws and turbine speed and clutch (A) speed sensors. For more information see Clutch Control Harness (W5) Component Location . (Group 9015-10.) [6] - Install connectors. [7] - Install bracket and cap screws. [8] IMPORTANT: Do not drop cap screw (7) into the transmission during removal. If the transmission is run after dropping the cap screw into the transmission, machine damage will occur. Apply clean shop rags under the immediate area of the cap screw and use a magnet to capture the cap screw during removal.

<- Go to Section TOC

Section 03 page 193

TM12408-REPAIR TECHNICAL MANUAL

Section 03 - TRANSMISSION

Group 0350: Gear, Shafts, and Power Shift Clutches

LEGEND: 6 7 8

Connector Cap Screw Bracket

Cap Screw and Bracket Remove connector (6), and cap screw (7), and bracket (8). [9] LEGEND: 9 Cap Screw 10 Secondary Step Speed Sensor

Speed Sensor Remove cap screw (9) and secondary step speed sensor (10). [10] - Install secondary step speed sensor and cap screw (9). For more information see Retarder Control Harness (W6) Component Location . (Group 9015-10.) [11] - Install bracket, cap screw (9), and connector. [12] LEGEND: 11 12

Cap Screw (6 used) Cover

Cover Remove cap screw (11) and cover (12). [13] -

<- Go to Section TOC

Section 03 page 194

TM12408-REPAIR TECHNICAL MANUAL

Section 03 - TRANSMISSION

Group 0350: Gear, Shafts, and Power Shift Clutches

LEGEND: 13 14

Sensor Cup Connector

LEGEND: 15 16

Cap Screw Output Speed Sensor

Sensor Cup Remove sensor cup (13) and connector (14). [14] -

Speed Sensor Remove cap screw (15) and output speed sensor (16). [15] - Install output speed sensor and cap screw. For more information see Output Speed Sensor Harness (W7) Component Location . (Group 9015-10.) [16] - Install sensor cup and connector. [17] - Install cover and cap screws. [18] - Install transmission control valve. See Transmission Control Valve Remove and Install . (Group 0360.)

<- Go to Section TOC

Section 03 page 195

TM12408-REPAIR TECHNICAL MANUAL

Section 03 - TRANSMISSION

Group 0350: Gear, Shafts, and Power Shift Clutches

Transmission Clutch (F) Hi/Lo Planetary Remove and Install Specifications SPECIFICATIONS Transmission Clutch (F) Hi/Lo Planetary Weight

100 kg 220 lb.

Transmission Clutch (F) Hi/Lo Planetary Weight

100 kg 220 lb.

Clutch (F) Mounting Cap Screw Torque

46 N·m 34 lb.-ft.

Clutch (F) Cap Screw Torque

62 N·m 46 lb.-ft.

Essential Tools ESSENTIAL TOOLS JDG11565 Eyebolt JDG11432 Thrust Piece

[1] - Remove transmission. See Transmission Remove and Install . (Group 0300.) [2] CAUTION: Repair stand D001003AA is rated for 2000 lb. Prevent crushing injury from heavy component. Remove transmission components before mounting transmission to repair stand. See Transmission Disassemble and see Transmission Assemble . (Group 0350.) Support transmission on floor using blocks. [3] LEGEND: 1

Plug with O-Ring

Plug Remove plug with O-ring (1). [4] -

<- Go to Section TOC

Section 03 page 196

TM12408-REPAIR TECHNICAL MANUAL

Section 03 - TRANSMISSION

Group 0350: Gear, Shafts, and Power Shift Clutches

LEGEND: 2 3

Cap Screw Cap Screw (18 used)

LEGEND: 4 5

Eyebolt Jack Screw (3 used)

Cap Screws Remove cap screw (2) and cap screws (3). [5] -

Tooling Install eyebolt (4). Separate cover from housing evenly using M10 fully threaded jack screws (5) of appropriate length. Eyebolt JDG11565 Clutch (F) Removal [6] CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device. LEGEND: 6 Transmission Clutch (F) Hi/Lo Planetary

Assembly Removal <- Go to Section TOC

Section 03 page 197

TM12408-REPAIR TECHNICAL MANUAL

Section 03 - TRANSMISSION

Group 0350: Gear, Shafts, and Power Shift Clutches

Remove transmission clutch (F) Hi/Lo planetary (6). Item

Measurement

Specification

Transmission Clutch (F) Hi/Lo Planetary

Weight

100 kg 220 lb.

[7] LEGEND: 7 8

Spring (4 used) O-Ring

LEGEND: 10

Pin (3 used)

Springs and O-Rings Remove springs (7) and O-ring (8). [8] -

O-Ring LEGEND: 9 Remove O-ring (9).

O-Ring

[9] -

Pins Drive pins (10) flush with housing. <- Go to Section TOC

Section 03 page 198

TM12408-REPAIR TECHNICAL MANUAL

Section 03 - TRANSMISSION

Group 0350: Gear, Shafts, and Power Shift Clutches

[10] - Clean, inspect, repair, or replace transmission clutch (F) Hi/Lo planetary as required. [11] LEGEND: 11 12

Pressure Port O-Ring

Pressure Port Apply compressed air to pressure port (11), audible confirmation of the clutch opening and closing must be heard before proceeding. Grease and install O-ring (12). [12] LEGEND: 13 14

O-Ring Spring (4 used)

Springs and O-Ring Install O-ring (13) and springs (14). [13] CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device. Using alignment tools (15), install transmission clutch (F) Hi/Lo planetary (16). Drive pins (17) flush with cover. LEGEND: 15 Alignment Tool (2 used) 16 Transmission Clutch (F) Hi/Lo Planetary 17 Pin (3 used)

Tooling <- Go to Section TOC

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Section 03 - TRANSMISSION

Group 0350: Gear, Shafts, and Power Shift Clutches

Item

Measurement

Specification

Transmission Clutch (F) Hi/Lo Planetary

Weight

100 kg 220 lb.

[14] LEGEND: 18

Cap Screw (18 used)

Cap Screws Install cap screws (18). Item

Measurement

Specification

Clutch (F) Mounting Cap Screw

Torque

46 N·m 34 lb.-ft.

[15] LEGEND: 19

Cap Screw

Cap Screw Install cap screw (19). [16] LEGEND: 20

JDG11432 Thrust Piece

Tooling Slide JDG11432 thrust piece (20) onto extension then install socket. Insert tooling through cover and tighten thrust piece with an appropriate open end wrench. Thrust Piece <- Go to Section TOC

Section 03 page 200

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Section 03 - TRANSMISSION

Group 0360: Hydraulic System

JDG11432 Holds planetary in place while cap screw is being torqued. Item

Measurement

Specification

Clutch (F) Cap Screw

Torque

62 N·m 46 lb.-ft.

[17] LEGEND: 21 22

Plug O-Ring

Plug and O-Ring Install plug (21) and O-ring (22). [18] - Install transmission. See Transmission Remove and Install . (Group 0300.)

<- Go to Section TOC

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Section 03 - TRANSMISSION

Group 0360: Hydraulic System

Group 0360 - Hydraulic System Transmission Oil Cooler Thermal Bypass Valve Remove and Install [1] - Prepare Machine for Maintenance . (Group 0001.) [2] - Turn battery disconnect switch to the OFF position. [3] - Remove right fender. See Fender Remove and Install . (Group 1910.) [4] LEGEND: 1 2 3 4 5

Line Line Line Bypass Valve Nut

Thermal Bypass Valve Remove line (1) and drain hydraulic fluid into a suitable container. Close all openings using caps and plugs. [5] - Remove lines (2 and 3). Close all openings using caps and plugs. [6] - Support bypass valve (4) and remove nut (5). [7] - Remove bypass valve. [8] - Clean, inspect, repair, or replace bypass valve as required. [9] - Install bypass valve and hold position with nut. Do not tighten nut at this time. [10] - Install hydraulic lines. [11] - Tighten nut. [12] - Check and fill transmission oil level. See Check Transmission Oil Level . (Operator’s Manual.) [13] - Install fender. See Fender Remove and Install . (Group 1910.) [14] - Turn battery disconnect switch to the ON position.

<- Go to Section TOC

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Section 03 - TRANSMISSION

Group 0360: Hydraulic System

Transmission Control Valve Remove and Install Specifications SPECIFICATIONS Transmission Control Valve Mounting Cap Screw Torque

23 N·m 19 lb.-ft.

Transmission Control Unit (TCU) Mounting Cap Screw Torque

9.5 N·m 7 lb.-ft.

[1] - Tilt Cab . (Operator’s Manual.) [2] →NOTE: Transmission calibration must be performed after servicing the transmission control valve. See Electronic Clutch Calibration . (Group 9020-25.) Remove three wire connectors and four mounting cap screws from TCU (1). [3] LEGEND: 1 Transmission Control Unit 2 Cap Screw (28 used) 3 Transmission Control Valve

Transmission Control Valve Remove the TCU. [4] - Remove cap screws (2). [5] - Lift transmission control valve (3). Identify and remove wire connectors from inside transmission. [6] - Remove transmission control valve and seal. [7] - Clean and inspect parts. Repair or replace parts as necessary. See Transmission Control Valve Disassemble and Assemble . (Group 0360.) [8] - Install new seal. [9] - Connect wire harness inside transmission. [10] - Install transmission control valve with mounting cap screws. Item

Measurement

Specification

Transmission Control Valve Mounting Cap Screw

Torque

23 N·m 19 lb.-ft.

[11] - Install TCU with mounting cap screws. Item

Measurement

Specification

TCU Mounting Cap Screw

Torque

9.5 N·m 7 lb.-ft.

[12] <- Go to Section TOC

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Section 03 - TRANSMISSION

Group 0360: Hydraulic System

→NOTE: Transmission calibration must be performed after servicing the transmission control valve. See Electronic Clutch Calibration . (Group 9020-25.) Connect wire harness to the transmission control unit (TCU). [13] - Return cab to original position. See Tilt Cab . (Operator’s Manual.)

Torque Converter Remove and Install IMPORTANT: Anytime the torque converter is removed, the torque converter main seal must be replaced. For proper torque converter main seal replacement, the torque converter housing must be removed. Removing the torque converter housing exposes the non-reusable gasket between transmission retarder and main body of the transmission. Avoid possible oil leaks from reusing seals and gaskets during assembly. Replace all required seals and gaskets when removing and installing the torque converter. To remove and install the torque converter, see Transmission Retarder Remove and Install . (Group 0360.)

Clutch Control Valve Remove and Install IMPORTANT: Anytime the torque converter is removed, the torque converter main seal must be replaced. For proper torque converter main seal replacement, the torque converter housing must be removed. Removing the torque converter housing exposes the non-reusable gasket between transmission retarder and main body of the transmission. Avoid possible oil leaks from reusing seals and gaskets during assembly. Replace all required seals and gaskets when removing and installing the clutch control valve. To remove and install the clutch control valve, see Transmission Retarder Remove and Install . (Group 0360.)

Retarder Control Valve Remove and Install IMPORTANT: Anytime the torque converter is removed, the torque converter main seal must be replaced. For proper torque converter main seal replacement, the torque converter housing must be removed. Removing the torque converter housing exposes the non-reusable gasket between transmission retarder and main body of the transmission. Avoid possible oil leaks from reusing seals and gaskets during assembly. Replace all required seals and gaskets when removing and installing the retarder control valve. To remove and install the retarder control valve, see Transmission Retarder Remove and Install . (Group 0360.)

Oil Pump Remove and Install IMPORTANT: Anytime the torque converter is removed, the torque converter main seal must be replaced. For proper torque converter main seal replacement, the torque converter housing must be removed. Removing the torque converter housing exposes the non-reusable gasket between transmission retarder and main body of the transmission. Avoid possible oil leaks from reusing seals and gaskets during assembly. Replace all required seals and gaskets when removing and installing the oil pump. To remove and install the oil pump, see Transmission Retarder Remove and Install . (Group 0360.)

<- Go to Section TOC

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Section 03 - TRANSMISSION

Group 0360: Hydraulic System

Transmission Retarder Remove and Install Specifications SPECIFICATIONS Transmission Weight

1180 kg 2600 lb.

Torque Converter Assembly Weight

137 kg 300 lb.

Torque Converter Housing Weight

61 kg 135 lb.

Retarder Mounting Cap Screw Torque

23 N·m 17 lb.-ft.

Allen Head Cap Screw M10 Torque

46 N·m 34 lb.-ft.

Allen Head Cap Screw M8 Torque

23 N·m 17 lb.-ft.

Hex Head Cap Screw with Washer Torque

23 N·m 17 lb.-ft.

Torx Head Cap Screw M6 Torque

9.5 N·m 7 lb.-ft.

Torx Head Cap Screw M8 Torque

23 N·m 17 lb.-ft.

Torque Converter Housing Cap Screw Torque

46 N·m 34 lb.-ft.

Torque Converter Housing Fitting Torque

145 N·m 107 lb.-ft.

Torque Converter Flange Shaft Cap Screw Torque

120 N·m 89 lb.-ft.

Input Flange Temperature

120 °C 248 °F

Input Flange Cap Screw Torque

68 N·m 50 lb.-ft.

Torque Converter Cover Cap Screw Torque

46 N·m 34 lb.-ft.

Essential Tools ESSENTIAL TOOLS JDG11430 Stator Lifting Device JDG11433 Installer

[1] CAUTION: Repair Stand D001003AA is rated for 907 kg. (2000 lb.) Prevent crushing injury from heavy component. Remove transmission components before mounting transmission to repair stand. See Transmission Disassemble and see Transmission Assemble . (Group 0350.) Remove transmission. See Transmission Remove and Install . (Group 0300.) [2] - Support transmission on floor using blocks. [3] CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device. Support transmission with torque converter housing facing up. <- Go to Section TOC

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Section 03 - TRANSMISSION

Group 0360: Hydraulic System

Item

Measurement

Specification

Transmission

Weight

1180 kg 2600 lb.

[4] →NOTE: Transmission calibration must be performed after servicing the transmission. See Electronic Clutch Calibration . (Group 9020-25.) LEGEND: 1 Cap Screw (12 used) 2 Cover 3 Torque Converter Housing

Torque Converter Housing Remove cap screws (1) and place alignment marks on cover (2) and torque converter housing (3). [5] CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device. LEGEND: 4 Assembly 5 Torque Converter Housing

Torque Converter Assembly Remove assembly (4) from torque converter housing (5). Item

Measurement

Specification

Torque Converter Assembly

Weight

137 kg 300 lb.

[6] -

<- Go to Section TOC

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Section 03 - TRANSMISSION

Group 0360: Hydraulic System

LEGEND: 6 7

Cap Screw (2 used) Washer

LEGEND: 8

Output Flange

Cap Screws Remove cap screws (6) and washer (7). [7] -

Output Flange Remove output flange (8). [8] LEGEND: 9 10

Torque Converter Shaft Cover

Cover Removal Press torque converter shaft (9) through cover (10). [9] -

<- Go to Section TOC

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Section 03 - TRANSMISSION

Group 0360: Hydraulic System

LEGEND: 11 12

Cap Screw (10 used) Flange Shaft

LEGEND: 13

Fitting (3 used)

LEGEND: 14

Pipe

Flange Shaft Remove cap screws (11) and flange shaft (12). [10] -

Torque Converter Housing Remove fittings (13). [11] -

Cooler Recirculation Pressure Pipe Remove pipe (14). [12] →NOTE: Pins are internally threaded. Use a slide hammer with an M6 x 1.0 attachment to remove pins.

<- Go to Section TOC

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Section 03 - TRANSMISSION

Group 0360: Hydraulic System

LEGEND: 15

Pin (2 used)

LEGEND: 16

Inspection Cover

LEGEND: 17

Cap Screw (28 used)

Pins Remove pins (15). [13] -

Inspection Cover Remove inspection cover (16). [14] -

Torque Converter Housing Remove cap screws (17). [15] CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device.

<- Go to Section TOC

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Section 03 - TRANSMISSION

Group 0360: Hydraulic System

LEGEND: 18

Torque Converter Housing

Torque Converter Housing Remove torque converter housing (18). Item

Measurement

Specification

Torque Converter Housing

Weight

61 kg 135 lb.

[16] LEGEND: 19

Seal

LEGEND: 20 21 22

Connector Connector Connector (4 used)

Seal Remove seal (19). [17] -

Electrical Connectors Remove electrical connectors (20—22) from the clutch control and retarder control valves. [18] -

<- Go to Section TOC

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Section 03 - TRANSMISSION

Group 0360: Hydraulic System

LEGEND: 23

Clutch Control Valve

LEGEND: 24

Retarder Control Valve

Clutch Control Valve Remove clutch control valve (23). [19] -

Retarder Control Valve Remove retarder control valve (24). [20] LEGEND: 25

Oil Pump

Oil Pump Remove oil pump (25). [21] IMPORTANT: Gasket (26) cannot be reused. Replace with new part during assembly, or machine damage may occur.

<- Go to Section TOC

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Section 03 - TRANSMISSION

Group 0360: Hydraulic System

LEGEND: 26

Gasket

Gasket Remove gasket (26). [22] LEGEND: 27 28

Pin (2 used) Cap Screw (9 used)

Pins and Cap Screws Remove pins (27) and cap screws (28). [23] LEGEND: 29 Retarder 30 JDG11430 Stator Lifting Device

Retarder Remove retarder (29) using JDG11430 stator lifting device (30). Stator Lifting Device JDG11430 Transmission Retarder Removal [24] IMPORTANT: Gasket (31) cannot be reused. Replace with new part during assembly, or machine damage may occur.

<- Go to Section TOC

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Section 03 - TRANSMISSION

Group 0360: Hydraulic System

LEGEND: 31

Gasket

Gasket Remove gasket (31). [25] - Clean, inspect, and replace parts as required. [26] IMPORTANT: Gasket (32) cannot be reused. Replace with new part during assembly, or machine damage may occur. LEGEND: 32

Gasket

LEGEND: 33

Retarder

Gasket Using alignment tools, install gasket (32). [27] -

Retarder Install retarder (33). [28] -

<- Go to Section TOC

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Section 03 - TRANSMISSION

Group 0360: Hydraulic System

LEGEND: 34 35

Pin (2 used) Cap Screw (9 used)

Pins and Cap Screws Install pins (34) and cap screws (35). Item

Measurement

Specification

Retarder Mounting Cap Screw

Torque

23 N·m 17 lb.-ft.

[29] IMPORTANT: Gasket (36) cannot be reused. Replace with new part during assembly, or machine damage may occur. LEGEND: 36

Gasket

Gasket Install gasket (36). [30] LEGEND: 37 Allen Head Cap Screw M10 38 Hex Head Cap Screw with Washer (6 used) 39 Torx Head Cap Screw M8 (4 used)

Oil Pump Install oil pump. Tighten cap screws (37—39) to specification. [31] <- Go to Section TOC

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Section 03 - TRANSMISSION

Group 0360: Hydraulic System

LEGEND: 40 Allen Head Cap Screw M10 (3 used) 41 Hex Head Cap Screw with Washer (9 used) 42 Torx Head Cap Screw M8 (18 used)

Retarder Control Valve Install retarder control valve. Tighten cap screws (40—42) to specification. [32] LEGEND: 43 Allen Head Cap Screw M8 (4 used) 44 Hex Head Cap Screw with Washer (2 used) 45 Torx Head Cap Screw M6 (18 used) 46 Torx Head Cap Screw M8 (3 used)

Clutch Control Valve Install clutch control valve. Tighten cap screws (43—46) to specification. Item

Measurement

Specification

Allen Head Cap Screw M10

Torque

46 N·m 34 lb.-ft.

Item

Measurement

Specification

Allen Head Cap Screw M8

Torque

23 N·m 17 lb.-ft.

Item

Measurement

Specification

Hex Head Cap Screw with Washer

Torque

23 N·m 17 lb.-ft.

Item

Measurement

Specification

Torx Head Cap Screw M6

Torque

9.5 N·m 7 lb.-ft.

Item

Measurement

Specification

Torx Head Cap Screw M8

Torque

23 N·m 17 lb.-ft.

[33] - Install electrical connectors to retarder and clutch control valves. [34] →NOTE: Grease sealing lip and wet the outer diameter of seal prior to installation.

<- Go to Section TOC

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Section 03 - TRANSMISSION

Group 0360: Hydraulic System

LEGEND: 47 48

JDG11433 Installer Seal

LEGEND: 49

Torque Converter Housing

Tooling

Seal Use JDG11433 Installer (47) to install seal (48). Installer JDG11433 Installs Torque Converter Housing Seal [35] -

Torque Converter Housing Install torque converter housing (49). [36] -

<- Go to Section TOC

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Section 03 - TRANSMISSION

Group 0360: Hydraulic System

LEGEND: 50 51

Pin (2 used) Cap Screw (28 used)

Pins and Cap Screws Install locating pins (50) and cap screws (51) and install inspection cover. Item

Measurement

Specification

Torque Converter Housing Cap Screw

Torque

46 N·m 34 lb.-ft.

[37] LEGEND: 52 53

Pipe O-Ring (2 used)

Pressure Pipe Location

Pressure Pipe Install pipe (52) using new O-rings (53). [38] -

<- Go to Section TOC

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Section 03 - TRANSMISSION

Group 0360: Hydraulic System

LEGEND: 54

Fitting (3 used)

Fittings Install fittings (54). Item

Measurement

Specification

Torque Converter Housing Fitting

Torque

145 N·m 107 lb.-ft.

[39] LEGEND: 55 56 57

Flange Shaft Torque Converter Cap Screw (10 used)

Flange Shaft Install flange shaft (55) to torque converter (56) using cap screws (57). Item

Measurement

Specification

Torque Converter Flange Shaft Cap Screw

Torque

120 N·m 89 lb.-ft.

[40] LEGEND: 58

Cover

Cover Install torque converter cover (58). [41] -

<- Go to Section TOC

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Section 03 - TRANSMISSION

Group 0360: Hydraulic System

LEGEND: 59 60 61

Input Flange Washer Cap Screw (2 used)

Flange Heat and install input flange (59), washer (60) and cap screws (61). Item

Measurement

Specification

Input Flange

Temperature

120 °C 248 °F

Item

Measurement

Specification

Input Flange Cap Screw

Torque

68 N·m 50 lb.-ft.

[42] LEGEND: 62 63

Assembly Torque Converter Housing

LEGEND: 64

Cap Screw (12 used)

Torque Converter Assembly Align and install assembly (62) to torque converter housing (63). [43] -

Cap Screws Install cap screws (64) and tighten to specification. Item

Measurement

Specification

Torque Converter Cover Cap Screw

Torque

46 N·m

<- Go to Section TOC

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Section 03 - TRANSMISSION Item

Group 0360: Hydraulic System Measurement

Specification 34 lb.-ft.

[44] →NOTE: Transmission calibration must be performed after servicing the transmission. See Electronic Clutch Calibration . (Group 9020-25.) Install transmission. See Transmission Remove and Install . (Group 0300.)

<- Go to Section TOC

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Section 03 - TRANSMISSION

Group 0360: Hydraulic System

Transmission Control Valve Disassemble and Assemble Specifications SPECIFICATIONS 9.5 N·m 7 lb.-ft.

Cap Screw Torque

[1] - Remove transmission control valve. See Transmission Control Valve Remove and Install . (Group 0360.) [2] LEGEND: 1 2

Connector (9 used) Bracket (2 used)

LEGEND: 3 4

Wire Harness Cap Screw

Brackets and Electrical Connectors Identify and remove connectors (1) and brackets (2). [3] -

Wire Harness Remove wire harness (3) and cap screw (4). [4] LEGEND: 5 Clip 6 Differential Lock Solenoid 7 Cap Screw (26 used) 8 Cap Screw (6 used)

Transmission Control Valve <- Go to Section TOC

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Section 03 - TRANSMISSION

Group 0360: Hydraulic System

Remove clip (5) and differential lock solenoid (6). [5] - Remove cap screws (7 and 8). [6] LEGEND: 9 10

Transmission Control Valve Seal

Transmission Control Valve Remove transmission control valve (9) and seal (10) from transmission top cover. [7] →NOTE: Note the position of the transmission clutch solenoid connectors. LEGEND: 11 Clip (6 used) 12 Transmission Clutch Solenoid (6 used)

Transmission Clutch Solenoids Remove clips (11) and transmission clutch solenoids (12). [8] LEGEND: 13

Retainer (6 used)

Retainer Preload modulation valve pistons and remove retainers (13). [9] <- Go to Section TOC

Section 03 page 222

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Section 03 - TRANSMISSION

Group 0360: Hydraulic System

LEGEND: 14 Modulation Valve Piston (6 used) 15 Modulation Valve Spring (6 used)

Modulation Valve Pistons Remove modulation valve pistons (14) and modulation valve springs (15). [10] LEGEND: 16

Retaining Ring

LEGEND: 17 18 19

Plug Spring Piston

Retaining Ring Remove retaining ring (16). [11] -

Pressure Reducing Valve Remove plug (17), spring (18), and piston (19). [12] - Inspect all components. Replace components as necessary. [13] - Check free travel of moving parts in housing. [14] - Clean and oil all components prior to installation. [15] - Install pressure reducing valve, piston, spring, and plug. Secure with retaining ring.

<- Go to Section TOC

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Section 03 - TRANSMISSION

Group 0360: Hydraulic System

[16] - Install modulation valve springs and pistons. Preload modulation valve pistons and install slides. [17] →NOTE: Note the position of the transmission clutch solenoid connectors. Install transmission clutch solenoids and retainers. [18] - Install cap screws to secure transmission clutch solenoid retaining clips. Item

Measurement

Specification

Cap Screw

Torque

9.5 N·m 7 lb.-ft.

[19] - Using alignment pins, install transmission control valve and new seal to transmission top cover. [20] - Install differential lock solenoid, clip, and cap screw. Item

Measurement

Specification

Cap Screw

Torque

9.5 N·m 7 lb.-ft.

[21] - Install wire harness, making correct connector assignments. [22] - Install brackets and remaining cap screws. Item

Measurement

Specification

Cap Screw

Torque

9.5 N·m 7 lb.-ft.

[23] - Install transmission control valve. See Transmission Control Valve Remove and Install . (Group 0360.)

<- Go to Section TOC

Section 03 page 224

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Section 03 - TRANSMISSION

Group 0360: Hydraulic System

Clutch Control Valve Disassemble and Assemble Specifications SPECIFICATIONS Cap Screw Torque (approximate)

9.5 N·m 7 lb.-ft.

Sensor Torque (approximate)

36 N·m 27 lb.-ft.

[1] - Remove clutch control valve. See Transmission Retarder Remove and Install . (Group 0360.) [2] IMPORTANT: Install identification tags on parts for proper location during assembly, or machine damage may result. LEGEND: 1 2

Sensor Cap Screw (4 used)

LEGEND: 3 4

Clamping Plate Solenoid (4 used)

Clutch Control Valve Remove sensor (1) and cap screws (2). [3] -

Clutch Control Valve Remove clamping plate (3) and solenoids (4). [4] -

<- Go to Section TOC

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Section 03 - TRANSMISSION

Group 0360: Hydraulic System

LEGEND: 5 6 7

Retainer (4 used) Valve (4 used) Spring (4 used)

Clutch Control Valve Preload valves (6). Remove retainers (5). Remove valves and springs (7). [5] LEGEND: 8 9 10 11

Retaining Ring Valve Bushing Spring Valve

Clutch Control Valve Preload valve bushing (9). Remove retaining ring (8). Remove valve bushing, spring (10), and valve (11). [6] LEGEND: 12 13 14 15

Retaining Ring Valve Bushing Spring Valve

Clutch Control Valve Preload valve bushing (13). Remove retaining ring (12). Remove valve bushing, spring (14), and valve (15). [7] -

<- Go to Section TOC

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Section 03 - TRANSMISSION

Group 0360: Hydraulic System

IMPORTANT: Install identification tags on individual parts for proper location during assembly, or machine damage may result. Clean, inspect, and replace parts as required. [8] LEGEND: 16 17 18 19

Valve Spring Valve Bushing Retaining Ring

Clutch Control Valve Install valve (16), spring (17), and valve bushing (18). Preload valve bushing and install retaining ring (19). [9] LEGEND: 20 21 22 23

Valve Spring Valve Bushing Retaining Ring

Clutch Control Valve Install valve (20), spring (21), and valve bushing (22). Preload valve bushing and install retaining ring (23). [10] -

<- Go to Section TOC

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Section 03 - TRANSMISSION

Group 0360: Hydraulic System

LEGEND: 24 25 26

Spring (4 used) Valve (4 used) Retainer (4 used)

Clutch Control Valve Install springs (24) and valves (25). Preload valves and install retainers (26). [11] LEGEND: 27 28

Solenoid (4 used) Clamping Plate

LEGEND: 29 30

Cap Screw (4 used) Sensor

Clutch Control Valve Install solenoids (27) and clamping plate (28). [12] -

Clutch Control Valve Install cap screws (29) and sensor (30). Item

Measurement

Specification

Cap Screw

Torque (approximate)

9.5 N·m 7 lb.-ft.

<- Go to Section TOC

Section 03 page 228

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Section 03 - TRANSMISSION

Group 0360: Hydraulic System

Item

Measurement

Specification

Sensor

Torque (approximate)

36 N·m 27 lb.-ft.

[13] - Install clutch control valve. See Transmission Retarder Remove and Install . (Group 0360.)

<- Go to Section TOC

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Section 03 - TRANSMISSION

Group 0360: Hydraulic System

Retarder Control Valve Disassemble and Assemble [1] - Remove retarder control valve. See Transmission Retarder Remove and Install . (Group 0360.) [2] IMPORTANT: Install identification tags on individual parts for proper location during assembly, or machine damage may result. LEGEND: 1

Retainer

Retarder Control Valve Preload spring through the slot in the retainer (1). [3] LEGEND: 2 3

Spring Cooler Safety Valve

Cooler Safety Valve Remove retainer, spring (2), and cooler safety valve (3). [4] -

<- Go to Section TOC

Section 03 page 230

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Section 03 - TRANSMISSION

Group 0360: Hydraulic System

LEGEND: 4 5

Valve Bushing Retainer

LEGEND: 4 6 7

Valve Bushing Spring Valve

Converter Pressure Backup Valve Preload valve bushing (4) and remove retainer (5). [5] -

Converter Pressure Backup Valve Remove valve bushing, spring (6), and valve (7). [6] IMPORTANT: Install identification tags on individual parts for proper location during assembly, or machine damage may result. LEGEND: 8 9 10 11 12

Valve Bushing (2 used) Piston Retainer (3 used) Spring (3 used) Valve (3 used)

Main Pressure, Converter Safety, and Retarder Valves <- Go to Section TOC

Section 03 page 231

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Section 03 - TRANSMISSION

Group 0360: Hydraulic System

Preload valve bushings (8) and piston (9). Remove retainers (10), springs (11), and valves (12). [7] - Clean, inspect, and replace parts as required. [8] LEGEND: 13 14 15 16 17

Valve (3 used) Spring (3 used) Valve Bushing (2 used) Piston Retainer (3 used)

Main Pressure, Converter Safety, and Retarder Valves Install valves (13), springs (14), valve bushings (15), and piston (16). [9] - Preload valve bushings, and piston. Install retainers (17). [10] LEGEND: 18 19 20

Valve Spring Valve Bushing

LEGEND: 21

Retainer

Converter Pressure Backup Valve Install valve (18), spring (19), and valve bushing (20). [11] -

Retarder Control Valve <- Go to Section TOC

Section 03 page 232

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Section 03 - TRANSMISSION

Group 0360: Hydraulic System

Preload valve bushing and install retainer (21). [12] -

Cooler Changeover Valve LEGEND: 22 23 Install valve (22) and spring (23).

Valve Spring

[13] LEGEND: 24

Retainer

Retainer Preload spring and install retainer (24). [14] - Install retarder control valve. See Transmission Retarder Remove and Install . (Group 0360.)

<- Go to Section TOC

Section 03 page 233

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Section 03 - TRANSMISSION

Group 0360: Hydraulic System

Oil Pump Disassemble and Assemble Specifications SPECIFICATIONS 20 N·m 15 lb.-ft.

Oil Pump Cover Cap Screw Torque

[1] - Remove the oil pump. See Transmission Retarder Remove and Install . (Group 0360.) [2] LEGEND: 1 2

Cap Screw (6 used) Cover

Oil Pump Cover Remove cap screws (1) and cover (2). [3] IMPORTANT: One edge of the oil pump rotor is chamfered. Note the position of the rotor when it is removed. If pump rotor is installed in the wrong direction, the oil pump will seize. LEGEND: 3 4

Rotor Pump Housing

Oil Pump Rotor Remove, clean, and inspect rotor (3), and pump housing (4). [4] - The oil pump cannot be repaired, if the pump is damaged, it must be replaced as an assembly. [5] IMPORTANT: One edge of the oil pump rotor is chamfered. Note the position of the rotor when it is removed. If pump rotor is installed in the wrong direction, the oil pump will seize. Install rotor to pump housing. <- Go to Section TOC

Section 03 page 234

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Section 03 - TRANSMISSION

Group 0360: Hydraulic System

[6] - Install oil pump cover and cap screws. Item

Measurement

Specification

Oil Pump Cover Cap Screw

Torque

15 lb.-ft. 20 N·m

[7] - Install the oil pump. See Transmission Retarder Remove and Install . (Group 0360.)

<- Go to Section TOC

Section 03 page 235

TM12408-REPAIR TECHNICAL MANUAL

Section 03 - TRANSMISSION

Group 0360: Hydraulic System

Transmission Retarder Disassemble and Assemble Specifications SPECIFICATIONS Stator Mounting Cap Screw Torque

9.5 N·m 7 lb.-ft.

Sealing Washer Cap Screw Torque

23 N·m 17 lb.-ft.

[1] - Remove transmission retarder. See Transmission Retarder Remove and Install . (Group 0350.) [2] LEGEND: 1 Retangular Retaining Ring 2 Cap Screw (16 used) 3 Sealing Washer

Retaining Ring Remove rectangular retaining ring (1). Remove cap screws (2) and sealing washer (3). [3] →NOTE: Bend tabs enough to clear housing when sealing sleeve (5) is removed. LEGEND: 4 5

Tab (3 used) Sealing Sleeve

Ring Tabs Bend tabs (4) up on sealing sleeve. [4] -

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Section 03 page 236

TM12408-REPAIR TECHNICAL MANUAL

Section 03 - TRANSMISSION

Group 0360: Hydraulic System

LEGEND: 6

Tool

Sealing Sleeve Using a suitable tool (6), press the sealing sleeve from the sealing washer. [5] LEGEND: 7 8

Rotor Axial Washer

LEGEND: 9

Axial Bearing

Rotor Remove rotor (7) and axial washer (8). [6] -

Axial Bearing Remove axial bearing (9). [7] IMPORTANT: Different length cap screws are used to secure the stator. Note the position of cap screws for installation purposes, or machine damage could occur. <- Go to Section TOC

Section 03 page 237

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Section 03 - TRANSMISSION

Group 0360: Hydraulic System

LEGEND: 10 11

Cap Screw (14 used) Stator

Stator Remove cap screws (10) and stator (11). [8] - Mark the hole locations in the shaft flange in relation to the oil supply flange to aid assembly. [9] LEGEND: 12

Shaft

Shaft Remove shaft (12) using soft-faced dead blow hammer. [10] LEGEND: 13

Locating Pin (2 used)

Hollow Shaft Locating Pins Remove locating pins (13). [11] -

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Section 03 page 238

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Section 03 - TRANSMISSION

Group 0360: Hydraulic System

LEGEND: 14

O-Ring (3 used)

O-Rings Remove O-rings (14). [12] IMPORTANT: Oil pipe will be destroyed during removal. Replace oil pipe with new part or machine damage may occur. LEGEND: 15

Oil Pipe

LEGEND: 16 17

Oil Pipe O-Ring (3 used)

Oil Pipe Inspect oil pipe (15) for wear; replace as required. [13] -

Oil Pipe If oil pipe was removed, wet the new oil pipe (16) with oil and press into shaft. Install new O-rings (17). [14] <- Go to Section TOC

Section 03 page 239

TM12408-REPAIR TECHNICAL MANUAL

Section 03 - TRANSMISSION

Group 0360: Hydraulic System

LEGEND: 18 19

Shaft Flange Oil Supply Flange

Shaft Install Install alignment pin tools to shaft flange (18). Align shaft and alignment pin tools to the holes in oil supply flange (19) (marked in step 8). Press shaft to oil supply flange. [15] LEGEND: 20

Locating Pin (2 used)

LEGEND: 21 22

Alignment Pin Tool (2 used) Stator

Locating Pins Remove alignment pin tools and install locating pins (20). [16] -

Stator Install alignment pin tools (21) to stator and install stator (22). [17] -

<- Go to Section TOC

Section 03 page 240

TM12408-REPAIR TECHNICAL MANUAL

Section 03 - TRANSMISSION

Group 0360: Hydraulic System

LEGEND: 23 24

Stator Oil Supply Flange

Oil Supply Flange Install stator (23) to oil supply flange (24). [18] IMPORTANT: Different length cap screws are used to secure the stator. Note the position of cap screws for installation purposes, or machine damage could occur. LEGEND: 25 26

Cap Screw (10 used) Cap Screw (2 used)

Oil Supply Flange Remove alignment pins, and install stator mounting cap screws (25 and 26). Item

Measurement

Specification

Stator Mounting Cap Screw

Torque

9.5 N·m 7 lb.-ft.

[19] LEGEND: 27 28

<- Go to Section TOC

Section 03 page 241

Axial Bearing Rotor

TM12408-REPAIR TECHNICAL MANUAL

Section 03 - TRANSMISSION

Group 0360: Hydraulic System

Axial Bearing Oil axial bearing (27) and install to rotor (28). [20] LEGEND: 29 30

Axial Washer Rotor

LEGEND: 31 32

Tab (3 used) Sealing Sleeve

Rotor Install axial washer (29) and rotor (30). [21] -

Sealing Sleeve Align tabs (31) and install sealing sleeve (32) with proper tool and press. [22] LEGEND: 33

Tab (3 used)

Tabs Fold the tabs (33) into the installed position. [23] <- Go to Section TOC

Section 03 page 242

TM12408-REPAIR TECHNICAL MANUAL

ENGINE

(g) by Belgreen v2.0

LEGEND: 34 35 36

Sealing Washer Cap Screw (16 used) Rectangular Ring

Retarder Install sealing washer (34) and sealing washer cap screws (35). Grease and install rectangular ring (36). Item

Measurement

Specification

Sealing Washer Cap Screw

Torque

23 N·m 17 lb.-ft.

<- Go to Section TOC

Section 04 page 243

TM12408-REPAIR TECHNICAL MANUAL

TM12408-REPAIR TECHNICAL MANUAL

(g) by Belgreen v2.5

Section 04 - ENGINE Table of contents Group 0400 - Removal and Installation ................................................................................................ 1 John Deere Engine ................................................................................................................................ 1 Engine Remove .................................................................................................................................... 2 Engine Install ........................................................................................................................................ 8 Engine Crankshaft Damper Remove and Install ................................................................................. 13 Serpentine Belt Remove and Install ................................................................................................... 14

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TM12408-REPAIR TECHNICAL MANUAL

Section 04 - ENGINE

Group 0400: Removal and Installation

Group 0400 - Removal and Installation John Deere Engine This machine uses a John Deere PowerTech ™ 13.5 liter diesel engine. The engine model is 6135HDW05. To identify the model of engine, see Engine Serial Number Plate Information . (CTM104919.) For theory of operation on John Deere PowerTech ™ engines, model 6135HDW05 not contained in this group, see the following: General Engine Operation . (CTM104919.) Lubrication System Operation . (CTM104919.) Cooling System Operation . (CTM104919.) Fuel System Operation . (CTM104919.) Air Intake and Exhaust System Operation . (CTM104919.) Aftertreatment System Operation . (CTM104919.) Engine Control Unit (ECU) Circuits Theory of Operation . (Group 9015-15.) For additional information, see 6135 PowerTech™ OEM Diesel Engines (Interim Tier 4/Stage III B platform) . (CTM104919.)

<- Go to Section TOC

Section 04 page 1

TM12408-REPAIR TECHNICAL MANUAL

Section 04 - ENGINE

Group 0400: Removal and Installation

Engine Remove Specifications SPECIFICATIONS Rear Hood Support Weight

46 kg 101 lb.

Engine Weight (approximate)

1724 kg 3800 lb.

Service Equipment and Tools SERVICE EQUIPMENT AND TOOLS JDG11324P1 Lifting Strap JDG11325 Lifting Strap JDG23 Lifting Beam

[1] - Park and prepare machine for service safely. See Prepare Machine for Maintenance . (Group 0001.) [2] - Turn battery disconnect switch to the OFF position. See Battery Disconnect Switch and Battery Circuit Breakers . (Operator’s Manual.) [3] IMPORTANT: Avoid damage to batteries and cables. Battery cables are secured to fuel tank. Disconnect cables. Disconnect battery cables at batteries. See Remove and Replace Batteries . (Operator’s Manual.) [4] - Remove hood. See Hood Remove and Install . (Group 1910.) [5] - Remove serpentine belt. See Serpentine Belt Remove and Install . (Group 0400.) [6] →NOTE: Leave air conditioner lines connected to air conditioner compressor. Remove air conditioner compressor mounting cap screws and set compressor aside. See Compressor Remove and Install . (Group 1830.) [7] - Drain cooling system. See Drain, Flush, and Refill Engine Cooling System . (Operator’s Manual.) [8] - Disconnect engine block-to-machine frame ground strap (W37) and starter-to-remote charge positive post cable. See Power and Ground Component Location . (Group 9015-10.) [9] LEGEND: 1 Right Upper Radiator Hose 2 Upper Radiator Tube 3 Air Intake Tube 4 Exhaust Tube 5 Coolant Overflow Line (3 used) 6 Upper Radiator Hose 7 Left Upper Radiator Hose 8 Charge Air Cooler Tube 9 Upper Radiator Tube

Intake and Radiator Tubes and Hoses <- Go to Section TOC

Section 04 page 2

TM12408-REPAIR TECHNICAL MANUAL

Section 04 - ENGINE

Group 0400: Removal and Installation

Remove parts (1—9). Close all openings using caps and plugs. [10] LEGEND: 10 Fuel Filter Header-to-Fuel Dosing Pump Return Line 11 Fuel Filter Header-to-Fuel Dosing Supply Line 12 Left Side Fan Pump G3 Alternator M1 Starter W18 Engine Interface Harness X5015 Engine Interface Connector X5016 Engine Interface Connector Y9 Left Side Fan Speed Solenoid Connector

Left Side of Engine Disconnect fuel filter header-to-fuel dosing pump return line (10) and fuel filter header-to-fuel dosing supply line (11). Cap all openings using caps and plugs. [11] →NOTE: Leave left side fan pump hydraulic lines connected. Remove left side fan pump (12) mounting cap screws and set aside. [12] - Disconnect wiring harness at alternator (G3), starter (M1) and left side fan speed solenoid connector (Y9). [13] - Disconnect engine interface connectors (X5015 and X5016). [14] - Remove all mounting cap screws securing clamps on engine interface harness (W18) and set aside. See Engine Interface Harness (W18) Component Location . (Group 9010.) [15] LEGEND: 13 Coolant Pump-to-Lower Radiator Tube Hose 14 Fuel Line (2 used) 15 Charge Air Precooler-to-Thermal Bypass Hose 16 Engine Oil Fill Tube Assembly

Front Engine Components Remove coolant pump-to-lower radiator tube hose (13). Close all openings using caps and plugs. [16] - Tag and disconnect fuel lines (14). Close all openings using caps and plugs. [17] - Disconnect charge air precooler-to-thermal bypass hose (15). Close all openings using caps and plugs. [18] - Remove engine oil fill tube assembly (16) from engine. [19] <- Go to Section TOC

Section 04 page 3

TM12408-REPAIR TECHNICAL MANUAL

Section 04 - ENGINE

Group 0400: Removal and Installation

LEGEND: 17 Engine Oil Line (2 used) 18 Surge Tank-to-Coolant Pump Hose

Right Side of Engine Disconnect engine oil lines (17). Close all openings using caps and plugs. [20] - Disconnect surge tank-to-coolant pump hose (18). Close all openings using caps and plugs. [21] - Raise cab. See Tilt Cab . (Operators Manual.) [22] -

<- Go to Section TOC

Section 04 page 4

TM12408-REPAIR TECHNICAL MANUAL

Section 04 - ENGINE

Group 0400: Removal and Installation

Rear Hood Support LEGEND: 19 Rear Hood Support 20 Mounting Nut (3 used) 21 Mounting Cap Screw (3 used) 22 Cap Screw (3 used) 23 Nut (3 used) 24 Mounting Cap Screw (2 used) Remove cap screws (22) and nuts (23) that secure hose bracket. [23] CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device. Attach an appropriate lifting device to hood support (19). Item

Measurement

Specification

Rear Hood Support

Weight

46 kg 101 lb.

. [24] - Remove mounting cap screws (21 and 24) and mounting nuts (20) at hood support. [25] - Remove hood support. [26] - Remove engine to transmission drive shaft. See Engine-to-Transmission Drive Shaft Remove and Install . (Group 0325.) [27] - Remove exhaust tube from turbocharger. See Exhaust Tube Remove and Install . (Group 0530.) [28] IMPORTANT: Battery cables are secured to the fuel tank. Damage to batteries and cables can occur if not disconnected. Lower fuel tank and bottom guard to access motor mounts. See Fuel Tank Remove and Install . (Group 0560.) [29] CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device. Attach JDG11324P1 Engine Lift Strap to right front of engine and JDG11325 Engine Lift Strap to left rear of engine. Attach JDG23 Lifting Beam to engine lift straps. Support engine. Item

Measurement

Specification

Engine

Weight (approximate)

1724 kg 3800 lb.

Lifting Strap JDG11324P1 Engine Lifting Lifting Strap JDG11325 Engine Lifting Lifting Beam JDG23 <- Go to Section TOC

Section 04 page 5

TM12408-REPAIR TECHNICAL MANUAL

Section 04 - ENGINE

Group 0400: Removal and Installation

Engine Lifting

Support Engine [30] →NOTE: Note orientation of upper isolator (27) and lower isolator (30). Remove left and right side motor mounts.

Motor Mounts LEGEND: 25 26 27 <- Go to Section TOC

Cap Screw (4 used) Upper Washer (4 used) Upper Isolator (4 used) Section 04 page 6

TM12408-REPAIR TECHNICAL MANUAL

Section 04 - ENGINE

28 29 30 31 32 33

Group 0400: Removal and Installation

Lower Washer (4 used) Rear Engine Mount Bracket (2 used) Lower Isolator (4 used) Washer (4 used) Nut (4 used) Front Engine Mount Bracket (2 used)

a. Remove cap screws (25) and nuts (32). b. Remove upper and lower washers (26 and 28) and upper and lower isolators (27 and 30) from rear engine mount brackets (29) and front engine mount brackets (33). [31] CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device. Remove engine from machine. Item

Measurement

Specification

Engine

Weight (approximate)

1724 kg 3800 lb.

[32] - Repair or replace engine as necessary. See Mount Engine on Repair Stand . (CTM104919.)

<- Go to Section TOC

Section 04 page 7

TM12408-REPAIR TECHNICAL MANUAL

Section 04 - ENGINE

Group 0400: Removal and Installation

Engine Install Specifications SPECIFICATIONS Engine Weight (approximate)

1724 kg 3800 lb.

Front Engine Mount Cap Screw Torque

1070 N·m 789 lb.-ft.

Rear Engine Mount Cap Screw Torque

620 N·m 457 lb.-ft.

Rear Hood Support Weight

46 kg 101 lb.

Fan Pump Mounting Cap Screw Torque

101 N·m 74 lb.-ft.

Service Equipment and Tools SERVICE EQUIPMENT AND TOOLS JDG11324P1 Lifting Strap JDG11325 Lifting Strap JDG23 Lifting Beam

[1] CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device. Item

Measurement

Specification

Engine

Weight (approximate)

1724 kg 3800 lb.

Attach JDG11324P1 Engine Lift Strap to right front of engine and JDG11325 Engine Lift Strap to left rear of engine. Attach JDG23 Lifting Beam to engine lift straps. Support engine. Lifting Strap JDG11324P1 Engine Lifting Lifting Strap JDG11325 Engine Lifting Lifting Beam JDG23 Engine Lifting

<- Go to Section TOC

Section 04 page 8

TM12408-REPAIR TECHNICAL MANUAL

Section 04 - ENGINE

Group 0400: Removal and Installation

Support Engine [2] CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device. Item

Measurement

Specification

Engine

Weight (approximate)

1724 kg 3800 lb.

Install engine into machine. [3] -

Motor Mounts LEGEND: <- Go to Section TOC

Section 04 page 9

TM12408-REPAIR TECHNICAL MANUAL

Section 04 - ENGINE

Group 0400: Removal and Installation

1 Cap Screw (4 used) 2 Upper Washer (4 used) 3 Upper Isolator (4 used) 4 Lower Washer (4 used) 5 Rear Engine Mount Bracket (2 used) 6 Lower Isolator (4 used) 7 Washer (4 used) 8 Nut (4 used) 9 Front Engine Mount Bracket (2 used) Install front and rear motor mount cap screws, assemble as shown. Item

Measurement

Specification

Front Engine Mount Cap Screw

Torque

1070 N·m 789 lb.-ft.

Item

Measurement

Specification

Rear Engine Mount Cap Screw

Torque

620 N·m 457 lb.-ft.

a. Install upper and lower washers (2 and 4) and upper and lower isolators (3 and 6) to rear engine mount brackets (5) and front engine mount brackets (9). b. Install cap screws and nuts (1 and 8). [4] - Install exhaust tube to turbocharger. See Exhaust Tube Remove and Install . (Group 0530.) [5] - Install engine to transmission drive shaft. See Engine-to-Transmission Drive Shaft Remove and Install . (Group 0325.) [6] CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device.

<- Go to Section TOC

Section 04 page 10

TM12408-REPAIR TECHNICAL MANUAL

Section 04 - ENGINE

Group 0400: Removal and Installation

Rear Hood Support LEGEND: 10 Rear Hood Support 11 Mounting Nut (3 used) 12 Mounting Cap Screw (3 used) 13 Cap Screw (3 used) 14 Nut (3 used) 15 Mounting Cap Screw (2 used) Attach an appropriate lifting device to hood support (10) and set into mounting location. Item

Measurement

Specification

Rear Hood Support

Weight

46 kg 101 lb.

[7] - Install mounting cap screws (12 and 15) and mounting nuts (11). [8] - Install cap screws (13) and nuts (14). [9] - Lower Cab. See Tilt Cab . (Operator’s Manual.) [10] -

<- Go to Section TOC

Section 04 page 11

TM12408-REPAIR TECHNICAL MANUAL

Section 04 - ENGINE

Group 0400: Removal and Installation

LEGEND: 16 Engine Oil Line (2 used) 17 Surge Tank-to-Coolant Pump Hose

Right Side of Engine Connect engine oil lines (16) and surge tank-to-coolant pump hose (17). [11] LEGEND: 18 Fuel Line (2 used) 19 Charge Air Precooler-to-Thermal Bypass Hose 20 Engine Oil Fill Tube Assembly 21 Coolant Pump-to-Lower Radiator Tube Hose

Front Engine Components Install engine oil fill tube assembly (20) to engine. [12] - Connect charge air precooler-to-thermal bypass hose (19). [13] - Connect fuel lines (18). [14] - Install coolant pump-to-lower radiator tube hose (21). [15] LEGEND: 22 Fuel Filter Header-to-Fuel Dosing Pump Return Line 23 Fuel Filter Header-to-Fuel Dosing Supply Line 24 Left Side Fan Pump G3 Alternator M1 Starter W18 Engine Interface Harness X5015 Engine Interface Connector X5016 Engine Interface Connector Y9 Left Side Fan Speed Solenoid Connector

Left Side Engine Components Install all mounting brackets on engine interface harness (W18) to engine block. See Engine Interface Harness (W18) <- Go to Section TOC

Section 04 page 12

TM12408-REPAIR TECHNICAL MANUAL

Section 04 - ENGINE

Group 0400: Removal and Installation

Component Location . (Group 9010.) [16] - Connect engine interface connectors (X5015 and X5016). [17] - Connect wiring harness at alternator (G3), starter (M1), and left side fan speed solenoid connector (Y9). [18] - Install left side fan pump (24). Item

Measurement

Specification

Fan Pump Mounting Cap Screw

Torque

101 N·m 74 lb.-ft.

[19] - Connect fuel filter header-to-fuel dosing pump return line (22) and fuel filter header-to-fuel dosing supply line (23). [20] LEGEND: 25 Right Upper Radiator Hose 26 Upper Radiator Tube 27 Air Intake Tube 28 Exhaust Tube 29 Coolant Overflow Line (3 used) 30 Upper Radiator Hose 31 Left Upper Radiator Hose 32 Charge Air Cooler Tube 33 Upper Radiator Tube

Intake and Radiator Tubes and Hoses Install parts (25—33) as shown. [21] - Connect engine block-to-machine frame ground strap (W37) and starter-to-remote charge positive post cable. See Power and Ground Component Location (Group 9010.) [22] - Fill cooling system. See Drain, Flush, and Refill Engine Cooling System . (Operator’s Manual.) [23] - Install air conditioner compressor. See Compressor Remove and Install . (Group 1830.) [24] - Install serpentine belt. See Serpentine Belt Remove and Install . (Group 0400.) [25] - Install hood. See Hood Remove and Install . (Group 1910.) [26] - Raise fuel tank and secure bottom guard. See Fuel Tank Remove and Install . (Group 0560.) [27] - Connect battery cables to battery. See Remove and Replace Batteries . (Operator’s Manual.) [28] - Turn battery disconnect switch to the ON position. [29] - Start machine and check for fluid leaks. [30] - Check for diagnostic trouble codes. See Operational Checkout . Group (9005-10.) [31] - Verify correct engine fluid levels.

Engine Crankshaft Damper Remove and Install [1] - Prepare Machine for Maintenance . (Group 0001.) [2] - Turn battery disconnect switch to the OFF position. See Battery Disconnect Switch and Battery Circuit Breakers . (Operator’s Manual.) [3] - Remove serpentine belt. See Serpentine Belt Remove and Install . (Group 0400.) [4] <- Go to Section TOC

Section 04 page 13

TM12408-REPAIR TECHNICAL MANUAL

Section 04 - ENGINE

Group 0400: Removal and Installation

LEGEND: 1 2

Cap Screw (4 used) Damper Pulley

LEGEND: 3 4

Cap Screw (2 used) Belt Guard Bracket

Damper Pulley Remove cap screws (1), and remove damper pulley (2). [5] -

Belt Guard Bracket Remove cap screws (3), and remove belt guard bracket (4). [6] - Remove engine crankshaft damper. See Crankshaft Vibration Damper and Hub — Removal . (CTM104919.) [7] - Install engine crankshaft damper. See Crankshaft Vibration Damper and Hub — Installation . (CTM104919.) [8] - Install belt guard bracket and damper pulley. [9] - Install serpentine belt. See Serpentine Belt Remove and Install . (Group 0400.) [10] - Turn battery disconnect switch to the ON position.

Serpentine Belt Remove and Install [1] - Park and prepare machine for service safely. See Prepare Machine for Maintenance . (Group 0001.) [2] - Turn battery disconnect switch to the OFF position. See Battery Disconnect Switch and Battery Circuit Breakers . (Operator’s Manual.) [3] - Open front service door. [4] -

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Section 04 page 14

TM12408-REPAIR TECHNICAL MANUAL

ENGINE AUXILIARY SYSTEM

(g) by Belgreen v2.0

LEGEND: 1 2 3

Belt Guard Belt Guard Cap Screw (7 used)

Serpentine Belt Guard Remove cap screws (3) and remove serpentine belt guards (1 and 2). [5] IMPORTANT: If the serpentine belt is stretched to the point that the belt tensioning assembly is against the stop, serpentine belt must be replaced. LEGEND: 4 5

Serpentine Belt Belt Tensioner

Serpentine Belt Routing Check serpentine belt for cracks, frayed edges, and wear at bottom of grooves. [6] - Replace serpentine belt (4), if necessary, by rotating the belt tensioner (5) clockwise until belt can be removed from pulleys. [7] - Install serpentine belt by rotating belt tensioner clockwise and sliding belt over pulleys. [8] - Install serpentine belt guard and cap screws. [9] - Close front service door.

<- Go to Section TOC

Section 05 page 15

TM12408-REPAIR TECHNICAL MANUAL

TM12408-REPAIR TECHNICAL MANUAL

(g) by Belgreen v2.5

Section 05 - ENGINE AUXILIARY SYSTEM Table of contents Group 0505 - Cold Weather Starting Aids ............................................................................................ 1 Cold Start Aid—Starting Fluid Nozzle Remove and Install—If Equipped ................................................ 1 Cold Start Aid—Starting Fluid Solenoid Remove and Install—If Equipped ............................................ 3 Cold Start Aid—Block Heater Remove and Install—If Equipped ............................................................ 4 Group 0510 - Cooling Systems ............................................................................................................... 6 Charge Air Cooler Remove and Install .................................................................................................. 6 Left Radiator Remove and Install ......................................................................................................... 8 Right Radiator Remove and Install ..................................................................................................... 10 Hydraulic Oil Cooler Remove and Install ............................................................................................. 12 Transmission Oil Cooler Remove and Install ....................................................................................... 14 Fuel Cooler Remove and Install .......................................................................................................... 15 Front Axle Oil Cooler Remove and Install ........................................................................................... 17 Middle Axle Oil Cooler Remove and Install ......................................................................................... 19 Group 0520 - Intake System ................................................................................................................. 21 Air Cleaner Remove and Install .......................................................................................................... 21 Group 0530 - External Exhaust Systems ............................................................................................ 22 Exhaust Tube Remove and Install ...................................................................................................... 22 Dump Body Heater Pipe Remove and Install ...................................................................................... 23 Dump Body Heater Exhaust Collar Adjust .......................................................................................... 25 Dump Body Heat Diverter Actuator Remove and Install ..................................................................... 26 Exhaust Bellows Alignment Procedure ............................................................................................... 30 Diesel Particulate Filter (DPF) Remove and Install .............................................................................. 35 Exhaust Filter Remove and Install ...................................................................................................... 39 Service Filter Cleaning ........................................................................................................................ 44 Group 0560 - External Fuel Supply Systems ..................................................................................... 45 Fuel Tank Remove and Install ............................................................................................................. 45 Fuel Transfer Pump Remove and Install ............................................................................................. 50 Fast Fill Fuel System Disassemble and Assemble—If Equipped .......................................................... 52

<- Go to Global Table of contents

TM12408-REPAIR TECHNICAL MANUAL

Section 05 - ENGINE AUXILIARY SYSTEM

Group 0505: Cold Weather Starting Aids

Group 0505 - Cold Weather Starting Aids Cold Start Aid—Starting Fluid Nozzle Remove and Install—If Equipped Other Material OTHER MATERIAL 271 Loctite ™ Thread Lock and Sealer (high strength)

[1] - Park and prepare machine for service. See Prepare Machine for Maintenance . (Group 0001.) [2] - Turn battery disconnect switch to the OFF position. See Battery Disconnect Switch and Battery Circuit Breakers . (Operator’s Manual.) [3] - Open engine hood. [4] -

Cold Start Aid—Starting Fluid Nozzle LEGEND: 1 Starting Fluid Line 2 Starting Fluid Nozzle 3 Starting Fluid Nozzle Jam Nut 4 Starting Fluid Nozzle O-Ring 5 Red Paint Dot Indexing Mark

Cold Start Aid—Starting Fluid Nozzle Alignment Disconnect starting fluid line (1) from starting fluid nozzle (2). [5] - Loosen starting fluid nozzle jam nut (3) from starting fluid nozzle. [6] - Remove starting fluid nozzle from air inlet. [7] - Clean or replace parts as necessary. [8] →NOTE: Red paint dot indexing mark (5) on nozzle indicates direction of nozzle opening. <- Go to Section TOC

Section 05 page 1

TM12408-REPAIR TECHNICAL MANUAL

Section 05 - ENGINE AUXILIARY SYSTEM

Group 0505: Cold Weather Starting Aids

Apply PM37421 Thread Lock and Sealer (high strength) to starting fluid nozzle before installing into air inlet with red paint dot indexing mark (5) pointing upwards, and tighten starting fluid nozzle jam nut (3). Number

Name

Use

• PM37421 Loctite ™ (us)

Thread Lock and Sealer (high strength)

Apply to starting fluid nozzle.

[9] - Connect starting fluid line to starting fluid nozzle. [10] - Close engine hood. [11] - Remove articulation lock bar.

<- Go to Section TOC

Section 05 page 2

TM12408-REPAIR TECHNICAL MANUAL

Section 05 - ENGINE AUXILIARY SYSTEM

Group 0505: Cold Weather Starting Aids

Cold Start Aid—Starting Fluid Solenoid Remove and Install—If Equipped [1] - Park and prepare machine for service. See Prepare Machine for Maintenance . (Group 0001.) [2] IMPORTANT: When operating machine without cold start aid starting fluid solenoid installed, protect components by installing dust cap.

Cold Start Aids LEGEND: 1 Engine Block Heater 4 Starting Fluid Container 5 Fluid Nozzle Y15 Start Aid Solenoid Open right side engine access door and loosen starting fluid container mounting clamp. [3] - Remove starting fluid container (4) and starting fluid line from start aid solenoid (Y15). [4] - Repair or replace parts as necessary. [5] - Install starting fluid components. Remove safety cap from new starting fluid container. Turn starting fluid container clockwise onto starting fluid solenoid to install. [6] - Tighten starting fluid container mounting clamp. [7] - Close engine hood. [8] - Remove articulation lock bar.

<- Go to Section TOC

Section 05 page 3

TM12408-REPAIR TECHNICAL MANUAL

Section 05 - ENGINE AUXILIARY SYSTEM

Group 0505: Cold Weather Starting Aids

Cold Start Aid—Block Heater Remove and Install—If Equipped Specifications SPECIFICATIONS 34 N·m 25 lb.-ft.

Cold Start Aid—Block Heater Nut Torque

Cold Start Aids LEGEND: 4 5 Y15

Starting Fluid Container Starting Fluid Nozzle Starting Fluid Solenoid

[1] - Park and prepare machine for service. See Prepare Machine for Maintenance . (Group 0001.) [2] 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 relieve pressure before removing completely. Drain cooling system into appropriate container for storage or disposal. See 370E, 410E, and 460E Drain and Refill Capacities . (Operator’s Manual.) [3] CAUTION: Prevent possible shocking injury. Keep electrical connectors clean to prevent arching. Only plug cold start aid block heater into electrical power if heater element is immersed in coolant. Sheath could burst and result in personal injury. Use a heavy-duty grounded cord to connect cold start aid block heater to electrical power. <- Go to Section TOC

Section 05 page 4

TM12408-REPAIR TECHNICAL MANUAL

Section 05 - ENGINE AUXILIARY SYSTEM

Group 0510: Cooling Systems

Tilt Cab . (Operator’s manual.)

Cold Start Aid Block Heater LEGEND: 1 2 3

Block Heater Element Block Heater Nut Block Heater Power Cord

[4] - Disconnect block heater power cord (3). [5] - Remove block heater nut (2) and remove block heater element (1). [6] →NOTE: The cold start aid block heater element (1) cannot be repaired. Replace if necessary. Inspect and replace parts as necessary. [7] - Install block heater element (1) into cylinder block at the rear of engine. [8] - Install block heater nut (2) on heater element (1) [9] - Hold in place and tighten block heater nut (2) to specification. Item

Measurement

Specification

Cold Start Aid—Block Heater Nut

Torque

34 N·m 25 lb.-ft.

[10] →NOTE: Supply voltage for cold start aid block heater element can be 220 V or 110 V. Ensure the correct engine block heater is used for the correct supply voltage. Install block heater power cord (3). [11] - Lower cab. [12] - Fill cooling system. See 370E, 410E, and 460E Drain and Refill Capacities . (Operator’s Manual.) [13] - Remove articulation lock bar.

<- Go to Section TOC

Section 05 page 5

TM12408-REPAIR TECHNICAL MANUAL

Section 05 - ENGINE AUXILIARY SYSTEM

Group 0510: Cooling Systems

Group 0510 - Cooling Systems Charge Air Cooler Remove and Install Specifications SPECIFICATIONS 91 kg 200 lb.

Cooler Package Weight (approximate)

Cooler Package LEGEND: 1 2 3 4 5 6 7 8

Charge Air Cooler Coupling (2 used) Cap Screw (2 used) Hydraulic Line (4 used) Cap Screw (4 used) Shim (5 used) Cap Screw (16 used) Air Conditioner Condenser Latch Bracket Cap Screw (6 used)

[1] - Park and prepare machine for service. See Prepare Machine for Maintenance . (Group 0001.) [2] - Turn battery disconnect switch to the OFF position. See Battery Disconnect Switch and Battery Circuit Breakers . (Operator’s Manual.) [3] - Open hood. [4] - Open left side cooler door. [5] - Disconnect upper and lower charge air cooler couplings (1). Close all openings using caps and plugs. [6] - Remove cap screws (2) securing cooler door in place. [7] - Disconnect upper and lower hydraulic lines (3). Close all openings using caps and plugs. [8] - Remove air conditioner condenser (7). See Condenser Remove and Install . (Group 1830.) [9] <- Go to Section TOC

Section 05 page 6

TM12408-REPAIR TECHNICAL MANUAL

Section 05 - ENGINE AUXILIARY SYSTEM

Group 0510: Cooling Systems

CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device. Support cooler package with hoist. Item

Measurement

Specification

Cooler Package

Weight (approximate)

91 kg 200 lb.

[10] - Remove cap screws (4) and shims (5). [11] - Remove cooler package. [12] - Remove cap screws (6) to charge air cooler. [13] - Repair or replace parts as necessary. [14] - Install charge air cooler and install cap screws (6). [15] CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device. Support cooler package with hoist. Item

Measurement

Specification

Cooler Package

Weight (approximate)

91 kg. 200 lb.

[16] - Install cooler package, cap screws (4) and shims (5). [17] - Install air conditioner condenser (7). See Condenser Remove and Install . (Group 1830.) [18] - Connect upper and lower hydraulic lines (3). [19] - Install cap screws (2) securing cooler door in place. [20] - Install charge air cooler couplings (1). [21] - Close left cooler side door. [22] - Close hood. [23] - Turn battery disconnect switch to the ON position. See Battery Disconnect Switch and Battery Circuit Breakers . (Operator’s Manual.)

<- Go to Section TOC

Section 05 page 7

TM12408-REPAIR TECHNICAL MANUAL

Section 05 - ENGINE AUXILIARY SYSTEM

Group 0510: Cooling Systems

Left Radiator Remove and Install Specifications SPECIFICATIONS 91 kg 200 lb.

Radiator Weight (approximate)

[1] - Prepare Machine for Maintenance . (Operator’s Manual.) [2] - Open hood and left side fan door. [3] - Release latch and open radiator. [4] - Drain cooling system. See Drain, Flush, and Refill Engine Cooling System . (Operator’s Manual.) [5] - Remove upper radiator hose (1) and lower radiator hose (2). Close openings using caps and plugs. LEGEND: 1 Upper Radiator Hose 2 Lower Radiator Hose 3 Cap Screw (4 used) 4 Radiator Hinge Mount 5 Overflow Hose 6 Radiator

Left Side Radiator [6] - Remove overflow hose (5). Close openings using caps and plugs. [7] CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device. Attach an appropriate lifting device to radiator (6). Item

Measurement

Specification

Radiator

Weight (approximate)

91 kg 200 lb.

[8] - Remove cap screws (3) from radiator hinge mount (4). [9] - Remove radiator. [10] - Repair or replace radiator. [11] CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device. Install radiator using appropriate lifting device.

<- Go to Section TOC

Section 05 page 8

TM12408-REPAIR TECHNICAL MANUAL

Section 05 - ENGINE AUXILIARY SYSTEM

Group 0510: Cooling Systems

[12] - Install cap screws (3) to secure radiator (6) to radiator hinge mount (4). [13] - Install upper radiator hose (1) and lower radiator hose (2). [14] - Install overflow hose (5). [15] - Fill cooling system. See Drain, Flush, and Refill Engine Cooling System . (Operator’s Manual.) [16] - Close the radiator and left side fan. [17] - Close hood.

<- Go to Section TOC

Section 05 page 9

TM12408-REPAIR TECHNICAL MANUAL

Section 05 - ENGINE AUXILIARY SYSTEM

Group 0510: Cooling Systems

Right Radiator Remove and Install Specifications SPECIFICATIONS 91 kg 200 lb.

Radiator Weight (approximate)

[1] - Prepare Machine for Maintenance . (Operator’s Manual.) [2] - Open hood and right side fan door. [3] - Release latch and open radiator. [4] - Drain cooling system. See Drain, Flush, and Refill Engine Cooling System . (Operator’s Manual.) [5] - Remove upper radiator hose (1) and lower radiator hose (2). Close openings using caps and plugs. LEGEND: 1 Upper Radiator Hose 2 Lower Radiator Hose 3 Cap Screw (4 used) 4 Radiator Hinge Mount 5 Overflow Hose 6 Radiator

Right Side Radiator [6] - Remove overflow hose (5). Close openings using caps and plugs. [7] CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device. Attach an appropriate lifting device to radiator (6). Item

Measurement

Specification

Radiator

Weight (approximate)

91 kg 200 lb.

[8] - Remove cap screws (3) from radiator hinge mount (4). [9] - Remove radiator. [10] - Repair or replace radiator. [11] CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device. install radiator using appropriate lifting device.

<- Go to Section TOC

Section 05 page 10

TM12408-REPAIR TECHNICAL MANUAL

Section 05 - ENGINE AUXILIARY SYSTEM

Group 0510: Cooling Systems

[12] - Install cap screws (3) to secure radiator (6) to radiator hinge mount (4). [13] - Install upper radiator hose (1) and lower radiator hose (2). [14] - Install overflow hose (5). [15] - Fill cooling system. See Drain, Flush, and Refill Engine Cooling System . (Operator’s Manual.) [16] - Close radiator and right side fan door. [17] - Close hood.

<- Go to Section TOC

Section 05 page 11

TM12408-REPAIR TECHNICAL MANUAL

Section 05 - ENGINE AUXILIARY SYSTEM

Group 0510: Cooling Systems

Hydraulic Oil Cooler Remove and Install Specifications SPECIFICATIONS 91 kg 200 lb.

Cooler Package Weight (approximate)

Cooler Package LEGEND: 1 2 3 4 5 6 7 8 9 10

Transmission Oil Cooler Hydraulic Oil Cooler Tranmission Oil Cooler Hydraulic Line (2 used) Hydraulic Oil Cooler Hydraulic Line (2 used) Cap Screw (8 used) Cap Screw (4 used) Shim (5 used) Cap Screw (2 used) Fuel Cooler Cap Screw (6 used)

[1] - Park and prepare machine for service. See Prepare Machine for Maintenance . (Group 0001.) [2] - Turn battery disconnect switch to the OFF position. See Battery Disconnect Switch and Battery Circuit Breakers . (Operator’s Manual.) [3] - Open hood. [4] - Open right fan door. [5] - Open radiator door. [6] - Remove cap screws (8), nuts, and washers securing cooler door. [7] - Remove upper and lower transmission oil cooler hydraulic lines (3). Close all openings using caps and plugs. [8] - Remove fuel cooler (9). See Fuel Cooler Remove and Install . (Group 0510.) [9] - Remove upper and lower hydraulic oil cooler lines (4). Close all openings using caps and plugs. <- Go to Section TOC

Section 05 page 12

TM12408-REPAIR TECHNICAL MANUAL

Section 05 - ENGINE AUXILIARY SYSTEM

Group 0510: Cooling Systems

[10] CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device. Support cooler package with hoist. Item

Measurement

Specification

Cooler Package

Weight (approximate)

91 kg 200 lb.

[11] - Remove cap screws (6) and shims (7) securing cooler package. [12] - Remove cooler package. [13] - Remove cap screws (5) from hydraulic oil cooler to transmission oil cooler. [14] - Repair or replace parts as necessary. [15] - Install cap screws (5) from hydraulic oil cooler to transmission oil cooler. [16] - Install cooler package with hoist. [17] - Install cap screws (6) and shims (7). [18] - Connect upper and lower hydraulic oil cooler lines (4). [19] - Install fuel cooler (9). See Fuel Cooler Remove and Install . (Group 0510.) [20] - Install upper and lower transmission oil cooler hydraulic lines (3). [21] - Install cap screws (8), nuts, and washers securing cooler door. [22] - Close radiator door and right fan door. [23] - Turn battery disconnect switch to the ON position. See Battery Disconnect Switch and Battery Circuit Breakers . (Operator’s Manual.)

<- Go to Section TOC

Section 05 page 13

TM12408-REPAIR TECHNICAL MANUAL

Section 05 - ENGINE AUXILIARY SYSTEM

Group 0510: Cooling Systems

Transmission Oil Cooler Remove and Install Specifications SPECIFICATIONS 91 kg 200 lb.

Cooler Package Weight (approximate)

Cooler Package LEGEND: 1 2 3 4 5 6 7 8 9 10

Transmission Oil Cooler Hydraulic Oil Cooler Tranmission Oil Cooler Hydraulic Line (2 used) Hydraulic Oil Cooler Hydraulic Line (2 used) Cap Screw (8 used) Cap Screw (4 used) Shim (5 used) Cap Screw (2 used) Fuel Cooler Cap Screw (6 used)

[1] - Park and prepare machine for service. See Prepare Machine for Maintenance . (Group 0001.) [2] - Turn battery disconnect switch to the OFF position. See Battery Disconnect Switch and Battery Circuit Breakers . (Operator’s Manual.) [3] - Open hood. [4] - Open right fan door. [5] - Open radiator door. [6] - Remove cap screws (8), nuts, and washers securing cooler door. [7] - Remove upper and lower transmission oil cooler hydraulic lines (3). Close all openings using caps and plugs. [8] - Remove fuel cooler (9). See Fuel Cooler Remove and Install . (Group 0510.) [9] <- Go to Section TOC

Section 05 page 14

TM12408-REPAIR TECHNICAL MANUAL

Section 05 - ENGINE AUXILIARY SYSTEM

Group 0510: Cooling Systems

CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device. Support cooler package with hoist. Item

Measurement

Specification

Cooler Package

Weight (approximate)

91 kg 200 lb.

[10] - Remove cap screws (5) from hydraulic oil cooler to transmission oil cooler. [11] - Remove transmission oil cooler (1). [12] - Repair or replace parts as necessary. [13] - Install transmission oil cooler (1) with hoist. [14] - Install cap screws (5) from transmission oil cooler to hydraulic oil cooler. [15] - Connect upper and lower transmission oil cooler hydraulic lines (3). [16] - Install fuel cooler (9). See Fuel Cooler Remove and Install . (Group 0510.) [17] - Install cap screws (8), nuts, and washers securing cooler door. [18] - Close radiator door and right fan door. [19] - Turn battery disconnect switch to the ON position. See Battery Disconnect Switch and Battery Circuit Breakers . (Operator’s Manual.)

Fuel Cooler Remove and Install [1] - Prepare Machine for Maintenance . (Operator’s Manual.) [2] - Open hood and right side fan door. [3] - Disconnect fuel lines (3). Close all openings using caps and plugs. LEGEND: 1 2 3

Cap Screw (4 used) Fuel Cooler Fuel Line (2 used)

Fuel Cooler [4] - Remove cap screws (1) and fuel cooler (2). [5] - Repair or replace fuel cooler. <- Go to Section TOC

Section 05 page 15

TM12408-REPAIR TECHNICAL MANUAL

Section 05 - ENGINE AUXILIARY SYSTEM

Group 0510: Cooling Systems

[6] - Install fuel cooler and secure with cap screws. [7] - Connect fuel lines. [8] - Bleed Fuel System . (Operator’s Manual.)

<- Go to Section TOC

Section 05 page 16

TM12408-REPAIR TECHNICAL MANUAL

Section 05 - ENGINE AUXILIARY SYSTEM

Group 0510: Cooling Systems

Front Axle Oil Cooler Remove and Install Specifications SPECIFICATIONS 91 kg 200 lb.

Cooler Package Weight (approximate)

Cooler Package LEGEND: 1 2 3 4 5 6 7 8

Charge Air Cooler Coupling (2 used) Cap Screw (2 used) Hydraulic Line (4 used) Cap Screw (4 used) Shim (5 used) Cap Screw (16 used) Air Conditioner Condenser Cap Screw (6 used)

[1] - Park and prepare machine for service. See Prepare Machine for Maintenance . (Group 0001.) [2] - Turn battery disconnect switch to the OFF position. See Battery Disconnect Switch and Battery Circuit Breakers . (Operator’s Manual.) [3] - Open hood. [4] - Open left side cooler door. [5] - Disconnect upper and lower charge air cooler couplings (1). Close all openings using caps and plugs. [6] - Remove cap screws (2) securing cooler door in place. [7] - Disconnect upper and lower hydraulic lines (3). Close all openings using caps and plugs. [8] - Remove air conditioner condenser (7). See Condenser Remove and Install . (Group 1830.) [9] -

<- Go to Section TOC

Section 05 page 17

TM12408-REPAIR TECHNICAL MANUAL

Section 05 - ENGINE AUXILIARY SYSTEM

Group 0510: Cooling Systems

CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device. Support cooler package with hoist. Item

Measurement

Specification

Cooler Package

Weight (approximate)

91 kg 200 lb.

[10] - Remove cap screws (4) and shims (5). [11] - Remove cooler package. [12] - Remove cap screws (6) to axle oil cooler. [13] - Repair or replace parts as necessary. [14] - Install axle oil cooler and install cap screws (6). [15] CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device. Support cooler package with hoist. Item

Measurement

Specification

Cooler Package

Weight (approximate)

91 kg 200 lb.

[16] - Install cooler package. [17] - Install cap screws (4) and shims (5). [18] - Install air conditioner condenser (7). See Condenser Remove and Install . (Group 1830.) [19] - Connect upper and lower hydraulic lines (3). [20] - Install cap screws (2) securing cooler door in place. [21] - Install charge air cooler couplings (1). [22] - Close left cooler side door. [23] - Close hood. [24] - Turn battery disconnect switch to the ON position. See Battery Disconnect Switch and Battery Circuit Breakers . (Operator’s Manual.)

<- Go to Section TOC

Section 05 page 18

TM12408-REPAIR TECHNICAL MANUAL

Section 05 - ENGINE AUXILIARY SYSTEM

Group 0510: Cooling Systems

Middle Axle Oil Cooler Remove and Install

Middle Axle Oil Cooler LEGEND: 1 2 3 4 5 6

Cap Screw (2 used) Cap Screw (6 used) Hydraulic Line (2 used) Cooler Guard Cap Screw (8 used) Middle Axle Oil Cooler

[1] - Park and prepare machine for service. See Prepare Machine for Maintenance . (Group 0001.) [2] - Turn battery disconnect switch to the OFF position. See Battery Disconnect Switch and Battery Circuit Breakers . (Operator’s Manual.) [3] - Open hood. [4] - Open left side cooler door. [5] - Remove cap screws (1) that secure cooler door latch weldment in place. [6] - Disconnect upper and lower hydraulic lines (3). Close all openings using caps and plugs. [7] - Remove cap screws that secure cooler guard (4) to middle axle oil cooler (6). [8] - Support middle axle oil cooler. [9] - Remove cap screws (5) that secure middle axle oil cooler to front axle oil cooler. [10] - Remove middle axle oil cooler. [11] - Repair or replace parts as necessary. [12] - Install middle axle oil cooler. [13] - Install cap screws, securing middle axle oil cooler to front axle oil cooler. [14] - Install cap screws, securing cooler guard to cooler. <- Go to Section TOC

Section 05 page 19

TM12408-REPAIR TECHNICAL MANUAL

Section 05 - ENGINE AUXILIARY SYSTEM

Group 0520: Intake System

[15] - Connect upper and lower hydraulic lines. [16] - Install cap screws, securing cooler door latch weldment in place. [17] - Close left side cooler door. [18] - Close hood. [19] - Turn battery disconnect switch to the ON position. See Battery Disconnect Switch and Battery Circuit Breakers . (Operator’s Manual.)

<- Go to Section TOC

Section 05 page 20

TM12408-REPAIR TECHNICAL MANUAL

Section 05 - ENGINE AUXILIARY SYSTEM

Group 0530: External Exhaust Systems

Group 0520 - Intake System Air Cleaner Remove and Install [1] - See Prepare Machine for Maintenance . (Group 0001) [2] - Open front service door and turn battery disconnect switch to the OFF position. See Battery Disconnect Switch and Battery Circuit Breakers . (Operator’s Manual.) [3] LEGEND: 1 Clamp 2 Air Cleaner-to-Turbo Tube 3 Air Cleaner Assembly

Air Cleaner Assembly Loosen clamp (1) and disconnect air cleaner-to-turbo tube (2) from air cleaner assembly (3). Close all openings using caps and plugs. [4] LEGEND: 4 5 6

Clamp Dust Extraction Tube Cap Screw (2 used)

Air Cleaner Mounting Bracket Loosen clamp (4) and disconnect dust extraction tube (5) from air cleaner assembly. Close all openings using caps and plugs. [5] - Remove cap screws (6) and remove air cleaner assembly from machine. [6] - Repair or replace as necessary. [7] - Install air cleaner assembly to machine and secure with cap screws (6). [8] - Connect dust extraction tube (5) to air cleaner assembly. Secure with clamp (4). [9] - Connect air cleaner-to-turbo tube (2) at air cleaner assembly (3). Secure with clamp (1). [10] - Turn battery disconnect switch to the ON position and close front service door. See Battery Disconnect Switch and Battery Circuit Breakers . (Operator’s Manual.)

<- Go to Section TOC

Section 05 page 21

TM12408-REPAIR TECHNICAL MANUAL

Section 05 - ENGINE AUXILIARY SYSTEM

Group 0530: External Exhaust Systems

Group 0530 - External Exhaust Systems Exhaust Tube Remove and Install [1] - Prepare Machine for Maintenance . (Group 0001.) [2] - Tilt Cab . (Operator′s Manual.) [3] - Open hood and right side fan door. [4] CAUTION: Prevent possible burn injury from hot exhaust components. Allow exhaust system to cool before service. Allow exhaust parts to cool before servicing. [5] - Repair or replace parts (1—8), as necessary.

Exhaust Pipes LEGEND: 1 2 3 4 5 6 7 8

Turbo Outlet Exhaust Pipe Exhaust Tube Exhaust Clamp (4 used) Metal Gasket (4 used) Mounting Clamp (2 used) Exhaust Bellows Exhaust Filter Bracket

IMPORTANT: Do not reuse metal gaskets (4). If reused, exhaust leaks can occur.

<- Go to Section TOC

Section 05 page 22

TM12408-REPAIR TECHNICAL MANUAL

Section 05 - ENGINE AUXILIARY SYSTEM

Group 0530: External Exhaust Systems

Dump Body Heater Pipe Remove and Install

Dump Body Heater Exhaust Pipes LEGEND: 1 2 3 4 <- Go to Section TOC

Exhaust Pipe Elbow Lock Nut (6 used) Spring Washer (12 used) Spring (6 used) Section 05 page 23

TM12408-REPAIR TECHNICAL MANUAL

Section 05 - ENGINE AUXILIARY SYSTEM

5 6 7 8 9 10 11 12 13 14

Group 0530: External Exhaust Systems

Plate (2 used) Sealing Ring (2 used) Ball Fitting Clamp (2 used) Cap Screw (6 used) Flexible Exhaust Pipe Ball Joint Retainer Sealing Ring (2 used) Ball Fitting Exhaust Collar

[1] - Prepare Machine for Maintenance . (Group 0001.) [2] - Install dump body locking bar. See Install Dump Body Locking Bar . (Operator’s Manual.) [3] CAUTION: Avoid possible burn injury from hot exhaust components. Allow exhaust components to cool before service. Allow exhaust parts to cool before servicing. [4] - Remove and repair or replace parts (1—14) as necessary. [5] - Tighten cap screws on clamps (8). [6] - Adjust dump body heater exhaust collar if necessary. See Dump Body Heater Exhaust Collar Adjust . (Group 0530.) [7] - Tighten cap screws (9) and lock nuts (2) on ball fittings enough to compress springs (4). Swivel must turn freely against sealing rings (6 and 12) when machine frames articulate and oscillate.

<- Go to Section TOC

Section 05 page 24

TM12408-REPAIR TECHNICAL MANUAL

Section 05 - ENGINE AUXILIARY SYSTEM

Group 0530: External Exhaust Systems

Dump Body Heater Exhaust Collar Adjust

Exhaust Collar LEGEND: 1 2 3 4 5

Spring Retaining Cap Screw (3 used) Exhaust Collar Flexible Exhaust Tube Mounting Plate Mounting Cap Screw (4 used)

[1] - Prepare Machine for Maintenance . (Group 0001.) [2] CAUTION: Avoid possible burn injury from hot exhaust components. Allow exhaust components to cool before service. Remove flexible exhaust tube (3). See Dump Body Heater Pipe Remove and Install . (Group 0530.) [3] - Tighten spring retaining cap screws (1). [4] - Loosen mounting cap screws (5). [5] - Move exhaust collar (2) so mounting plate (4) is centered on frame bracket holes. [6] - Put hardwood blocks approximately 40 mm (1.6 in.) thick on each side of rear frame under front rubber dump body pads. Lower dump body onto blocks. [7] - Check alignment and adjust position of exhaust collar, if necessary. [8] - Remove hardwood blocks and float dump body down until at rest. Check exhaust collar position. [9] - Raise dump body and install dump body locking bar. See Install Dump Body Locking Bar . (Operator’s Manual.) [10] - Tighten exhaust collar mounting cap screws. [11] - Install flexible exhaust tube. <- Go to Section TOC

Section 05 page 25

TM12408-REPAIR TECHNICAL MANUAL

Section 05 - ENGINE AUXILIARY SYSTEM

Group 0530: External Exhaust Systems

Dump Body Heat Diverter Actuator Remove and Install [1] - Prepare Machine for Maintenance . (Group 0001.) [2] CAUTION: Escaping fluid under pressure can penetrate the skin causing serious injury. Avoid the hazard by relieving pressure before disconnecting hydraulic or other lines. Tighten all connections before applying pressure. Search for leaks with a piece of cardboard. Protect hands and body from high pressure fluids. If an accident occurs, see a doctor immediately. Any fluid injected into the skin must be surgically removed within a few hours or gangrene may result. Doctors unfamiliar with this type of injury should reference a knowledgeable medical source. Such information is available from Deere & Company Medical Department in Moline, Illinois, U.S.A. Discharge brake accumulator pressure by pumping service brake pedal (approximately 20 applications). Relieve hydraulic pressure; turn steering wheel back and forth three times. [3] - Turn battery disconnect switch to the OFF position. See Battery Disconnect Switch and Battery Circuit Breakers . (Operator’s Manual.) [4] CAUTION: Avoid possible burn injuries from hot exhaust components. Allow exhaust components to cool completely before service. Allow exhaust pipes to cool before servicing. [5] -

<- Go to Section TOC

Section 05 page 26

TM12408-REPAIR TECHNICAL MANUAL

Section 05 - ENGINE AUXILIARY SYSTEM

Group 0530: External Exhaust Systems

Diverter Actuator Shield

<- Go to Section TOC

Section 05 page 27

TM12408-REPAIR TECHNICAL MANUAL

Section 05 - ENGINE AUXILIARY SYSTEM

Group 0530: External Exhaust Systems

Exhaust Pipe Removal LEGEND: 1 Nut (4 used) 2 Shield Mounting Clamp (2 used) 3 Shield 4 Outer Exhaust Clamp 5 Spring Retaining Cap Screw (3 used) 6 Nut (3 used) 7 Mounting Clamp (2 used) 8 Exhaust Pipe Remove nuts (1) securing shield mounting clamps (2). Remove shield (3). [6] - Loosen outer exhaust clamp (4). [7] - Remove nuts (6) and spring retaining cap screws (5). [8] - Remove mounting clamps (7) and exhaust pipe (8). [9] -

<- Go to Section TOC

Section 05 page 28

TM12408-REPAIR TECHNICAL MANUAL

Section 05 - ENGINE AUXILIARY SYSTEM

Group 0530: External Exhaust Systems

Diverter Actuator Removal LEGEND: 9 Hydraulic Line (2 used) 10 Inner Exhaust Clamp 11 Diverter Actuator With exhaust pipe removed, install identification tags and disconnect hydraulic lines (9) from diverter actuator (11). Close all openings using caps and plugs. [10] - Loosen inner exhaust clamp (10) and remove diverter actuator. [11] - Install diverter actuator, clamps, and hydraulic hoses. [12] - Install exhaust pipe, cap screws, clamps, and nuts. [13] - Install diverter actuator shield.

<- Go to Section TOC

Section 05 page 29

TM12408-REPAIR TECHNICAL MANUAL

Section 05 - ENGINE AUXILIARY SYSTEM

Group 0530: External Exhaust Systems

Exhaust Bellows Alignment Procedure Specifications SPECIFICATIONS 35 N·m 26 lb.-ft.

Exhaust System Clamp Nut Torque

Essential Tools ESSENTIAL TOOLS JDG11341 Exhaust Bellows Alignment Fixture

IMPORTANT: Service life of the exhaust bellows is dependent on being properly aligned. If not aligned correctly, the life of the exhaust bellows will be significantly decreased and may risk releasing unfiltered exhaust into the atmosphere. →NOTE: Graphic is for reference only.

Axial, Angular, and Lateral Specifications LEGEND: 1 Axial 2 Angular 3 Lateral Service life of exhaust bellows is dependent on how well exhaust bellows is aligned axially (1), angularly (2), and laterally (3). This procedure is to be performed whenever the following occurs: Exhaust tube removal and installation. Engine removal and installation. Turbocharger discharge pipe removal and installation. Exhaust bellows are held at nominal alignment by JDG11341 Exhaust Bellows Alignment Tool. While bellows are held at nominal alignment, the technician can adjust the exhaust tube position as needed for proper installation. Exhaust Bellows Alignment Fixture JDG11341 <- Go to Section TOC

Section 05 page 30

TM12408-REPAIR TECHNICAL MANUAL

Section 05 - ENGINE AUXILIARY SYSTEM

Group 0530: External Exhaust Systems

Holds exhaust bellows at nominal alignment for exhaust bellows adjustment and instillation. [1] - See Prepare Machine for Maintenance . (Group 0001.) [2] - Turn battery disconnect switch to the OFF position. See Battery Disconnect Switch and Battery Circuit Breakers . (Operator’s Manual.) [3] - Raise cab. See Tilt Cab . (Operator’s Manual.) [4] LEGEND: 4 Cap Screw (4 used) 5 Exhaust Bellows Cover (2 used)

Exhaust Bellows Covers Remove cap screws (4) and exhaust bellows covers (5). [5] -

<- Go to Section TOC

Section 05 page 31

TM12408-REPAIR TECHNICAL MANUAL

Section 05 - ENGINE AUXILIARY SYSTEM

Group 0530: External Exhaust Systems

Adjustment Brackets LEGEND: 6 Clamp (2 used) 7 Cap Screw (2 used) 8 Adjustable Flywheel Bracket 9 Nut (2 used) 10 Cap Screw (3 used) 11 Adjustable Frame Bracket 12 Nut (3 used) 13 Bellows 14 Clamp Loosen clamps (6 and 14). [6] - Loosen clamp at the exhaust filter inlet. See Exhaust Tube Remove and Install . (Group 0530.) [7] - Secure nuts (9) and loosen cap screws (7). Move adjustable flywheel bracket (8) for vertical adjustment. [8] - Secure nuts (12) and loosen cap screws (10). Move adjustable frame bracket (11) for horizontal adjustment. [9] -

<- Go to Section TOC

Section 05 page 32

TM12408-REPAIR TECHNICAL MANUAL

Section 05 - ENGINE AUXILIARY SYSTEM

Group 0530: External Exhaust Systems

LEGEND: 8 Adjustable Flywheel Bracket 10 Cap Screw (3 used) 11 Adjustable Frame Bracket 15 JDG11341 Exhaust Bellows Alignment Fixture

JDG11341 Exhaust Bellows Alignment Fixture Install JDG11341 Exhaust Bellows Alignment Fixture (15) to the exhaust bellows (13). [10] LEGEND: 15 JDG11341 Exhaust Bellows Alignment Fixture 16 Bellows Contact

Correct Bellows Mounting Perform adjustments at brackets as needed until even bellows contact (16) and even pressure is made at the exhaust bellows flange and exhaust tube mating flange. [11] IMPORTANT: Torque exhaust clamps before removing JDG11341 Exhaust Bellows Alignment Fixture. Improper alignment can result causing premature wear to the exhaust bellows if clamps are not torqued prior to removal of the JDG11341 Exhaust Bellows Alignment Fixture. Tighten exhaust clamps (6 and 14) to specification. Item

Measurement

Specification

Exhaust System Clamp Nut

Torque

35 N·m 26 lb.-ft.

[12] - Tighten exhaust clamp at exhaust filter inlet. Torque to specification. See Exhaust Tube Remove and Install . (Group 0530.) Item

Measurement

Specification

Exhaust System Clamp Nut

Torque

35 N·m 26 lb.-ft.

[13] - Remove JDG11341 Exhaust Bellows Alignment Fixture. [14] - Install exhaust bellows cover. [15] - Lower cab. See Tilt Cab . (Operator’s Manual.) <- Go to Section TOC

Section 05 page 33

TM12408-REPAIR TECHNICAL MANUAL

Section 05 - ENGINE AUXILIARY SYSTEM

Group 0530: External Exhaust Systems

[16] - Turn battery disconnect switch to the OFF position. See Battery Disconnect Switch and Battery Circuit Breakers . (Operator’s Manual.) [17] - Operate machine and check for exhaust leaks.

<- Go to Section TOC

Section 05 page 34

TM12408-REPAIR TECHNICAL MANUAL

Section 05 - ENGINE AUXILIARY SYSTEM

Group 0530: External Exhaust Systems

Diesel Particulate Filter (DPF) Remove and Install Specifications SPECIFICATIONS Diesel Particulate Filter (DPF) Weight (approximate)

37 kg 80 lb.

Mounting Band Nut Torque

39—44 N·m 29—33 lb.-ft.

Diesel Particulate Filter (DPF) Clamp Torque

20 N·m 177 lb.-in.

DPF Outlet Temperature Sensor Torque

35 N·m 310 lb.-in.

DPF Differential Pressure Sensor Outlet Line Torque

35 N·m 310 lb.-in.

Nozzle Clamp Torque

35 N·m 310 lb.-in.

Other Material OTHER MATERIAL 41205 U.S. Loctite ™ Heavy Duty Anti-Seize

CAUTION: Avoid possible burn injury from hot exhaust components. Allow exhaust components to cool before service. [1] - Prepare Machine for Maintenance . (Group 0001.) [2] - Turn battery disconnect switch to the OFF position. See Battery Disconnect Switch and Battery Circuit Breakers . (Operator’s Manual.) [3] LEGEND: 1 2

Cap Screw (6 used) Exhaust Cover

Exhaust Cover Remove cap screws (1) and exhaust cover (2). [4] →NOTE: For ease of installation, mark location of outlet cone (12) and diesel particulate filter (DPF) (10).

<- Go to Section TOC

Section 05 page 35

TM12408-REPAIR TECHNICAL MANUAL

Section 05 - ENGINE AUXILIARY SYSTEM

Group 0530: External Exhaust Systems

Diesel Particulate Filter (DPF) LEGEND: 3 Nozzle 4 Clamp 5 Diesel Particulate Filter (DPF) Differential Pressure Sensor Outlet Line 6 Mounting Band Nut (2 used) 7 Cap Screw (2 used) 8 Mounting Band 9 Mounting Bracket 10 Diesel Particulate Filter (DPF) 11 Clamp (2 used) 12 Outlet Cone (2 used) B5513 Diesel Particulate Filter (DPF) Outlet Temperature Sensor Remove clamp (4) and nozzle (3). Close all openings using appropriate material. [5] - Install identification tags and disconnect diesel particulate filter (DPF) differential pressure sensor outlet line (5). Close all openings using caps and plugs. [6] - Disconnect diesel particulate filter (DPF) outlet temperature sensor (B5513).

<- Go to Section TOC

Section 05 page 36

TM12408-REPAIR TECHNICAL MANUAL

Section 05 - ENGINE AUXILIARY SYSTEM

Group 0530: External Exhaust Systems

[7] - Remove clamps (11) connecting DPF to the diesel oxidation catalyst (DOC) and outlet cone (12). Remove outlet cone. [8] - Remove mounting band nuts (6), cap screws (7), mounting bracket (9), and mounting band (8). [9] CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device. Remove diesel particulate filter (DPF) (10) from DOC. Item

Measurement

Specification

Diesel Particulate Filter (DPF)

Weight (approximate)

37 kg 80 lb.

[10] - Inspect and replace parts as necessary. See Diesel Particulate Filter Maintenance and Service . (CTM104819.) [11] CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device. Install DPF to DOC. If DPF was not replaced, line up scribe marks made during removal. Item

Measurement

Specification

Diesel Particulate Filter (DPF)

Weight (approximate)

37 kg 80 lb.

[12] - Install mounting band and bracket. Tighten to specification. Item

Measurement

Specification

Mounting Band Nut

Torque

39—44 N·m 29—33 lb.-ft.

[13] - Install clamp (11). Tighten to specification. Item

Measurement

Specification

Diesel Particulate Filter (DPF) Clamp

Torque

20 N·m 177 lb.-in.

[14] - Apply 41205 Heavy Duty Anti-Seize to threads of DPF outlet temperature sensor (B5513). Install sensor and tighten to specification. Number

Name

• 41205 (us) Loctite ™ Heavy Duty Anti-Seize

Use To prevent corrosion from high temperatures. High temperature anti-seize lubricant.

Item

Measurement

Specification

DPF Outlet Temperature Sensor

Torque

35 N·m 310 lb.-in.

[15] - Apply 41205 Heavy Duty Anti-Seize to threads of DPF differential pressure sensor outlet line. Install line and tighten to specification. Number

Name

• 41205 (us) Loctite ™ Heavy Duty Anti-Seize

Use To prevent corrosion from high temperatures. High temperature anti-seize lubricant.

Item

Measurement

Specification

DPF Differential Pressure Sensor Outlet Line

Torque

35 N·m 310 lb.-in.

[16] - Apply 41205 Heavy Duty Anti-Seize to inside of nozzle diameter. Install nozzle and clamp to top of exhaust filter. Tighten <- Go to Section TOC

Section 05 page 37

TM12408-REPAIR TECHNICAL MANUAL

Section 05 - ENGINE AUXILIARY SYSTEM

Group 0530: External Exhaust Systems

clamp to specification. Item

Measurement

Specification

Nozzle Clamp

Torque

35 N·m 310 lb.-in.

[17] - Install exhaust filter cover to machine. [18] - Turn battery disconnect switch to the ON position. See Battery Disconnect Switch and Battery Circuit Breakers . (Operator’s Manual.)

<- Go to Section TOC

Section 05 page 38

TM12408-REPAIR TECHNICAL MANUAL

Section 05 - ENGINE AUXILIARY SYSTEM

Group 0530: External Exhaust Systems

Exhaust Filter Remove and Install Specifications SPECIFICATIONS Exhaust Filter Weight (approximate)

55 kg 120 lb.

Mounting Plate-to-Exhaust Filter Cap Screw Torque

320 N·m 236 lb.-ft.

Exhaust Clamp Torque

20 N·m 177 lb.-in.

Mounting Band Nut Torque

39—44 N·m 29—33 lb.-ft.

DOC Inlet Temperature Sensor Torque

35 N·m 310 lb.-in.

DPF Outlet Temperature Sensor Torque

35 N·m 310 lb.-in.

DOC Outlet Temperature Sensor Torque

35 N·m 310 lb.-in.

DPF Differential Pressure Sensor Outlet Port Line Torque

35 N·m 310 lb.-in.

DPF Differential Pressure Sensor Inlet Port Line Torque

26 N·m 230 lb.-in.

Nozzle Clamp Torque

35 N·m 310 lb.-in.

Other Material OTHER MATERIAL 41205 Loctite ™ Heavy Duty Anti-Seize

CAUTION: Avoid possible burn injury from hot exhaust components. Allow exhaust components to cool before service. [1] - Prepare Machine for Maintenance . (Group 0001.) [2] - Turn battery disconnect switch to the OFF position. See Battery Disconnect Switch and Battery Circuit Breakers . (Operator’s Manual.) [3] LEGEND: 1 2

Cap Screw (6 used) Exhaust Cover

Exhaust Cover Remove cap screws (1) and exhaust cover (2). [4] <- Go to Section TOC

Section 05 page 39

TM12408-REPAIR TECHNICAL MANUAL

Section 05 - ENGINE AUXILIARY SYSTEM

Group 0530: External Exhaust Systems

LEGEND: Diesel Particulate Filter (DPF) Differential Pressure 4 Sensor Inlet Port Line Diesel Particulate Filter (DPF) Differential Pressure 5 Sensor Outlet Port Line Diesel Oxidation Catalyst (DOC) Inlet Temperature B5511 Sensor Diesel Oxidation Catalyst (DOC) Outlet B5512 Temperature Sensor Diesel Particulate Filter (DPF) Outlet Temperature B5513 Sensor

Exhaust Filter Sensor Removal Install identification tags and disconnect diesel particulate filter (DPF) differential pressure sensor inlet port line (4). Close all openings using caps and plugs. [5] - Install identification tags and disconnect DPF differential pressure sensor outlet port line (5). Close all openings using caps and plugs. [6] - Remove diesel oxidation catalyst (DOC) inlet temperature sensor (B5511). Close all openings using caps and plugs. [7] - Remove DOC outlet temperature sensor (B5512). Close all openings using caps and plugs. [8] - Remove DPF outlet temperature sensor (B5513). Close all openings using caps and plugs. [9] LEGEND: 6 7 8 9 10 11 12

<- Go to Section TOC

Section 05 page 40

Nozzle Nozzle Clamp Mounting Band Cap Screw (2 used) Nut (2 used) Mounting Bracket Exhaust Clamp

TM12408-REPAIR TECHNICAL MANUAL

Section 05 - ENGINE AUXILIARY SYSTEM

Group 0530: External Exhaust Systems

Exhaust Filter Clamp Removal Remove nozzle clamp (7) and nozzle (6). Close all openings using appropriate materials. [10] - Remove exhaust clamp (12). [11] - Remove nuts (10), cap screws (9), mounting band (8), and mounting bracket (11). [12] CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device. Attach appropriate lifting device to lifting points (13).

Exhaust Filter Removal LEGEND: 13 14 15 16 17 <- Go to Section TOC

Lifting Point (2 used) Exhaust Filter Mounting Plate Washer (3 used) Mounting Cap Screw (3 used) Section 05 page 41

TM12408-REPAIR TECHNICAL MANUAL

Section 05 - ENGINE AUXILIARY SYSTEM

Group 0530: External Exhaust Systems

Item

Measurement

Specification

Exhaust Filter Assembly

Weight (approximate)

91 kg 200 lb.

[13] - Outline location of washers (16) on mounting plate for proper alignment during assembly. [14] - Remove mounting cap screws (17) and washers (16) to separate exhaust filter (14) from mounting plate (15). [15] - Repair or replace exhaust filter as necessary. [16] CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device. Install exhaust filter to mounting plate. Hand tighten mounting cap screws and washers. Item

Measurement

Specification

Exhaust Filter

Weight (approximate)

55 kg 120 lb.

[17] - Install mounting band and mounting bracket, hand tighten cap screws. [18] IMPORTANT: Exhaust flange gasket must be replaced when removed. If not replaced, exhaust leakage can occur. →NOTE: Verify proper installation of exhaust flange gasket (18) before installing exhaust clamp.

Exhaust Filter Inlet Flange LEGEND: 14 Exhaust Filter 18 Flange Gasket 19 Exhaust Tube Check and adjust alignment of exhaust filter inlet flange to exhaust tube (19). The exhaust filter inlet flange should align evenly with exhaust tube. [19] - Install exhaust clamp to exhaust filter inlet flange. Tighten exhaust clamp to specification.

<- Go to Section TOC

Section 05 page 42

TM12408-REPAIR TECHNICAL MANUAL

Section 05 - ENGINE AUXILIARY SYSTEM

Group 0530: External Exhaust Systems

Item

Measurement

Specification

Exhaust Clamp

Torque

20 N·m 177 lb.-in.

[20] - Tighten exhaust filter mounting cap screws to specification. Item

Measurement

Specification

Mounting Plate-to-Exhaust Filter Cap Screw

Torque

320 N·m 236 lb.-ft.

[21] - Tighten exhaust filter mounting band cap screws to specification. Item

Measurement

Specification

Mounting Band Nut

Torque

39—44 N·m 29—33 lb.-ft.

[22] - Apply 41205 Heavy Duty Anti-Seize to threads of DOC inlet temperature sensor (B5511). Install sensor and tighten to specification. Number

Name

• 41205 (us) Loctite ™ Heavy Duty Anti-Seize

Use To prevent corrosion from high temperatures. High temperature anti-seize lubricant.

Item

Measurement

Specification

DOC Inlet Temperature Sensor

Torque

35 N·m 310 lb.-in.

[23] - Apply 41205 Heavy Duty Anti-Seize to threads of DPF outlet temperature sensor (B5513). Install sensor and tighten to specification. Number

Name

• 41205 (us) Loctite ™ Heavy Duty Anti-Seize

Use To prevent corrosion from high temperatures. High temperature anti-seize lubricant.

Item

Measurement

Specification

DPF Outlet Temperature Sensor

Torque

35 N·m 310 lb.-in.

[24] - Apply 41205 Heavy Duty Anti-Seize to threads of DOC outlet temperature sensor (B5512). Install sensor and tighten to specification. Number

Name

• 41205 (us) Loctite ™ Heavy Duty Anti-Seize

Use To prevent corrosion from high temperatures. High temperature anti-seize lubricant.

Item

Measurement

Specification

DOC Outlet Temperature Sensor

Torque

35 N·m 310 lb.-in.

[25] - Apply 41205 Heavy Duty Anti-Seize to threads of DPF differential pressure sensor outlet port line (5). Install sensor and tighten to specification. Number

Name

• 41205 (us) Loctite ™ Heavy Duty Anti-Seize

Use To prevent corrosion from high temperatures. High temperature anti-seize lubricant.

Item

Measurement

Specification

DPF Differential Pressure Sensor Outlet Port Line

Torque

35 N·m 310 lb.-in.

[26] - Apply 41205 Heavy Duty Anti-Seize to threads of DPF differential pressure sensor inlet port line (4). Install sensor and tighten to specification. Number

Name

• 41205 (us) Loctite ™ Heavy Duty Anti-Seize <- Go to Section TOC

Use To prevent corrosion from high temperatures. High temperature anti-seize lubricant. Section 05 page 43

TM12408-REPAIR TECHNICAL MANUAL

Section 05 - ENGINE AUXILIARY SYSTEM

Group 0560: External Fuel Supply Systems

Item

Measurement

Specification

DPF Differential Pressure Sensor Inlet Port Line

Torque

26 N·m 230 lb.-in.

[27] - Apply 41205 Heavy Duty Anti-Seize to inside of nozzle diameter. Install nozzle and clamp to top of exhaust filter. Tighten clamp to specification. Item

Measurement

Specification

Nozzle Clamp

Torque

35 N·m 310 lb.-in.

[28] - Install exhaust filter cover to machine. [29] - Turn battery disconnect switch to the ON position. See Battery Disconnect Switch and Battery Circuit Breakers . (Operator’s Manual.)

Service Filter Cleaning For information on service filter cleaning, see Service Filter Cleaning . (Group 9010-20.)

<- Go to Section TOC

Section 05 page 44

TM12408-REPAIR TECHNICAL MANUAL

Section 05 - ENGINE AUXILIARY SYSTEM

Group 0560: External Fuel Supply Systems

Group 0560 - External Fuel Supply Systems Fuel Tank Remove and Install Specifications SPECIFICATIONS Fuel Tank Capacity

609 L 161 gal.

Bottom Guard Weight

498 kg 1098 lb.

[1] - Prepare Machine for Maintenance . (Group 0001.) [2] - Turn battery disconnect switch to the OFF position. See Battery Disconnect Switch and Battery Circuit Breakers . (Operator’s Manual.) [3] IMPORTANT: Avoid damage to batteries and cables. Battery cables are secured to fuel tank. Disconnect cables. Disconnect battery cables at batteries. See Remove and Replace Batteries . (Operator’s Manual.) [4] - Drain fuel from fuel tank into suitable containers. Item

Measurement

Specification

Fuel Tank

Capacity

609 L 161 gal.

[5] CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device. Attach appropriate lifting device to bottom guard. Item

Measurement

Specification

Bottom Guard

Weight

498 kg 1098 lb.

[6] - Remove cap screws (1). Repeat process for opposite side on bottom guard. LEGEND: 1 Cap Screw (6 used)

Right Rear Bottom Guard Mounting Cap Screws [7] - Remove cap screws (2) from filler neck bracket (3).

<- Go to Section TOC

Section 05 page 45

TM12408-REPAIR TECHNICAL MANUAL

Section 05 - ENGINE AUXILIARY SYSTEM

Group 0560: External Fuel Supply Systems

LEGEND: 2 3

Cap Screw (2 used) Filler Neck Bracket

Filler Neck [8] - Remove cap screws (4) and washers (5).

Mounting Cap Screws LEGEND: 4 5 6 7 8

Cap Screw (8 used) Washer (8 used) Cap Screw (4 used) Spacer (4 used) Bottom Guard

[9] - Remove cap screws (6) and spacers (7). [10] CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device. Using appropriate lifting device, lower bottom guard and fuel tank to the ground. Item

Measurement

Specification

Bottom Guard

Weight

498 kg 1098 lb.

[11] - Remove fuel filler neck (9). Close openings using caps and plugs. <- Go to Section TOC

Section 05 page 46

TM12408-REPAIR TECHNICAL MANUAL

Section 05 - ENGINE AUXILIARY SYSTEM

Group 0560: External Fuel Supply Systems

LEGEND: 9 10 11 12 13 14 B37

Fuel Filler Neck Fast Fuel Fill Hose Fuel Tank-to-Inline Filter Line Fuel Cooler-to-Fuel Tank Line Fuel Tank Breather Hose Battery Cable (2 used) Fuel Level Sensor

Fuel Tank Components [12] - Remove fast fuel fill hose (10). Close openings using caps and plugs [13] - Disconnect fuel tank-to-inline filter line (11). Close openings using caps and plugs. [14] - Disconnect fuel cooler-to-fuel tank line (12). Close openings using caps and plugs. [15] - Remove fuel tank breather hose (13). Close openings using caps and plugs. [16] - Remove battery cables (14) from fuel tank. [17] - Disconnect fuel level sensor (B37). [18] - Secure nuts (15) and remove cap screws (16). LEGEND: 15 16 17 18

Nut (2 used) Cap Screw (2 used) Strap (2 used) Fuel Tank

LEGEND: 19 20 21 22 23

Fuel Tank Bottom Guard Strap (2 used) Nut (2 used) Cap Screw (2 used)

Fuel Tank [19] - Remove straps (17). [20] - Remove fuel tank (18). [21] - Repair or replace fuel tank as necessary. [22] - Install fuel tank (19) into bottom guard (20).

Fuel Tank

<- Go to Section TOC

Section 05 page 47

TM12408-REPAIR TECHNICAL MANUAL

Section 05 - ENGINE AUXILIARY SYSTEM

Group 0560: External Fuel Supply Systems

[23] - Install straps (21) and secure with nuts (22) and cap screws (23). [24] - Install fuel filler neck (24) and fast fill fuel hose (25). LEGEND: 24 25 26 27 28 29 B37

Fuel Fillter Neck Fast Fuel Fill Hose Fuel Tank-to-Inline Filter Line Fuel Cooler-to-Fuel Tank Line Fuel Tank Breather Hose Battery Cable (2 used) Fuel Level Sensor

Fuel Tank Components [25] - Install fuel tank-to-inline filter line (26) and fuel cooler-to-fuel tank line (27). [26] - Install fuel tank breather hose (28). [27] - Route battery cables (29) correctly below the strap. [28] - Connect fuel level sensor (B37). [29] - Install washers (30) and cap screws (31).

Mounting Cap Screws LEGEND: 30 31 32 33

Washer (8 used) Cap Screw (8 used) Cap Screw (4 used) Spacer (4 used)

[30] - Install spacers (33) and cap screws (32). [31] - Secure filler neck bracket (35) using cap screws (34).

<- Go to Section TOC

Section 05 page 48

TM12408-REPAIR TECHNICAL MANUAL

Section 05 - ENGINE AUXILIARY SYSTEM

Group 0560: External Fuel Supply Systems

LEGEND: 34 35

Cap Screw (2 used) Filler Neck Bracket

LEGEND: 36

Cap Screw (6 used)

Filler Neck [32] - Install cap screws (36). Repeat process for opposite side.

Right Rear Bottom Guard Mounting Cap Screws [33] - Connect battery cables at batteries. See Battery Disconnect Switch and Battery Circuit Breakers . (Operator’s Manual.) [34] - Turn battery disconnect switch to the ON position. Battery Disconnect Switch and Battery Circuit Breakers . (Operator’s Manual.) [35] - Fill fuel tank and bleed fuel system. See Bleed Fuel System . (Operator’s Manual.) [36] - Check fuel system for leaks.

<- Go to Section TOC

Section 05 page 49

TM12408-REPAIR TECHNICAL MANUAL

Section 05 - ENGINE AUXILIARY SYSTEM

Group 0560: External Fuel Supply Systems

Fuel Transfer Pump Remove and Install [1] - Prepare machine for service safely. See Prepare Machine for Maintenance . (Group 0001.) [2] - Open front service door and turn battery disconnect switch to the OFF position. See Battery Disconnect Switch and Battery Circuit Breakers . (Operator’s Manual.) [3] - Drain fuel filters and water separator. See Drain Fuel Filters (Water Separators) . (Operator’s Manual.) [4] LEGEND: 1 Fuel Transfer Pump Electrical Connector 2 Water-in-Fuel Sensor Electrical Connector

Electrical Connectors Disconnect fuel transfer pump electrical connector (1). [5] - Disconnect water-in-fuel sensor electrical connector (2). [6] - Disconnect low pressure fuel pressure sensor, high pressure fuel pressure sensor, and fuel temperature sensor electrical connectors. See Engine Harness (W17) Component Location . (Group 9015-10.) [7] - Tag and disconnect all fuel hoses at fuel transfer pump. Close all openings using caps and plugs. See Engine Fuel System Component location . (Group 9010-15.) [8] LEGEND: 3

Cap Screw (3 used)

Fuel Transfer Pump Mounting Cap Screws <- Go to Section TOC

Section 05 page 50

TM12408-REPAIR TECHNICAL MANUAL

Section 05 - ENGINE AUXILIARY SYSTEM

Group 0560: External Fuel Supply Systems

Remove cap screws (3) and remove fuel transfer pump from machine. [9] - Repair or replace as necessary. [10] - Install fuel transfer pump to machine and tighten cap screws. [11] - Connect all fuel hoses at fuel transfer pump. See Engine Fuel System Component Location . (Group 9010-15.) [12] - Connect low pressure fuel pressure sensor, high pressure fuel pressure sensor, and fuel temperature sensor electrical connectors. See Engine Harness (W17) Component Location . (Group 9015-10.) [13] - Connect water-in-fuel sensor electrical connector (2). [14] - Connect fuel transfer pump electrical connector (1). [15] - Bleed air from the fuel system. See Bleed Fuel System . (Operator’s Manual.) [16] - Inspect all fuel lines and fittings for leaks. [17] - Close front service door.

<- Go to Section TOC

Section 05 page 51

TM12408-REPAIR TECHNICAL MANUAL

Section 05 - ENGINE AUXILIARY SYSTEM

Group 0560: External Fuel Supply Systems

Fast Fill Fuel System Disassemble and Assemble—If Equipped [1] - Prepare Machine for Maintenance . (Group 0001.) [2] - Turn battery disconnect switch to the OFF position. See Battery Disconnect Switch and Battery Circuit Breakers . (Operator’s Manual.) [3] - Remove cap (1), receiver valve mount (3), and receiver valve (2). [4] - Remove fuel tank. See Fuel Tank Remove and Install . (Group 0560.) [5] - Remove fast fill hose (4).

Fast Fill Fuel System LEGEND: 1 2 3 4 5 6 7 8 9 10

Cap Receiver Valve Receiver Valve Mount Fast Fill Hose Inlet Valve Mount Inlet Valve Signal Line Gasket (2 used) Fast Fuel Shutoff Float Fuel Tank

[6] - Remove inlet valve mount (5) from fuel tank (10). [7] - Disconnect signal line (7) from inlet valve (6). [8] - Remove fast fuel shut off float (9) and gasket (8) from fuel tank. [9] - Repair or replace parts as necessary. [10] - Install fast fuel shutoff float and gasket onto fuel tank. [11] - Connect signal line onto inlet valve. [12] - Install inlet valve mount onto fuel tank. <- Go to Section TOC

Section 05 page 52

TM12408-REPAIR TECHNICAL MANUAL

DAMPER DRIVE

(g) by Belgreen v2.0

[13] - Install fast fill hose. [14] - Install fuel tank. See Fuel Tank Remove and Install . (Group 0560.) [15] - Install receiver valve into receiver valve mount. Install receiver valve mount. [16] - Turn battery disconnect switch to the ON position. See Battery Disconnect Switch and Battery Circuit Breakers . (Operator’s Manual.)

<- Go to Section TOC

Section 07 page 53

TM12408-REPAIR TECHNICAL MANUAL

TM12408-REPAIR TECHNICAL MANUAL

(g) by Belgreen v2.5

Section 07 - DAMPER DRIVE Table of contents Group 0752 - Elements ............................................................................................................................ 1 Output Damper Remove and Install ..................................................................................................... 1

<- Go to Global Table of contents

TM12408-REPAIR TECHNICAL MANUAL

STEERING SYSTEM

(g) by Belgreen v2.0

Group 0752 - Elements Output Damper Remove and Install Specifications SPECIFICATIONS 95 N·m 70 lb.-ft.

Engine Output Damper Cap Screw Torque

[1] - Prepare machine for service safely. See Prepare Machine for Maintenance . (Group 0001.) [2] - Raise cab. See Tilt Cab . (Operator’s Manual.) [3] IMPORTANT: Avoid damage to batteries and cables. Battery cables are secured to fuel tank. Disconnect cables. Disconnect batteries and lower fuel tank. See Fuel Tank Remove and Install . (Group 0560.) [4] - Disconnect drive shaft from engine and move to side. See Engine-to-Transmission Drive Shaft Remove and Install . (Group 0325.) [5] LEGEND: 1 Cap Screw (12 used) 2 Engine Output Damper

Engine Output Damper Remove cap screws (1) and engine output damper (2). [6] - Repair or replace damper. [7] - Install cap screws. Tighten to specification. Item

Measurement

Specification

Engine Output Damper Cap Screw

Torque

95 N·m 70 lb.-ft.

[8] - Connect drive shaft to engine. See Engine-to-Transmission Drive Shaft Remove and Install . (Group 0325.) [9] - Raise fuel tank and connect battery cables. See Fuel Tank Remove and Install . (Group 0560.) [10] - Lower cab. See Tilt Cab . (Operator’s Manual.)

<- Go to Section TOC

Section 09 page 1

TM12408-REPAIR TECHNICAL MANUAL

TM12408-REPAIR TECHNICAL MANUAL

(g) by Belgreen v2.5

Section 09 - STEERING SYSTEM Table of contents Group 0930 - Secondary Steering ......................................................................................................... 1 Secondary Steering Pump Remove and Install ..................................................................................... 1 Group 0960 - Hydraulic System ............................................................................................................. 4 Steering Valve Remove and Install ....................................................................................................... 4 Steering Cylinder Remove and Install ................................................................................................... 8 Steering Bushing Replacement .......................................................................................................... 10

<- Go to Global Table of contents

TM12408-REPAIR TECHNICAL MANUAL

Section 09 - STEERING SYSTEM

Group 0930: Secondary Steering

Group 0930 - Secondary Steering Secondary Steering Pump Remove and Install Specifications SPECIFICATIONS Secondary Steering Pump Weight (approximate)

25 kg 55 lb.

Cap Screw Torque

73 N·m 53 lb.-ft.

[1] LEGEND: 1 Secondary Steering Pump-to-Hydraulic Reservoir Hose 2 Hydraulic Reservoir-to-Secondary Steering Pump Hose 3 Secondary Steering Pump-to-Main Hydraulic Pump Hose Hydraulic System Manifold-to-Secondary Steering Pump 4 Hose Secondary Steering Pump-to-Hydraulic System Manifold 5 Hose 6 Cap Screw (2 used) 7 Secondary Steering Pump

Secondary Steering Pump (S.N. —664888) Prepare Machine for Maintenance . (Group 0001.) [2] CAUTION: Escaping fluid under pressure can penetrate the skin causing serious injury. Avoid the hazard by relieving pressure before disconnecting hydraulic or other lines. Tighten all connections before applying pressure. Search for leaks with a piece of cardboard. Protect hands and body from high pressure fluids. If an accident occurs, see a doctor immediately. Any fluid injected into the skin must be surgically removed within a few hours or gangrene may result. Doctors unfamiliar with this type of injury should reference a knowledgeable medical source. Such information is available from Deere & Company Medical Department in Moline, Illinois, U.S.A.

<- Go to Section TOC

Section 09 page 1

TM12408-REPAIR TECHNICAL MANUAL

Section 09 - STEERING SYSTEM

Group 0930: Secondary Steering

LEGEND: 1 Secondary Steering Pump-to-Hydraulic Reservoir Hose 2 Hydraulic Reservoir-to-Secondary Steering Pump Hose 3 Secondary Steering Pump-to-Main Hydraulic Pump Hose Hydraulic System Manifold-to-Secondary Steering Pump 4 Hose Secondary Steering Pump-to-Hydraulic System Manifold 5 Hose 6 Cap Screw (2 used) 7 Secondary Steering Pump

Secondary Steering Pump (S.N. 664889— ) Discharge brake accumulator pressure by pumping service brake pedal (approximately 20 applications). Relieve hydraulic pressure; turn steering wheel back and forth a minimum of three times. [3] - Turn battery disconnect switch to the OFF position. See Battery Disconnect Switch and Battery Circuit Breakers . (Operator’s Manual.) [4] - Drain oil from hydraulic reservoir or apply vacuum. See Change Hydraulic Oil . (Operator’s Manual.) [5] - Label and disconnect hydraulic hoses (1—5). Close all openings using caps and plugs. [6] CAUTION: Avoid possible crushing injury from heavy component. Use appropriate lifting device. Remove cap screws (6), and secondary steering pump (7). Item

Measurement

Specification

Secondary Steering Pump

Weight (approximate)

25 kg 55 lb.

[7] - Repair or replace secondary steering pump as necessary. [8] IMPORTANT: Replace all oil seals and O-rings. Old seals and O-rings will leak. Install pump and secure cap screws. Tighten to specification. Item

Measurement

Specification

Cap Screw

Torque

73 N·m 53 lb.-ft.

[9] - Connect hydraulic hoses (1—5). [10] - Fill hydraulic reservoir to proper level. See Check Hydraulic Oil Level . (Operator’s Manual.) [11] - Turn battery disconnect switch to the ON position. See Battery Disconnect Switch and Battery Circuit Breakers . (Operator’s Manual.)

<- Go to Section TOC

Section 09 page 2

TM12408-REPAIR TECHNICAL MANUAL

Section 09 - STEERING SYSTEM

Group 0960: Hydraulic System

[12] - Test secondary steering pump for proper operation. See Operational Checkout . Group (9005-10.)

<- Go to Section TOC

Section 09 page 3

TM12408-REPAIR TECHNICAL MANUAL

Section 09 - STEERING SYSTEM

Group 0960: Hydraulic System

Group 0960 - Hydraulic System Steering Valve Remove and Install Specifications SPECIFICATIONS 28 kg 62 lb.

Steering Valve Weight (approximate)

[1] - Prepare Machine for Maintenance . (Group 0001). [2] CAUTION: Escaping fluid under pressure can penetrate the skin causing serious injury. Avoid the hazard by relieving pressure before disconnecting hydraulic or other lines. Tighten all connections before applying pressure. Search for leaks with a piece of cardboard. Protect hands and body from high pressure fluids. If an accident occurs, see a doctor immediately. Any fluid injected into the skin must be surgically removed within a few hours or gangrene may result. Doctors unfamiliar with this type of injury should reference a knowledgeable medical source. Such information is available from Deere & Company Medical Department in Moline, Illinois, U.S.A. Discharge brake accumulator pressure by pumping service brake pedal a minimum of 20 applications. Relieve hydraulic pressure; turn steering wheel back and forth three times. [3] - Turn battery disconnect switch to the OFF position. See Battery Disconnect Switch and Battery Circuit Breakers . (Operator’s Manual.) [4] LEGEND: 1 Cap Screw (4 used) 2 CAN Monitor Unit 3 Steering Shaft Cap Screw

Instrument Panel

Steering Shaft Coupling Remove cap screws (1) from instrument panel, set CAN monitor unit (2) aside. [5] - Remove steering shaft cap screw (3) from steering shaft coupling. <- Go to Section TOC

Section 09 page 4

TM12408-REPAIR TECHNICAL MANUAL

Section 09 - STEERING SYSTEM

Group 0960: Hydraulic System

[6] - Remove cap screws (4) and cover (5). LEGEND: 4 5

Cap Screw (4 used) Cover

Steering Valve Cover [7] - Label and disconnect lines (6 and 9) and close all openings using caps and plugs. LEGEND: 6 Hydraulic Line (4 used) 7 Upper Cap Screw (3 used) 8 Lower Cap Screw (2 used) 9 Hydraulic Line (2 used) 10 Mounting Bracket

Steering Valve

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Section 09 page 5

TM12408-REPAIR TECHNICAL MANUAL

Section 09 - STEERING SYSTEM

Group 0960: Hydraulic System

Steering Valve [8] CAUTION: Avoid possible crushing injury from heavy component. Use appropriate lifting device. Support steering valve with appropriate lifting device. Item

Measurement

Specification

Steering Valve

Weight (approximate)

28 kg 62 lb.

[9] - Remove cap screws (7 and 8) from mounting bracket (10). Remove steering valve from cab. [10] - Remove cap screws (11) and separate steering valve from mounting bracket (10). LEGEND: 10 Mounting Bracket 11 Cap Screw (4 used)

Bracket [11] - Repair or replace steering valve as necessary. [12] - Install mounting bracket onto steering valve. <- Go to Section TOC

Section 09 page 6

TM12408-REPAIR TECHNICAL MANUAL

Section 09 - STEERING SYSTEM

Group 0960: Hydraulic System

[13] →NOTE: To achieve proper alignment of steering valve assembly, connect steering shaft coupling prior to securing steering valve assembly to cab. Install steering valve assembly. Align steering shaft coupling and install steering shaft cap screw. [14] - Install mounting bracket cap screws. [15] - Install cap screws to instrument panel. [16] - Connect lines (6 and 9) as marked. [17] CAUTION: Escaping fluid under pressure can penetrate the skin causing serious injury. Avoid the hazard by relieving pressure before disconnecting hydraulic or other lines. Tighten all connections before applying pressure. Search for leaks with a piece of cardboard. Protect hands and body from high pressure fluids. If an accident occurs, see a doctor immediately. Any fluid injected into the skin must be surgically removed within a few hours or gangrene may result. Doctors unfamiliar with this type of injury should reference a knowledgeable medical source. Such information is available from Deere & Company Medical Department in Moline, Illinois, U.S.A. Operate machine and check for leaks. [18] - Verify hydraulic oil level. See Check Hydraulic Oil Level . (Operator’s Manual.)

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Section 09 page 7

TM12408-REPAIR TECHNICAL MANUAL

Section 09 - STEERING SYSTEM

Group 0960: Hydraulic System

Steering Cylinder Remove and Install Specifications SPECIFICATIONS Steering Cylinder Weight (approximate)

62 kg 137 lb.

Steering Cylinder Mounting Cap Screws Torque

350 N·m 255 lb.-ft.

Service Equipment and Tools SERVICE EQUIPMENT AND TOOLS JT07372 Heavy Duty Wheel Chock

[1] - Turn front of truck so steering cylinder to be removed is fully extended. Install wheel chocks. Discharge hydraulic pressure. See Prepare Machine for Maintenance . (Group 0001.) Heavy Duty Wheel Chock JT07372 Used to block the wheels during repair to prevent machine movement. [2] - Remove fender from side of machine where steering cylinder is to be removed. See Fender Remove and Install . (Group 1910.) [3] LEGEND: 1 Hydraulic Hose (2 used) 2 Mounting Pin Cap Screw (2 used) 3 Bushing (2 used) 4 Pin (2 used)

Right Steering Cylinder Label and disconnect hydraulic hoses (1). Close all openings using caps and plugs. [4] CAUTION: Avoid possible crushing injury from heavy component. Use appropriate lifting device. Attach appropriate lifting device to steering cylinder (9). Item

Measurement

Specification

Steering Cylinder

Weight (approximate)

62 kg 137 lb.

[5] -

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Section 09 page 8

TM12408-REPAIR TECHNICAL MANUAL

Section 09 - STEERING SYSTEM

Group 0960: Hydraulic System

Steering Cylinder Mounting LEGEND: 2 Mounting Pin Cap Screw (2 used) 3 Bushing (2 used) 4 Pin (2 used) 5 Pin Seal 6 Seal Bushing (4 used) 7 Bushing Seal (2 used) 8 Bushing 9 Steering Cylinder Remove mounting pin cap screw (2) and bushing (3). [6] - Remove parts (2—8). [7] - Remove steering cylinder. [8] - Clean, inspect, repair, or replace parts as necessary. [9] - Apply grease to all pivot parts and assemble as shown. [10] CAUTION: Avoid possible crushing injury from heavy component. Use appropriate lifting device. Using appropriate lifting device, install steering cylinder. [11] - Install steering cylinder mounting cap screws and tighten to specification. Item

Measurement

Specification

Steering Cylinder Mounting Cap Screws

Torque

350 N·m 255 lb.-ft.

[12] - Connect hydraulic lines. <- Go to Section TOC

Section 09 page 9

TM12408-REPAIR TECHNICAL MANUAL

SERVICE BRAKES

(g) by Belgreen v2.0

[13] - Repeat procedure for opposite side if required.

Steering Bushing Replacement [1] - Remove steering cylinder from machine. See Steering Cylinder Remove and Install . (Group 0960.) [2] - Remove upper and lower seal. [3] - Remove bushing from bore. [4] - Align new bushing with bore. [5] - Using a C-clamp and a piece of flat steel on each side of assembly, press bushing into bore. [6] - Release the C-clamp and add a seal on the side that is being pressed in. [7] - Press seal and bushing into bore until flush with surface. [8] - Release the C-clamp and add a seal on the remaining side of the bushing. [9] - Press seal into bore until flush. [10] - Install steering cylinder on machine. See Steering Cylinder Remove and Install . (Group 0960.)

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Section 10 page 10

TM12408-REPAIR TECHNICAL MANUAL

TM12408-REPAIR TECHNICAL MANUAL

(g) by Belgreen v2.5

Section 10 - SERVICE BRAKES Table of contents Group 1011 - Active Elements ............................................................................................................... 1 Service Brake Assembly Remove and Install ........................................................................................ 1 Group 1060 - Hydraulic System ............................................................................................................. 2 Bleed Service Brake ............................................................................................................................. 2 Brake Accumulator Remove and Install ................................................................................................ 3 Brake Valve Remove and Install ........................................................................................................... 5 Electronic Brake Valve Remove and Install .......................................................................................... 6

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TM12408-REPAIR TECHNICAL MANUAL

Section 10 - SERVICE BRAKES

Group 1060: Hydraulic System

Group 1011 - Active Elements Service Brake Assembly Remove and Install For more information on service brake assembly, see Brake Group List . (CTM115319.)

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Section 10 page 1

TM12408-REPAIR TECHNICAL MANUAL

Section 10 - SERVICE BRAKES

Group 1060: Hydraulic System

Group 1060 - Hydraulic System Bleed Service Brake The brake system must be bled anytime that maintenance or repair, which could cause air to enter the hydraulic system, is performed on the brake system. The following procedure must be used to bleed the brake system when brake bleeding equipment is not available: [1] - Park and prepare machine for service safely. See Prepare Machine for Maintenance . (Group 0001.) [2] - Verify hydraulic oil level is correct. [3] - Apply park brake. [4] - Start engine and operate at low idle during bleeding procedure. [5] LEGEND: 1

Brake Bleed Screw

Brake Bleed Screw Attach a clear plastic hose to brake bleed screw (1) on one of the axles. [6] - Direct other end of hose into a 1 L (1 qt) container. [7] - Push and hold brake pedal down. [8] - Open bleed screw on brake caliper approximately 1/4 turn. [9] - When clean, air-free oil flows from brake bleed screw through the plastic tube, close the bleed screw. [10] - Bleed front and middle axles. →NOTE: Front and middle axle brake bleed procedure is the same. Rear axle is not equipped with service brakes. [11] - Inspect bleed screws on axle for leaks. [12] - Dispose of waste oil properly. [13] - Check hydraulic oil level and fill if necessary. See Check Hydraulic Oil Level . (Operator’s Manual.)

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Section 10 page 2

TM12408-REPAIR TECHNICAL MANUAL

Section 10 - SERVICE BRAKES

Group 1060: Hydraulic System

Brake Accumulator Remove and Install [1] - Park and prepare machine for service safely. See Prepare Machine for Maintenance . (Group 0001.) [2] - Turn battery disconnect switch to the OFF position. See Battery Disconnect Switch and Battery Circuit Breakers . (Operator’s Manual.) [3] - Raise cab. See Tilt Cab . (Operator’s Manual.) [4] 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. LEGEND: 1 Brake Accumulator (4 used) 2 Mounting Bracket with Accumulators (2 used) 3 Cap Screw (8 used) 4 Hydraulic Hose (2 used)

Brake Accumulators

Hydraulic Lines Relieve brake accumulator pressure. Pump service brake pedal repeatedly until no oil “hiss” is heard from accumulators. [5] - Install identification tags and disconnect hydraulic hoses (4). Close all openings using caps and plugs. [6] →NOTE: Remove mounting brackets with accumulators one set at a time.

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

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Section 10 page 3

TM12408-REPAIR TECHNICAL MANUAL

Section 10 - SERVICE BRAKES

Group 1060: Hydraulic System

Secure mounting bracket and accumulators (2) with appropriate lifting device. Item

Measurement

Specification

Mounting Bracket with Accumulators

Weight (approximate)

54 kg 120 lb.

[7] - Remove cap screws (3) and remove mounting bracket with accumulators. [8] LEGEND: 5 6 7 8

Hydraulic Line Clamp (4 used) Cap Screw (8 used) Nut (8 used)

Mounting Clamps Remove hydraulic line (5). [9] - Secure nuts (8) and remove cap screws (7). Remove clamps (6). [10] - Remove accumulators (1). [11] - Recharge or replace accumulators as required. [12] - Install accumulators and secure to mounting bracket with clamps. [13] - Install hydraulic line. [14] CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device. Using appropriate lifting device, install mounting bracket with accumulators. Secure mounting bracket with cap screws. Item

Measurement

Specification

Mounting Bracket with Accumulators

Weight (approximate)

54 kg 120 lb.

[15] - Connect hydraulic hoses. [16] - Bleed service brake system. See Bleed Service Brake . (Group 1060.)

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Section 10 page 4

TM12408-REPAIR TECHNICAL MANUAL

Section 10 - SERVICE BRAKES

Group 1060: Hydraulic System

Brake Valve Remove and Install [1] - Park and prepare machine for service safely. See Prepare Machine for Maintenance . (Group 0001.) [2] - Relieve brake accumulator pressure. Pump service brake pedal repeatedly until no oil “hiss” is heard from accumulators. [3] - Turn battery disconnect switch to the OFF position. See Battery Disconnect Switch and Battery Circuit Breakers . (Operator’s Manual.) [4] - Open hood. [5] 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.

Cover Removal

Hydraulic Lines <- Go to Section TOC

Section 10 page 5

TM12408-REPAIR TECHNICAL MANUAL

Section 10 - SERVICE BRAKES

Group 1060: Hydraulic System

LEGEND: 1 Cap Screw (4 used) 2 Cover 3 Hydraulic Hose (6 used) 4 Brake Valve Remove cap screws (1) and cover (2). [6] - Install identification tags and disconnect hydraulic hoses (3). Close all openings using caps and plugs [7] LEGEND: 5 6 7 X49

Cap Screw (2 used) Pin (2 used) Brake Pedal Brake Switch Connector

Brake Valve Disconnect brake switch connector (X49). [8] - Remove pins (6) and brake pedal (7). [9] - Remove cap screws (5). [10] - Remove brake valve (4). [11] - Inspect, repair, or replace parts as necessary. [12] - Install brake valve. [13] - Install brake pedal and pins. [14] - Install hydraulic hoses. [15] - Install cover. [16] - Bleed service brake system. See Bleed Service Brake . (Group 1060.)

Electronic Brake Valve Remove and Install [1] - Park and prepare machine for service safely. See Prepare Machine for Maintenance . (Group 0001.) [2] - Relieve brake accumulator pressure. Pump service brake pedal repeatedly until no oil “hiss” is heard from accumulators. [3] - Turn battery disconnect switch to the OFF position. See Battery Disconnect Switch and Battery Circuit Breakers . (Operator’s Manual.) [4] - Raise cab. See Tilt Cab . (Operator’s Manual.) [5] 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. <- Go to Section TOC

Section 10 page 6

TM12408-REPAIR TECHNICAL MANUAL

PARK BRAKE

(g) by Belgreen v2.0

LEGEND: 1 Hydraulic Hose (4 used) 2 Electronic Brake Valve 3 Cap Screw (2 used) Y8 Electronic Brake Valve Solenoid Connector

Electronic Brake Valve Disconnect electronic brake valve solenoid connector (Y8). [6] - Install identification tags and disconnect hydraulic hoses (1). Close all openings using caps and plugs. [7] - Remove cap screws (3). [8] - Remove electronic brake valve (2). [9] - Inspect, repair, or replace parts as necessary. [10] - Install brake valve and cap screws. [11] - Connect hydraulic hoses and solenoid connector. [12] - Lower cab. See Tilt Cab . (Operator’s Manual.) [13] - Bleed service brake system. See Bleed Service Brake . (Group 1060.)

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Section 11 page 7

TM12408-REPAIR TECHNICAL MANUAL

TM12408-REPAIR TECHNICAL MANUAL

(g) by Belgreen v2.5

Section 11 - PARK BRAKE Table of contents Group 1111 - Active Elements ............................................................................................................... 1 Park Brake Pads Remove and Install .................................................................................................... 1 Park Brake Caliper Remove and Install ................................................................................................. 2 Park Brake Disk Remove and Install ..................................................................................................... 5 Park Brake Chamber Remove and Install ............................................................................................. 7 Group 1160 - Hydraulic System ............................................................................................................. 9 Park Brake Control Valve Remove and Install ....................................................................................... 9

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TM12408-REPAIR TECHNICAL MANUAL

Section 11 - PARK BRAKE

Group 1111: Active Elements

Group 1111 - Active Elements Park Brake Pads Remove and Install [1] - Prepare Machine for Maintenance . (Group 0001.) [2] - Release the park brake. See Mechanically Releasing Park Brake . (Operator’s Manual.) [3] - Raise dump body and install locking bar. See Install Dump Body Locking Bar . (Operator’s Manual.) [4] LEGEND: 1 Retaining Bar Pin 2 Retaining Bar 3 Retaining Clip (2 used) 4 Brake Pad (2 used)

Park Brake Pads Remove retaining bar pin (1). [5] - Move retaining bar (2) aside. [6] - Remove brake pads (4). [7] - Remove retaining clips (3) from pads. [8] - Clean and inspect parts for wear or damage. [9] - Install retaining clips on pads and install pads. [10] - Install retaining bar and secure with retaining pin. [11] - Start machine and verify proper park brake operation. See Parking the Machine . (Operator’s Manual.)

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Section 11 page 1

TM12408-REPAIR TECHNICAL MANUAL

Section 11 - PARK BRAKE

Group 1111: Active Elements

Park Brake Caliper Remove and Install Specifications SPECIFICATIONS Park Brake Caliper Assembly Weight (approximate)

48 kg 106 lb.

Cap Screw Torque

620 N·m 457 lb.-ft.

[1] - Prepare Machine for Maintenance . (Group 0001.) [2] - Raise dump body and install locking bar. See Install Dump Body Locking Bar . (Operator’s Manual.) [3] - Mechanically release park brake. See Mechanically Releasing Park Brake . (Operator’s Manual.) [4] - Remove park brake pads. See Park Brake Pads Remove and Install . (Group 1111.) [5] CAUTION: To avoid injury from escaping fluid under pressure, stop engine and relieve pressure in the system before disconnecting or connecting hydraulic or other lines. Tighten all connections before applying pressure. If an accident occurs, see a doctor immediately. Any fluid injected into skin must be surgically removed within a few hours or gangrene may result. Doctors unfamiliar with this type of injury should reference a knowledgeable medical source. Such information is available from Deere & Company Medical Department in Moline, Illinois, U.S.A. Release applied pressure at park brake by pulling release handle. See Mechanically Releasing Park Brake . (Operator’s Manual.) [6] LEGEND: 1 Chamber 2 Cap Screw (4 used) 3 Shim (8 used) 4 Park Brake Caliper Assembly

Park Brake Caliper Remove park brake chamber. See Park Brake Chamber Remove and Install . (Group 1111.) [7] CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device. <- Go to Section TOC

Section 11 page 2

TM12408-REPAIR TECHNICAL MANUAL

Section 11 - PARK BRAKE

Group 1111: Active Elements

Remove cap screws (2) and shims (3). [8] - Remove park brake caliper assembly (4). Item

Measurement

Specification

Park Brake Caliper Assembly

Weight (approximate)

48 kg 106 lb.

[9] -

Caliper Mounting Bracket LEGEND: 5 Park Brake Caliper 6 Plug 7 Caliper Saddle Remove plug (6), exposing cap screw and pin. Remove cap screw. [10] - Remove park brake caliper (5) from caliper saddle (7). [11] - Repair or replace components as necessary. [12] CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device. Install park brake caliper to caliper saddle. [13] - Install cap screws and tighten to specification. <- Go to Section TOC

Section 11 page 3

TM12408-REPAIR TECHNICAL MANUAL

Section 11 - PARK BRAKE

Group 1111: Active Elements

Item

Measurement

Specification

Cap Screw

Torque

620 N·m 457 lb.-ft.

[14] -

Park Brake Caliper Shims Shim park brake caliper until park brake disk is centered as shown. [15] - Connect hydraulic line at chamber. [16] - Install park brake pads. See Park Brake Pads Remove and Install . (Group 1111.) [17] - Start machine and verify proper park brake operation. See Parking the Machine . (Operator’s Manual.)

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Section 11 page 4

TM12408-REPAIR TECHNICAL MANUAL

Section 11 - PARK BRAKE

Group 1111: Active Elements

Park Brake Disk Remove and Install Specification Specification 295 N-m 217.6 lb.-ft.

Disk Cap Screw Torque

Other Material OTHER MATERIAL 271 Loctite ™ Thread Lock and Sealer (high strength)

[1] - Prepare Machine for Maintenance . (Group 0001.) [2] - Release the park brake. See Mechanically Releasing Park Brake . (Operator’s Manual.) [3] - Raise dump body and install locking bar. See Install Dump Body Locking Bar . (Operator’s Manual.) [4] - Remove park brake pads. See Park Brake Pads Remove and Install . (Group 1111.) [5] - Remove park brake caliper. See Park Brake Caliper Remove and Install . (Group 1111.) [6] - Remove park brake-to-middle axle drive shaft. See Park Brake-to-Middle Axle Drive Shaft Remove and Install . (Group 0225.) [7] LEGEND: 1 Cap Screw (4 used) 2 Caliper Mounting Bracket 3 Cap Screw (16 used) 4 Park Brake Disk

Park Brake Disk Remove cap screws (1) and caliper mounting bracket (2). [8] - Remove cap screws (3). [9] - Remove or replace park brake disk (4). [10] - Apply PM37421 Loctite Thread Lock and Sealer (high strength) to threads of cap screws (3). [11] - Install park brake disk (4) and cap screws (3). Tighten cap screws to specification. Item

Measurement

Specification

Disk Cap Screw

Torque

295 N-m 217.6 lb.-ft.

[12] - Install caliper mounting bracket (2) and cap screws (1). [13] - Install park brake to middle axle drive shaft. See Park Brake-to-Middle Axle Drive Shaft Remove and Install . (Group <- Go to Section TOC

Section 11 page 5

TM12408-REPAIR TECHNICAL MANUAL

Section 11 - PARK BRAKE

Group 1111: Active Elements

0225.) [14] - Install park brake caliper. See Park Brake Caliper Remove and Install . (Group 1111.) [15] - Install park brake pads. See Park Brake Pads Remove and Install . (Group 1111.) [16] - Start machine and verify proper park brake operation. See Parking the Machine . (Operator’s Manual.)

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Section 11 page 6

TM12408-REPAIR TECHNICAL MANUAL

Section 11 - PARK BRAKE

Group 1111: Active Elements

Park Brake Chamber Remove and Install [1] - Prepare Machine for Maintenance . (Group 0001.) [2] - Raise dump body and install locking bar. See Install Dump Body Locking Bar . (Operator’s Manual.) [3] 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. If an accident occurs, see a doctor immediately. Any fluid injected into skin must be surgically removed within a few hours or gangrene may result. Doctors unfamiliar with this type of injury should reference a knowledgeable medical source. Such information is available from Deere & Company Medical Department in Moline, Illinois, U.S.A.

Escaping Fluid Under Pressure Release park brake and applied pressure at park brake. See Mechanically Releasing Park Brake . (Operator’s Manual.) [4] LEGEND: 1 2

Chamber Hydraulic Line

Park Brake Chamber Front View Disconnect hydraulic line (2) at chamber (1). Close all openings using caps and plugs. [5] -

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Section 11 page 7

TM12408-REPAIR TECHNICAL MANUAL

Section 11 - PARK BRAKE

Group 1160: Hydraulic System

Park Brake Chamber Rear View LEGEND: 1 Chamber 2 Nut (2 used) 3 Washer (2 used) 4 Boot 5 Spacer 6 Lever Arm 7 Clevis Assembly 8 Clevis Pin 9 Cotter Pin 10 Mounting Bracket Remove cotter pin (9) and clevis pin (8). [6] - Detach clevis assembly (7) from lever arm (6). [7] - Remove nuts (2) and washers (3) from mounting bracket (10). [8] - Detach chamber, spacer (5), and boot (4) from mounting bracket. [9] - Repair or replace components as necessary. [10] - Install boot, spacer, and chamber on mounting bracket. [11] - Install washers and nuts. [12] - Assemble and install clevis assembly. Secure with clevis pin and cotter pin. [13] - Connect hydraulic line at chamber. [14] - Ensure secure connections. Start machine and verify proper park brake operation. See Parking the Machine . (Operator’s Manual.)

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Section 11 page 8

TM12408-REPAIR TECHNICAL MANUAL

Section 11 - PARK BRAKE

Group 1160: Hydraulic System

Group 1160 - Hydraulic System Park Brake Control Valve Remove and Install [1] - Park and prepare machine for service safely. See Prepare Machine for Maintenance . (Group 0001.) [2] - Turn battery disconnect switch to the OFF position. See Battery Disconnect Switch and Battery Circuit Breakers . (Operator’s Manual.) [3] LEGEND: B15 Park Brake Pressure Switch Y45 Park Brake Release Solenoid 2 Y46 Park Brake Release Solenoid 1

Park Brake Control Valve Disconnect connector at park brake pressure switch (B15). [4] - Disconnect connector at park brake release solenoid 2 (Y45) and connector park brake release solenoid 1 (Y46). [5] LEGEND: 1 Hydraulic Hose (2 used) 2 Nut (2 used) 3 Cap Screw (2 used) 4 Hydraulic Control Valve

Park Brake Control Valve Install identification tags and disconnect hydraulic hoses (1). Close all openings using caps and plugs. [6] - Secure nuts (2) and remove cap screws (3). [7] - Remove hydraulic control valve (4). [8] - Repair or replace park brake control valve. [9] - Install hydraulic control valve. Secure with cap screws and nuts. [10] - Connect hydraulic hoses. [11] - Connect connector at park brake release solenoid 2 (Y45) and connector park brake release solenoid 1 (Y46). [12] - Connect connector at park brake pressure switch (B15).

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Section 11 page 9

TM12408-REPAIR TECHNICAL MANUAL

FRAME OR SUPPORTING STRUCTURE

(g) by Belgreen v2.0

[13] - Turn battery disconnect switch to the ON position. See Battery Disconnect Switch and Battery Circuit Breakers . (Operator’s Manual.)

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Section 17 page 10

TM12408-REPAIR TECHNICAL MANUAL

TM12408-REPAIR TECHNICAL MANUAL

(g) by Belgreen v2.5

Section 17 - FRAME OR SUPPORTING STRUCTURE Table of contents Group 1740 - Frame Installation ........................................................................................................... 1 Welding on Machine ............................................................................................................................. 1 Front and Rear Frames Separate .......................................................................................................... 2 Articulation Frame Remove and Install ................................................................................................. 9 Articulation Frame Bearings Disassemble and Assemble ................................................................... 12 Articulation Frame Bearings Adjust .................................................................................................... 14 Oscillation Joint Disassemble and Assemble ....................................................................................... 17 Oscillation Joint Bearing Cap Screw Installation ................................................................................. 19

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TM12408-REPAIR TECHNICAL MANUAL

Section 17 - FRAME OR SUPPORTING STRUCTURE

Group 1740: Frame Installation

Group 1740 - Frame Installation Welding on Machine Use caution when welding on machine. See Welding on Machine . (Operator′s Manual.)

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Section 17 page 1

TM12408-REPAIR TECHNICAL MANUAL

Section 17 - FRAME OR SUPPORTING STRUCTURE

Group 1740: Frame Installation

Front and Rear Frames Separate Specifications SPECIFICATIONS Pin Cap Screw Torque

256—384 N·m 188—283 lb.-ft.

Retaining Plate Cap Screw Torque

102—154 N·m 75—113 lb.-ft.

Service Equipment and Tools SERVICE EQUIPMENT AND TOOLS JT07372 Heavy Duty Wheel Chock DFT1344 Front Frame Support

[1] - Park and prepare machine for service safely. See Prepare Machine for Maintenance . (Group 0001.) [2] - Raise dump body and install dump body locking bar. See Install Dump Body Locking Bar . (Operator’s Manual.) [3] - Turn battery disconnect switch to the OFF position. See Battery Disconnect Switch and Battery Circuit Breakers . (Operator’s Manual.) [4] - Install JT07372 Heavy Duty Wheel Chocks under all wheels. Heavy Duty Wheel Chock JT07372 Used to block the wheels during repair to prevent machine movement. [5] LEGEND: 1 Hydraulic Hose (10 used) 2 Hose Bundle 3 Dump Body Heater Tube W11 Articulation Harness Hydraulic Harness-to-Articulation harness 21-Pin X3 Connector

Electrical and Hydraulic Connections Install identification tags and disconnect hydraulic hoses (1). Close all openings using caps and plugs. [6] - Remove steering cylinders (4) from articulation frame. See Steering Cylinder Remove and Install . (Group 0960.)

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Section 17 page 2

TM12408-REPAIR TECHNICAL MANUAL

Section 17 - FRAME OR SUPPORTING STRUCTURE

Group 1740: Frame Installation

LEGEND: 4 Steering Cylinder (2 used)

Steering Cylinders [7] - Disconnect hydraulic harness-to-articulation harness 21-pin connector (X3). Remove articulation harness (W11) from front frame section. See Articulation Harness (W11) Component Location . (Group 9015-10.) [8] - Remove hose bundle (2) from spring hanger and secure to rear frame section for storage. [9] - Remove dump body heater tube (3) if equipped. See Dump Body Heater Pipe Remove and Install . (Group 0530.) [10] - Remove park brake-to-middle axle drive shaft. See Park Brake-to-Middle Axle Drive Shaft Remove and Install . (Group 0225.) [11] - Remove transmission-to-oscillation joint drive shaft. See Transmission-to-Front Axle Drive Shaft or Transmission-toOscillation Joint Drive Shaft Remove and Install . (Group 0225) [12] - Remove rod (5) from articulation angle sensor (B26). LEGEND: 5 B26

Rod Articulation Angle Sensor

Articulation Angle Sensor [13] -

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Section 17 page 3

TM12408-REPAIR TECHNICAL MANUAL

Section 17 - FRAME OR SUPPORTING STRUCTURE

Group 1740: Frame Installation

LEGEND: 6

Front Support (2 used)

Front Engine Frame Support Support front of engine frame using two DFT1344 Supports (6). (Group 9900.) Front Frame Support DFT1344 [ Fabricated tool, dealer made. (Group 9900.) ]

Support front of engine frame while separating frames. [14] LEGEND: 7 20-Ton Shop Stand (2 used)

Rear Engine Frame Support Support rear of engine frame using two 20-ton shop stands (7). [15] -

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Section 17 page 4

TM12408-REPAIR TECHNICAL MANUAL

Section 17 - FRAME OR SUPPORTING STRUCTURE

Group 1740: Frame Installation

LEGEND: 8 Middle Machine Frame Tiedown Point (2 used)

Middle Machine Frame Tiedown Point Support middle of machine using appropriate lifting device. Attach lifting device at middle machine frame tiedown points (8). [16] -

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Section 17 page 5

TM12408-REPAIR TECHNICAL MANUAL

Section 17 - FRAME OR SUPPORTING STRUCTURE

Group 1740: Frame Installation

Upper Pin Cap Screws LEGEND: 9 Pin Cap Screw (5 used) 10 Retaining Plate Cap Screw (8 used) 11 Retaining Plate 12 Nut (5 used) Secure nuts (12) and remove pin cap screws (9). [17] - Remove retaining plate cap screws (10) and remove retaining plate (11). [18] - Remove the upper joint pin (13) downwards from the upper joint pin bore (14).

Upper Joint Pin LEGEND: 13 14

Upper Joint Pin Upper Joint Pin Bore

[19] - Remove cap screw (15).

<- Go to Section TOC

Section 17 page 6

TM12408-REPAIR TECHNICAL MANUAL

Section 17 - FRAME OR SUPPORTING STRUCTURE

Group 1740: Frame Installation

Lower Joint Pin LEGEND: 15 16 17

Cap Screw Lower Joint Pin Lower Joint Pin Bore

[20] - Remove the lower joint pin (16) upwards from the lower joint pin bore (17). [21] CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device. Using appropriate lifting device and equipment, remove wheel chocks at middle and rear wheels and roll the rear frame away from the front engine frame to separate. [22] - Install JT07372 Heavy Duty Wheel Chocks at middle and rear wheels. Heavy Duty Wheel Chock JT07372 Used to block the wheels during repair to prevent machine movement. [23] - Support rear frame (19) using two 20-ton shop stands (18).

<- Go to Section TOC

Section 17 page 7

TM12408-REPAIR TECHNICAL MANUAL

Section 17 - FRAME OR SUPPORTING STRUCTURE

Group 1740: Frame Installation

LEGEND: 18 19

20-Ton Shop Stand (2 used) Rear Frame

Rear Frame Support [24] - Repair or replace articulation joint and components as necessary. [25] CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device. Using appropriate lifting device and equipment, remove wheel chocks at middle and rear wheels. Roll the rear frame forward to the front engine frame mounting pin locations. [26] - Install lower and upper joint pins. Torque the pin cap screws and retaining plate cap screws to specification. Item

Measurement

Specification

Pin Cap Screw

Torque

256—384 N·m 188—283 lb.-ft.

Retaining Plate Cap Screw

Torque

102—154 N·m 75—113 lb.-ft.

[27] - Install articulation angle sensor rod. [28] - Install transmission-to-oscillation joint drive shaft. See Transmission-to-Front Axle Drive Shaft or Transmission-toOscillation Joint Drive Shaft Remove and Install . (Group 0225.) [29] - Install park brake-to-middle axle drive shaft. See Park Brake-to-Middle Axle Drive Shaft Remove and Install . (Group 0225.) [30] - Install steering cylinders to articulation frame. See Steering Cylinder Remove and Install . (Group 0960.) [31] - Install dump body heater tube. See Dump Body Heater Pipe Remove and Install . (Group 0530.) [32] - Install hose bundle to spring hanger. [33] - Connect hydraulic harness-to-articulation harness 21-pin connector (X3). Install articulation harness (W11) to front frame section. See Articulation Harness (W11) Component Location . (Group 9015-10.) [34] - Connect hydraulic hoses. [35] - Turn battery disconnect switch to the ON position. See Battery Disconnect Switch and Battery Circuit Breakers . (Operator’s Manual.) [36] - Remove dump body locking bar and lower dump body.

<- Go to Section TOC

Section 17 page 8

TM12408-REPAIR TECHNICAL MANUAL

Section 17 - FRAME OR SUPPORTING STRUCTURE

Group 1740: Frame Installation

Articulation Frame Remove and Install Specifications SPECIFICATIONS Articulation Frame Weight (approximate)

734 kg 1618 lb.

Mounting Cap Screw Torque

1070 N·m 789 lb. ft.

[1] - Park and prepare machine for service safely. See Prepare Machine for Maintenance . (Group 0001.) [2] - Turn battery disconnect switch to the OFF position. See Battery Disconnect Switch and Battery Circuit Breakers . (Operator’s Manual.) [3] - Remove park brake-to-middle axle drive shaft. See Park Brake-to-Middle Axle Drive Shaft Remove and Install . (Group 0225.) [4] - Remove park brake caliper. See Park Brake Caliper Remove and Install . (Group 1111.) [5] - Remove park brake disk. See Park Brake Disk Remove and Install . (Group 1111.) [6] - Remove oscillation joint drive shaft. See Oscillation Joint Drive Shaft Remove and Install . (Group 0225.) [7] LEGEND: 1 2 3

Cap Screw (2 used) Cover Grease Line (3 used)

Articulation Frame Cover Remove cap screws (1) and remove cover (2). [8] - Remove grease lines (3). [9] - Separate front and rear frames. See Front and Rear Frames Separate . (Group 1740.) [10] -

<- Go to Section TOC

Section 17 page 9

TM12408-REPAIR TECHNICAL MANUAL

Section 17 - FRAME OR SUPPORTING STRUCTURE

Group 1740: Frame Installation

LEGEND: 4 Articulation Frame 5 Nut (18 used) 6 Mounting Cap Screw (18 used)

Mounting Cap Screws Using appropriate lifting device, secure articulation frame (4). [11] - Secure nuts (5) and remove mounting cap screws (6). [12] CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device. Using appropriate lifting device, remove articulation frame. Item

Measurement

Specification

Articulation Frame

Weight (approximate)

734 kg 1618 lb.

Articulation Frame Removal [13] - Repair or replace articulation frame as necessary. See Articulation Frame Bearings Disassemble and Assemble . (Group 1740.) [14] - Using appropriate lifting device, install articulation frame. [15] - Secure articulation frame with mounting cap screws. Torque to specification. Item

Measurement

Specification

Mounting Cap Screw

Torque

1070 N·m 789 lb. ft.

[16] - Connect front and rear frames. See Front and Rear Frames Separate . (Group 1740.) [17] <- Go to Section TOC

Section 17 page 10

TM12408-REPAIR TECHNICAL MANUAL

Section 17 - FRAME OR SUPPORTING STRUCTURE

Group 1740: Frame Installation

LEGEND: 7 8 9

Cover Cap Screw (2 used) Grease Line (3 used)

Articulation Frame Cover Install articulation cover (7). Secure with cap screws (8). [18] - Install grease lines (9). [19] - Install oscillation joint drive shaft. See Oscillation Joint Drive Shaft Remove and Install . (Group 0225.) [20] - Install park brake disk. See Park Brake Disk Remove and Install . (Group 1111.) [21] - Install park brake caliper. See Park Brake Caliper Remove and Install . (Group 1111.) [22] - Install park brake-to-middle axle drive shaft. See Park Brake-to-Middle Axle Drive Shaft Remove and Install . (Group 0225.) [23] - Turn battery disconnect switch to the ON position. See Battery Disconnect Switch and Battery Circuit Breakers . (Operator’s Manual.)

<- Go to Section TOC

Section 17 page 11

TM12408-REPAIR TECHNICAL MANUAL

Section 17 - FRAME OR SUPPORTING STRUCTURE

Group 1740: Frame Installation

Articulation Frame Bearings Disassemble and Assemble Service Equipment and Tools SERVICE EQUIPMENT AND TOOLS D01045AA Bushing, Bearing, and Seal Driver Set

[1] -

Articulation Frame Bearings LEGEND: 1 Articulation Frame 2 Spacer 3 Seal (2 used) 4 Upper Bearing 5 Upper Cover 6 Shim 7 Shim 8 Shim (2 used) 9 Locking Collar 10 Washer (10 used) 11 Cap Screw (10 used) 12 Spacer 13 Seal (2 used) 14 Lower Bearing 15 Lower Cover 16 Shim 17 Shim 18 Shim (2 used) 19 Grease Fitting (2 used) 20 Upper Pin Park and prepare machine for service safely. Prepare Machine for Maintenance . (Group 0001.) [2] - Separate front and rear frames. See Front and Rear Frames Separate . (Group 1740.) [3] -

<- Go to Section TOC

Section 17 page 12

TM12408-REPAIR TECHNICAL MANUAL

Section 17 - FRAME OR SUPPORTING STRUCTURE

Group 1740: Frame Installation

IMPORTANT: Do not mix bearings and spacers from upper and lower joints. Bearings and spacers must be replaced as a set or bearing damage can occur. Clean, inspect, and replace components (1—20) as necessary. →NOTE: Do not reuse seals (3 and 13). [4] - Install bearings in bores. Make sure that each bearing assembly is centered vertically in bore, to allow grease to flow to rollers through grooves in bores. [5] - Install new seals using D01045AA Bushing, Bearing, and Seal Driver Set. Bushing, Bearing, and Seal Driver Set D01045AA Install new seals. [6] - Connect front and rear frame sections. See Front and Rear Frames Separate . (Group 1740.) [7] - Grease articulation joint. See Lubricate Articulation Joint, Oscillation Joint, and Through Drive Bearing . (Operator’s Manual.)

<- Go to Section TOC

Section 17 page 13

TM12408-REPAIR TECHNICAL MANUAL

Section 17 - FRAME OR SUPPORTING STRUCTURE

Group 1740: Frame Installation

Articulation Frame Bearings Adjust Specifications SPECIFICATIONS 128 N·m 94 lb. ft.

Cap Screw Torque

[1] - Park and prepare machine for service safely. See Prepare Machine for Maintenance . (Group 0001.) [2] - Turn battery disconnect switch to the OFF position. See Battery Disconnect Switch and Battery Circuit Breakers . (Operator’s Manual.) [3] - Separate front and rear frames. See Front and Rear Frames Separate . (Group 1740.) [4] IMPORTANT: If bearing does not contact upper bearing cover plate, incorrect adjustments can be made. Verify bearing is contacting upper bearing cover plate. →NOTE: Tighten cap screws but do not torque. Remove any shims that are present. Install three cap screws (1) to secure upper bearing cover plate (2) to upper bearing housing (3).

Cover Plate LEGEND: 1 2 <- Go to Section TOC

Cap Screw (3 used) Upper Bearing Cover Plate Section 17 page 14

TM12408-REPAIR TECHNICAL MANUAL

Section 17 - FRAME OR SUPPORTING STRUCTURE

3

Group 1740: Frame Installation

Upper Bearing Housing

[5] - Using a feeler gauge, check and record measurements at locations (4—6). Determine the average from all three measurement locations.

Shim Measurement LEGEND: 4 5 6

Measurement Location 1 Measurement Location 2 Measurement Location 3

[6] - Subtract (0.005 in.) from average at step 5. The result is the amount of shims that need to be added. [7] - Install calculated amount of shims.

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Section 17 page 15

TM12408-REPAIR TECHNICAL MANUAL

Section 17 - FRAME OR SUPPORTING STRUCTURE

Group 1740: Frame Installation

Adding Correct Shims LEGEND: 7 8 9

Shim (0.005 in.) Shim (0.010 in.) Shim (0.020 in.)

[8] - Install the upper bearing cover plate. Secure with cap screws. Torque cap screws to specification. Item

Measurement

Specification

Cap Screw

Torque

128 N·m 94 lb. ft.

[9] - Connect front and rear frame sections. See Front and Rear Frames Separate . (Group 1740.) [10] - Turn battery disconnect switch to the OFF position. See Battery Disconnect Switch and Battery Circuit Breakers . (Operator’s Manual.)

<- Go to Section TOC

Section 17 page 16

TM12408-REPAIR TECHNICAL MANUAL

Section 17 - FRAME OR SUPPORTING STRUCTURE

Group 1740: Frame Installation

Oscillation Joint Disassemble and Assemble [1] -

Oscillation Joint (exploded view) LEGEND: 1 Articulation Frame 2 Seal 3 Bearing with Housing 4 Seal 5 Seal 6 Bearing 7 Housing 8 Washer (18 used) 9 Cap Screw (18 used) Prepare machine for maintenance. See Prepare Machine for Maintenance . (Operator′s Manual.) [2] - Separate front and rear frames. See Front and Rear Frames Separate . (Group 1740.) [3] - Remove articulation frame. See Articulation Frame Remove and Install . (Group 1740.) [4] LEGEND: 6 7 10

Bearing Housing Puller

Housing Removal <- Go to Section TOC

Section 17 page 17

TM12408-REPAIR TECHNICAL MANUAL

Section 17 - FRAME OR SUPPORTING STRUCTURE

Group 1740: Frame Installation

Install puller (10) to housing (7) to remove housing from bearing (6). [5] - Clean, inspect, and replace components (2—9) as necessary. [6] - Install cap screws (9). See Oscillation Joint Bearing Cap Screw Installation . (Group 1740.) [7] - Assemble front and rear frames. See Front and Rear Frames Separate . (Group 1740.) [8] - Grease oscillation joint. See Lubricate Articulation Joint, Oscillation Joint, and Through Drive Bearing . (Operator’s Manual.)

<- Go to Section TOC

Section 17 page 18

TM12408-REPAIR TECHNICAL MANUAL

Section 17 - FRAME OR SUPPORTING STRUCTURE

Group 1740: Frame Installation

Oscillation Joint Bearing Cap Screw Installation Specifications SPECIFICATIONS 920 N·m 679 lb·ft

Cap Screw Torque

Other Material OTHER MATERIAL Loctite® Silver Grade Anti-Seize

[1] IMPORTANT: Prevent possible machine damage. Always use proper oscillation joint bearing cap screw installation procedure when installing bearing. LEGEND: 1 2 3 4

Cap Screw (18 used) Washer (18 used) Bearing Articulation Frame

Oscillation Joint Bearing Cap Screw Installation Clean threads of cap screws (1) and articulation frame (4). Clean mating surfaces of cap screws, washers (2), and bearing (3). [2] - Install washers to cap screws. [3] IMPORTANT: Number

Name

Use

• PM37566 (us)

Loctite® Silver Grade Anti-Seize

Use to allow proper wet torque at cap screws

Prevent possible machine damage. Ensure Loctite ™ Silver Grade Anti-Seize is applied only to threaded end of cap screw. Cap screw head, washer, or bearing surface lubricated with Loctite Silver Grade AntiSeize may result in improper clamp force and component stress. Apply Loctite Silver Grade Anti-Seize to threaded end of cap screws. [4] - Install cap screws and washers to bearing. Do not tighten. [5] - Tighten eight cap screws to specification as shown in torque sequence 1. Item

Measurement

Specification

Cap Screw

Torque

920 N·m 679 lb·ft

<- Go to Section TOC

Section 17 page 19

TM12408-REPAIR TECHNICAL MANUAL

OPERATOR′S STATION

(g) by Belgreen v2.0

Torque Sequence 1 [6] -

Torque Sequence 2 Tighten all cap screws to specification as shown in torque sequence 2. Item

Measurement

Specification

Cap Screw

Torque

920 N·m 679 lb·ft

<- Go to Section TOC

Section 18 page 20

TM12408-REPAIR TECHNICAL MANUAL

TM12408-REPAIR TECHNICAL MANUAL

(g) by Belgreen v2.5

Section 18 - OPERATOR′S STATION Table of contents Group 1810 - Operator Enclosure .......................................................................................................... 1 Cab Remove and Install ........................................................................................................................ 1 Cab Mount Remove and Install ........................................................................................................... 10 Cab Tilt Pump and Cylinder Remove and Install ................................................................................. 12 Cab Tilt Pump and Cylinder Disassemble and Assemble .................................................................... 16 Windowpanes Remove and Install ...................................................................................................... 18 Cab Door Window Installation ............................................................................................................. 21 Group 1821 - Seat and Seat Belt ......................................................................................................... 24 Operator’s Seat Remove and Install ................................................................................................... 24 Seat Belt Remove and Install .............................................................................................................. 25 Group 1830 - Heating and Air Conditioning ...................................................................................... 27 R134a Refrigerant Cautions and Proper Handling .............................................................................. 27 R134a Refrigerant Oil Information ...................................................................................................... 28 R134a Refrigerant Recovery/Recycling and Charging Station Installation Procedure ........................ 31 R134a Refrigerant Recover ................................................................................................................ 32 Air Conditioning System Flush and Purge ........................................................................................... 33 R134a System Evacuate ..................................................................................................................... 34 R134a System Charge ........................................................................................................................ 35 Compressor Remove and Install ......................................................................................................... 37 Condenser Remove and Install ........................................................................................................... 38 High/Low Pressure Switch Remove and Install ................................................................................... 39 Receiver-Dryer Remove and Install .................................................................................................... 40 Expansion Valve Remove and Install .................................................................................................. 41 Heater Core and Evaporator Core Remove and Install ....................................................................... 43 Freeze Control Switch Remove and Install ......................................................................................... 46 Heater Control Valve Remove and Install ........................................................................................... 46 Heater Control Valve Leak Check ....................................................................................................... 47 Blower Motor Assembly Remove and Install ....................................................................................... 48 Mode Door Remove and Install ........................................................................................................... 49

<- Go to Global Table of contents

TM12408-REPAIR TECHNICAL MANUAL

Section 18 - OPERATOR′S STATION

Group 1810: Operator Enclosure

Group 1810 - Operator Enclosure Cab Remove and Install Specifications SPECIFICATIONS Cab Weight

962 kg 2120 lb.

Cab Mount Cap Screw Torque

320 N·m 236 lb.-ft.

Essential Tools ESSENTIAL TOOLS JT05551 16 mm Ringbolt

[1] - Park and prepare machine for service safely. See Prepare Machine for Maintenance . (Group 0001.) [2] - Open hood and left side fan door. [3] CAUTION: Escaping fluid under pressure can penetrate the skin causing serious injury. Avoid the hazard by relieving pressure before disconnecting hydraulic or other lines. Tighten all connections before applying pressure. Search for leaks with a piece of cardboard. Protect hands and body from high pressure fluids. If an accident occurs, see a doctor immediately. Any fluid injected into the skin must be surgically removed within a few hours or gangrene may result. Doctors unfamiliar with this type of injury should reference a knowledgeable medical source. Such information is available from Deere & Company Medical Department in Moline, Illinois, U.S.A. Discharge brake accumulator pressure by pumping service brake pedal (approximately 20 applications). Relieve hydraulic pressure; turn steering wheel back and forth three times. [4] - Turn battery disconnect switch to the OFF position. See Battery Disconnect Switch and Battery Circuit Breakers . (Operator’s Manual.) [5] - Drain engine coolant. See Drain, Flush, and Refill Engine Cooling System . (Operator’s Manual.) [6] - Follow refrigerant cautions and proper handling procedures. See R134a Refrigerant Cautions and Proper Handling . (Group 1830.) [7] - Recover air conditioning refrigerant. See R134a Refrigerant Recover . (Group 1830.) [8] - Raise cab. See Tilt Cab . (Operator’s Manual.) [9] -

<- Go to Section TOC

Section 18 page 1

TM12408-REPAIR TECHNICAL MANUAL

Section 18 - OPERATOR′S STATION

Group 1810: Operator Enclosure

LEGEND: 1 Cap Screw (4 used) 2 Steering Valve Cover

Cover Removal Remove cap screws (1) and steering valve cover (2). [10] LEGEND: 3 Hydraulic Line (4 used) 4 Steering Valve 5 Air Conditioner Line (2 used) 6 Cap Screw (2 used) 7 Hydraulic Line (2 used)

Steering Valve and Air Conditioner Lines

<- Go to Section TOC

Section 18 page 2

TM12408-REPAIR TECHNICAL MANUAL

Section 18 - OPERATOR′S STATION

Group 1810: Operator Enclosure

Steering Valve Lines Tag and disconnect hydraulic lines (3 and 7) from steering valve (4). Close all openings using caps and plugs. [11] - Tag and disconnect air conditioner lines (5). Close all openings using caps and plugs. [12] - Remove cap screws (6) from line bracket and set aside air conditioner lines. [13] -

Heater Hoses and Electrical Connectors <- Go to Section TOC

Section 18 page 3

TM12408-REPAIR TECHNICAL MANUAL

Section 18 - OPERATOR′S STATION

Group 1810: Operator Enclosure

LEGEND: 8 Heater Hose (2 used) X8 Cab Harness-to-Hydraulic Harness 31-Pin Connector X9 Cab Harness-to-Hydraulic Harness 31-Pin Connector X10 Cab Harness-to-Hydraulic Harness 31-Pin Connector X14 Cab Harness-to-Front Frame Harness 21-Pin Connector X15 Cab Harness-to-Front Frame Harness 9-Pin Connector X16 Cab Harness-to-Engine Interface Harness 14-Pin Connector X67 Rear View Frame Camera Articulation 4-Pin Connector Tag and disconnect heater hoses (8). Close all openings using caps and plugs. [14] - Tag and disconnect electrical connectors (X8, X9, X10, X14, X15, X16, and X67) at right front of cab. See Cab Harness (W3) Component Location . (Group 9015-10.) [15] - Tag and disconnect all hydraulic lines at service brake valve. Close all openings using caps and plugs. See Brake Valve Remove and Install . (Group 1060.) [16] - Disconnect washer fluid supply line at base of the wiper arm. [17] LEGEND: S5 Differential Lock Floor Switch

Differential Lock Floor Switch Tag and disconnect differential lock floor switch (S5). [18] - Disconnect ground strap (W36) from right front cab mount. See Power and Ground Component Location . (Group 9015-10.) [19] LEGEND: 9 10

Cap Screw (5 used) Right Side Fender

Right Side Fender Mounts <- Go to Section TOC

Section 18 page 4

TM12408-REPAIR TECHNICAL MANUAL

Section 18 - OPERATOR′S STATION

Group 1810: Operator Enclosure

Remove cap screws (9) at right side fender (10). [20] CAUTION: Avoid possible crushing injury from heavy component. Use appropriate lifting device. LEGEND: 11

Auxiliary Cab Tilt Location

Auxiliary Cab Tilt Location Using appropriate lifting device, support cab at auxiliary cab tilt location (11). Item

Measurement

Specification

Cab

Weight

962 kg 2120 lb.

[21] -

Cab Support Cap Screw

<- Go to Section TOC

Section 18 page 5

TM12408-REPAIR TECHNICAL MANUAL

Section 18 - OPERATOR′S STATION

Group 1810: Operator Enclosure

Cab Stay Detent LEGEND: 12 Cab Support Cap Screw 13 Detent Position Verify proper engagement of the cab support cap screw (12) to the detent position (13). [22] -

<- Go to Section TOC

Section 18 page 6

TM12408-REPAIR TECHNICAL MANUAL

Section 18 - OPERATOR′S STATION

Group 1810: Operator Enclosure

LEGEND: 14 15

Retaining Pin Cylinder Pin

Cab Tilt Cylinder Remove retaining pin (14) and cylinder pin (15). Note location and number of spacers for installation. [23] - Remove cab support cap screw (12). [24] CAUTION: Avoid possible injury from crushing. Stay clear of cab while lowering. Rotate cab pump valve lever clockwise to the LOWER position. Slowly lower cab using appropriate lifting device. See Tilt Cab . (Operator’s Manual.) Item

Measurement

Specification

Cab

Weight

962 kg 2120 lb.

[25] LEGEND: 16

Cap Screw (2 used)

Cab Roof Remove cap screws (16) from cab roof and install two JT05551 Ringbolts. 16 mm Ringbolt JT05551 Cab removal [26] -

<- Go to Section TOC

Section 18 page 7

TM12408-REPAIR TECHNICAL MANUAL

Section 18 - OPERATOR′S STATION

Group 1810: Operator Enclosure

Cab Lifting Attach appropriate lifting device to JT05551 Ringbolts and support cab as shown. 16 mm Ringbolt JT05551 Cab removal Item

Measurement

Specification

Cab

Weight

962 kg 2120 lb.

[27] - Remove remaining cab mount cap screws and remove cab. [28] - Repair or replace cab components as necessary. [29] CAUTION: Avoid possible crushing injury from heavy component. Use appropriate lifting device. Install cab to machine and install only right side cab mount cap screws. Tighten to specification. Item

Measurement

Specification

Cab Mount Cap Screw

Torque

320 N·m 236 lb.-ft.

[30] - Remove JT05551 Ringbolts from cab roof, and install cap screws. 16 mm Ringbolt JT05551 Cab removal [31] -

<- Go to Section TOC

Section 18 page 8

TM12408-REPAIR TECHNICAL MANUAL

Section 18 - OPERATOR′S STATION

Group 1810: Operator Enclosure

CAUTION: Avoid possible crushing injury from heavy component. Use appropriate lifting device. Attach appropriate lifting device to auxiliary cab tilt location. Tilt cab using lifting device. Item

Measurement

Specification

Cab

Weight

962 kg 2120 lb.

[32] - Install cab support cap screw and slowly lower cab into detent position. See Tilt Cab . (Operator’s Manual.) [33] - Rotate cab pump valve lever counterclockwise to the RAISE position. Operate cab lift pump until cab lift cylinder pin can be installed. Install spacers in correct location and install retaining pin. [34] - Connect ground strap (W36) to right front cab mount. See Power and Ground Component Location . (Group 9015-10.) [35] - Install cap screws to right side fender. [36] - Connect washer fluid supply line. [37] - Connect differential lock floor switch (S5). [38] - Connect all hydraulic lines at service brake valve. See Brake Valve Remove and Install . (Group 1060.) [39] - Connect air conditioner lines and install cap screws to bracket. [40] - Connect all hydraulic lines at steering valve and install cap screws to steering valve cover. [41] - Connect electrical connectors (X8, X9, X10, X14, X15, X16, and X67) at right front of cab. See Cab Harness (W3) Component Location . (Group 9015-10.) [42] CAUTION: Avoid possible injury from crushing. Stay clear of cab while lowering. Remove lifting device from cab tilting location on cab. Lower cab and install remaining cab mount cap screws. Tighten to specification. See Tilt Cab . (Operator’s Manual.) Item

Measurement

Specification

Cab Mount Cap Screw

Torque

320 N·m 236 lb.-ft.

[43] - Turn battery disconnect switch to the ON position. See Battery Disconnect Switch and Battery Circuit Breakers . (Operator’s Manual.) [44] - Fill engine cooling system. See Drain, Flush, and Refill Engine Cooling System . (Operator’s Manual.) [45] - Evacuate air conditioning system. See R134a System Evacuate . (Group 1830.) [46] - Charge air conditioning system. See R134a System Charge . (Group 1830.) [47] - Check hydraulic oil level. Add oil if necessary. See Check Hydraulic Oil Level . (Operator’s Manual.) [48] - Close hood and left side fan door.

<- Go to Section TOC

Section 18 page 9

TM12408-REPAIR TECHNICAL MANUAL

Section 18 - OPERATOR′S STATION

Group 1810: Operator Enclosure

Cab Mount Remove and Install Specifications SPECIFICATIONS Cab Weight (approximate)

885 kg 1950 lb.

Cab Mount Cap Screw Torque

320 N·m 236 lb.-ft.

Essential Tools ESSENTIAL TOOLS JT05551 16 mm Ringbolt

[1] -

Cab Lifting Prepare Machine for Maintenance . (Group 0001.) [2] CAUTION: Avoid crushing injury from heavy component. Use appropriate lifting device. Using two JT05551 Ringbolts, attach hoist to cab as shown. 16 mm Ringbolt JT05551 Cab Removal Item

Measurement

Specification

Cab

Weight (approximate)

885 kg 1950 lb.

[3] <- Go to Section TOC

Section 18 page 10

TM12408-REPAIR TECHNICAL MANUAL

Section 18 - OPERATOR′S STATION

Group 1810: Operator Enclosure

LEGEND: 1

Rubber Mount (4 used)

Cab Mount Remove all cap screws, washers, and nuts from rubber mounts (1) as necessary. [4] - Lift cab slightly and remove rubber mount(s). [5] - Install rubber mount(s). [6] - Install all cap screws, washers, and nuts. [7] - Lower cab onto rubber mounts. [8] - Tighten cap screws and nuts. Item

Measurement

Specification

Cab Mount Cap Screw

Torque

320 N·m 236 lb.-ft.

<- Go to Section TOC

Section 18 page 11

TM12408-REPAIR TECHNICAL MANUAL

Section 18 - OPERATOR′S STATION

Group 1810: Operator Enclosure

Cab Tilt Pump and Cylinder Remove and Install Specifications SPECIFICATIONS 885 kg 1950 lb.

Cab Weight (approximate)

[1] - Prepare Machine for Maintenance . (Group 0001.) [2] - Tilt cab. Cab support cap screw (2) must be in the detent position. See Tilt Cab . (Operator′s Manual.) [3] CAUTION: Avoid possible crushing injury from heavy component. Use appropriate lifting device to support cab during service. Using appropriate lifting device, support and lift cab at auxiliary cab tilt location (1). Item

Measurement

Specification

Cab

Weight (approximate)

885 kg 1950 lb.

LEGEND: 1 Auxiliary Cab Tilt Location 2 Cab Support Cap Screw

Auxiliary Cab Tilt Location

Cab Support Cap Screw <- Go to Section TOC

Section 18 page 12

TM12408-REPAIR TECHNICAL MANUAL

Section 18 - OPERATOR′S STATION

Group 1810: Operator Enclosure

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

Cab Tilt Cylinder and Pump

<- Go to Section TOC

Section 18 page 13

TM12408-REPAIR TECHNICAL MANUAL

Section 18 - OPERATOR′S STATION

Group 1810: Operator Enclosure

Cab Tilt Cylinder-to-Cab Components LEGEND: 2 Cab Support Cap Screw 3 Pump 4 Support Strut 5 Pump-to-Cylinder Head End Line 6 Pump-to-Clylinder Rod End Line 7 Cylinder 8 Cylinder Pin 9 Washer (5 used) 10 Cab Frame 11 Spring Washer (S.N. 664451— ) 12 Grommet 13 Bushing 14 Cotter Pin Turn pump valve lever clockwise to LOWER position to relieve hydraulic pressure. [5] - Apply vacuum to hydraulic tank. [6] - Remove components (2—8) as necessary. [7] - Inspect, repair, and replace parts as needed. [8] →NOTE: Fill each component with oil during assembly, working from bottom to top. Install cylinder, if removed. [9] - Install lines, if removed. <- Go to Section TOC

Section 18 page 14

TM12408-REPAIR TECHNICAL MANUAL

Section 18 - OPERATOR′S STATION

Group 1810: Operator Enclosure

[10] - Install pump, if removed. [11] - Lower and raise cab several times with pump to bleed air from system. [12] - With cab lowered, remove plug from fill port on top of pump and add oil as necessary. [13] - Lower cab and install cab mounting hardware. See Tilt Cab . (Operator’s Manual.)

<- Go to Section TOC

Section 18 page 15

TM12408-REPAIR TECHNICAL MANUAL

Section 18 - OPERATOR′S STATION

Group 1810: Operator Enclosure

Cab Tilt Pump and Cylinder Disassemble and Assemble

Cab Tilt Cylinder LEGEND: 1 2 3 4 <- Go to Section TOC

Bushing (2 used) Rod Hydraulic Cylinder Seal Section 18 page 16

TM12408-REPAIR TECHNICAL MANUAL

Section 18 - OPERATOR′S STATION

5 6 7 8 9 10 11 12 14 15 16 17 18 19 20 21 22 23 24 25 26

Group 1810: Operator Enclosure

Seal Snap Ring O-Ring Snap Ring Washer O-Ring Hydraulic Cylinder Rod Guide Wear Ring Seal Kit O-Ring Piston Ring Piston Elbow Nut Barrel Hydraulic Cylinder Rod Guide Kit Cylinder Bore Seal Kit O-Ring (2 used) Elbow Fitting O-Ring (2 used) Piston Kit

For cylinder repair procedures, see Cylinder Identification . (CTM120519.)

<- Go to Section TOC

Section 18 page 17

TM12408-REPAIR TECHNICAL MANUAL

Section 18 - OPERATOR′S STATION

Group 1810: Operator Enclosure

Windowpanes Remove and Install Specifications SPECIFICATIONS 6 mm 0.25 in.

Adhesive Bead Size

Other Material OTHER MATERIAL TT208103 U.S. Self-Adhesive Gasket Urethane Adhesive

CAUTION: Avoid personal injury. Follow manufacturer’s instructions for using activator, primer and adhesive. IMPORTANT: Urethane adhesive manufactured by Henkel Corporation or equivalent is recommended. DO NOT use any other type of adhesive. IMPORTANT: Windowpanes must include an ultraviolet barrier around edge to prevent adhesive deterioration. Windowpanes ordered through John Deere Parts include ultraviolet barrier. If windowpane is purchased through glass dealer, the dealer must incorporate ultraviolet barrier on the glass. DO NOT paint border of glass. The adhesive used to secure windowpanes is a urethane adhesive used on automobile windshields. Urethane adhesive manufactured by Henkel Corporation or equivalent is recommended. DO NOT use any other type of adhesive. It is recommended that an auto glass dealer install windowpanes. If auto glass dealer does not install windowpanes, proceed as follows: [1] -

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Section 18 page 18

TM12408-REPAIR TECHNICAL MANUAL

Section 18 - OPERATOR′S STATION

Group 1810: Operator Enclosure

Cab Windowpanes LEGEND: 1 Cab 2 Front Windowpane 3 Sliding Window 4 Self-Adhesive Gasket (as needed) 5 Rear Windowpane 6 Left Windowpane Remove windowpane from cab (1). [2] - Remove self-adhesive gasket (4). [3] - Scrape any broken glass and adhesive from cab flange. [4] IMPORTANT: Avoid windowpane damage. Adhesive will not bond to dirty surface. Lightly sand flange to clean surface. <- Go to Section TOC

Section 18 page 19

TM12408-REPAIR TECHNICAL MANUAL

Section 18 - OPERATOR′S STATION

Group 1810: Operator Enclosure

Lightly sand flange of cab with sandpaper to clean flange surface. [5] - Wipe cab windowpane flange to remove any dirt or dust from surface. [6] - Wipe cab windowpane flange with flex activator. Allow flex activator to dry. [7] - Apply primer to cab windowpane flange using a lint-free cloth. [8] - Install TT208103 self adhesive gasket (4) to cab windowpane flange. Number

Name

Use

• TT208103 (us)

Self-Adhesive Gasket

Secure windowpane

[9] IMPORTANT: Avoid windowpane damage. Follow manufacturer’s instructions for using adhesive. Allow adhesive to cure before operating machine. Apply a bead of adhesive on cab windowpane flange. Item

Measurement

Specification

Adhesive Bead

Size

6 mm 0.25 in.

Number

Name

Use

Urethane Adhesive

Secure windowpane

[10] - Position windowpane in cab frame. Use hand pressure to force windowpane down until edges are even with frame. [11] IMPORTANT: Avoid windowpane damage. Allow adhesive to cure for 8 hours before operating machine. Secure windowpane with duct tape or tie straps and wood blocks around cab to hold and maintain windowpane position until adhesive cures. Allow adhesive to cure for 8 hours before operating machine.

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Section 18 page 20

TM12408-REPAIR TECHNICAL MANUAL

Section 18 - OPERATOR′S STATION

Group 1810: Operator Enclosure

Cab Door Window Installation [1] - Wipe window flange with ethanol (ethyl alcohol) or isopropyl alcohol (isopropanol) using a clean dry cloth. Allow to dry for 5 minutes. [2] - Apply Terostat ™ 8519P All-in-One Primer to frame flange with wipe-on wipe-off method and allow to dry for a minimum of 10 minutes or a maximum of 2 hours. [3] - Wipe door flange with ethanol (ethyl alcohol) or isopropyl alcohol (isopropanol). Allow to dry for 5 minutes. [4] - Apply Terostat® 8519P All-in-One Primer to frame flange with wipe-on wipe-off method and allow to dry for a minimum of 10 minutes or a maximum of 2 hours. [5] - Using a clean dry cloth, apply Terostat® 8519P All-in-One Primer to F/Glass Flange. Allow to dry for a minimum of 20 minutes or a maximum of 24 hours. [6] -

Fitting Gasket Roll Stock Fit gasket roll stock around entire door opening as shown. [7] →NOTE: Ensure that quantity of Terostat® 9096PL Primerless DGX in gun is sufficient to complete task.

Applying Terostat® 9096PL Primerless DGX to Window Frame

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Section 18 page 21

TM12408-REPAIR TECHNICAL MANUAL

Section 18 - OPERATOR′S STATION

Group 1810: Operator Enclosure

Applying Terostat® 9096PL Primerless DGX to Door Opening Apply Terostat® 9096PL Primerless DGX using application gun around window frame and around door opening as shown. [8] -

Fitting Window To Door Fit window to door starting at the bottom (as shown) and finishing at the top. [9] - Apply some force to window frame ensuring proper engagement all around door opening. [10] -

Sealing Around Window with Terostat® 9096PL Primerless DGX. <- Go to Section TOC

Section 18 page 22

TM12408-REPAIR TECHNICAL MANUAL

Section 18 - OPERATOR′S STATION

Group 1821: Seat and Seat Belt

Seal around the edge of the window with Terostat® 9096PL Primerless DGX. [11] -

Removing Excess Terostat® 9096PL Primerless DGX with Terostat® FL+. Remove any excess Terostat® 9096PL Primerless DGX from window frame and door opening using a clean cloth and Terostat® FL+ leaving a neat seal with no gaps as shown. [12] -

Checking Quality of Installation Ensure door is clean and window is fitted correctly. Allow Terostat® 9096PL Primerless DGX to cure.

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Section 18 page 23

TM12408-REPAIR TECHNICAL MANUAL

Section 18 - OPERATOR′S STATION

Group 1821: Seat and Seat Belt

Group 1821 - Seat and Seat Belt Operator’s Seat Remove and Install Specifications SPECIFICATIONS 37 N·m 27 lb-ft

Seat Assembly Cap Screw Torque

[1] - Turn battery disconnect switch to the OFF position. [2] - Disconnect electrical connectors (X65 and X66). LEGEND: X65 X66

Seat Heater Connector Seat Compressor Connector

Seat Electrical Connectors [3] LEGEND: 2 3

Slot Cap Screw (6 used)

Seat Assembly-to-Cab Floor Installation Loosen cap screws (3) at base of seat frame. →NOTE: Cap screws must protrude approximately 6 mm (0.24 in.) above cab floor. [4] - Slide seat assembly rearward to disengage seat from cap screws (3) in slots (2) and remove seat from cab. [5] LEGEND: 3

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Section 18 page 24

Cap Screw (6 used)

TM12408-REPAIR TECHNICAL MANUAL

Section 18 - OPERATOR′S STATION

Group 1821: Seat and Seat Belt

Cap Screw Installation Remove cap screws (3) from cab floor and inspect. Replace if necessary. →NOTE: Cap screws must protrude approximately 6 mm (0.24 in.) above cab floor. [6] - Install cap screws (3) to threaded inserts in cab floor. [7] - Install seat assembly over cap screws (3) installed in cab floor. [8] - Slide seat assembly forward to engage cap screws (3) in slots (2). [9] - Tighten cap screws (3) to specification. Item

Measurement

Specification

Seat Assembly Cap Screw

Torque

37 N·m 27 lb.-ft.

[10] - Connect electrical connectors (X65 and X66). [11] - Turn battery disconnect switch to the ON position.

Seat Belt Remove and Install [1] LEGEND: 1 2 3

Seat Belt Buckle Seat Belt Cover

Buckle Installation

Belt Installation Remove cover from seat belt buckle (1), not shown, and remove cap screw. [2] - Remove cover from seat belt (2) and remove cap screw from seat belt (2). [3] - Repair or replace as necessary. [4] - Install seat belt buckle (1) to left side of seat and tighten to specification. Item

Measurement

Specification

Seat Belt Buckle Cap Screw

Torque

50 N·m 37 lb-ft

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Section 18 page 25

TM12408-REPAIR TECHNICAL MANUAL

Section 18 - OPERATOR′S STATION

Group 1830: Heating and Air Conditioning

[5] - Install cover over seat belt buckle (1), not shown. [6] - Install seat belt (2) and seat belt cover (3) to right side of seat and tighten to specification. Item

Measurement

Specification

Seat Belt Cap Screw

Torque

50 N·m 37 lb-ft

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Section 18 page 26

TM12408-REPAIR TECHNICAL MANUAL

Section 18 - OPERATOR′S STATION

Group 1830: Heating and Air Conditioning

Group 1830 - Heating and Air Conditioning R134a Refrigerant Cautions and Proper Handling CAUTION: Do not allow liquid refrigerant to contact eyes or skin. Liquid refrigerant will freeze eyes or skin on contact. Wear goggles, gloves, and protective clothing. If liquid refrigerant contacts eyes or skin, do not rub the area. Splash large amounts of cool water on affected area. Go to a physician or hospital immediately for treatment. Do not allow refrigerant to contact open flames or very hot surfaces such as electric welding arc, electric heating element, and lighted smoking materials. Do not heat refrigerant over 52°C (125°F) in a closed container. Heated refrigerant will develop high pressure which can burst the container. Keep refrigerant containers away from heat sources. Store refrigerant in a cool place. Do not handle damp refrigerant container with 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. The U.S. Environmental Protection Agency prohibits discharge of any refrigerant into the atmosphere, and requires that refrigerant be recovered using the approved recovery equipment. IMPORTANT: Use correct refrigerant recovery/recycling and charging stations. Do not use refrigerant, hoses, fittings, components or refrigerant oils intended for use with R12 refrigerant. Refrigerant recovery/recycling and charging stations for R12 and R134a refrigerants must not be interchanged. Systems containing R12 refrigerant use a different oil than systems using R134a. Certain seals are not compatible with both types of refrigerants. Charging Station

JT02046 [ Used with JT02050 Recovery/Recycling Station. JT02047 Recovery/Recycling and Charging Station can be substituted for JT02046 and JT02050 ]

Used for servicing air conditioning systems using R134a refrigerant. Number

<- Go to Section TOC

Name

Use

Refrigerant R134a

To charge air conditioning system.

Section 18 page 27

TM12408-REPAIR TECHNICAL MANUAL

Section 18 - OPERATOR′S STATION

Group 1830: Heating and Air Conditioning

R134a Refrigerant Oil Information Specifications SPECIFICATIONS New Compressor Oil Volume

180 mL 6.09 fl. oz.

Used Compressor and System Flushed Oil Volume

118.30 mL 4.0 fl. oz.

New Compressor Operating Oil Level Volume

45 mL 1.5 fl. oz.

Used Compressor Drained Oil Volume

45 mL 1.5 fl. oz.

Used Compressor Flushed Oil Volume

60 mL 2.0 fl. oz.

Evaporator Oil Volume

30 mL 1.0 fl. oz.

Condenser Oil Volume

30 mL 1.0 fl. oz.

Receiver-Dryer Oil Volume

30 mL 1.0 fl. oz.

Hose Oil Volume

3 mL per 30 cm (0.1 fl. oz. per ft)

Other Material OTHER MATERIAL TY16134 U.S. R134a Flushing Solvent TY22025 U.S. R134a Compressor Oil (8.5 fl. oz.)

CAUTION: Liquid refrigerant will freeze eyes or skin on contact. Wear goggles, gloves, and protective clothing. See R134a Refrigerant Cautions and Proper Handling . (Group 1830.) CAUTION: All new compressors are charged with a mixture of nitrogen and TY22101 (R134a) Refrigerant Oil. Wear safety goggles and discharge the compressor slowly to avoid possible injury. IMPORTANT: DO NOT leave system or R134a compressor oil containers open. Refrigerant 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 to eliminate accidental mixing of different oils. IMPORTANT: Avoid adding more oil than required, or maximum cooling will be reduced. Compressors can be divided into three categories when determining correct oil for system. New compressor from parts depot Used compressor removed from operation Compressor internally washed with flushing solvent [1] - When complete system, lines, and components are flushed, add correct amount of oil to the compressor as described. A new compressor from parts depot contains 180 mL (5.41 fl. oz.) of new oil. Item

Measurement

Specification

New Compressor

Oil Volume

180 mL 6.09 fl. oz.

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Section 18 page 28

TM12408-REPAIR TECHNICAL MANUAL

Section 18 - OPERATOR′S STATION

Group 1830: Heating and Air Conditioning

Drain oil from new compressor and return 118.30 mL (4.0 oz) of new oil to compressor. Used compressor removed from operation, oil drained, and compressor flushed requires 118.30 mL (4.0 oz) of new oil. Item

Measurement

Specification

Used Compressor and System Flushed

Oil Volume

118.30 mL 4.0 fl. oz.

[2] - When complete system was not flushed, add correct amount of oil for compressor plus amount of oil for each component that was serviced. New compressor from parts depot. Drain and return 45 mL (1.5 fl. oz.) of oil to compressor. Item

Measurement

Specification

New Compressor Operating Oil Level

Volume

45 mL 1.5 fl. oz.

Used compressor removed from operation and oil drained. Add 45 mL (1.5 fl. oz.) of new oil. Item

Measurement

Specification

Used Compressor Drained Oil

Volume

45 mL 1.5 fl. oz.

Used compressor removed from operation. Oil drained and flushed. Add 60 mL (2.0 fl. oz.) of new oil. Item

Measurement

Specification

Used Compressor Flushed Oil

Volume

60 mL 2.0 fl. oz.

Components listed below, which have been removed, drained, and flushed, require removal of compressor to determine correct oil. Use the following chart as a guide for adding oil to components: Item

Measurement

Specification

Evaporator Oil

Volume

30 mL 1.0 fl. oz.

Condenser Oil

Volume

Receiver-Dryer Oil

Volume

30 mL 1.0 fl. oz. 30 mL 1.0 fl. oz.

Flushed Compressor Oil

Volume

60 mL 2.0 fl. oz.

Hose Oil

Volume

3 mL per 30 cm 0.1 fl. oz. per ft

→NOTE: Hoses = 3 mL per 30 cm (0.1 fl. oz. per ft). Approximate total length equals 600 cm (20 ft). If any section of hose is removed and flushed or replaced, measure length of hose and use the formula 3 mL per 30 cm (0.1 fl. oz. per ft ) to determine correct amount of oil to be added. Drain compressor oil into graduated container while rotating compressor shaft and record amount. If oil drained from a compressor removed from operation is very black or amount of oil is less than 6 mL (0.2 fl. oz.), perform the following and discard oil properly: Determine if R134a leakage was detected, remove component, and repair or replace component. Remove and discard receiver-dryer. Flush complete system with TY16134 Air Conditioning Flushing Solvent. Number ▪ TY16134 (us)

Name

Use

R134a Flushing Solvent

Flush R134a air conditioning system.

[3] - If component is serviceable, pour flushing solvent in ports and internally wash out old oil. Discard oil properly. [4] - Install a new receiver-dryer. See Receiver-Dryer Remove and Install . (Group 1830.) [5] - Install required amount of TY22025 Refrigerant Oil in compressor. Number

Name

Use

• TY22025 (us)

R134a Compressor Oil (8.5 fl. oz.)

Lubricate R134a air conditioning system.

<- Go to Section TOC

Section 18 page 29

TM12408-REPAIR TECHNICAL MANUAL

Section 18 - OPERATOR′S STATION

Group 1830: Heating and Air Conditioning

[6] - Connect all components. [7] - Evacuate and charge system. See R134a System Evacuate and see R134a System Charge . (Group 1830.)

<- Go to Section TOC

Section 18 page 30

TM12408-REPAIR TECHNICAL MANUAL

Section 18 - OPERATOR′S STATION

Group 1830: Heating and Air Conditioning

R134a Refrigerant Recovery/Recycling and Charging Station Installation Procedure IMPORTANT: Use only John Deere approved R134a refrigerant products. Mixing of products not compatible will cause system damage and contaminate recovery/recycling and charging station equipment. Care must be taken to identify and use equipment, refrigerant oil, and refrigerant designed only for R134a refrigerant systems. Refrigerant should be tested for type and purity before recovery/recycling or charging of system. JT02167A Prism Pro Refrigerant Identification Instrument should be used before any testing or repair to system is performed. Prism Pro Refrigerant Identification Instrument JT02167A To safely identify type and check purity of refrigerant prior to recovery, recycling and recharging of A/C systems. IMPORTANT: Use only John Deere approved refrigerant recovery/recycling and charging stations. DO NOT mix refrigerant, hoses, fittings, components, or refrigerant oils. [1] - Follow refrigerant cautions and proper handling procedures. See R134a Refrigerant Cautions and Proper Handling . (Group 1830.) [2] -

Charging Station Installation LEGEND: 1 2

Refrigerant Recovery/Recycling and Charging Station Blue Hose

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Section 18 page 31

TM12408-REPAIR TECHNICAL MANUAL

Section 18 - OPERATOR′S STATION

Group 1830: Heating and Air Conditioning

3 Red Hose 4 Low Pressure Charge Port 5 High Pressure Charge Port Close both high-side and low-side valves on refrigerant recovery/recycling and charging station (1). HFC134a Deluxe Recovery/Recycling and Charging Station JT02045 Used to remove refrigerant from system. Charging Station JT02046 [ Used with JT02050 Recovery and Recycling Station. ]

Servicing air conditioning system using R134a refrigerant. Recovery and Recycling Station JT02050 [ Used with JT02046 Charging Station. ]

Servicing air conditioning system using R134a refrigerant. [3] - Remove cap from low pressure charge port (4) and connect blue hose (2). [4] - Remove cap from high pressure charge port (5) and connect red hose (3).

R134a Refrigerant Recover IMPORTANT: Use correct refrigerant recovery/recycling and charging stations. DO NOT mix refrigerant, hoses, fittings, components, or refrigerant oils. [1] - Follow refrigerant cautions and proper handling procedures. See R134a Refrigerant Cautions and Proper Handling . (Group 1830.) [2] - Run air conditioning system for 3 minutes to help in recovery process. Turn air conditioning system off before proceeding with recovery steps. [3] - With engine OFF, identify refrigerant type using JT02167A Prism Pro Refrigerant Identification Instrument. Prism Pro Refrigerant Identification Instrument JT02167A To safely identify type and check purity of refrigerant prior to recovery, recycling and recharging of A/C systems. [4] - Connect refrigerant recovery system. See R134a Refrigerant Recovery/Recycling and Charging Station Installation Procedure . (Group 1830.) [5] - Follow manufacturer’s instructions when using the refrigerant recovery/recycling and charging station.

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Section 18 page 32

TM12408-REPAIR TECHNICAL MANUAL

Section 18 - OPERATOR′S STATION

Group 1830: Heating and Air Conditioning

Air Conditioning System Flush and Purge This procedure should only be performed on machines that have had a catastrophic air conditioner compressor malfunction. Cleanup procedure must be performed prior to returning machine air conditioning system back into service. CAUTION: Liquid refrigerant will freeze eyes or skin on contact. Wear goggles, gloves, and protective clothing. See Refrigerant Cautions and Proper Handling . (Group 1830.) →NOTE: Anytime air conditioning system is discharged, a new receiver-dryer must be installed. [1] - Recover R134a refrigerant. See R134a Refrigerant Recover . (Group 1830.) [2] IMPORTANT: DO NOT attempt to flush through compressor or receiver-dryer. Flushing solution may not be completely removed from these components and could cause system malfunction. Remove air conditioner compressor. See Compressor Remove and Install . (Group 1830.) [3] →NOTE: Anytime air conditioning system is discharged, a new receiver-dryer and must be installed. Remove and discard receiver-dryer. See Receiver-Dryer Remove and Install . (Group 1830.) [4] - Remove and discard expansion valve. See Expansion Valve Remove and Install . (Group 1830.) [5] - Divide system into condenser and evaporator circuits, including hoses. Flush and purge procedure is the same for both circuits. [6] - Flush and purge air conditioner condenser circuit: Connect flusher outlet hose to inlet end of air conditioner compressor discharge line using adapter from JT02098 Air Conditioning Fitting Kit. Air Conditioning Flushing Kit JT02098 Adapter to connect flusher outlet hose to inlet end of compressor discharge line. Connect hoses at continuos loop condenser with an adapter from JT02098 Air Conditioning Fitting Kit. Air Conditioning Flushing Kit JT02098 Adapter to connect hoses at continuos loop condenser. Attach a return hose and aerator nozzle to end of receiver-dryer inlet hose using JT03197 Reducer. Put nozzle in container to collect flushing solvent. Reducer JT03197 Attach a return hose and aerator nozzle to outlet end of receiver-dryer inlet hose. Add TY25601 ACC-Flush-II Flushing Solution to system with JT02075 Air Conditioning Flusher using fittings from JT02098 Air Conditioning Fitting Kit. Number ▪ TY25601 (us)

Name

Use

ACC-Flush-II Flushing Solution

Used to flush R134a air conditioning system.

Air Conditioning Flusher JT02075 To be used with air conditioning flushing kit. <- Go to Section TOC

Section 18 page 33

TM12408-REPAIR TECHNICAL MANUAL

Section 18 - OPERATOR′S STATION

Group 1830: Heating and Air Conditioning

Air Conditioning Flushing Kit JT02098 Flush air conditioning system and adjust expansion valve. Fill air conditioning system flusher tank with 4 L (1 gal.) of solvent and tighten all connections. Item

Measurement

Specification

Air Conditioning System Flusher Tank

Capacity

4L 1 gal.

→NOTE: Air pressure must be at least 620 kPa (6.2 bar) (90 psi) for flushing and purging. Item

Measurement

Specification

Air Conditioning System

Air Pressure (minimum for flushing and purging)

620 kPa 6.2 bar 90 psi

Connect supply line of moisture-free compressed air or dry nitrogen to flusher air valve. Open air valve to force flushing solvent into air conditioner circuit. Flusher tank is empty when hose pulsing stops. Disconnect flusher tank and connect to flushed circuit discharge hose end. IMPORTANT: Additional flushing cycles are required if system is heavily contaminated with burned oil or metal particles. Fill flusher tank and repeat flushing procedure in reverse direction. →NOTE: Purging takes 10—12 minutes to thoroughly remove solvent. Disconnect hose from aeration nozzle to check circuit for solvent. Hold discharge hose close to a piece of cardboard. Continue purging until cardboard is dry, and proceed to next step. Flush and purge air conditioner evaporator: a. Remove evaporator. See Heater Core and Evaporator Core Remove and Install . (Group 1830.) b. Follow the same flush and purge procedure used on condenser, using adapters from JT02098 Air Conditioning Fitting Kit. Air Conditioning Flushing Kit JT02098 Adapter to connect flusher outlet hose to inlet end of compressor discharge line. c. Install evaporator and proceed to next step. See Heater Core and Evaporator Core Remove and Install . (Group 1830.) [7] →NOTE: Anytime air conditioning system is discharged, a new receiver-dryer and accumulator (if equipped) must be installed. Install new receiver-dryer. See Receiver-Dryer Remove and Install . (Group 1830.) [8] - Install new expansion valve. See Expansion Valve Remove and Install . (Group 1830.) [9] - Install new compressor. See Compressor Remove and Install . (Group 1830.) [10] - Add required R134a refrigerant oil to air conditioning system. See R134a Refrigerant Oil Information . (Group 1830.) [11] - Evacuate and charge air conditioning system. See R134a System Evacuate and see R134a System Charge . (Group 1830.)

R134a System Evacuate CAUTION: Liquid refrigerant will freeze eyes or skin on contact. Wear goggles, gloves, and protective clothing. See R134a Refrigerant Cautions and Proper Handling . (Group 1830.) <- Go to Section TOC

Section 18 page 34

TM12408-REPAIR TECHNICAL MANUAL

Section 18 - OPERATOR′S STATION

Group 1830: Heating and Air Conditioning

[1] - Connect refrigerant recovery system. See R134a Refrigerant Cautions and Proper Handling . (Group 1830.) [2] - Open low-side and high-side valves on refrigerant recovery/recycling and charging station. [3] - Follow manufacturer’s instructions and evacuate system. [4] →NOTE: 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. Evacuate system until low-side gauge registers 98 kPa (980 mbar) (29 in. Hg) vacuum. Item

Measurement

Specification

Evacuate System

Vacuum

98 kPa 980 mbar 29 in. Hg

If specified vacuum cannot be obtained in 15 minutes, test the system for leaks. See Refrigerant Leak Test . (Group 9031-25.) [5] - When vacuum reaches specification, close low-side and high-side valves. Turn vacuum pump off. [6] - If vacuum decreases more than specification in 5 minutes, the system has a leak. Item

Measurement

Specification

Evacuate System

Vacuum

3.4 kPa 34 mbar 1 in. Hg

[7] - Repair leak. [8] - Evacuate system for 30 minutes after 98 kPa (980 mbar) (29 in. Hg) vacuum is reached. [9] - Close low-side and high-side valves. Stop evacuation. [10] - Charge air conditioning system. See R134a System Charge . (Group 1830.)

R134a System Charge IMPORTANT: Use only John Deere approved refrigerant recovery/recycling and charging stations. DO NOT mix refrigerant, hoses, fittings, components or refrigerant oils. [1] - Follow refrigerant cautions and proper handling procedures. See R134a Refrigerant Cautions and Proper Handling . (Group 1830.) [2] - Identify refrigerant type using JT02167A Prism Pro Refrigerant Identification Instrument. Prism Pro Refrigerant Identification Instrument JT02167A To safely identify type and check purity of refrigerant prior to recovery, recycling and recharging of A/C systems. [3] - Connect R134a Refrigerant Recovery/Recycling and Charging Station. See R134a Refrigerant Recovery/Recycling and Charging Station Installation Procedure . (Group 1830.) [4] - Evacuate system. See R134a System Evacuate . (Group 1830.) [5] -

<- Go to Section TOC

Section 18 page 35

TM12408-REPAIR TECHNICAL MANUAL

Section 18 - OPERATOR′S STATION

Group 1830: Heating and Air Conditioning

→NOTE: Before beginning to charge air conditioning system, the following conditions must exist: Engine STOPPED, pump must be capable of pulling at least 96.9 kPa (969 mbar) (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. Item

Measurement Specification

Evacuate System Vacuum

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

Follow manufacturer’s instructions and charge system. [6] - Add 1.8 kg (3.97 lb) refrigerant to system. Item

Measurement

Specification

Air Conditioning System Refrigerant

Capacity

1.8 kg 3.97 lb

[7] - Check air conditioning system for proper function. See Air Conditioner and Heater Operational Checks . (Group 9031-25.)

<- Go to Section TOC

Section 18 page 36

TM12408-REPAIR TECHNICAL MANUAL

Section 18 - OPERATOR′S STATION

Group 1830: Heating and Air Conditioning

Compressor Remove and Install [1] - Prepare Machine for Maintenance . (Operator’s Manual.) [2] CAUTION: Liquid refrigerant will freeze eyes or skin on contact. Wear goggles, gloves, and protective clothing. See R134a Refrigerant Cautions and Proper Handling . (Group 1830.) Recover refrigerant. See R134a Refrigerant Recover . (Group 1830.) [3] - Remove serpentine belt. See Serpentine Belt Remove and Install . (Group 0400.) [4] - Remove discharge line (1) and suction line (2) from air conditioner compressor (4). To prevent contamination of air conditioning system, close all openings using caps and plugs. LEGEND: 1 Discharge Line 2 Suction Line 3 Cap Screw (3 used) 4 Air Conditioner Compressor Y22 Air Conditioner Compressor Clutch

Air Conditioner Compressor Removal [5] - Disconnect air conditioner compressor clutch (Y22) connector. See Front Frame Harness (W2) Component Location . (Group 9015-10.) [6] - Remove cap screws (3) and remove air conditioner compressor. [7] - Inspect, repair, or replace parts as necessary. [8] - Before installing air conditioner compressor, check oil. See R134a Refrigerant Oil Information . (Group 1830.) [9] - Install air conditioner compressor. Install cap screws. [10] - Connect air conditioner compressor clutch (Y22). See Front Frame Harness (W2) Component Location . (Group 9015-10.) [11] IMPORTANT: Always use new O-rings and seals. Damaged or used O-rings and seals will leak. Using new O-rings, connect discharge and suction lines. [12] - Install serpentine belt. [13] - Install serpentine belt covers. [14] - Evacuate system. See R134a System Evacuate . (Group 1830.) [15] - Charge system. See R134a System Charge . (Group 1830.)

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Section 18 page 37

TM12408-REPAIR TECHNICAL MANUAL

Section 18 - OPERATOR′S STATION

Group 1830: Heating and Air Conditioning

Condenser Remove and Install [1] - Prepare Machine for Maintenance . (Operator’s Manual.) [2] CAUTION: Liquid refrigerant will freeze eyes or skin on contact. Wear goggles, gloves, and protective clothing. See R134a Refrigerant Cautions and Proper Handling . (Group 1830.) →NOTE: It is not necessary to remove condenser to flush and purge system. See Air Conditioning System Flush and Purge . (Group 1830.) Recover refrigerant. See R134a Refrigerant Recover . (Group 1830.) [3] - Open hood and left-hand fan door. [4] -

Condenser Lines

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Section 18 page 38

TM12408-REPAIR TECHNICAL MANUAL

Section 18 - OPERATOR′S STATION

Group 1830: Heating and Air Conditioning

Condenser Removal LEGEND: 1 Condenser-to-Receiver-Dryer Line 2 Compressor-to-Condensor Line 3 Cap Screw (4 used) 4 Condenser Tag and disconnect condenser-to-receiver dryer line (1) and compressor-to-condenser line (2). To prevent contamination of air conditioning system, close all openings using caps and plugs. [5] - Remove cap screws (3) and remove condenser (4). [6] - Before installing condenser, add refrigerant oil. See R134a Refrigerant Oil Information . (Group 1830.) [7] - Install condenser to machine. [8] IMPORTANT: Always use new O-rings and seals. Damaged or used O-rings and seals will leak. Using new O-rings, connect condenser-to-receiver dryer line and compressor-to-condenser line. [9] - Evacuate system. See R134a System Evacuate . (Group 1830.) [10] - Charge system. See R134a System Charge . (Group 1830.)

High/Low Pressure Switch Remove and Install [1] - Prepare Machine for Maintenance . (Operator’s Manual.) [2] <- Go to Section TOC

Section 18 page 39

TM12408-REPAIR TECHNICAL MANUAL

Section 18 - OPERATOR′S STATION

Group 1830: Heating and Air Conditioning

LEGEND: 1 Cap Screw (2 used) 2 Air Conditioner Unit Cover

Air Conditioner Unit Cover Remove cap screws (1) and open air conditioner unit cover (2) to access the air conditioner high/low pressure switch. [3] CAUTION: Liquid refrigerant will freeze eyes or skin on contact. Wear goggles, gloves, and protective clothing. See R134a Refrigerant Cautions and Proper Handling . (Group 1830.) →NOTE: It is not necessary to recover the system. A valve prevents the system from discharging when switch is removed. LEGEND: B27 Air Conditioner High/Low Pressure Switch A31 Air Conditioner High/Low Pressure Switch Circuit J01B Air Conditioner High/Low Pressure Switch Circuit

High/Low Pressure Switch Disconnect air conditioner high/low pressure switch circuit (A31) and air conditioner high/low pressure switch circuit (J01B). See Cab Harness (W3) Wiring Diagram . (Group 9015-10.) [4] - Remove air conditioner high/low pressure switch (B27) and install new switch. [5] - Connect air conditioner high/low pressure switch circuit (A31) and air conditioner high/low pressure switch circuit (J01B). [6] - Close and secure air conditioner unit cover.

Receiver-Dryer Remove and Install [1] - Prepare Machine for Maintenance . (Operator’s Manual.) [2] - Open hood and right-hand side fan door to access receiver-dryer. [3] CAUTION: Liquid refrigerant freezes eyes or skin on contact. Wear goggles, gloves, and protective clothing. See R134a Refrigerant Cautions and Proper Handling . (Group 1830.) <- Go to Section TOC

Section 18 page 40

TM12408-REPAIR TECHNICAL MANUAL

Section 18 - OPERATOR′S STATION

Group 1830: Heating and Air Conditioning

Recover refrigerant. See Recover R134a Refrigerant . (Group 1830.) [4] LEGEND: 1 Condenser-to-Receiver-Dryer Line 2 Receiver-Dryer-to-Expansion Valve Line 3 Clamp (2 used) 4 Receiver-Dryer

Receiver-Dryer Disconnect lines (1 and 2). To prevent contamination of air conditioning system, close all openings using caps and plugs. [5] - Loosen clamps (3) to remove receiver-dryer (4). [6] - Before installing new receiver-dryer, add refrigerant oil. See R134a Refrigerant Oil Information . (Group 1830.) [7] - Install new receiver-dryer. Tighten clamps. [8] IMPORTANT: Always use new O-rings and seals. Damaged or used O-rings and seals leak. Using new O-rings, connect and tighten condenser-to-receiver-dryer line and receiver-dryer-to-expansion valve line. [9] - Evacuate system. See Evacuate R134a System . (Group 1830.) [10] - Charge system. See Charge R134a System . (Group 1830.) [11] - Close hood and right-hand side fan door.

Expansion Valve Remove and Install [1] - Prepare Machine for Maintenance . (Operator’s Manual.) [2] LEGEND: 1 Cap Screw (2 used) 2 Air Conditioner Unit Cover

Air Conditioner Unit Cover Remove cap screws (1) and open air conditioner unit cover (2) to access air conditioner unit. [3] <- Go to Section TOC

Section 18 page 41

TM12408-REPAIR TECHNICAL MANUAL

Section 18 - OPERATOR′S STATION

Group 1830: Heating and Air Conditioning

CAUTION: Liquid refrigerant will freeze eyes or skin on contact. Wear goggles, gloves, and protective clothing. See R134a Refrigerant Cautions and Proper Handling . (Group 1830.) Recover refrigerant. See R134a Refrigerant Recover . (Group 1830.) [4] - Remove side panel from air conditioner unit. [5] LEGEND: 3

Expansion Valve

Expansion Valve Disconnect lines and remove expansion valve (3). Close all openings using caps and plugs. [6] IMPORTANT: Always use new O-rings and seals. Damaged or used O-rings and seals will leak. Install new expansion valve and connect lines. [7] - Install air conditioner unit side panel. [8] - Evacuate system. See R134a System Evacuate . (Group 1830.) [9] - Charge system. See R134a System Charge . (Group 1830.) [10] - Close and secure air conditioner unit cover.

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Section 18 page 42

TM12408-REPAIR TECHNICAL MANUAL

Section 18 - OPERATOR′S STATION

Group 1830: Heating and Air Conditioning

Heater Core and Evaporator Core Remove and Install [1] - Remove air conditioner box from machine. a. Follow refrigerant cautions and proper handling procedures. See R134a Refrigerant Cautions and Proper Handling . (Group 1830.) b. Recover refrigerant. See R134a Refrigerant Recover . (Group 1830.) c. Drain radiator. See Drain, Flush, and Refill Engine Cooling System . (Operator’s Manual.) d. Disconnect wiring connectors and air ducts from air conditioner box. e. Disconnect refrigerant lines, heater hoses, and drain tubes. Close all openings using caps and plugs. f. Tilt cab to access air conditioner box mounting fasteners. See Tilt Cab . (Operator’s Manual). g. Remove air conditioner box from right-side compartment. [2] - Remove heater core (3) and evaporator core (2) from air conditioner box. a. Remove side panel from air conditioner box. b. Disconnect freeze control switch (4) from top panel. Remove top panel from air conditioner box. c. Disconnect evaporator lines from expansion valve (6). Disconnect heater hoses from heater core. Close all openings using caps and plugs. d. Remove heater core and evaporator core as an assembly. e. Remove clips to disconnect evaporator core from heater core. [3] -

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Section 18 page 43

TM12408-REPAIR TECHNICAL MANUAL

Section 18 - OPERATOR′S STATION

Group 1830: Heating and Air Conditioning

Heater Core and Evaporator Core Removal (S.N. —664056) LEGEND: 1 Air Filter 2 Evaporator Core 3 Heater Core 4 Freeze Control Switch 5 Defrost Actuator 6 Expansion Valve 7 Floor Vent Actuator 8 Heater Control Valve 9 Blower 10 Recirculating Damper 11 Recirculation Vent Actuator Repair or replace parts as necessary. [4] -

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Section 18 page 44

TM12408-REPAIR TECHNICAL MANUAL

Section 18 - OPERATOR′S STATION

Group 1830: Heating and Air Conditioning

Heater Core and Evaporator Core Removal (S.N. 664057— ) LEGEND: 1 Air Filter 2 Evaporator Core 3 Heater Core 4 Freeze Control Switch 5 Defrost Actuator 6 Expansion Valve 7 Floor Vent Actuator 8 Heater Control Valve 9 Blower 10 Recirculating Damper 11 Recirculation Vent Actuator Return cab to original position. Tilt cab as required to access fastener locations. [5] - Install heater and evaporator cores in air conditioner box. a. Before installing evaporator core, add refrigerant oil. See R134a Refrigerant Oil Information . (Group 1830.) <- Go to Section TOC

Section 18 page 45

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Section 18 - OPERATOR′S STATION

Group 1830: Heating and Air Conditioning

b. Install clips to connect evaporator core to heater core. c. Install heater core and evaporator core in air conditioner box as an assembly. d. Connect evaporator lines to expansion valve. Connect heater hoses to heater core. e. Install top panel. Connect freeze control switch to top panel. f. Connect all electrical connectors. g. Install side panel on air conditioner box. [6] - Install air conditioner box in machine. a. Connect air ducts. Connect electrical connectors. b. Connect air conditioner lines, heater hoses, and drain tubes. c. Fill radiator. See Drain, Flush, and Refill Engine Cooling System . (Operator’s Manual.) d. Evacuate system. See R134a System Evacuate . (Group 1830.) e. Charge system. See R134a System Charge . (Group 1830.)

Freeze Control Switch Remove and Install [1] - Remove air conditioner box from machine. See Heater Core and Evaporator Core Remove and Install . (Group 1830.) [2] - Remove side panel from air conditioner box. [3] LEGEND: 1 Evaporator Core 2 Freeze Control Switch

Freeze Control Switch (S.N. –664056) Disconnect freeze control switch (2) from top panel. Disconnect wire leads. [4] - Disconnect top panel from air conditioner box. Lift top panel enough to remove capillary tube from evaporator core (1). [5] - Inspect and replace parts as necessary. [6] - Install capillary tube in evaporator core. [7] - Connect wire leads to freeze control switch. Install top panel. Connect freeze control switch to top panel. [8] - Install side panel. [9] - Install air conditioner box in machine. See Heater Core and Evaporator Core Remove and Install . (Group 1830.)

Heater Control Valve Remove and Install

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Section 18 page 46

TM12408-REPAIR TECHNICAL MANUAL

Section 18 - OPERATOR′S STATION

Group 1830: Heating and Air Conditioning

LEGEND: 1 Electrical Connector 2 Upper Heater Hose Clamp Location 3 Upper Heater Hose (2 used) 4 Heater Control Valve

Heater Control Valve [1] - Turn battery disconnect switch to the OFF position. See Battery Disconnect Switch and Battery Circuit Breakers . (Operator’s Manual.) [2] - Lift air conditioner box access panel. [3] - Remove air conditioner box side panel. [4] - Disconnect electrical connector (1) from heater control valve. [5] - Clamp upper heater hose (2) on outside of air conditioner box. [6] - Remove upper heater hose (3) and heater control valve (4). [7] - Inspect and test heater control valve as required. [8] - Install heater control valve and hoses. [9] - Remove clamps from heater hoses. [10] - Connect electrical connector to heater control valve. [11] - Install air conditioner box side panel. [12] - Close air conditioner box access panel. [13] - Check coolant level. See Drain, Flush, and Refill Engine Cooling System . (Operator’s Manual.) [14] - Turn battery disconnect switch to the ON position. See Battery Disconnect Switch and Battery Circuit Breakers . (Operator’s Manual.)

Heater Control Valve Leak Check [1] - Before removal inspect valve for any cracks, leakage, or pinched lines. [2] - Remove heater control valve. See Heater Control Valve Remove and Install . (Group 1830.) [3] - After removal, perform a visual inspection of valve for cracks, debris, and restricted movement of the valve. [4] →NOTE: The heater control valve is serviced as an assembly. Replace heater control valve if valve is damaged or leaks. <- Go to Section TOC

Section 18 page 47

TM12408-REPAIR TECHNICAL MANUAL

Section 18 - OPERATOR′S STATION

Group 1830: Heating and Air Conditioning

[5] - Install heater control valve. See Heater Control Valve Remove and Install . (Group 1830.)

Blower Motor Assembly Remove and Install LEGEND: 1 Heater Control Valve 2 Lower Heater Hose 3 Electrical Connector 4 Cap Screw (3 used) 5 Blower Motor Assembly

Blower Motor [1] - Turn battery disconnect switch to the OFF position. [2] - Remove heater control valve (1). See Heater Control Valve Remove and Install . (Group 1830.) [3] - Clamp lower heater hose on outside of air conditioner box. [4] - Remove lower heater hose (2). [5] - Disconnect electrical connector (3). [6] - Remove cap screws (4). [7] - Remove blower motor assembly (5). [8] - Repair or replace parts as necessary. [9] - Install blower motor assembly. [10] - Install cap screws. [11] - Install heater control valve. See Heater Control Valve Remove and Install . (Group 1830.) [12] - Install lower heater hose. [13] - Remove clamp from lower heater hose. [14] - Connect electrical connector. [15] - Turn battery disconnect switch to the ON position.

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Section 18 page 48

TM12408-REPAIR TECHNICAL MANUAL

Section 18 - OPERATOR′S STATION

Group 1830: Heating and Air Conditioning

Mode Door Remove and Install REMOVAL [1] - Park and prepare for service safely. See Park and Prepare for Service Safely . (Group 0001.) [2] LEGEND: 1 Cap Screw (11 used) 2 Outer Cover 3 Cap Screw (1 used) 4 Cap Screw (3 used) 5 Bracket 6 Cap Screw (2 used) 7 Cap Screw (6 used) 8 Inner Right Cover

Outer Cover

Bracket

Inner Right Cover Remove cap screws (1) and remove outer cover (2). [3] - Loosen cap screw (3), remove cap screws (4), and remove outer cover mounting bracket (5). <- Go to Section TOC

Section 18 page 49

TM12408-REPAIR TECHNICAL MANUAL

SHEET METAL AND STYLING

(g) by Belgreen v2.0

[4] - Loosen cap screws (6), remove cap screws (7), and remove inner right cover (8) to access air conditioner unit. [5] LEGEND: 12 13 14 15 16 17 18

Nut (3 used) Mode Door Actuator Cap Screw (5 used) Washer (5 used) Access Panel Mode Door Duct

Mode Door Remove Remove nuts (12), mode door actuator (13), cap screws and washers (14 and 15), access panel (16), and mode door (17) from duct (18). [6] - Repair or replace parts as necessary.

INSTALLATION Installation is reverse of removal procedure.

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Section 19 page 50

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TM12408-REPAIR TECHNICAL MANUAL

(g) by Belgreen v2.5

Section 19 - SHEET METAL AND STYLING Table of contents Group 1910 - Hood or Engine Enclosure .............................................................................................. 1 Hood Remove and Install ...................................................................................................................... 1 Hood Adjust .......................................................................................................................................... 3 Engine Service Door Remove and Install .............................................................................................. 6 Left Fan Grille Remove and Install ........................................................................................................ 8 Right Fan Grille Remove and Install .................................................................................................... 10 Group 1927 - Fenders ............................................................................................................................ 12 Fender Remove and Install ................................................................................................................. 12

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TM12408-REPAIR TECHNICAL MANUAL

Section 19 - SHEET METAL AND STYLING

Group 1910: Hood or Engine Enclosure

Group 1910 - Hood or Engine Enclosure Hood Remove and Install Specifications SPECIFICATIONS 82 kg 180 lb.

Hood Weight (approximate)

Strut and Hinge LEGEND: 1 2 3

Hinge (2 used) Nut (2 used) Strut (2 used)

[1] - Prepare Machine for Maintenance . (Operator’s Manual.) [2] - Open engine service door. [3] CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device. Item

Measurement

Specification

Hood

Weight (approximate)

82 kg 180 lb.

Open hood. Secure hood with hoist and straps. [4] - Remove nuts (2) and struts (3). [5] - Close hood. DO NOT LATCH. [6] - Disconnect hinges (1). <- Go to Section TOC

Section 19 page 1

TM12408-REPAIR TECHNICAL MANUAL

Section 19 - SHEET METAL AND STYLING

Group 1910: Hood or Engine Enclosure

[7] - Remove hood. [8] - Repair or replace as necessary. [9] - Secure hood with hoist. [10] - Install hood to machine. [11] - Connect hinges (1). [12] - Install struts (3) and nuts (2). [13] - Adjust hood latch. See Hood Adjust . (Group 1910.)

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Section 19 page 2

TM12408-REPAIR TECHNICAL MANUAL

Section 19 - SHEET METAL AND STYLING

Group 1910: Hood or Engine Enclosure

Hood Adjust Specifications SPECIFICATIONS 13 mm 0.5 in.

Stopper Tip-to-Hood Lower Surface Initial Setup Distance

[1] LEGEND: 1

Catch Pin Assembly

Catch Pin Assembly Remove catch pin assembly (1) from machine. Clean catch pin and strike plate. [2] -

Hood Latch Linkage LEGEND: 1 2 3 <- Go to Section TOC

Return Spring Latch Arm Catch Pin Section 19 page 3

TM12408-REPAIR TECHNICAL MANUAL

Section 19 - SHEET METAL AND STYLING

Group 1910: Hood or Engine Enclosure

4 Linkage Rod 5 Latch Release Lever Adjust linkage rod (4) so latch release lever (5) and latch arm (2) move smoothly through full range of motion. Ensure latch arm (2) returns to engaged position around catch pin (3) when lever is released. Replace return spring (1), if necessary. Clean latch arm and catch pin tube. [3] LEGEND: 1 2

Stopper (2 used) Nut (2 used)

Stopper Adjust stoppers (1) to initial setup specification. Item

Measurement

Specification

Stopper Tip-to-Hood Lower Surface Initial Setup

Distance

13 mm 0.5 in.

[4] LEGEND: 1 Hinge Pivot Cap Screw (4 used) 2 Hood-Mounted Flange (2 used) 3 Frame-Mounted Flange (2 used)

Hinge Loosen hinge pivot cap screws (1) enough to allow adjustment of flanges (2 and 3), but ensure that there is no gap between contact surfaces. [5] -

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Section 19 page 4

TM12408-REPAIR TECHNICAL MANUAL

Section 19 - SHEET METAL AND STYLING

Group 1910: Hood or Engine Enclosure

LEGEND: 1

Hood-to-Grille Gap

Hood Left-Right Adjustment Lower hood. Adjust hood left-to-right alignment. Hood-to-grille gaps (1) should be equal on left and right sides. [6] - Raise hood slowly. Ensure that hood does not shift left or right. Tighten hood-mounted flanges of hinges. [7] - Lower hood. Adjust hood front-to-rear alignment. Ensure that weather seal at hood rear edge aligns with mating surface on front of cab. [8] - Raise hood. Install catch pin assembly. Tighten hardware enough to eliminate gaps between contact surfaces, but ensure that assembly is loose enough on mounting surface to allow adjustment. Move assembly to centered position. [9] - Lubricate latch linkage, latch arm, hinges, strike plate, and catch pin with multipurpose grease or dry graphite as necessary. [10] - Lower hood. Latch arm should engage catch pin. [11] - Pull latch release lever. Latch should move smoothly with slight resistance. Latch arm should release catch pin. [12] - Raise hood slowly. Ensure that catch pin assembly does not shift out of alignment. Tighten catch pin assembly. [13] - Lower hood and engage latch. Examine hood-to-frame contact. Weather seal surfaces should make even contact. Stoppers should contact frame, but not be excessively compressed. [14] - Adjust height of catch pin and stoppers, if necessary, and recheck. Tighten nuts on catch pin and stoppers when adjustment is complete.

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Section 19 page 5

TM12408-REPAIR TECHNICAL MANUAL

Section 19 - SHEET METAL AND STYLING

Group 1910: Hood or Engine Enclosure

Engine Service Door Remove and Install Specifications SPECIFICATIONS 44 kg 97 lb.

Engine Service Door Weight (approximate)

[1] - Park and prepare machine for service. See Prepare Machine for Maintenance . (Group 0001.) [2] - Disconnect work light electrical connector (E21). LEGEND: 1 Door Strut 2 Hinge Plate Cap Screw (4 used) E21 Work Light Electrical Connector

Engine Service Door [3] - Support door with hoist and lifting straps.

Engine Service Door Supported [4] - Remove door strut (1) from door. [5] - Mark location of door hinge plate cap screws (2) and washers on mounting plate. [6] CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device.

Item

Measurement

Specification

Engine Service Door

Weight (approximate)

44 kg 97 lb.

Support engine service door with hoist. [7] - Remove engine hinge plate cap screws (2). <- Go to Section TOC

Section 19 page 6

TM12408-REPAIR TECHNICAL MANUAL

Section 19 - SHEET METAL AND STYLING

Group 1910: Hood or Engine Enclosure

[8] - Repair or replace parts as necessary. [9] - Install door hinge plate cap screws (2). [10] - Connect door strut (1) to door. [11] - Connect work light electrical connector (E21). [12] - Turn battery disconnect switch to the ON position.

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Section 19 page 7

TM12408-REPAIR TECHNICAL MANUAL

Section 19 - SHEET METAL AND STYLING

Group 1910: Hood or Engine Enclosure

Left Fan Grille Remove and Install Specifications SPECIFICATIONS 25 kg 55 lb.

Fan Grille Weight (approximate)

[1] - Park and prepare machine for service. See Prepare Machine for Maintenance . (Group 0001.) [2] - Disconnect headlights (E7 and E8) and turn signal (E6) electrical connectors. LEGEND: E6 Turn Signal Electrical Connector E7 Headlight Electrical Connector E8 Headlight Electrical Connector

Electrical Connectors [3] - Remove inner grille-to-hinge frame bracket cap screws (2). LEGEND: 1 Hex Head Cap Screw (17 used) 2 Grille-to-Hinge Frame Bracket Cap Screw (3 used)

Left Fan Grille [4] - Remove grille-to-engine door hex head cap screws (1). Leave top right and left screws in place. [5] CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device. Support grille with appropriate device. Item

Measurement

Specification

Fan Grille

Weight (approximate)

25 kg 55 lb.

[6] - Remove remaining hex head cap screws (1). <- Go to Section TOC

Section 19 page 8

TM12408-REPAIR TECHNICAL MANUAL

Section 19 - SHEET METAL AND STYLING

Group 1910: Hood or Engine Enclosure

[7] - Repair or replace parts as necessary. [8] Support grille with appropriate device and install top left and right hex head cap screws (1). [9] - Remove hoist and install remaining hex head cap screws (1). [10] - Connect headlights (E7 and E8) and turn signal (E6) electrical connectors. [11] - Install inner grille-to-hinge frame bracket cap screws (2). [12] - Remove articulation lock bar.

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Section 19 page 9

TM12408-REPAIR TECHNICAL MANUAL

Section 19 - SHEET METAL AND STYLING

Group 1910: Hood or Engine Enclosure

Right Fan Grille Remove and Install Specifications SPECIFICATIONS 25 kg 55 lb.

Right Fan Grille Weight (approximate)

[1] - Park and prepare machine for service. See Prepare Machine for Maintenance . (Group 0001.) [2] - Disconnect headlights (E4 and E5) and turn signal (E3) electrical connectors. LEGEND: E3 Turn Signal Electrical Connector E4 Headlight Electrical Connector E5 Headlight Electrical Connector

Headlight Electrical Connectors [3] - Remove inner grille-to-hinge frame bracket cap screws (2). LEGEND: 1 Hex Head Cap Screw (17 used) 2 Grille-to-Hinge Frame Bracket Cap Screw (3 used)

Right Fan Grille [4] - Remove grille-to-engine door hex head cap screws (1). Leave top right and left screws in place. [5] CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device. Support grille with appropriate device. Item

Measurement

Specification

Right Fan Grille

Weight (approximate)

25 kg 55 lb.

[6] - Remove remaining hex head cap screws (1). <- Go to Section TOC

Section 19 page 10

TM12408-REPAIR TECHNICAL MANUAL

Section 19 - SHEET METAL AND STYLING

Group 1927: Fenders

[7] - Repair or replace parts as necessary. [8] Support grille with appropriate device and install top left and right hex head cap screws (1). [9] - Remove hoist and install remaining hex head cap screws (1). [10] - Connect headlights (E4 and E5) and turn signal (E3) electrical connectors. [11] - Install inner grille-to-hinge frame bracket cap screws (2). [12] - Remove articulation lock bar.

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Section 19 page 11

TM12408-REPAIR TECHNICAL MANUAL

Section 19 - SHEET METAL AND STYLING

Group 1927: Fenders

Group 1927 - Fenders Fender Remove and Install Specifications SPECIFICATIONS 158 kg 348 lb.

Fender Weight (approximate)

[1] - Prepare Machine for Maintenance . (Group 0001.) [2] - Open hood and fan door at side that fender is to be removed. [3] →NOTE: Right side fender shown; left side fender similar. LEGEND: 1 2

Cap Screw (3 used) Cap Screw (5 used)

Front Mounting Cap Screws Remove cap screws (1) at front of fender. [4] - Loosen but do not remove cap screws (2) at inside of fender. [5] LEGEND: 2 3

Cap Screw (5 used) Cap Screw (3 used)

Rear Mounting Cap Screws Remove cap screws (3) at rear fender mounting bracket. [6] -

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Section 19 page 12

TM12408-REPAIR TECHNICAL MANUAL

MAIN HYDRAULIC SYSTEM

(g) by Belgreen v2.0

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

Measurement

Specification

Fender

Weight (approximate)

158 kg 348 lb.

Secure fender with appropriate lifting straps. [7] →NOTE: Picture shown without wheel and tire to provide clarity. Wheel and tire do not need to be removed. LEGEND: 4

Cap Screw (8 used)

Inner Mounting Cap Screws Remove cap screws (4). [8] - Repair or replace fenders as necessary. [9] CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device. Item

Measurement

Specification

Fender

Weight (approximate)

158 kg 348 lb.

Install fender. [10] - Install mounting cap screws.

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Section 21 page 13

TM12408-REPAIR TECHNICAL MANUAL

TM12408-REPAIR TECHNICAL MANUAL

(g) by Belgreen v2.5