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850J Crawler Dozer Repair (PIN: 1T0850JX_ _D130886—311988)

TECHNICAL MANUAL 850J Crawler Dozers Repair Manual (PIN: 1T0850JX_ _D130886—311988) TM1731 28JAN20

(ENGLISH)

Worldwide Construction And Forestry Division PRINTED IN U.S.A.

Introduction Foreword This manual is written for an experienced technician. Essential tools required in performing certain service work are identified in this manual and are recommended for use. Live with safety: Read the safety messages in the introduction of this manual and the cautions presented throughout the text of the manual.

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.

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 concise guides for specific machines. They are on-the-job guides containing only the vital information needed for diagnosis, analysis, testing, and repair.

Technical manuals are divided in two parts: repair and operation and tests. Repair sections tell how to repair the components. Operation and tests sections help you identify the majority of routine problems quickly.

Fundamental service information is available from other sources covering basic theory of operation, fundamentals of troubleshooting, general maintenance, and basic type of problems and their causes. TX,750C,SS2406 -19-13JUL95-1/1

TM1731 (28JAN20)

850J Crawler (S.N. 130886—311988) 012820 PN=2

Introduction

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

John Deere Dubuque Works 18600 South John Deere Road Attn: Publications, Dept. 324 Dubuque, IA 52004-0538 USA

FAX NUMBER:

1-563-589-5800 (USA)

Publication Number:

Page Number:

Ideas, Comments:

Name:

Phone:

Email Address:

THANK YOU! TX,TM,FAX -19-03JUL01-1/1

TM1731 (28JAN20)

850J Crawler (S.N. 130886—311988) 012820 PN=3

Introduction

TM1731 (28JAN20)

850J Crawler (S.N. 130886—311988) 012820 PN=4

Contents Section 00—General Information

Group 1830—Heating and Air Conditioning

Group 01—Safety Group 03—Torque Values

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

Section 01—Tracks Group 0130—Track System

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

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

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

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

Section 42—Ground Conditioning Tool Group —Ripper

Section 04—Engine

Section 9900—Dealer Fabricated Tools

Group 0400—Removal and Installation

Group 0999—Dealer Fabricated Tools

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

Section 07—Dampener Drive Group 0752—Elements

Section 11—Park Brake Group 1100—Park Brake Group 1115—Control Linkage Group 1160—Hydraulic System

Section 15—Equipment Attaching Group 1511—Drawbar

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

Section 18—Operator’s Station Group 1800—Removal and Installation Group 1810—Operator Enclosure Group 1821—Seat and Seat Belt

Original Instructions. All information, illustrations and specifications in this manual are based on the latest information available at the time of publication. The right is reserved to make changes at any time without notice. COPYRIGHT © 2020 DEERE & COMPANY Moline, Illinois All rights reserved. A John Deere ILLUSTRUCTION ™ Manual Previous Editions Copyright © 2006, 2007, 2008, 2009, 2010, 2011, 2012, 2013, 2015, 2016, 2017, 2018, 2019

TM1731 (28JAN20)

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Contents

TM1731 (28JAN20)

850J Crawler (S.N. 130886—311988) 012820 PN=2

Contents

Section 00 General Information

Page Page

Group 01—Safety Recognize Safety Information ....................... 00-01-1 Follow Safety Instructions.............................. 00-01-1 Operate Only If Qualified ............................... 00-01-1 Wear Protective Equipment........................... 00-01-2 Avoid Unauthorized Machine Modifications.............................................. 00-01-2 Inspect Machine ............................................ 00-01-2 Stay Clear of Moving Parts............................ 00-01-2 Avoid High-Pressure Fluids ........................... 00-01-3 Beware of Exhaust Fumes ............................ 00-01-3 Prevent Fires ................................................. 00-01-4 Prevent Battery Explosions ........................... 00-01-4 Handle Chemical Products Safely.................. 00-01-4 Dispose of Waste Properly ............................ 00-01-5 Prepare for Emergencies............................... 00-01-5 Add Cab Guarding For Special Uses .......................................................... 00-01-5 Use Steps and Handholds Correctly .................................................... 00-01-6 Start Only From Operator's Seat ................... 00-01-6 Use and Maintain Seat Belt ........................... 00-01-6 Prevent Unintended Machine Movement.................................................. 00-01-6 Avoid Work Site Hazards............................... 00-01-7 Keep Riders Off Machine .............................. 00-01-7 Avoid Backover Accidents ............................. 00-01-7 Avoid Machine Tip Over ................................ 00-01-8 Add and Operate Attachments Safely......................................................... 00-01-8 Park And Prepare For Service Safely......................................................... 00-01-9 Service Cooling System Safely ..................... 00-01-9 Remove Paint Before Welding or Heating ...................................................... 00-01-9 Make Welding Repairs Safely ..................... 00-01-10 Drive Metal Pins Safely ............................... 00-01-10

Service Recommendations for Flared Connections—Straight or Tapered Threads ....................................... 00-03-7 Service Recommendations For Flat Face O-Ring Seal Fittings .................. 00-03-8 O-Ring Face Seal Fittings with SAE Inch Hex Nut and Stud End for High Pressure...........................00-03-9 O-Ring Face Seal Fittings with Metric Hex Nut and Stud End for Standard Pressure..................00-03-11 O-Ring Face Seal Fittings with Metric Hex Nut and Stud End for High Pressure.........................00-03-13 Service Recommendations for Metric Series Four Bolt Flange Fitting....................................................... 00-03-15 Service Recommendations For Inch Series Four Bolt Flange Fittings ..................................................... 00-03-16 Inch Series Four Bolt Flange Fitting For High Pressure Service Recommendations................................... 00-03-17 Service Recommendations For Non-Restricted Banjo (Adjustable) Fittings................................. 00-03-18 Service Recommendations For O-Ring Boss Fittings With Shoulder .................................................. 00-03-19 Metric 24 O-Ring Seal DIN 20078...........00-03-21

Group 03—Torque Values Torque Value Metric Bolt and Cap Screw........................00-03-1 Additional Metric Cap Screw Torque Values ............................................ 00-03-2 Unified Inch Bolt and Cap Screw ..............00-03-3 Service Recommendations for 37° Flare and 30° Cone Seat Connectors ................................................ 00-03-4 Service Recommendations for O-Ring Boss Fittings.................................. 00-03-4 Service Recommendation O-Ring Boss Fittings In Aluminum HousingExcavators.................................................................00-03-6

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Group 01

Safety Recognize Safety Information T133555 —UN—15APR13

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.

T133588 —19—28AUG00

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

TX03679,00016CC -19-08JAN18-1/1

Follow Safety Instructions T133556 —UN—24AUG00

Read the safety messages in this manual and on the machine. Follow these warnings and instructions carefully. Review them frequently. Keep safety signs in good condition. Replace missing or damaged safety signs. Be sure new equipment components and repair parts include the current safety signs. Replacement safety signs are available from your John Deere dealer. Be sure all operators of this machine understand every safety message. Replace operator's manual and safety labels immediately if missing or damaged.

TX03679,00016F9 -19-14JAN08-1/1

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. TX03679,00016FA -19-03JAN07-1/1

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Safety

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

TS206 —UN—15APR13

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

TX03679,00016D0 -19-05MAY10-1/1

Avoid Unauthorized Machine Modifications Modifications of this machine, or addition of unapproved products or attachments, may affect machine stability or reliability, and may create a hazard for the operator or others near the machine. The installer of any modification which may affect the electronic controls of this machine is

responsible for establishing that the modification does not adversely affect the machine or its performance. Always contact an authorized dealer before making machine modifications that change the intended use, weight or balance of the machine, or that alter machine controls, performance or reliability. TX03679,00016B7 -19-12AUG03-1/1

Inspect Machine

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.

T6607AQ —UN—15APR13

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

TX03679,0001734 -19-08JAN08-1/1

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.

T133592 —UN—15APR13

Stay Clear of Moving Parts

TX03679,00016D2 -19-08JAN08-1/1

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Safety

Avoid High-Pressure Fluids

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

T133840 —UN—20SEP00

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

T133509 —UN—15APR13

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

TX03679,00016D3 -19-07SEP06-1/1

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

T133546 —UN—24AUG00

Beware of Exhaust Fumes

TX03679,00016D4 -19-23JUN08-1/1

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Safety

T133552 —UN—15APR13

Prevent Fires 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 and electrical wiring. Never store oily rags or flammable materials inside a machine compartment.

T133553 —UN—07SEP00

Maintain Hoses and Wiring: Replace hydraulic hoses immediately if they begin to leak, and clean up any oil spills. Examine electrical wiring and connectors frequently for damage. Keep A Fire Extinguisher Available: Always keep a multipurpose fire extinguisher on or near the machine. Know how to use extinguisher properly.

T133554 —UN—07SEP00

TX03679,00016F5 -19-25SEP00-1/1

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

TS204 —UN—15APR13

Never check battery charge by placing a metal object across the posts. Use a voltmeter or hydrometer. Do not charge a frozen battery; it may explode. Warm battery to 16°C (60°F).

TX03679,000174A -19-08JAN08-1/1

Handle Chemical Products Safely

If uncertain about safe handling or use of these chemical products, contact your authorized dealer for a Material Safety Data Sheet (MSDS) or go to internet website http://www.jdmsds.com. The MSDS describes physical and health hazards, safe use procedures, and emergency response techniques for chemical substances. Follow

T133580 —UN—25AUG00

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

MSDS recommendations to handle chemical products safely. TX03679,00016D7 -19-03JAN07-1/1

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Safety

Improper disposal of waste can threaten the environment. Fuel, oils, coolants, filters and batteries used with this machine may be harmful if not disposed of properly. Never pour waste onto the ground, down a drain, or into any water source. Air conditioning refrigerants can damage the atmosphere. Government regulations may require using a certified service center to recover and recycle used refrigerants.

T133567 —UN—25AUG00

Dispose of Waste Properly

If uncertain about the safe disposal of waste, contact your local environmental or recycling center or your authorized dealer for more information. TX03679,0001733 -19-08JAN08-1/1

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

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

TS291 —UN—15APR13

Keep a first aid kit and fire extinguisher handy.

TX03679,000174B -19-08JAN08-1/1

Special work situations or machine attachments may expose the operator to intruding or flying objects. Using this machine in a forestry application or woods environment, or with attachments such as a winch, requires added guarding to protect the operator. Forestry protection packages or special screens should be installed when working in areas where logs or branches may strike the operator. A rear screen should always be used with a winch to protect against a snapping cable. Contact your authorized dealer for information on protective guarding before operating in any hazardous environment.

T139005 —UN—05MAR01

Add Cab Guarding For Special Uses

TX03768,0000B77 -19-14JAN08-1/1

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Safety

Use Steps and Handholds Correctly T133468 —UN—15APR13

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.

TX03679,00016F2 -19-12FEB07-1/1

T133715 —UN—15APR13

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

TX03679,0001799 -19-22APR10-1/1

Use and Maintain Seat Belt T133716 —19—17APR13

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

TX03679,00016DD -19-19MAR07-1/1

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

(LOCKED) UP POSITION

(UNLOCKED) DOWN POSITION

T159027 —19—30AUG02

Prevent Unintended Machine Movement

TX03768,0000B72 -19-14JAN08-1/1

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Safety

Avoid Work Site Hazards Avoid contact with gas lines, buried cables and water lines. Call utility line location services to identify all underground utilities before working below ground level. T139002 —UN—05MAR01

Avoid or correct hazardous work situations. Avoid operating near structures or objects that could fall onto the machine. Clear away debris that could move unexpectedly if run over. Keep bystanders clear at all times. Use barricades or a signal person to keep vehicles and pedestrians away. Always keep signal person in view. Instruct co-workers and bystanders not to approach the machine while it is operating.

T139003 —UN—05MAR01

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

TX03768,0000B76 -19-06MAR01-1/1

Keep Riders Off Machine Only allow operator on machine.

T137580 —UN—22FEB01

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

Keep Riders Off Machine TX03768,0000B73 -19-03JUN15-1/1

Before moving machine, be sure all persons are clear of the machine path. Turn around and look directly for best visibility. Use mirror to assist in checking behind the machine. Keep windows and mirror clean and in good repair. Be certain backup warning alarm is working properly. Use a signal person when backing if view is obstructed or when in close quarters. Keep signal person in view at all times. Use prearranged hand signals to communicate.

T138441 —UN—22FEB01

Avoid Backover Accidents

TX03768,0000B69 -19-14JUN11-1/1

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Safety

Avoid Machine Tip Over T133716 —19—17APR13

Use seat belt at all times. Do not jump if the machine tips. You will be unlikely to jump clear and the machine may crush you. Load and unload from trucks or trailers carefully. Be sure truck is wide enough and secured on a firm level surface. Use loading ramps and attach them properly to truck bed. Avoid trucks with steel beds because tracks slip more easily on steel.

T138416 —UN—22FEB01

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

T138415 —UN—22FEB01

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

TX03768,0000B6B -19-03NOV08-1/1

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

is required or recommended. Verify that all connections are secure and attachment responds properly to controls. Carefully read attachment manual and follow all instructions and warnings. In an area free of bystanders and obstructions, carefully operate attachment to learn its characteristics and range of motion. TX03679,00016F0 -19-12FEB07-1/1

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Safety

Park And Prepare For Service Safely Warn others of service work. Always park and prepare your machine for service or repair properly. and attachments to the ground.

• Place park lock lever in “lock” position. Stop engine and remove key.

• Attach a “Do Not Operate” tag in an obvious place in the operator's station.

Securely support machine or attachment before working under it.

T133332 —19—17APR13

• Park machine on a level surface and lower blade/bucket

• Do not support machine with blade/bucket or attachments.

• Do not support machine with cinder blocks or wooden pieces that may crumble or crush.

• Do not support machine with a single jack or other Understand service procedures before beginning repairs. Keep service area clean and dry. Use two people whenever the engine must be running for service work.

TS229 —UN—23AUG88

devices that may slip out of place.

TX03768,0000B6A -19-19OCT09-1/1

Service Cooling System Safely

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.

TS281 —UN—15APR13

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

TX,SURGE -19-19JAN11-1/1

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

T133546 —UN—24AUG00

Remove Paint Before Welding or Heating

Work outside or in a well-ventilated area. Dispose of waste, paint, and solvents properly. TX03679,0001732 -19-29AUG07-1/1

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Safety

Make Welding Repairs Safely

Avoid welding or heating near pressurized fluid lines. Flammable spray may result and cause severe burns if pressurized lines fail as a result of heating. Do not let heat go beyond work area to nearby pressurized lines. Remove paint properly. Do not inhale paint dust or fumes. Use a qualified welding technician for structural repairs.

T133547 —UN—15APR13

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

Make sure there is good ventilation. Wear eye protection and protective equipment when welding. TX03679,00016D5 -19-11SEP09-1/1

T133738 —UN—15APR13

Drive Metal Pins Safely Always wear protective goggles or safety glasses and other protective equipment before striking hardened parts. Hammering hardened metal parts such as pins and bucket teeth may dislodge chips at high velocity. Use a soft hammer or a brass bar between hammer and object to prevent chipping. Hardened Metal Parts OUO1065,0000090 -19-06JAN16-1/1

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Group 03

Torque Values Metric Bolt and Cap Screw Torque Values

TORQ2 —UN—15APR13

METRIC BOLT AND CAP SCREW TORQUE VALUES—Tolerance is ±10% unless otherwise specified

Top—Property Class and Head Markings; Bottom—Property Class and Nut Markings Class 4.8 Thread Size

Lubricateda Nm (lb-ft)

Class 8.8 or 9.8

Dryb Nm (lb-ft)

Class 10.9

Lubricateda Nm (lb-ft)

Dryb Nm (lb-ft)

Class 12.9

Lubricateda Nm (lb-ft)

Dryb Nm (lb-ft)

Lubricateda Nm (lb-ft)

Dryb Nm (lb-ft)

4.7 (3.5)

6 (4.4)

9 (6.6)

11.5 (8.5)

13 (9.5)

16.5 (12.2)

15.5 (11.5)

19.5 (14.5)

11.5 (8.5)

14.5 (10.7)

22 (16)

28 (20.5)

32 (23.5)

40 (29.5)

37 (27.5)

47 (35)

M10

23 (17)

29 (21)

43 (32)

55 (40)

63 (46)

80 (59)

75 (55)

95 (70)

M12

40 (29.5)

50 (37)

75 (55)

95 (70)

110 (80)

140 (105)

130 (95)

165 (120)

M14

63 (46)

80 (59)

120 (88)

150 (110)

175 (130)

220 (165)

205 (150)

260 (190)

M16

100 (74)

125 (92)

190 (140)

240 (175)

275 (200)

350 (255)

320 (235)

400 (300)

M18

135 (100)

170 (125)

265 (195)

330 (245)

375 (275)

475 (350)

440 (325)

560 (410)

M20

190 (140)

245 (180)

375 (275)

475 (350)

530 (390)

675 (500)

625 (460)

790 (580)

M22

265 (195)

330 (245)

510 (375)

650 (480)

725 (535)

920 (680)

850 (625)

1080 (800)

M24

330 (245)

425 (315)

650 (480)

820 (600)

920 (680)

1150 (850)

1080 (800)

1350 (1000)

M27

490 (360)

625 (460)

950 (700)

1200 (885)

1350 (1000)

1700 (1250)

1580 (1160)

2000 (1475)

M30

660 (490)

850 (625)

1290 (950)

1630 (1200)

1850 (1350)

2300 (1700)

2140 (1580)

2700 (2000)

M33

900 (665)

1150 (850)

1750 (1300)

2200 (1625)

2500 (1850)

3150 (2325)

2900 (2150)

3700 (2730)

M36

1150 (850)

1450 (1075)

2250 (1650)

2850 (2100)

3200 (2350)

4050 (3000)

3750 (2770)

4750 (3500)

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

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

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

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

Fasteners should be replaced with the same or higher property class. If higher property class fasteners are used, these should only be tightened to the strength of the original. Make sure fastener threads are clean and that you properly start thread engagement. This will prevent them from failing when tightening. Tighten plastic insert or crimped steel-type lock nuts to approximately 50 percent of the dry torque shown in the chart, applied to the nut, not to the bolt head. Tighten toothed or serrated-type lock nuts to the full torque value. OUT3035,TORQUE2 -19-22MAR04-1/1

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Torque Values

T6873AA —UN—15APR13

Additional Metric Cap Screw Torque Values CAUTION: Use only metric tools on metric hardware. Other tools may not fit properly. They may slip and cause injury. Check tightness of cap screws periodically. Torque values listed are for general use only. Do not use these values if a different torque value or tightening procedure is listed for a specific application.

T-Bolt

T6873AB —UN—18OCT88

Shear bolts are designed to fail under predetermined loads. Always replace shear bolts with identical grade. Fasteners should be replaced with the same or higher grade. If higher grade fasteners are used, these should only be tightened to the strength of the original. Make sure fastener threads are clean and that the thread engagement is properly started. This will prevent fasteners from failing when tightening.

H-Bolt

T6873AC —UN—18OCT88

Tighten cap screws having lock nuts to approximately 50 percent of amount shown in chart. METRIC CAP SCREW TORQUE VALUESa T-Bolt

H-Bolt

M-Bolt

Nominal Diameter

N·m

lb·ft

N·m

lb·ft

N·m

lb·ft

108

176

130

137

101

265

195

206

152

392

289

294

217

118

539

398

392

289

167

125

735

542

539

398

216

159

931

687

686

506

274

202

1372

1012

1029

759

392

289

1911

1410

1421

1049

539

398

2548

1890

1911

1410

735

542

3136

2314

2401

1772

931

687

M-Bolt

Torque tolerance is ±10%. 04T,90,M170 -19-09JUL19-1/1

TM1731 (28JAN20)

00-03-2

850J Crawler (S.N. 130886—311988) 012820 PN=20

Torque Values

Unified Inch Bolt and Cap Screw Torque Values

TORQ1A —UN—15APR13

UNIFIED INCH BOLT AND CAP SCREW TORQUE VALUES—Tolerance is ±10% unless otherwise specified

Top—SAE Grade and Head Markings; Bottom—SAE Grade and Nut Markings Grade 2a (No Mark)

Grade 1 (No Mark) Thread Size

Lubricated N·m (lb-ft)

Dry N·m (lb-ft)

Lubricatedb N·m (lb-ft)

Grade 5, 5.1 or 5.2

Dryc N·m (lb-ft)

Lubricatedb N·m (lb-ft)

Dryc N·m (lb-ft)

Grade 8 or 8.2 Lubricatedb N·m (lb-ft)

Dryc N·m (lb-ft)

1/4

3.8 (2.8)

4.7 (3.5)

6 (4.4)

7.5 (5.5)

9.5 (7)

12 (9)

13.5 (10)

17 (12.5)

5/16

7.7 (5.7)

9.8 (7.2)

12 (9)

15.5 (11.5)

19.5 (14.5)

25 (18.5)

28 (20.5)

35 (26)

3/8

13.5 (10)

17.5 (13)

22 (16)

27.5 (20)

35 (26)

44 (32.5)

49 (36)

63 (46)

7/16

22 (16)

28 (20.5)

35 (26)

44 (32.5)

56 (41)

70 (52)

80 (59)

100 (74)

1/2

34 (25)

42 (31)

53 (39)

67 (49)

85 (63)

110 (80)

120 (88)

155 (115)

9/16

48 (35.5)

60 (45)

76 (56)

95 (70)

125 (92)

155 (115)

175 (130)

220 (165)

5/8

67 (49)

85 (63)

105 (77)

135 (100)

170 (125)

215 (160)

240 (175)

305 (225)

3/4

120 (88)

150 (110)

190 (140)

240 (175)

300 (220)

380 (280)

425 (315)

540 (400)

7/8

190 (140)

240 (175)

190 (140)

240 (175)

490 (360)

615 (455)

690 (510)

870 (640)

285 (210)

360 (265)

285 (210)

360 (265)

730 (540)

920 (680)

1030 (760)

1300 (960)

1-1/8

400 (300)

510 (375)

400 (300)

510 (375)

910 (670)

1150 (850)

1450 (1075)

1850 (1350)

1-1/4

570 (420)

725 (535)

570 (420)

725 (535)

1280 (945)

1630 (1200)

2050 (1500)

2600 (1920)

1-3/8

750 (550)

950 (700)

750 (550)

950 (700)

1700 (1250)

2140 (1580)

2700 (2000)

3400 (2500)

1-1/2

990 (730)

1250 (930)

990 (730)

1250 (930)

2250 (1650)

2850 (2100)

3600 (2650)

4550 (3350)

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

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

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

Make sure fastener threads are clean and that you properly start thread engagement. This will prevent them from failing when tightening. Tighten plastic insert or crimped steel-type lock nuts to approximately 50 percent of the dry torque shown in the chart, applied to the nut, not to the bolt head. Tighten toothed or serrated-type lock nuts to the full torque value.

Fasteners should be replaced with the same or higher grade. If higher grade fasteners are used, these should only be tightened to the strength of the original. OUT3035,TORQUE1 -19-14JAN04-1/1

TM1731 (28JAN20)

00-03-3

850J Crawler (S.N. 130886—311988) 012820 PN=21

Torque Values

Service Recommendations for 37° Flare and 30° Cone Seat Connectors 1. Inspect flare and flare seat. They must be free of dirt or obvious defects. T6234AC —UN—15APR13

2. Defects in tube flare cannot be repaired. Overtightening a defective flared fitting will not stop leaks. 3. Align tube with fitting before attempting to start nut. 4. Lubricate male threads with hydraulic fluid or petroleum jelly. Cone Seat Connector

5. Index angle fittings and tighten by hand. 6. Tighten fitting or nut to torque value shown on torque chart. Do not allow hoses to twist when tightening fittings.

STRAIGHT FITTING OR SPECIAL NUT TORQUE CHART Thread Size

N·m

lb·ft

3/8 - 24 UNF

7/16 - 20 UNF

1/2 - 20 UNF

9/16 - 18 UNF

3/4 - 16 UNF

7/8 - 14 UNF

1-1/16 - 12 UN

102

1-3/16 - 12 UN

122

1-5/16 - 12 UN

142

105

1-5/8 - 12

190

140

1-7/8 - 12 UN

217

160

NOTE: Torque tolerance is ± 10%. T82,BHMA,EL -19-29SEP99-1/1

Service Recommendations for O-Ring Boss Fittings Straight Fitting T6243AE —UN—15APR13

1. Inspect O-ring boss seat for dirt or defects. 2. Lubricate O-ring with petroleum jelly. Place electrical tape over threads to protect O-ring. Slide O-ring over tape and into O-ring groove of fitting. Remove tape. 3. Tighten fitting to torque value shown on chart. Straight Fitting Continued on next page

TM1731 (28JAN20)

00-03-4

04T,90,K66 -19-29SEP99-1/2

850J Crawler (S.N. 130886—311988) 012820 PN=22

Torque Values Angle Fitting 1. Back off lock nut (A) and backup washer (B) completely to head end (C) of fitting. T6520AB —UN—15APR13

2. Turn fitting into threaded boss until backup washer contacts face of boss. 3. Turn fitting head end counterclockwise to proper index (maximum of one turn). NOTE: Do not allow hoses to twist when tightening fittings. 4. Hold fitting head end with a wrench and tighten locknut and backup washer to proper torque value.

Angle Fitting

STRAIGHT FITTING OR SPECIAL NUT TORQUE CHART Thread Size

N·m

lb·ft

3/8-24 UNF

7/16-20 UNF

1/2-20 UNF

9/16-18 UNF

3/4-16 UNF

7/8-14 UNF

1-1/16-12 UN

102

1-3/16-12 UN

122

1-5/16-12 UN

142

105

1-5/8-12 UN

190

140

1-7/8-12 UN

217

160

A—Lock Nut B—Backup Washer

C—Head End

NOTE: Torque tolerance is ± 10%. 04T,90,K66 -19-29SEP99-2/2

TM1731 (28JAN20)

00-03-5

850J Crawler (S.N. 130886—311988) 012820 PN=23

Torque Values

T196315 —UN—17NOV03

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

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

5— Hex Nut 6— Backup Washer

3— Stud End 4— Adjustable Fitting

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

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

Thread Size mm

Hex Nut Size mm

Nm (lb-ft)

Thread Size in.

M12 x 1.5

39 (29)

1/8

7.8 (5.80)

M14 x 1.5

39 (29)

1/4

11.8 (8.70)

M16 x 1.5

55 (41)

3/8

23 (17)

M22 x 1.5

75 (55)

1/2

39 (29)

M27 x 2

110 (81)

3/4

55 (41)

M30 x 2

141 (104)

86 (64)

M33 x 2

165 (122)

1-1/4

126 (93)

M38 x 2

165 (122)

1-1/2

157 (116)

M42 x 2

275 (203)

204 (150)

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

Nm (lb-ft)

1/8

—

1/4

28 (20)

3/8

39 (29)

1/2

75 (55)

3/4

126 (93)

165 (122)

1-1/8

—

1-1/4

259 (191)

1-3/8

—

1-1/2

330 (243)

1-3/4

—

Nm (lb-ft)

1. Inspect fitting and O-ring boss sealing surfaces and the O-ring. They must be free of dirt, scratches, nicks, or burrs. O-ring must be free of dirt, cuts, cracks, swelling or flatten condition. 2. Back the stud end hex nut (5) off as far as possible. Push backup washer (6) towards the nut to fully expose the turn down section of stud end. Washer must fit turned down section and not be too loose 3. Wrap electrical tape over threads to protect O-ring. Slide O-ring over the tape into turned down section. Remove tape. Apply hydraulic oil to the threads of stud end, turned down section, and O-ring. 4. Turn fitting into the boss by hand until face of nut or backup washer squeezes O-ring into the seat and contacts face of boss. Loosen an adjustable fitting no more than one turn for alignment. 5. Tighten straight fitting or hex nut to the torque value given. Hold body of adjustable fitting using a second wrench when tightening hex nut. OUT3035,0000353 -19-28MAY09-1/1

TM1731 (28JAN20)

00-03-6

850J Crawler (S.N. 130886—311988) 012820 PN=24

Torque Values

Service Recommendations for Flared Connections—Straight or Tapered Threads 1. Inspect flare and flare seat. They must be free of dirt or obvious defects. T6873AE —UN—15APR13

2. Defects in the tube flare cannot be repaired. Overtightening a defective flared fitting will not stop leaks. 3. Align the tube with the fitting before attempting to start the nut. 4. Lubricate the male threads with hydraulic fluid or petroleum jelly.

Straight Thread

5. Index angle fittings and tighten by hand. 6. Tighten fitting or nut to torque value shown on the chart. Do not allow hoses to twist when tightening fittings. Straight Thread b

Tapered Thread

Thread Size

N·m

lb·ft

1/8

1/4

3/8

1/2

lb·ft

3/4

176

130

157

116

343

253

1-1/2

196

145

539

398

255

188

588

434

T6873AD —UN—15APR13

TORQUE CHARTa

Tapered Thread

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

Torque tolerance is ±10%. b With seat face. 04T,90,M171 -19-28JAN92-1/1

TM1731 (28JAN20)

00-03-7

850J Crawler (S.N. 130886—311988) 012820 PN=25

Torque Values

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

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

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

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

3. Index angle fittings and tighten by hand pressing joint together to insure O-ring remains in place. 4. Tighten fitting or nut to torque value shown on the chart. Do not allow hoses to twist when tightening fittings, use backup wrench on straight hose couplings.

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

in.

6.35 9.52

Thread Size

Bulkhead Nut

Swivel Nut

in.

N·m

lb-ft

N·m

0.250

9/16-18

0.375

11/16-16

12.70

0.500

13/16-16

15.88

0.625

1-14

19.05

0.750

1 3/16-12

102

22.22

0.875

1 3/16-12

102

25.40

1.000

1 7/16-12

142

105

142

105

31.75

1.250

1 11/16-12

190

140

190

140

38.10

1.500

2-12

217

160

217

160

lb-ft

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

Straight Hex Size

Locknut Hex Size

Straight Fitting or Locknut Toque

Inch

N·m

lb-ft

3/8-24

5/8

9/16

7/16-20

5/8

1/2-20

3/4

11/16

9/16-18

3/4

3/4-16

7/8

15/16

7/8-14

1 1/16

104

1 1/16-12

1 1/4

1 3/8

176

130

1 3/16-12

1 3/8

1 1/2

230

170

1 5/16-12

1 1/2

1 5/8

285

210

*Torque tolerance is +15 -20% unless otherwise specified. 04T,90,K67 -19-02MAR00-1/1

TM1731 (28JAN20)

00-03-8

850J Crawler (S.N. 130886—311988) 012820 PN=26

Torque Values

O-Ring Face Seal Fittings With SAE Inch Hex Nut And Stud End For High Pressure Service Recommendations O-RING FACE SEAL FITTINGS WITH SAE INCH HEX NUT AND STUD END FOR HIGH PRESSURE, ABOVE 27 600 kPa (276 bar) (4000 psi), TORQUE VALUES—Tolerance is +15 -20% unless otherwise specified

H70406 —UN—15APR13

G E F

H F E

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

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

Nominal Tube OD or Hose ID Metric Tube OD

E—Stud End F— Tube Nut G—Swivel Nut H—Hex Nut Bulkhead Nut

O-Ring Face Seal Hose or Tube Swivel Nut

Inch Tube OD or Hose ID

Thread Size

Hex Size

Torque

Hex Size

Torque

Dash Size

mm (in.)

in.

Nm (lb-ft)

in.

Nm (lb-ft)

-3

4.78 (0.188)

—

-4

6.35 (0.250)

9/16-18

11/16

24 (18)

13/16

32 (24)

-5

7.92 (0.312)

—

-6

9.53 (0.375)

11/16-16

13/16

37 (27)

42 (31)

-8

12.70 (0.500)

13/16-16

15/16

75 (55)

1-1/8

93 (69)

-10

15.88 (0.625)

1-14

1-1/8

103 (76)

1-5/16

118 (87)

-12

19.05 (0.750)

1-3/16-12

1-3/8

152 (112)

1-1/2

175 (129)

-14

22.23 (0.875)

1-3/16-12

—

152 (112)

—

175 (129)

-16

25.40 (1.000)

1-7/16-12

1-5/8

214 (158)

1-3/4

247 (182)

-20

31.75 (1.250)

1-11/16-12

1-7/8

286 (211)

328 (242)

-24

38.10 (1.500)

2-12

2-1/4

326 (240)

2-3/8

374 (276)

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

Thread Size

Straight Hex Sizea

Adjustable Nut Hex Size

Steel or Gray Iron Torque

in.

Nm (lb-ft)

3/8-24

5/8

9/16

18 (13)

7/16-20

5/8

24 (18)

1/2-20

3/4

11/16

30 (22)

9/16-18

3/4

37 (27)

3/4-16

7/8

15/16

75 (55)

7/8-14

1-1/16

103 (76)

1-1/16-12

1-1/4

1-3/8

177 (131)

1-3/16-12

1-3/8

1-1/2

231 (170)

1-5/16-12

1-1/2

1-5/8

270 (199)

1-5/8-12

1-3/4

1-7/8

286 (211)

1-7/8-12

2-1/8

326 (240)

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

TM1731 (28JAN20)

00-03-9

OUT3035,0000420 -19-04MAY09-1/2

850J Crawler (S.N. 130886—311988) 012820 PN=27

Torque Values 1. Inspect fitting and connector sealing surfaces and the O-rings. They must be free of dirt, scratches, nicks, and burrs. O-ring must be free of dirt, cuts, cracks, swelling or flatten condition. 2. Back the stud end hex nut off as far as possible. Push backup washer towards the nut to fully expose the turn down section. Washer must fit turned down section and not be too loose

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

3. Lubricate O-rings using a thin film of clean hydraulic oil or as needed, petroleum jelly to hold O-ring in place. Install O-ring into groove making sure it is seated at the bottom. Excess petroleum jelly will prevent seating of O-ring and cause it to pop out.

5. Tighten fitting or nut to torque value shown. Use a second wrench to hold the fitting in position or to keep hose from twisting while tightening nut. OUT3035,0000420 -19-04MAY09-2/2

TM1731 (28JAN20)

00-03-10

850J Crawler (S.N. 130886—311988) 012820 PN=28

Torque Values

O-Ring Face Seal Fittings With Metric Hex Nut And Stud End For Standard Pressure Service Recommendations O-RING FACE SEAL AND FITTINGS WITH METRIC HEX NUT AND STUD END FOR STANDARD PRESSURE, BELOW 27 600 kPa (275.8 bar) (4,000 psi), TORQUE VALUES—Tolerance is +15 -20% unless otherwise specified

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

Nominal Tube OD or Hose ID Metric Tube OD

Inch Tube OD or Hose ID

T196337

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

T196337 —UN—15APR13

6— Tube Nut 7— Swivel Nut 8— Stud End 9— Hex Nut 10— O-Ring

11— Identification Groove

Bulkhead Nut

O-Ring Face Seal Hose or Tube Swivel Nut Thread Size

Hex Size

Torque

Hex Size

Torque

Dash Size

mm (in.)

in.

Nm (lb-ft)

-2

3.18 (0.125)

—

-3

4.78 (0.188)

—

-4

6.35 (0.250)

9/16-18

16 (12)

32 (24)

-5

7.92 (0.312)

—

-6

9.53 (0.375)

11/16-16

24 (18)

42 (31)

-8

12.70 (0.500)

13/16-16

50 (37)

93 (69)

-10

15.88 (0.625

1-14

69 (51)

118 (87)

-12

19.05 (0.750)

1-3/16-12

102 (75)

175 (129)

-14

22.23 (0.875)

1-3/16-12

102 (75)

175 (129)

-16

25.40 (1.000)

1-7/16-12

142 (105)

247 (182)

—

-20

31.75 (1.250)

1-11/16-12

190 (140)

328 (242)

-24

38.10 (1.500)

2-12

217 (160)

374 (276)

-32

50.80 (2.000)

—

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

Straight Hex Sizeb

Adjustable Nut Hex Size

Steel or Gray Iron Torque

Aluminum or Brass Torque

mm.

Nm (lb-ft)

M8 x 1

8 (6)

5 (4)

M10 x 1

15 (11)

10 (7)

M12 x 1.5

25 (18)

17 (12)

M14 x 1.5

40 (30)

27 (20)

M16 x 1.5

45 (33)

30 (22)

M18 x 1.5

50 (37) Continued on next page

TM1731 (28JAN20)

00-03-11

33 (25) OUT3035,0000366 -19-28MAY09-1/2

850J Crawler (S.N. 130886—311988) 012820 PN=29

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

Straight Hex Sizeb

Adjustable Nut Hex Size

Steel or Gray Iron Torque

Aluminum or Brass Torque

mm.

Nm (lb-ft)

M22 x 1.5

69 (51)

46 (34)

M27 x 2

100 (74)

67 (49)

M30 x 2

130 (96)

87 (64)

M33 x 2

160 (118)

107 (79)

M38 x 2

176 (130)

117 (87)

M42 x 2

210 (155)

140 (103)

M48 x 2

260 (192)

173 (128)

M60 x 2

315 (232)

210 (155)

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

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

1. Inspect fitting and connector sealing surfaces and the O-rings. They must be free of dirt, scratches, nicks, and burrs. O-ring must be free of dirt, cuts, cracks, swelling or flatten condition. 2. Back the stud end hex nut off as far as possible. Push backup washer towards the nut to fully expose the turn down section. Washer must fit turned down section and not be too loose

5. Tighten fitting or nut to torque value shown. Use a second wrench to hold the fitting in position or to keep hose from twisting while tightening nut. OUT3035,0000366 -19-28MAY09-2/2

TM1731 (28JAN20)

00-03-12

850J Crawler (S.N. 130886—311988) 012820 PN=30

Torque Values

O-Ring Face Seal Fittings With Metric Hex Nut And Stud End For High Pressure Service Recommendations O-RING FACE SEAL FITTINGS WITH METRIC HEX NUT AND STUD END FOR HIGH PRESSURE, ABOVE 27 600 kPa (275.8 bar) (4,000 psi), TORQUE VALUES—Tolerance is +15 -20% unless otherwise specified

10 T196337

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

Nominal Tube OD or Hose ID Metric Tube OD

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

T196337 —UN—15APR13

6— Tube Nut 7— Swivel Nut 8— Stud End 9— Hex Nut 10— O-Ring

11— Identification Groove

Bulkhead Nut

O-Ring Face Seal Hose or Tube Swivel Nut

Inch Tube OD or Hose ID

Thread Size

Hex Size

Torque

Hex Size

Torque

Dash Size

mm (in.)

in.

Nm (lb-ft)

-2

3.18 (0.125)

—

-3

4.78 (0.188)

—

-4

6.35 (0.250)

9/16-18

24 (18)

32 (24)

—

37 (27)

42 (31)

-5

7.92 (0.312)

—

-6

9.53 (0.375)

11/16-16

-8

12.70 (0.500)

13/16-16

75 (55)

93 (69)

-10

15.88 (0.625)

1-14

103 (76)

118 (87)

-12

19.05 (0.750)

1-3/16-12

152 (112)

175 (129)

-14

22.23 (0.875)

1-3/16-12

152 (112)

175 (129)

-16

25.40 (1.000)

1-7/16-12

214 (158)

247 (182)

—

-20

31.75 (1.250)

1-11/16-12

—

286 (211)

328 (242)

-24

38.10 (1.500)

2-12

—

326 (240)

374 (276)

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

Straight Hex Sizeb

Adjustable Nut Hex Size

Steel or Gray Iron Torque

mm.

Nm (lb-ft)

M8 x 1

8 (6)

M10 x 1

15 (11)

M12 x 1.5

35 (26)

M14 x 1.5

45 (33)

M16 x 1.5

55 (41)

M18 x 1.5

70 (52)

M22 x 1.5

100 (74)

M27 x 2

170 (125)

Continued on next page

TM1731 (28JAN20)

00-03-13

OUT3035,0000421 -19-28MAY09-1/2

850J Crawler (S.N. 130886—311988) 012820 PN=31

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

Straight Hex Sizeb

Adjustable Nut Hex Size

Steel or Gray Iron Torque

mm.

Nm (lb-ft)

M30 x 2

215 159)

M33 x 2

260 (192)

M38 x 2

320 (236)

M42 x 2

360 (266)

M48 x 2

420 (310)

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

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

5. Tighten fitting or nut to torque value shown. Use a second wrench to hold the fitting in position or to keep hose from twisting while tightening nut. OUT3035,0000421 -19-28MAY09-2/2

TM1731 (28JAN20)

00-03-14

850J Crawler (S.N. 130886—311988) 012820 PN=32

Torque Values

T6890BB —UN—15APR13

Service Recommendations for Metric Series Four Bolt Flange Fitting

Metric Series Four Bolt Flange Fitting A—Sealing Surface B—Split Flange

C—Pinched O-Ring D—Single Piece Flange

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

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

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

3. Split flange: Loosely assemble split flange (B) halves. Make sure split is centrally located and perpendicular to the port. Hand tighten cap screws to hold parts in place. Do not pinch O-ring (C). 4. Single piece flange (D): Place hydraulic line in center of flange and install four cap screws. Flange must be centrally located on port. Hand tighten cap screws to hold flange in place. Do not pinch O-ring. 5. After components are properly positioned and cap screws are hand tightened, tighten one cap screw, then tighten the diagonally opposite cap screw. Tighten two remaining cap screws. Tighten all cap screws as specified in the chart below.

Thread

N·m

lb·ft

M10

M12

M14

157

116

M16

217

160

M18

334

246

M20

421

318

Tolerance ± 10%. The torques given are enough for the given size connection with the recommended working pressure. Increasing cap screw torque beyond these amounts will result in flange and cap screw bending and connection failures. b Metric standard thread. 04T,90,K175 -19-29SEP99-1/1

TM1731 (28JAN20)

00-03-15

850J Crawler (S.N. 130886—311988) 012820 PN=33

Torque Values

T6890BB —UN—15APR13

Service Recommendations For Inch Series Four Bolt Flange Fittings

Flange Fittings A—Sealing Surface B—Split Flange

C—Pinched O-Ring D—Single Piece Flange

1. Clean sealing surfaces (A). Inspect. Scratches cause leaks. Roughness causes seal wear. Out-of-flat causes seal extrusion. If defects cannot be polished out, replace component. 2. Install O-ring (and backup washer if required) into groove using petroleum jelly to hold it in place.

TORQUE CHART N·m Nominal Flange Size

Cap Screw Size

1/2 3/4

3. Split flange: Loosely assemble split flange (B) halves. Make sure split is centrally located and perpendicular to port. Hand tighten cap screws to hold parts in place. Do not pinch O-ring (C). 4. Single piece flange (D): Place hydraulic line in center of flange and install cap screws. Flange must be centrally located on port. Hand tighten cap screws to hold flange in place. Do not pinch O-ring. 5. Tighten one cap screw, then tighten the diagonally opposite cap screw. Tighten two remaining cap screws. Tighten all cap screws as specified in the chart below.

lb·ft

Min

Max

Min

Max

5/16-18 UNC

3/8-16 UNC

1-1/4

7/16-14 UNC

1-1/2

1/2-13 UNC

131

1/2-13 UNC

131

2-1/2

1/2-13 UNC

107

131

5/8-11 UNC

158

264

117

195

3-1/2

5/8-11 UNC

158

264

117

195

5/8-11 UNC

158

264

117

195

5/8-11 UNC

158

264

117

195

DO NOT use air wrenches. DO NOT tighten one cap screw fully before tightening the others. DO NOT over tighten. 04T,90,K174 -19-01AUG94-1/1

TM1731 (28JAN20)

00-03-16

850J Crawler (S.N. 130886—311988) 012820 PN=34

Torque Values

T6890BB —UN—15APR13

Inch Series Four Bolt Flange Fitting For High Pressure Service Recommendations

A—Sealing Surface B—Split Flange

C—Pinched O-Ring D—Single Piece Flange

O-ring wear. Out-of-flat causes O-ring extrusion. If imperfection cannot be polished out, replace component.

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

Cap Screw Sizea

Min—Max Torque b

in.

Nm (lb-ft)

1/2

5/16-18 UNC

20—31 (15—23)

3/4

3/8-16 UNC

34—54 (25—40)

7/16-14 UNC

57—85 (42—63)

1-1/4

1/2-13 UNC

85—131 (63—97)

1-1/2

5/8-11 UNC

159—264 (117—195)

3/4-10 UNC

271—468 (200—345)

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

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

Single piece flange (D): Make sure flange is centrally located on port and line is centered in flange. Install the cap screws. Hand tighten cap screws to hold flange and line in place. Do not pinch O-ring.

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

1. Clean sealing surfaces (A). Inspect. Scratches, nicks, and burrs cause leaks. Roughness causes

4. Tighten one cap screw and then the diagonally opposite cap screw. Tighten the two remaining cap screws. Tighten cap screws within the specified torque values. OUT3035,0000422 -19-05MAR09-1/1

TM1731 (28JAN20)

00-03-17

850J Crawler (S.N. 130886—311988) 012820 PN=35

Torque Values

Service Recommendations For Non-Restricted Banjo (Adjustable) Fittings 1. Inspect all fitting sealing surfaces. They must be free of dirt and defects. 2. Inspect O-ring (A). It must be free of damage or defects. 3. Inspect sealing ring (B) for damage or defects. 4. Hold body in desired position while tightening stud by hand. 5. Tighten stud (C) to torque value shown on the chart. Do not allow body to twist when tightening stud. T113948 —UN—06MAR98

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

Metric Thread

N·m

lb·ft

6 L

M10 x 1

8 L

M12 x 1.5

10 L

M14 x 1.5

Non-Restricted Banjo Fitting Torque Value

12 L

M16 x 1.5

100

Tube Fitting O.D. Size

Inch Size

N·m

lb·ft

15 L

M18 x 1.5

130

6 L

1/8

18 L

M22 x 1.5

160

118

8 L

1/4

22 L

M26 x 1.5

250

184

10 L

1/4

28 L

M33 x 2

400

295

12 L

3/8

35 L

M42 x 2

600

443

15 L

1/2

130

42 L

M48 x 2

800

590

18 L

1/2

150

111

6 S

M12 x 1.5

22 L

3/4

250

184

8 S

M14 x 1.5

28 L

400

295

10 S

M16 x 1.5

100

35 L

1-1/4

600

443

12 S

M18 x 1.5

130

42 L

1-1/2

800

590

14 S

M20 x 1.5

160

118

6 S

1/4

16 S

M22 x 1.5

160

118

8 S

1/4

20 S

M27 x 2

250

184

10 S

3/8

25 S

M33 x 2

400

295

12 S

3/8

100

30 S

M42 x 2

600

443

14 S

1/2

130

38 S

M48 x 2

800

590

16 S

1/2

150

111

20 S

3/4

250

184

25 S

400

295

30 S

1-1/4

600

443

38 S

1-1/2

800

590

CED,OUO1002,562 -19-09MAR98-1/1

TM1731 (28JAN20)

00-03-18

850J Crawler (S.N. 130886—311988) 012820 PN=36

Torque Values

Service Recommendations For O-Ring Boss Fittings With Shoulder 1. Inspect component seal boss seat for dirt or defects. T113957 —UN—06MAR98

2. Inspect EOlastic seal (A) for damage. Replace seal or fitting as necessary. To replace seal, put electrical tape over threads to protect seal. Slide seal over tape and into seal groove of fitting. Remove tape. 3. Tighten fitting to torque value shown on chart. IMPORTANT: Do not allow hoses to twist when tightening fittings.

O-Ring Boss Fitting With Shoulder Torque Value

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

Metric Thread

N·m

lb·ft

6 L

M10 x 1

8 L

M12 x 1.5

10 L

M14 x 1.5

12 L

M16 x 1.5

15 L

M18 x 1.5

18 L

M22 x 1.5

130

22 L

M26 x 1.5

190

140

Tube Fitting O.D. Size

Inch Size

N·m

lb·ft

6 L

1/8

8 L

1/4

10 L

1/4

12 L

3/8

15 L

1/2

140

103

18 L

1/2

100

22 L

3/4

180

133

28 L

300

221

35 L

1-1/4

600

443

42 L

1-1/2

800

590

6 S

1/4

28 L

M33 x 2

300

221

35 L

M42 x 2

600

443

8 S

1/4

3/8

42 L

M48 x 2

800

590

10 S

6 S

M12 x 1.5

12 S

3/8

1/2

160

118

8 S

M14 x 1.5

14 S

10 S

M16 x 1.5

16 S

1/2

140

103

12 S

M18 x 1.5

110

20 S

3/4

250

184

400

295

14 S

M20 x 1.5

140

103

25 S

16 S

M22 x 1.5

170

125

30 S

1-1/4

650

479

38 S

1-1/2

800

590

20 S

M27 x 2

250

184

25 S

M33 x 2

450

332

30 S

M42 x 2

600

443

38 S

M48 x 2

800

590

Continued on next page

TM1731 (28JAN20)

00-03-19

CED,OUO1002,563 -19-09MAR98-1/2

850J Crawler (S.N. 130886—311988) 012820 PN=37

Torque Values Hex Socket Head Plugs Only Torque Value Thread Size

N·m

lb·ft

M10 x 1

M12 x 1.5

M14 x 1.5

M16 x 1.5

M18 x 1.5

M20 x 1.5

M22 x 1.5

100

M26 x 1.5

120

M27 x 2

150

111

M33 x 2

250

184

M42 x 2

400

295

M48 x 2

500

369

1/8

1/4

3/8

1/2

3/4

150

111

220

162

1-1/4

600

443

1-1/2

800

590 CED,OUO1002,563 -19-09MAR98-2/2

TM1731 (28JAN20)

00-03-20

850J Crawler (S.N. 130886—311988) 012820 PN=38

Torque Values

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

Heavy Fitting Size

Light Fitting Size

Torque

Turns

—

M12 x 1.5

M16 x 1.5

M14 x 1.5

M18 x 1.5

M16 x 1.5

M20 x 1.5

M18 x 1.5

M22 x 1.5

—

M22 x 1.5

M24 x 1.5

—

M26 x 1.5

M30 x 2

—

M30 x 2

M36 x 2

—

M36 x 2

M42 x 2

—

M45 x 2

M52 x 2

— T113889 —UN—15APR13

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

NOTE: These fittings are also referred to as EO and EO-2 Bite Type or Ermeto style fittings. IMPORTANT: In this style of fittings, there are “heavy” and “light” designs. Usually “heavy” is used for pressure lines and “light” for return lines. Some “heavy” and “light” sizes can be threaded together but do not seal properly. Be sure not to mix “heavy” and “light” fittings.

4. Align an adjustable fitting with the tube.

1. Inspect the fitting sealing surfaces. They must be free of dirt scratches, nicks, and burrs.

Hold connections together while tightening nut to ensure proper seal.

2. Inspect the O-ring. It must be free dirt, cuts, cracks, swelling or flatten condition.

5. Tighten nut (A) hand tight so O-ring contacts seat and then an additional 1/4—1/3 turn using a wrench.

3. Lubricate O-rings using a thin film of clean hydraulic oil. CED,OUO1002,517 -19-14JAN04-1/1

TM1731 (28JAN20)

00-03-21

850J Crawler (S.N. 130886—311988) 012820 PN=39

Torque Values

TM1731 (28JAN20)

00-03-22

850J Crawler (S.N. 130886—311988) 012820 PN=40

Contents

Section 01 Tracks

Page Page

Group 0130—Track System Welding On Machine ................................. 01-0130-1 Track Guides and Rock Guards Remove and Install................................ 01-0130-1 Carrier Roller Wear Inspection .................. 01-0130-4 Carrier Roller Remove and Install.............. 01-0130-5 Carrier Roller Disassemble and Assemble............................................... 01-0130-6 Metal Face Seals Inspection ..................... 01-0130-9 Carrier Roller Leakage Test..................... 01-0130-10 Track Roller Wear Inspection .................. 01-0130-10 Track Roller Remove and Install ............. 01-0130-11 Track Roller Disassemble and Assemble............................................. 01-0130-13 Track Roller Leakage Test....................... 01-0130-22 Track Shoe Grouser Wear Inspection ............................................ 01-0130-23 Track Shoe Remove and Install .............. 01-0130-24 Pivot Shaft Remove and Install ............... 01-0130-25 Pivot Shaft Disassemble and Assemble............................................. 01-0130-25 Crossbar Remove and Install .................. 01-0130-26 Crossbar Disassemble and Assemble............................................. 01-0130-29 Track Link Height Inspection ................... 01-0130-30 Bushing Outside Diameter for Lubricated Track Chain Inspection ............................................ 01-0130-31 Track Pitch for Lubricated Track Chain Inspection.................................. 01-0130-32 Lubricated Track Chain Remove and Install ............................................ 01-0130-32 Lubricated Track Chain to Turn Bushings and Lubricate Chain Disassemble ........................................ 01-0130-36 Lubricated Track Chain to Turn Bushings and Lubricate Chain Assemble............................................. 01-0130-38 Lubricated Track Chain to Turn Pins and Bushings and Not Lubricate Disassemble and Assemble ................ 01-0130-45 Track Sag Adjustment ............................. 01-0130-50 Track Adjuster Cylinder and Recoil Spring Remove and Install .................. 01-0130-51 Track Adjuster Recoil Spring Disassemble and Assemble ................ 01-0130-53 Track Adjuster Cylinder Disassemble and Assemble ................ 01-0130-62 Track Frame Remove and Install ............ 01-0130-64 Front Idler Wear Inspection ..................... 01-0130-69 Front Idler Remove and Install ................ 01-0130-69 Front Idler Disassemble and Assemble............................................. 01-0130-75 Front Idler Adjustment ............................. 01-0130-81 TM1731 (28JAN20)

Front Idler Oil Leakage Test .................... 01-0130-83 Sprocket Segment Remove and Install ................................................... 01-0130-84

01-1

850J Crawler (S.N. 130886—311988) 012820 PN=1

Contents

TM1731 (28JAN20)

01-2

850J Crawler (S.N. 130886—311988) 012820 PN=2

Group 0130

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

WELD METAL SPECIFICATIONS Item

Specification

Tensile Strength

482.6 MPa (70 000 psi)

Yield Strength

413.7 MPa (60 000 psi)

Elongation

22%

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

Remove or protect all parts that can be damaged by heat or weld splatter.

TX,WELD,II -19-07OCT14-1/1

Track Guides and Rock Guards Remove and Install

T133509 —UN—15APR13

CAUTION: High pressure release of oil from pressurized system can cause serious burns or penetrating injury. DO NOT remove grease fitting to increase track sag. DO NOT tamper with relief valve. It is fitted with a cover. Slowly loosen check valve fitting to release grease from track tension adjuster. 1. Track Guides Remove and Install—slowly turn check valve fitting (3) counterclockwise one turn to release track tension. See Adjust Track Sag. (Operators Manual.) 3— Check Valve

T206819C —UN—28JAN05

1— Grease Fitting 2— Relief Valve

Track Adjuster Check Valve Continued on next page

TM1731 (28JAN20)

01-0130-1

MM61211,000154D -19-08JUN06-1/5

850J Crawler (S.N. 130886—311988) 012820 PN=43

Track System

CAUTION: Prevent possible injury from unexpected track movement. Raise the machine off the ground and support with 20-Ton Floor Stands. Tracks MUST be free to rotate in either direction. 2. Raise machine off the ground and support with 20-Ton Floor Stands. Lower blade to ground. 4— Washer (2 used) 5— Cap Screw (2 used)

T205099A —UN—04DEC04

1— 20-Ton Floor Stand (4 used) 2— Floor Stand Adapter (2 used) 3— Floor Stand Rod

750J/850J Floor Stand Kit MM61211,000154D -19-08JUN06-2/5

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

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

1— Guide, Left Rear (2 used) 2— Cap Screw (28 used) 3— Cap Screw (12 used) 4— Guide, Right Rear (2 used) 5— Cap Screw (20 used)

7 9 8

6— Washer (12 used) 7— Guard, Left Sprocket (2 used) 8— Washer (48 used) 9— Guard, Right Sprocket (2 used) 10— Guide, Front Track (4 used)

2 8 5

8 10

Front and Rear Track Guides and Guards

Continued on next page

TM1731 (28JAN20)

1 4

T209551 —UN—15MAR05

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

01-0130-2

MM61211,000154D -19-08JUN06-3/5

850J Crawler (S.N. 130886—311988) 012820 PN=44

Track System

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

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

T209238 —UN—15MAR05

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

7. Inspect track guides and sprocket guards for wear and damage. Repair or replace as necessary. Center Track Guide

8. Apply PM38654 thread lock (high strength) and sealer to cap screws.

11— Cap Screw (8 used) 12— Washer (8 used)

9. Install sprocket guards, washers, and cap screws. Tighten cap screws to specification. Specification Sprocket Guard Cap Screw-to-Track Frame—Torque...........................................................................530 N·m 390 lb-ft

10. Install track guides, washers, and cap screws. Tighten cap screws to specification.

Specification Track Guide Cap Screw-to-Track Frame—Torque...........................................................................275 N·m 200 lb-ft

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

Continued on next page

TM1731 (28JAN20)

13— Guide, Center (2 used)

01-0130-3

MM61211,000154D -19-08JUN06-4/5

850J Crawler (S.N. 130886—311988) 012820 PN=45

Track System

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

Specification Rock Guard—Weight................................................. 73 kg Approximate 160 lb Approximate

T209074 —UN—03MAR05

10 4

1. Rock Guards Remove and Install—remove parts (1—10).

2. Inspect rock guards (1 and 2) for wear and damage. Repair or replace parts as necessary.

9 1

3. Apply PM38654 high strength thread lock and sealer to cap screws (4, 8, and 10).

Rock Guards

4. Install inner and outer rock guard, washers, and cap screws.

1— Guard (Left side, outside/Right side, inside) (2 used) 2— Guard (Right side, outside/Left side, inside) (2 used) 4— Cap Screw (10 used on standard track) (12 used on long track) 5— Spacer (10 used on standard track) (12 used on long track)

5. Put cap screws through inner guard, spacer, outer guard, washer, and nut. Tighten nuts to specification. Specification Rock Guard Cap Screw-to-Track Frame—Torque...........................................................................275 N·m 200 lb-ft

6— Nut (10 used on standard track) (12 used on long track) 8— Cap Screw (12 used on standard track) (14 used on long track) 9— Washer (16 used on standard track) (18 used on long track) 10— Cap Screw (4 used)

Specification Inner Rock Guard Cap Screw-to-Outer Rock Guard Nut—Torque.....................................................................530 N·m 390 lb-ft MM61211,000154D -19-08JUN06-5/5

Carrier Roller Wear Inspection NOTE: For additional information see 755K, 850J, 850K Carrier Roller Tread Diameter. (SP326.) T5819AC —UN—01NOV88

1. Position an outside calipers over the most worn area of roller running surface, and close until caliper tips just touch tread surface. 2. Measure caliper tip spread using the scale to the nearest 0.5 mm (0.02 in.) Specification Carrier Roller—OD (new)........................................................................................ 187.5 mm 7.38 in. Carrier Roller—OD (100 percent worn)........................................................................... 168.0 mm 6.61 in.

3. Check for flat spots on carrier roller thread, which indicate roller is not free to turn. MM61211,0001559 -19-12NOV13-1/1

TM1731 (28JAN20)

01-0130-4

850J Crawler (S.N. 130886—311988) 012820 PN=46

Track System

Carrier Roller Remove and Install

T206819C —UN—28JAN05

CAUTION: Escaping fluid under pressure can penetrate the skin causing serious injury. DO NOT remove grease fitting to increase sag. DO NOT tamper with relief valve. It is fitted with a cover. Slowly loosen check valve fitting to release grease from track tension adjuster. 1. Slowly turn check valve fitting (3) counterclockwise one turn to release track tension. See Adjust Track Sag. (Operators Manual.) 2. Raise and support track chain using a chain and hoist. 1— Grease Fitting 2— Relief Valve

Track Adjuster Check Valve

3— Check Valve

TE14778,000009B -19-31MAR05-1/2

CAUTION: Carrier roller is heavy and can cause injury if not moved properly. Use adequate lifting device to move carrier roller. T209559A —UN—15MAR05

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

3. Loosen cap screws (1) to remove front or rear carrier rollers. 4. Install carrier roller into support. Tighten cap screws. 5. Check for proper alignment of carrier rollers. 6. If out of alignment loosen cap screws (1) and adjust outward.

1— Cap Screw (2 used)

7. Adjust track sag. See Adjust Track Sag. (Operators Manual.) TE14778,000009B -19-31MAR05-2/2

TM1731 (28JAN20)

01-0130-5

850J Crawler (S.N. 130886—311988) 012820 PN=47

Track System

Carrier Roller Disassemble and Assemble

1. Remove snap ring (1).

2. Remove cover (3) using slide hammer. 3. Drain oil from housing.

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

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

8 4

6 9

7. Press shaft (12) out of seal retainer (11) using a press.

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

7 5 3 1

8. Remove metal face seals (10). Keep seal rings together as a matched set with faces together to protect lapped surfaces. See Metal Face Seals Inspection. (Group 0130.)

Carrier Roller Assembly 1— Snap Ring 2— Pipe Plug 3— Cover 4— O-Ring 5— Cap Screw (2 used) 6— Retainer Plate

9. Remove bearing cups (8) from roller shell. Inspect roller shell for grooved, burred or galled condition. 10. Replace parts as necessary.

Continued on next page

TM1731 (28JAN20)

T209436 —UN—10MAR05

6. Press inner bearing cone (7) from shaft using a press.

01-0130-6

7— Bearing Cone (2 used) 8— Bearing Cup (2 used) 9— Roller Shell 10— Metal Face Seal 11— Seal Retainer 12— Shaft MM61211,000155A -19-26APR17-1/3

850J Crawler (S.N. 130886—311988) 012820 PN=48

Track System

11. Cool bearing cups (8) to specification and press into roller shell.

Specification Bearing Cups—Temperature.................................................................................................. -18°C 0°F

10 8

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

Specification

13. Install shaft (12) in roller shell.

6 9

T209436 —UN—10MAR05

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

14. Heat outer bearing cone (7) to specification and install on shaft so bearing is even with end of shaft.

Specification

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

1 Carrier Roller Assembly

15. Install retainer plate (6) and cap screws (5). Tighten cap screws to specification.

1— Snap Ring 2— Pipe Plug 3— Cover 4— O-Ring 5— Cap Screw (2 used) 6— Retainer Plate

Specification Retainer Plate Cap Screws—Torque............................................................................47 N·m 35 lb-ft

IMPORTANT: O-ring and seat surfaces must be clean, dry and oil free so O-rings do not slip when roller is turning.

7— Bearing Cone (2 used) 8— Bearing Cup (2 used) 9— Roller Shell 10— Metal Face Seal 11— Seal Retainer 12— Shaft

16. Thoroughly clean O-rings and seat surfaces in roller, cover, and seal rings using a volatile, non-petroleum base solvent and lint-free tissues. Continued on next page

TM1731 (28JAN20)

01-0130-7

MM61211,000155A -19-26APR17-2/3

850J Crawler (S.N. 130886—311988) 012820 PN=49

Track System

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

T209590A —UN—16MAR05

18. Apply equal pressure with the fingers at four equally spaced points on seal ring face. O-ring and seal ring should seat squarely in bore. NOTE: A volatile, non-petroleum base solvent or talcum powder may be used as a lubricant. 19. Wipe both metal seal ring faces dry with a lint-free tissue. 20. Apply a thin film of oil, as used in the roller, to the shiny sealing area on both metal seal rings.

Metal Face Seal Installation Tool 10— Metal Face Seal 11— Seal Retainer

21. Apply PM37479 thread lock (high strength) and sealer to shoulder area of shaft to bond seal retainer.

13— JDG205 Installation Tool

22. Install seal retainer (11) on shaft. Cover is a press fit. 23. Fill roller with clean oil. See Track Rollers, Front Idler, Carrier Roller, and Track Frame Pivot Oil for correct grade. (Operator's Manual.)

25. Install cover (3) with O-ring (4) into carrier roller (9). 26. Install snap ring (1). 27. Perform Carrier Roller Leakage Test. (Group 0130.)

Specification Carrier Roller Oil—Quantity................................................................................. 320 ml 10.8 oz.

28. Apply PM37397 Pipe Sealant to carrier roller oil fill pipe plug. Install plug.

24. Apply TY24811 NEVER-SEEZ® Lubricant or an equivalent to outside diameter of cover (3) and snap ring (1). NEVER-SEEZ is a trademark of Emhart Chemical Group. MM61211,000155A -19-26APR17-3/3

TM1731 (28JAN20)

01-0130-8

850J Crawler (S.N. 130886—311988) 012820 PN=50

Track System

Metal Face Seals Inspection 1. Inspect for the following conditions to determine if seals can be reused:

• The narrow, highly polished sealing area (E) must be in the outer half of seal ring face (D).

• Sealing area must be uniform and concentric with the ID and OD of seal ring (A).

• Sealing area must not be chipped, nicked, or scratched.

D—Outer Half of Seal Ring Face E—Sealing Area (dark line)

T85079 —UN—24AUG93

A—Seal Ring B—Worn Area (shaded area) C—Seal Ring Face

Metal Face Seals T47,0130,5939HQ -19-09APR15-1/3

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

A—Seal Ring B—Worn Area (shaded area)

T85080 —UN—05DEC96

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

Cross Section of a Metal Face Seal T47,0130,5939HQ -19-09APR15-2/3

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

T82840 —UN—23FEB89

4. Wash seal rings and O-rings using a volatile, non-petroleum base solvent to remove all oil. Thoroughly dry parts using a lint-free tissue. Apply a thin film of oil to seal ring face. Put face of seal rings together and hold using tape.

Seal Face T47,0130,5939HQ -19-09APR15-3/3

TM1731 (28JAN20)

01-0130-9

850J Crawler (S.N. 130886—311988) 012820 PN=51

Track System

Carrier Roller Leakage Test SPECIFICATIONS Carrier Roller Leakage Test Air Pressure

107—127 kPa 0.8—1.2 bar 14—20 psi

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

4. Close valve and wait for two minutes. Make sure roller maintains air pressure and oil does not leak past O-ring or metal face seals. T211091A —UN—11MAY05

5. If roller leaks oil or does not maintain pressure, check O-ring or seals. Repair as necessary and recheck for leaks. 6. Install and tighten plug. 1— Pressure Gauge 0—689 kPa (0—6.89 bar) (0—100 psi) 2— T80937 Adapter (-6 M 9/16-18UNF-2A ORFS x 1/8-27 NPTF) 3— JT03456 O-Ring Face Seal (2 used) (17/16 -20 M JIC x 11/16-16 F ORFS)

4— Shut-Off Valve 5— Regulator 6— 38H1030 Tee (-6 F ORFS x -6 M ORFS x -6 M ORFS) Parker No. (6R6LOS)

TE14778,0000090 -19-07JUL05-1/1

Track Roller Wear Inspection CAUTION: Prevent possible injury from unexpected track movement. Raise the machine off the ground and support with 20-Ton Floor Stands and JDG10013 Floor Stand Kit. 1. Raise machine off the ground and support with 20-Ton Floor Stands and JDG10013 Floor Stand Kit. Lower blade to ground. 4— Washer (2 used) 5— Cap Screw (2 used)

T205099A —UN—04DEC04

1— 20-Ton Floor Stand (4 used) 2— Floor Stand Adapter (2 used) 3— Floor Stand Rod

750J/850J Floor Stand Kit Continued on next page

TM1731 (28JAN20)

01-0130-10

OUO1020,000157A -19-12NOV13-1/3

850J Crawler (S.N. 130886—311988) 012820 PN=52

Track System

T206819C —UN—28JAN05

CAUTION: Escaping fluid under pressure can penetrate the skin causing serious injury. DO NOT remove grease fitting to increase track sag. DO NOT tamper with relief valve. It is fitted with a cover. Slowly loosen check valve fitting to release grease from track tension adjuster. 2. Slowly turn check valve fitting (3) counterclockwise one turn to release track tension. See Adjust Track Sag. (Operators Manual.) 1— Grease Fitting 2— Relief Valve

3— Check Valve Track Adjuster Check Valve

OUO1020,000157A -19-12NOV13-2/3

NOTE: 100 Percent Worn is the maximum allowable wear for rebuilding roller tread. Measure roller tread diameter using a caliper such as JT07193 Special Roller Caliper from JT05518A Undercarriage Inspection Kit.

T6813AM —UN—29JAN98

Specification Track Roller Tread—OD (new)........................................................................................ 227.0 mm 8.94 in. Track Roller Tread—OD (100 percent worn)................................................................... 188.4 mm 7.42 in.

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

See Track Rollers. (SP326.) See 755K, 850J, 850K Track Roller Tread Diameter. (SP326.)

NOTE: Reference Undercarriage Appraisal Manual SP326 for additional information. OUO1020,000157A -19-12NOV13-3/3

Track Roller Remove and Install

T206819C —UN—28JAN05

CAUTION: Escaping fluid under pressure can penetrate the skin causing serious injury. Do not remove grease fitting to increase track sag. Do not tamper with relief valve. It is fitted with a cover. Slowly loosen check valve fitting to release grease from track tension adjuster. 1. Slowly turn check valve fitting (3) counterclockwise one turn to release track tension. Put a piece of pipe between the sprocket and the track chain and rotate track to retract the adjusting cylinder if required.See Adjust Track Sag. (Operators Manual.)

Track Adjuster Check Valve 1— Grease Fitting 2— Relief Valve Continued on next page

TM1731 (28JAN20)

01-0130-11

3— Check Valve

OUO1020,000157B -19-05JUN06-1/3

850J Crawler (S.N. 130886—311988) 012820 PN=53

Track System

CAUTION: Prevent possible injury from unexpected track movement. Raise the machine off the ground and support with 20-ton floor stands and floor stand kit. 2. Raise machine off the ground and support with D01182AA 20-Ton Floor Stands and JDG10013 750J/850J Floor Stand Kit. Lower blade to ground.

1— 20-Ton Floor Stand (4 used) 2— 750J/850J Floor Stand Kit (2 used) 3— Floor Stand Rod

T205099A —UN—04DEC04

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

750J/850J Floor Stand Kit OUO1020,000157B -19-05JUN06-2/3

CAUTION: Heavy component; use a hoist.

T209622A —UN—17MAR05

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

4. Remove cap screws (1) and track roller (2). NOTE: All machines with 40 link chains have seven track rollers. Single and double flange rollers are used alternately starting at idler with a single flange roller. All machines with 45 link chains have eight track rollers. Single and double flange rollers are used alternately starting at idler with two single flange rollers.

Track Roller Cap Screws 1— Cap Screw

2— Track Roller

5. Install track roller (2) with oil fill plug toward outside of unit. 6. Carefully lower crawler until roller cap screws can be installed. 7. Apply PM38654 Thread Lock and Sealer (High Strength) to track roller cap screws before installing rollers onto track frame.

Specification 850J Track Rollerto-Track Frame Cap Screw—Torque...........................................................................530 N·m. 390 lb-ft

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

8. Tighten cap screws (1) to specification. OUO1020,000157B -19-05JUN06-3/3

TM1731 (28JAN20)

01-0130-12

850J Crawler (S.N. 130886—311988) 012820 PN=54

Track System

Track Roller Disassemble and Assemble Track Roller Disassemble

18 12

4 5

2 3

11 14

16 1 T210108 —UN—05APR05

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

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

11— O-Ring (2 used) 12— Roller Shell 13— Outer Bracket 14— Plug (Rubber) 15— Plug (Plastic) 16— Lock Washer (4 used) Continued on next page

TM1731 (28JAN20)

01-0130-13

17— Cap Screw (12 used) 18— Lock Washer (12 used)

TE14778,000009A -19-26APR17-1/16

850J Crawler (S.N. 130886—311988) 012820 PN=55

Track System

NOTE: Single and double flange rollers are of the same design. Disassembly procedures are the same for both types of rollers.

T80426 —UN—26OCT88

1. Compress the metal face seals slightly using a 1 3/8 inch diameter disk (1) from D01045AA Bushing, Bearing, and Seal Driver Set and a press. Remove the snap ring (2) from both sides of roller shaft (3).

TE14778,000009A -19-26APR17-2/16

2. Remove outer and inner brackets (1). NOTE: Metal face seals are a matched set. Seals are not interchangeable with other seals.

T80427 —UN—26OCT88

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

Continued on next page

TM1731 (28JAN20)

01-0130-14

TE14778,000009A -19-26APR17-3/16

850J Crawler (S.N. 130886—311988) 012820 PN=56

Track System

4. Remove and inspect metal face seals. See Metal Face Seals Inspection. (Group 0130.) 5. Remove O-rings (2) from both ends of shaft. T6018BC —UN—26OCT88

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

TE14778,000009A -19-26APR17-4/16

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

T80432 —UN—26OCT88

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

Continued on next page

TM1731 (28JAN20)

01-0130-15

TE14778,000009A -19-26APR17-5/16

850J Crawler (S.N. 130886—311988) 012820 PN=57

Track System Track Roller Assemble 9— Lock Washer (12 used) 12— Dowel Pin (2 used) 13— Bushing (2 used) 14— O-Ring (2 used) 15— Roller Shell 16— Bushing Case (2 used) 17— Shaft 18— Bracket (2 used)

T209988 —UN—31MAR05

1— O-Ring (2 used) 2— Plug (Rubber) 3— Washer (4 used) 4— Cap Screw (4 used) 5— Snap Ring (2 used) 6— Plug (Plastic) 7— Metal Face Seal (2 used) 8— Cap Screw (12 used)

Double Flange Track Roller Shown Continued on next page

TM1731 (28JAN20)

01-0130-16

TE14778,000009A -19-26APR17-6/16

850J Crawler (S.N. 130886—311988) 012820 PN=58

Track System

NOTE: Assembly of single and double flange roller is the same. Single flange shown. 1. Cool bushing (1) and heat bushing case (3) to specification. Specification Bushing—Temperature.................................................................... -18°C 0°F Specification Bushing Case—Temperature............................................................................................... 121°C 250°F

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

4. When bushing case cools, install O-ring (5) on bushing case. 1— Bushing 2— Dowel Pin 3— Bushing Case

4— Disk (4 inch diameter) 5— O-Ring 6— Alignment Mark

Continued on next page

TM1731 (28JAN20)

01-0130-17

T210063A —UN—31MAR05

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

TE14778,000009A -19-26APR17-7/16

850J Crawler (S.N. 130886—311988) 012820 PN=59

Track System

5. Install bushing case (1) using aligning studs (2), 89 mm (3 1/2 inch) diameter x 6.3 mm (1/4 inch) wall pipe (5), 3 9/16 inch diameter disk (4), and a press. 6. Remove aligning studs. Install cap screws and lock washers. Tighten cap screws. 7. Turn roller (3) over and carefully install roller shaft. 8. Install bushing case (1) using aligning studs (2), 89 mm (3 1/2 inch) diameter x 6.3 mm (1/4) inch wall pipe (5), 3 9/16 inch diameter disk (4), and a press. 9. Remove studs. Install cap screws and lock washers. Tighten cap screws. 4— Disk (3 9/16 inch diameter) 5— Pipe

T80440 —UN—26OCT88

1— Bushing Case 2— Stud 3— Roller

TE14778,000009A -19-26APR17-8/16

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

T6018BA —UN—26OCT88

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

Continued on next page

TM1731 (28JAN20)

01-0130-18

TE14778,000009A -19-26APR17-9/16

850J Crawler (S.N. 130886—311988) 012820 PN=60

IMPORTANT: The metal face seal must be extremely clean during assembly. Use a volatile, non-petroleum base type solvent to clean the metal seal ring (2) and rubber seal (1). DO NOT keep the rubber seal in a volatile, non-petroleum base type solvent for more than one minute. Wipe the seals dry with lint-free tissue to remove finger prints and foreign material. 12. Install rubber seal (1) on the metal seal ring (2). Make sure the rubber seal sits evenly on metal seal ring.

T80574 —UN—26OCT88

Track System

TE14778,000009A -19-26APR17-10/16

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

1— Seal Ring Flange 2— JDG205 Seal Installation Tool

T6077AV —UN—26OCT88

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

TE14778,000009A -19-26APR17-11/16

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

1— JDG205 Seal Installation Tool

T80577 —UN—26OCT88

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

Continued on next page

TM1731 (28JAN20)

01-0130-19

TE14778,000009A -19-26APR17-12/16

850J Crawler (S.N. 130886—311988) 012820 PN=61

Track System

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

T80578 —UN—26OCT88

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

TE14778,000009A -19-26APR17-13/16

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

T80426 —UN—26OCT88

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

Continued on next page

TM1731 (28JAN20)

01-0130-20

TE14778,000009A -19-26APR17-14/16

850J Crawler (S.N. 130886—311988) 012820 PN=62

Track System

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

T6090AI —UN—26OCT88

24. Insert nozzle in roller shaft with flat side up, as far as possible. 25. Slowly pump recommended oil into shaft using adapter (2) and grease gun (3) until oil without air bubbles is seen leaking past the flat on nozzle. See Track Rollers, Front Idler, Carrier Roller, and Track Frame Pivot Oil. (Operator's Manual.) NOTE: Perform Track Roller Leakage Test BEFORE installing plugs. 26. Perform Track Roller Leakage Test. (Group 0130.)

1— JD313-1 Lube Nozzle 2— JD313-2 Adapter

3— Grease Gun

TE14778,000009A -19-26APR17-15/16

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

Specification

28. Install track roller. See Track Roller Remove and Install . (Group 0130.) 14— Plug (rubber) 15— Plug (plastic)

19— Track Roller Oil Plug Depth

15 T210171 —UN—07APR05

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

TE14778,000009A -19-26APR17-16/16

TM1731 (28JAN20)

01-0130-21

850J Crawler (S.N. 130886—311988) 012820 PN=63

Track System

Track Roller Leakage Test 1. Remove plug from track roller. 2. Fill track roller with recommended oil. See Track Rollers, Front Idler, Carrier Roller, and Track Frame Pivot Oil. (Operator's Manual.) 3. Turn roller several times to seal metal face seals. 4. Assemble parts (1—5) as shown. 5. Pressurize roller with compressed air to specification and close valve (4). Specification Track Roller Leakage Test—Air Pressure............................................................ 107—127 kPa 0.8—1.2 bar 14—20 psi

1— Pressure Gauge 207 kPa (2.07 bar) (0—30 psi) 2— T149247 Rubber Plug 3— Male Barb-to-Male pipe Fitting (1/8-27 NPTF) Park No. (125HBL-4-2)

T211097A —UN—11MAY05

6. Track roller must maintain air pressure for two minutes. Oil must not leak past metal seals or rubber plug. If oil leaks past seals, repair as necessary. 4— Shut-Off Valve 5— Regulator

TE14778,00000D1 -19-26APR17-1/2

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

Specification

14— Plug (rubber) 15— Plug (plastic)

19— Track Roller Oil Plug Depth

15 T210171 —UN—07APR05

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

TE14778,00000D1 -19-26APR17-2/2

TM1731 (28JAN20)

01-0130-22

850J Crawler (S.N. 130886—311988) 012820 PN=64

Track System

Track Shoe Grouser Wear Inspection

NOTE: For additional information, reference Undercarriage Appraisal Manual SP326.

TX1098691 —UN—23SEP11

The maximum allowable wear for rebuilding grouser bars with weld is 100 percent worn.

See 850J, 850K Single Bar Grouser Height—Moderate Service Track Shoes. (SP326.)

See 850J, 850K Single Bar Grouser Height—Extreme Service Track Shoes. (SP326.) Measure grouser height of several track shoes to find an average using a depth gauge such as the JT05521 200 mm Ruler, JT05534 Right Angle Attachment, and D-05231ST 300 mm Ruler from JT05518A Undercarriage Inspection Kit. Specification Grouser (moderate service track shoes)—Height (new)................................................................. 65.5 mm 2.58 in. Grouser (moderate service track shoes)—Height (100 percent worn)............................................................................. 24.5 mm 0.96 in. Specification Grouser (extreme service track shoes)—Height (new).......................................................................................... 71.5 mm 2.81 in.

Measure Grouser Height A—Grouser Height

B—Plate Thickness

Grouser (extreme service track shoes)—Height (100 percent worn)..................................................................... 25.4 mm 1.00 in.

Use plate thickness (B) specifications to identify moderate service and extreme service track shoes. Specification Moderate Service Track Shoe—Plate Thickness.............................................................. 12.0 mm 0.47 in. Extreme Service Track Shoe—Plate Thickness.............................................................. 14.7 mm 0.58 in. OUO1020,000157C -19-12NOV13-1/1

TM1731 (28JAN20)

01-0130-23

850J Crawler (S.N. 130886—311988) 012820 PN=65

Track System

Track Shoe Remove and Install

1. Remove nuts and cap screws using DFT1041 Track Nut Removal Tool. For instructions to make tool See DFT1041 Track Nut Removal Tool. (Group 9900.) 2. Before installing shoes, clean paint, dirt, and debris from mounting surfaces of shoes and links. 3. For all cap screws except those for split master links and shoe, apply oil (SAE 30) to threads and bearing surface under head.

T96291 —UN—23FEB89

NOTE: Cap screws hold the master shoe and split master link together. Link side of master shoe has machined surfaces.

IMPORTANT: Never use an impact wrench to start cap screws in split master link to avoid cross-threading. 4. Install new cap screws. Install new nuts using DFT1041 Track Nut Removal Tool with rounded edges (A) against link and chamfered edges (B) away from link. See DFT1041 Track Nut Removal Tool. (Group 9900.)

T96292 —UN—23FEB89

For split master link and shoe cap screws, apply John Deere NEVER-SEEZ® Lubricant or an equivalent to threads and bearing surface under head.

Specification 850J Track Shoe Cap Screw—Torque Turn....................................... 270 N·m + 1/3 Turn (120°) 199 lb-ft + 1/3 Turn (120°) 850J Split Master Link Shoe Cap Screw—Torque Turn....................................... 270 N·m + 1/2 Turn (180°) 199 lb-ft + 1/2 Turn (180°)

T6352AH —UN—23FEB89

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

6. Check torque after 50—100 hours of operation to make sure cap screws are tightened to minimum torque. Specification 850J Track Shoe Cap Screws 50—100 Hour Check—Minimum Torque.........................................................................................597 N·m 440 lb-ft NEVER-SEEZ is a registered trademark of Emhart Chemical Group OUO1020,000157E -19-15JAN08-1/1

TM1731 (28JAN20)

01-0130-24

850J Crawler (S.N. 130886—311988) 012820 PN=66

Track System

Pivot Shaft Remove and Install

85 kg 188 lb

Pivot Shaft Cap Screw Torque

530 N·m 390 lb·ft

T209976 —UN—29MAR05

SPECIFICATIONS Pivot Shaft Weight (approximate)

OTHER MATERIAL Loctite® 271™ Threadlocker (high strength)

1 CAUTION: Pivot shaft is heavy and can cause injury if not moved properly. Use adequate lifting device to move pivot shaft. Specification Pivot Shaft—Weight (approximate).................................................................................. 85 kg 188 lb

1. Remove pivot shaft cap screws (3), washers (2), and pivot shaft (1). Repair or replace necessary. See Pivot Shaft Disassemble and Assemble. (Group 0130.)

Pivot Shaft 1— Pivot Shaft (2 used) 2— Washer (42 used)

3— Cap Screw (42 used)

Specification Pivot Shaft Cap Screw—Torque............................................................................530 N·m 390 lb·ft

2. Apply Loctite® 271™ Threadlocker (high strength) and sealer to pivot shaft mounting cap screws (3). 3. Install pivot shaft onto main frame using hoist. Tighten cap screws to specification. Loctite and its related brand marks are trademarks of Henkel Corporation MM61211,000155B -19-31OCT17-1/1

Pivot Shaft Disassemble and Assemble DISASSEMBLE Remove and disassemble components as shown.

2 4

Inspect and repair or replace components as necessary.

ASSEMBLE Assemble components as shown. 5— Seal 6— Ring 7— Pivot Shaft

1 5 6

XJ1245678 —UN—03NOV17

1— Track Frame Retainer (2 used) 2— Washer (8 used) 3— Cap Screw (8 used) 4— Pivot Shaft Cover

Pivot Shaft (exploded view) VK00427,00000F0 -19-31OCT17-1/1

TM1731 (28JAN20)

01-0130-25

850J Crawler (S.N. 130886—311988) 012820 PN=67

Track System

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

T205099A —UN—04DEC04

CAUTION: Prevent possible injury from unexpected track movement. Raise the machine off the ground and support with 20-Ton Floor Stands. Tracks must be free to rotate in either direction. 2. Raise machine off the ground and support with 20-Ton Floor Stands. Lower blade to ground. 3. Remove track chain. See Lubricated Track Chain Remove and Install. (Group 0130.) 1— 20-Ton Floor Stand (4 used) 2— Floor Stand Adapter (2 used) 3— Floor Stand Rod

4— Washer (2 used) 5— Cap Screw (2 used)

750J/850J Floor Stand Kit

MM61211,000155C -19-27APR17-1/6

4. Disconnect crossbar lube hose (6) from track frame on both sides.

CAUTION: Prevent possible injury from unexpected crossbar and track frame movement. Track frame on opposite side will pivot down. Before removing track frame always block track frame on opposite side.

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

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

6 1

1— Crossbar 2— Pivot Pin, Crossbar-to-Main Frame 3— Pivot Pin, Crossbar-toTrack Frame (2 used) 4— Cap Screw (3 used)

5— Bushing (3 used) 6— Lubrication Hose (2 used) 7— Nut (2 used)

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

T209845 —UN—28MAR05

7 3

6. Remove front and middle bottom guards.

Continued on next page

TM1731 (28JAN20)

01-0130-26

MM61211,000155C -19-27APR17-2/6

850J Crawler (S.N. 130886—311988) 012820 PN=68

Track System

CAUTION: Crossbar is heavy and can cause injury if not moved properly. Use adequate lifting device to move crossbar. T209808A —UN—24MAR05

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

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

MM61211,000155C -19-27APR17-3/6

11. Remove crossbar. 12. Apply NEVER-SEEZ® Lubricant or an equivalent to inside diameter of crossbar-to-track frame bushings and corresponding pivot pins (3).

3 1— Crossbar 2— Pivot Pin, Crossbar-to-Main Frame 3— Pivot Pin, Crossbar-toTrack Frame (2 used) 4— Cap Screw (3 used)

5— Bushing (3 used) 6— Lubrication Hose (2 used) 7— Nut (2 used)

T209845 —UN—28MAR05

6 7

NEVER-SEEZ is a trademark of Emhart Chemical Group. Continued on next page

TM1731 (28JAN20)

01-0130-27

MM61211,000155C -19-27APR17-4/6

850J Crawler (S.N. 130886—311988) 012820 PN=69

Track System

CAUTION: Crossbar is heavy and can cause injury if not moved properly. Use adequate lifting device to move crossbar. T209846A —UN—28MAR05

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

13. Guide crossbar (1) into main frame using hoist. 14. Push crossbar through main frame and align crossbar self-aligning bushing with track frame bore. 15. Apply PM37479 thread lock (high strength) and sealer to crossbar-to-track frame cap screws (4). CAUTION: Front bottom guard is heavy and can cause injury if not moved properly. Use adequate lifting device to move front bottom guard.

16. Install crossbar-to-track frame pin (3), bushing (5), and cap screw (4). Tighten cap screw to specification. Specification Pivot Pin-To-Track Frame Cap Screw—Torque....................................................................275 N·m 200 lb-ft

17. Align crossbar synthetic bushing with main frame bore. 18. Apply high strength thread lock and sealer to crossbar-to-main frame cap screw (4). 19. Install crossbar-to-main frame pin (3), bushing (5), and cap screw (4). Tighten cap screw to specification. Specification Pivot Pin-To-Main Frame Cap Screw—Torque....................................................................275 N·m 200 lb-ft

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

20. Install front and middle bottom guards. 21. Install track frame. See Track Frame Remove and Install. (Group 0130.) 22. Connect crossbar lube hose (6) to track frame on both sides.

MM61211,000155C -19-27APR17-5/6

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

T209856 —UN—28MAR05

24. Fill track frame with oil. See Track Rollers, Front Idler, Carrier Roller, and Track Frame Pivot Oil. (Operators Manual. 25. Apply PM37397 pipe sealant to pipe plug (10) and install. Install plug (12). 26. Install track chain. See Lubricated Track Chain Remove and Install. (Group 0130.) 27. Install pushbeam and blade assembly (Outside Dozer). See Outside Dozer Push Beams Remove and Install. (Group 3240.)

Track Frame Oil Fill 10— Pipe Plug

12— Plug MM61211,000155C -19-27APR17-6/6

TM1731 (28JAN20)

01-0130-28

850J Crawler (S.N. 130886—311988) 012820 PN=70

Track System

Crossbar Disassemble and Assemble

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

Remove synthetic bushing (3) using 3 7/16 inch diameter disk from D01045AA Bushing, Bearing, and Seal Driver Set.

Remove self-aligning bushings (6) using 83 mm (3 1/4 in.) diameter pipe and 3 7/16 inch diameter disk.

8 5

6 4 4

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

5 3

T209376 —UN—10MAR05

4. Inspect bushings (3 and 6). Replace if necessary. 1— Crossbar 2— Seal (2 used) 3— Synthetic Bushing 4— Seal (4 used)

7 6 4

Crossbar TE14778,000008C -19-08MAR05-1/3

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

Specification

T209384 —UN—10MAR05

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

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

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

Continued on next page

TM1731 (28JAN20)

01-0130-29

9— Synthetic Bushing Depth 10— Seal Depth TE14778,000008C -19-08MAR05-2/3

850J Crawler (S.N. 130886—311988) 012820 PN=71

Track System

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

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

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

11. Install elbow fittings and lubrication hoses. 4— Seal (4 used) 5— Snap Ring (4 used)

6— Self-Aligning Bushing (2 used)

T209385 —UN—10MAR05

9. Install second snap ring.

Self-Aligning Bushing and Seals TE14778,000008C -19-08MAR05-3/3

Track Link Height Inspection

Specification Track Link—Height (new)........................................................................................ 132.0 mm 5.20 in. Track Link—Height (100% worn)..............................................................................118.5 mm 4.67 in.

T5802AD —UN—02NOV88

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

2. Put the depth gauge on outside of track link against pin boss as shown. Measure two links to the nearest 0.5 mm (0.020 in.). NOTE: For additional information, see 755K, 850J, 850K Link Height. (SP326VOL1.) OUO1020,000157F -19-12NOV13-1/1

TM1731 (28JAN20)

01-0130-30

850J Crawler (S.N. 130886—311988) 012820 PN=72

Track System

Bushing Outside Diameter for Lubricated Track Chain Inspection

T5802AB —UN—26OCT88

1. Clean surfaces to be measured of two adjacent bushings and underside of track shoe in area between bushings. NOTE: Lubricated track chain bushings are measured for vertical wear only using calipers. Bushing vertical wear can be measured using the depth gauge method only after bushing turn procedure is used. For additional information, reference Undercarriage Appraisal Manual (SP326). 2. For caliper method, put caliper from JT05518A Undercarriage Inspection Service Tool Kit around bushing at area of vertical wear as shown. Measure several different bushings to nearest 0.5 mm (0.020 in.). Specification Bushing (standard and SC-2™ Extended Life)—OD (new)......................................................................... 72.9 mm 2.87 in. Bushing (standard and SC-2™ Extended Life)—OD (100% worn, normal impact applications)............................................................................... 62.7 mm 2.47 in. Bushing (standard and SC-2™ Extended Life)—OD (100% worn, high impact applications)............................................................................... 66.3 mm 2.61 in.

NOTE: For additional information:

Measure Bushing Outside Diameter

• See 755K, 850J, 850K Bushing Outer

Diameter—High Impact Applications. (SP326.)

• See 755K, 850J, 850K Bushing Outer

Diameter (Depth Gauge)—Normal Impact Applications. (SP326.) • See 755K, 850J, 850K Bushing Outer Diameter (Depth Gauge)—High Impact Applications. (SP326.) For SC-2™ Extended Life bushings:

• See 755K, 850J, 850K SC-2™ Extended

Life Bushing Outer Diameter—Normal Impact Applications. (SP326.) • See 755K, 850J, 850K SC-2™ Extended Life Bushing Outer Diameter—High Impact Applications. (SP326.) • See 755K, 850J, 850K SC-2™ Extended Life Bushing Outer Diameter (Depth Gauge)—Normal Impact Applications. (SP326.) • See 755K, 850J, 850K SC-2™ Extended Life Bushing Outer Diameter (Depth Gauge)—High Impact Applications. (SP326.)

• See 755K, 850J, 850K Bushing Outer

Diameter—Normal Impact Applications. (SP326.)

SC-2 is a trademark of Deere & Company RM58335,0001414 -19-26APR17-1/1

TM1731 (28JAN20)

01-0130-31

850J Crawler (S.N. 130886—311988) 012820 PN=73

Track System

Track Pitch for Lubricated Track Chain Inspection

T6813AL —UN—29JAN98

NOTE: For additional information, see 755K, 850J, 850K Chain Pitch. (SP326.) NOTE: Track pitch does not extend unless there is lubrication leakage, which causes a dry joint. Measure pitch only when there is a lubrication leakage or a visible extension of a joint. IMPORTANT: Track pin may be operated with a dry joint until it reaches wear limit specified. Then it must be repaired. A dry joint will not hold lubrication until it is repaired. Track pin may break if joint is not repaired after it reaches wear limit.

Measure Track Pitch

1. Place a pin or block between sprocket and track chain. Then move unit in reverse until track chain is tight. 2. Measure from left side of pin in dry joint across four links to left side of pin (as shown).

Specification Track Pitch—Length (new)........................................................................................ 812.8 mm 32.0 in. Track Pitch—Length (100% worn)............................................................................. 825.5 mm 32.5 in. RM58335,0001415 -19-12NOV13-1/1

Lubricated Track Chain Remove and Install CAUTION: Prevent possible injury from unexpected track movement. Raise the machine off the ground and support with 20-ton floor stands and floor stand kit. Tracks must be free to rotate in either direction.

1— 20-Ton Floor Stand (4 used) 2— Floor Stand Kit (2 used) 3— Floor Stand Rod

T205099A —UN—04DEC04

1. Raise machine off the ground and support with D01182AA 20-Ton Floor Stands and JDG10013 750J/850J Floor Stand Kit. Lower blade to ground. 4— Washer (2 used) 5— Cap Screw (2 used)

750J/850J Floor Stand Kit Continued on next page

TM1731 (28JAN20)

01-0130-32

OUO1020,0001582 -19-06JUN06-1/7

850J Crawler (S.N. 130886—311988) 012820 PN=74

Track System

T206819C —UN—28JAN05

CAUTION: Escaping fluid under pressure can penetrate the skin causing serious injury. Do not remove grease fitting to increase track sag. Do not tamper with relief valve. It is fitted with a cover. Slowly loosen check valve fitting to release grease from track tension adjuster. 2. Slowly turn check valve fitting (3) counterclockwise one turn to release track tension. Put a piece of pipe between the sprocket and the track chain and rotate track to retract the adjusting cylinder if required.See Track Sag Adjustment. (Group 0130.) 1— Grease Fitting 2— Relief Valve

Track Adjuster Check Valve

3— Check Valve

OUO1020,0001582 -19-06JUN06-2/7

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

T211292A —UN—11MAY05

IMPORTANT: Track chain must be installed under track frame with wide end of links toward rear of machine or accelerated wear to track chain will occur. 7. Install track chain by putting chain under track frame with the wide end of links toward rear of machine. 8. Block track shoes so master split link is positioned directly over idler. 1— Track Bolt (4 used)

2— Track Shoe

Continued on next page

TM1731 (28JAN20)

01-0130-33

OUO1020,0001582 -19-06JUN06-3/7

850J Crawler (S.N. 130886—311988) 012820 PN=75

Track System

9. Attach chain and hoist to track near the end of chain to support track chain. Guide track over sprocket while operator drives machine slowly forward guiding track chain over carrier rollers and front idler. T210051A —UN—31MAR05

10. Stop machine when ends of master links meet. 11. Remove any foreign material from master link tooth racks and ramp surfaces (1). Clean surface with wire brush if necessary. 12. Check for burrs, especially at tips (2) of master link ramps. Remove all burrs so ramp surfaces are flat. 13. Check bolt holes (3) in each master link. Bolt holes must be clean and free of foreign material. 1— Ramp Surface 2— Tip of Master Link Ramp

3— Holes

OUO1020,0001582 -19-06JUN06-4/7

IMPORTANT: To prevent damage to threads, do not use a pry bar in holes to align split master link.

T210052A —UN—31MAR05

14. Carefully assemble master links together and align bolt holes. 15. Install track bolts by hand to check alignment. 16. Apply John Deere NEVER-SEEZ®Lubricant or an equivalent to cap screw threads and bearing surface under head. 1— Master Link

NEVER-SEEZ is a registered trademark of Emhart Chemical Group Continued on next page

TM1731 (28JAN20)

01-0130-34

OUO1020,0001582 -19-06JUN06-5/7

850J Crawler (S.N. 130886—311988) 012820 PN=76

Track System

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

T211292A —UN—11MAY05

1— Track Bolt (4 used)

OUO1020,0001582 -19-06JUN06-6/7

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

19. Check torque after 50—100 hours of operation to make sure cap screws are tightened to the minimum torque specification. Specification 850J Lubricated Track Chain, Track Shoes 50—100 Hour Check—Torque............................................................................597 N·m 440 lb-ft

T210112 —UN—01APR05

Specification 850J Split Master Link Shoe Cap Screw—Torque Turn....................................... 270 N·m + 1/2 Turn (180°) 199 lb-ft + 1/2 Turn (180°)

Crisscross Tightening Sequence

20. Adjust track sag. See Track Sag Adjustment. (Group 0130.) OUO1020,0001582 -19-06JUN06-7/7

TM1731 (28JAN20)

01-0130-35

850J Crawler (S.N. 130886—311988) 012820 PN=77

Track System

Lubricated Track Chain to Turn Bushings and Lubricate Chain Disassemble

T96266 —UN—27OCT88

NOTE: The following procedure is for disassembly of track chain to inspect, clean, replace damaged or worn parts, turn bushings, and lubricate chain. If track chain is disassembled only to turn pins and bushings and no parts will be replaced, see Lubricated Track Chain to Turn Pins and Bushings and Not Lubricate Disassemble and Assemble. (Group 0130.) 1. Remove track shoes and track chain. See Track Shoe Remove and Install. (Group 0130.) See Lubricated Track Chain Remove and Install. (Group 0130.) NOTE: A clean track is necessary for proper disassembly. 2. Wash chain with high pressure water. It will not be necessary to wash links before reassembly if chain is thoroughly cleaned. 3. Use the appropriate track press tool set. NOTE: Tooling listed below is purchased through WTC Machinery Corporation (800) 248-8405

A—Left Ram B—Saddle C—Right Ram D—Right Link

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

“91” Series (Adjustable Camlock) Tooling 850J

910025—Jaw 910114—Side Plate (2 used) 910214—Side Plate (2 used) 910314—Shims (4 used) 912003—Adjustable Tool Holder (2 used) 912004—Stationary Tool Holder (2 used) 913013—Pin Disassembly Tool (2 used) 914015—Bushing Disassembly Tool (2 used) 915175—Pin Assembly Tool (2 used) 916240—Bushing Assembly Tool (2 used) 917060—Shim Group

E—Bushing F— Left Link G—Pin

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

“C” Style (Spring Loaded) Tooling 850J

(A2656-303).

IMPORTANT: Track press disassembly tools must be in proper alignment with links to prevent broaching of pin and bushing. Damaged link bores cannot be reused. 4. Start disassembly at pin-end half of split link. Check for proper alignment of tools with pin and bushing. Continued on next page

TM1731 (28JAN20)

01-0130-36

OUO1020,0001583 -19-04JAN08-1/4

850J Crawler (S.N. 130886—311988) 012820 PN=78

Track System

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

T96267 —UN—27OCT88

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

E—Right Link F— Bushing G—Left Link

OUO1020,0001583 -19-04JAN08-2/4

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

T6682AJ —UN—01NOV88

If there is internal wear at any joint, replace seal ring, pin, bushing, thrust ring, and load ring. These parts must be replaced to successfully lubricate chain. 12. If pin and bushing contains oil when disassembled, new pins, seals, bushings, or thrust rings are not necessary. Do not remove usable seals from link counterbore. Do not remove any dirt from around seals. 13. Repeat steps 4—12 to disassemble rest of chain. 14. Remove rubber plug (F) from pins using a drill. A—Bushing B—Seal Ring C—Load Ring

D—Thrust Ring E—Pin F— Rubber Plug OUO1020,0001583 -19-04JAN08-3/4

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

A—4 mm (0.16 in.) B—30°

T96269 —UN—27OCT88

16. Clean pins, bushings, and thrust rings in solvent. C—15° D—3 mm (0.12 in.)

OUO1020,0001583 -19-04JAN08-4/4

TM1731 (28JAN20)

01-0130-37

850J Crawler (S.N. 130886—311988) 012820 PN=79

Track System

Lubricated Track Chain to Turn Bushings and Lubricate Chain Assemble

T96272 —UN—27OCT88

CAUTION: Make sure all control levers of press are in the neutral position. 1. Assemble track using the following track press tool sets. NOTE: Tooling listed below is purchased through WTC Machinery Corporation (800) 248-8405 “91” Series (Adjustable Camlock) Tooling 850J

A—Rubber Plug

B—JDG190 Plug Installer

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

“C” Style (Spring Loaded) Tooling 850J

(A2656-303). OUO1020,0001584 -19-04JAN08-1/13

NOTE: The pin end halves of master split link must be temporarily assembled to bushing end halves of link for proper positioning on plungers. Pin end halves will later have to be separated for installation at end of chain. T96273 —UN—27OCT88

3. Assemble master split link halves using master shoe bolts and washers (as required). Tighten bolts just enough to hold links together. Split links are a matched set and must be assembled as a set. 4. Install assembled split links on ram plungers. 5. Install bushing (A) in front seat of saddle (B) so the mark is 180° opposite original location to expose a new wear surface.

A—Bushing Continued on next page

TM1731 (28JAN20)

01-0130-38

B—Saddle OUO1020,0001584 -19-04JAN08-2/13

850J Crawler (S.N. 130886—311988) 012820 PN=80

Track System

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

T96274 —UN—27OCT88

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

OUO1020,0001584 -19-04JAN08-3/13

Specification Bushing Projection—Height......................................................................1.75—2.25 mm 0.069—0.089 in.

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

TM1731 (28JAN20)

01-0130-39

T96275 —UN—27OCT88

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

OUO1020,0001584 -19-04JAN08-4/13

850J Crawler (S.N. 130886—311988) 012820 PN=81

Track System

T96276 —UN—27OCT88

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

OUO1020,0001584 -19-04JAN08-5/13

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

B—Cross-Drilled Hole

T96277 —UN—27OCT88

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

OUO1020,0001584 -19-04JAN08-6/13

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

T96278 —UN—27OCT88

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

Continued on next page

TM1731 (28JAN20)

01-0130-40

OUO1020,0001584 -19-04JAN08-7/13

850J Crawler (S.N. 130886—311988) 012820 PN=82

Track System

T96279 —UN—27OCT88

14. Apply PM37559 Aviation Gasket Sealant or an equivalent to the link bore. The sealant prevents loss of vacuum or lubricant leakage through the pin to link joint.

OUO1020,0001584 -19-04JAN08-8/13

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

T96280 —UN—27OCT88

B—Link C—Load Ring

Continued on next page

TM1731 (28JAN20)

01-0130-41

OUO1020,0001584 -19-04JAN08-9/13

850J Crawler (S.N. 130886—311988) 012820 PN=83

Track System

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

T96282 —UN—27OCT88

F— Right Link G—Bushing H—Shims I— Left Link

T96283 —UN—27OCT88

A—Left Ram B—Saddle C—Pin D—Plunger E—Right Ram

OUO1020,0001584 -19-04JAN08-10/13

NOTE: To ensure zero end play in joint, special spacers must be fabricated using a section of bushing.

IMPORTANT: Too much pressure will crush the thrust rings 18. Advance left ram using only minimum force required to push joint tight. Pressure must be approximately one half the relief valve setting. Remove spacer.

T96284 —UN—27OCT88

17. Retract left ram. Install special spacer (A) between the joint in rear seat of saddle and ram.

A—Special Spacer Continued on next page

TM1731 (28JAN20)

01-0130-42

OUO1020,0001584 -19-04JAN08-11/13

850J Crawler (S.N. 130886—311988) 012820 PN=84

Track System

19. After one complete joint has been assembled, check end play of track links to make sure bushing, thrust rings, and link counterbore faces are pressed solid against each other. Position base of dial indicator on one link assembly and pointer against the other link assembly. 20. Pry link assemblies in one direction then in opposite direction to measure the amount of end play. End play must be zero.

T96285 —UN—27OCT88

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

Continued on next page

TM1731 (28JAN20)

01-0130-43

OUO1020,0001584 -19-04JAN08-12/13

850J Crawler (S.N. 130886—311988) 012820 PN=85

Track System

Specification Bushing Projection—Height......................................................................1.75—2.25 mm 0.069—0.089 in.

23. Add oil (SAE 80W 90) using a No. 61119 Seal Tester and Lubricator for S.A.L.T. Crawler Equipment. Push nozzle through plug all the way into pin. Depress control lever on the handle enough to draw specified vacuum as indicated on the gauge.

T96286 —UN—27OCT88

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

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

T96287 —UN—01NOV88

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

26. For pins using rubber plug and plastic plug, immediately install plug using JDG190 Plug Installer after adding oil. For pins using self-sealing plug, slowly pull nozzle (C) out to allow any compressed air to escape through nozzle from first hole (A) to second hole (B).

T6465AY —UN—01NOV88

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

Add oil to each joint after assembling so only one joint would have to be disassembled if a vacuum leak occurs.

28. Install assembled split links on ram plungers, and advance rams to press split links together. 29. Install track shoes and track chain. See Track Shoe Remove and Install and see Lubricated Track Chain Remove and Install. (Group 0130.) A—First Hole B—Second Hole

C—Nozzle

T96288 —UN—27OCT88

27. Repeat step 10—26 for all joints.

OUO1020,0001584 -19-04JAN08-13/13

TM1731 (28JAN20)

01-0130-44

850J Crawler (S.N. 130886—311988) 012820 PN=86

Track System

Lubricated Track Chain to Turn Pins and Bushings and Not Lubricate Disassemble and Assemble

T96266 —UN—27OCT88

NOTE: The following procedure is for disassembly of track chain only to turn pins and bushings. (Chain is not lubricated after assembly.) If this procedure does not apply to the repair job, see Lubricated Track Chain to Turn Bushings and Lubricate Chain Disassemble. (Group 0130.) 1. Remove track shoes and track chain. See Track Shoe Remove and Install. (Group 0130.) See Lubricated Track Chain Remove and Install. (Group 0130.) 2. Use the appropriate track press tool set. NOTE: Tooling listed below is purchased through WTC Machinery Corporation (800) 248-8405 “91” Series (Adjustable Camlock) Tooling 850J

E—Bushing F— Left Link G—Pin

4. Make an index mark on bushings and pins to aid in reassembly, when turning bushings 1/2 turn (180°) to expose a new wear surface.

CAUTION: Always wear safety glasses when operating the press. Parts may break or chip, which could create a risk of personal injury. 5. Extend right ram (C) to push pin (G) and bushing (E) from the right link (D). The right link is forced against the side of saddle (B) as the pin and bushing are pushed out.

“C” Style (Spring Loaded) Tooling 850J

A—Left Ram B—Saddle C—Right Ram D—Right Link

(A2656-303)

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

6. Retract right ram. The right link, with seals and thrust ring, will stay on the ram tools.

3. Check for proper alignment of tools with pin and bushing. Continued on next page

TM1731 (28JAN20)

01-0130-45

MM61211,0001552 -19-04JAN08-1/10

850J Crawler (S.N. 130886—311988) 012820 PN=87

Track System

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

T96267 —UN—27OCT88

8. Retract left ram. The left link, with seal and thrust ring, will remain on the ram tools. 9. Remove links and bushing from press. 10. Repeat steps 4—9 to disassemble rest of chain. IMPORTANT: Pins must be installed so cross-drilled hole is toward link wear surface or they may break when chain is used. 11. All pins, bushings, seals, and thrust rings are used for assembly, because chain is not lubricated. Do not remove rubber plug and plastic plug from pins. Do not remove seals from track links.

A—Left Ram B—Saddle C—Pin D—Right Ram

E—Right Link F— Bushing G—Left Link

Turn pin end-for-end to get a new wear surface, then install it into bushing so cross-drilled hole is toward link wear surface. Install all pins so hole in end of pin is toward the same side of chain, either left or right side. MM61211,0001552 -19-04JAN08-2/10

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

B—3 mm (0.12 in.)

T5798AJ —UN—26OCT88

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

MM61211,0001552 -19-04JAN08-3/10

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

T96289 —UN—27OCT88

A—Track Link

Continued on next page

TM1731 (28JAN20)

01-0130-46

MM61211,0001552 -19-04JAN08-4/10

850J Crawler (S.N. 130886—311988) 012820 PN=88

Track System

14. Assemble track links using the following track press tool sets. 850J

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

850J

(A2656-303).

T96273 —UN—27OCT88

“91” Series (Adjustable Camlock) Tooling

“C” Style (Spring Loaded) Tooling

NOTE: The pin end halves of master split link must be temporarily assembled to bushing end halves of link for proper positioning of plungers. Pin end halves will later have to be separated for installation at end of chain.

A—Bushing

15. Assemble master split link halves using master shoe bolts and washers (as required). Tighten bolts just enough to hold link together.

B—Saddle

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

16. Install assembled split links on ram plungers.

MM61211,0001552 -19-04JAN08-5/10

18. Adjust track press pressure relief valve setting. Specification Track Press Relief Valve —Force.................................................................... 444 800 N Maximum 100,000 lb force Maximum

T96274 —UN—27OCT88

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

Continued on next page

TM1731 (28JAN20)

01-0130-47

MM61211,0001552 -19-04JAN08-6/10

850J Crawler (S.N. 130886—311988) 012820 PN=89

Track System

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

B—Cross-Drilled Hole

T96277 —UN—27OCT88

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

MM61211,0001552 -19-04JAN08-7/10

21. Install a thrust ring on each side of pin.

T96278 —UN—27OCT88

22. Move completed link assembly to rear seat of saddle.

Continued on next page

TM1731 (28JAN20)

01-0130-48

MM61211,0001552 -19-04JAN08-8/10

850J Crawler (S.N. 130886—311988) 012820 PN=90

Track System

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

F— Right Link G—Bushing H—Plunger Shims I— Left Link J— 23058 Track Shoe Gauge

T96290 —UN—27OCT88

A—Left Ram B—Saddle C—Pin D—Plunger E—Right Ram

T96283 —UN—27OCT88

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

MM61211,0001552 -19-04JAN08-9/10

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

T96286 —UN—27OCT88

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

26. Repeat steps 14—25 to assemble rest of chain. 27. The last link assembled is the split link pin ends. Assemble a set of extra "slave" split link bushing ends to pin ends using bolts and washers used in step 15. Tighten bolts just enough to hold together link. 28. Install assembled split links on ram plungers and advance rams to press split links together.

29. Install track shoes and track chain. See Track Shoe Remove and Install. (Group 0130.) See Lubricated Track Chain Remove and Install. (Group 0130.) MM61211,0001552 -19-04JAN08-10/10

TM1731 (28JAN20)

01-0130-49

850J Crawler (S.N. 130886—311988) 012820 PN=91

Track System

Track Sag Adjustment SPECIFICATIONS Track Sag Distance

45—57 mm 1.75—2.25 in.

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

T207100A —UN—01FEB05

T207501 —UN—15FEB05

1— Track Pin 2— Carrier Rollers

TE14778,00000A2 -19-11APR05-1/3

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

Continued on next page

TM1731 (28JAN20)

01-0130-50

T206820A —UN—07JAN05

Adjust Track Sag

TE14778,00000A2 -19-11APR05-2/3

850J Crawler (S.N. 130886—311988) 012820 PN=92

Track System

1— Grease Fitting 2— Relief Valve

T206819C —UN—28JAN05

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

TE14778,00000A2 -19-11APR05-3/3

Track Adjuster Cylinder and Recoil Spring Remove and Install SPECIFICATIONS 245 kg 539 lb.

T210131A —UN—06APR05

Track Adjuster Cylinder and Recoil Spring Weight (approximate)

CAUTION: Spring or rod may break if dropped while handling, transporting or disassembling. Nicks or weld craters in spring and rod assembly can cause stress concentration resulting in a weak spot. Weak spots can result in immediate or eventual failure creating a risk of personal injury. Put a heavy protective covering around spring assembly when handling, transporting, or disassembling. A compression tool must be used for disassemble and assemble because of the extreme preload on spring.

properly. Use adequate lifting device to move track adjuster cylinder and recoil spring. Specification Track Adjuster Cylinder and Recoil Spring—Weight (approximate)................................................................................ 245 kg 539 lb.

1. Remove track chain. See Lubricated Track Chain Remove and Install. (Group 0130.) 2. Remove front idler. See Front Idler Remove and Install. (Group 0130.) 3.

Track Adjuster

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

Slide track adjuster forward from rear of track frame using a pry bar. CAUTION: Track adjuster cylinder and recoil spring is heavy and can cause injury if not moved

Continued on next page

TM1731 (28JAN20)

01-0130-51

MM61211,000155D -19-10OCT11-1/3

850J Crawler (S.N. 130886—311988) 012820 PN=93

Track System

T212765A —UN—11JUL05

5. Inspect rubber shields (1) and track adjuster recoil spring. Repair or replace parts as necessary. See Track Adjuster Recoil Spring Disassemble and Assemble and see Track Adjuster Cylinder Disassemble and Assemble. (Group 0130.) 1— Rubber Shield (2 used)

MM61211,000155D -19-10OCT11-2/3

6. Attach track adjuster to hoist and slide into track frame. 7. Install front idler. See Front Idler Remove and Install. (Group 0130.) T210131A —UN—06APR05

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

Track Adjuster MM61211,000155D -19-10OCT11-3/3

TM1731 (28JAN20)

01-0130-52

850J Crawler (S.N. 130886—311988) 012820 PN=94

Track System

Track Adjuster Recoil Spring Disassemble and Assemble

11 10

SPECIFICATIONS Track Adjuster Cylinder and Recoil Spring Weight (approximate)

245 kg 539 lb

Recoil Spring Free Length

682 mm 26.85 in

Recoil Spring Compressed Length

607 mm 23.9 in

ESSENTIAL TOOLS

2 13

JT07368 Track Adjuster Recoil Spring Compressor JDG10022 Track Recoil Spring Kit

1 4

5 8

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

Track Adjuster Cylinder and Recoil Spring 1— Cap Screw 2— Relief Valve 3— Check Valve 4— Cylinder 5— Wiper Seal 6— Wear Ring (2 used) 7— Seal Kit Continued on next page

TM1731 (28JAN20)

T210132 —UN—29JUN05

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

01-0130-53

8— Piston 9— Spring 10— Plate 11— Rod Nut 12— Retaining Ring (2 used) 13— Guard

MM61211,0001553 -19-06APR17-1/19

850J Crawler (S.N. 130886—311988) 012820 PN=95

Track System

CAUTION: Track adjuster cylinder and recoil spring are heavy and can cause injury if not moved properly. Use adequate lifting device to move track adjuster cylinder and recoil spring. T210145A —UN—05APR05

Specification Track Adjuster Cylinder and Recoil Spring—Weight (approximate)................................................................................ 245 kg 539 lb

2. Place track adjuster cylinder and recoil spring (2) into spring compressor so that the rod nut (11) is centered in hole in spring compressor end plate (1). Specification Recoil Spring—Free Length......................................................................................... 682 mm 26.85 in Recoil Spring—Compressed Length............................................................................ 607 mm 23.9 in

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

2— Track Adjuster Cylinder and Recoil Spring

3. Place blocks under spring assembly to prevent parts from falling after track adjuster cylinder and recoil spring is disassembled. MM61211,0001553 -19-06APR17-2/19

T125867B —UN—16NOV99

IMPORTANT: DO NOT compress spring when extending the hydraulic rams to the specified position. If spring is compressed, relieve hydraulic pressure and thread adjustment collar away from hydraulic rams. DO NOT extend hydraulic rams more than 114 mm (4.5 in). Additional travel is required after spring compressor is adjusted with adjustment collar. 4. Extend hydraulic rams (5) 101.6 mm (4 in) to allow spring travel as tension is released. Hydraulic Rams Extended for Spring Travel 5— Hydraulic Ram (2 used) MM61211,0001553 -19-06APR17-3/19

5. Install JT07368-4 Spacer (19) 50.8 mm (2.00 in) wide between piston (8) and disc (3) as shown.

2— Track Adjuster Recoil Spring Assembly 3— Disc

T210146A —UN—05APR05

6. Thread retaining collar (4) tight against disc to ensure adequate clearance during disassembly. 4— Retaining Collar 19— JT07368-4 Spacer

Spring Compressor length Adjustment Continued on next page

TM1731 (28JAN20)

01-0130-54

MM61211,0001553 -19-06APR17-4/19

850J Crawler (S.N. 130886—311988) 012820 PN=96

Track System

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

T125868B —UN—16NOV99

8. Apply only enough hydraulic pressure to spring to hold recoil spring in position. 9. Remove lifting strap and close protective shields on spring compressor. 6— Adjustment Collar

Adjustment Collar Position MM61211,0001553 -19-06APR17-5/19

10. Increase pressure with hydraulic rams until spring tension is released from rod nut (8). 11. Thread rod nut onto shaft (7) until retaining rings (9) can be removed. Remove retaining rings.

7— Shaft 8— Rod Nut

T210147A —UN—05APR05

12. Remove rod nut from shaft. 9— Retaining Ring (2 used)

Recoil Spring Tension Nut MM61211,0001553 -19-06APR17-6/19

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

T125871B —UN—16NOV99

5— Hydraulic Ram (2 used)

Hydraulic Rams Released Continued on next page

TM1731 (28JAN20)

01-0130-55

MM61211,0001553 -19-06APR17-7/19

850J Crawler (S.N. 130886—311988) 012820 PN=97

Track System

T125872B —UN—16NOV99

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

Retaining Collar Adjustment MM61211,0001553 -19-06APR17-8/19

15. Release hydraulic pressure from hydraulic rams (5) so adjustment collar (6) is free to turn. 6— Adjustment Collar T125919B —UN—16NOV99

5— Hydraulic Ram (2 used)

Adjustment Collar Adjustment MM61211,0001553 -19-06APR17-9/19

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

T125867B —UN—16NOV99

5— Hydraulic Ram (2 used)

Hydraulic Rams Extended Continued on next page

TM1731 (28JAN20)

01-0130-56

MM61211,0001553 -19-06APR17-10/19

850J Crawler (S.N. 130886—311988) 012820 PN=98

Track System

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

T125868B —UN—16NOV99

6— Adjustment Collar

Adjustment Collar Adjustment Continued on next page

TM1731 (28JAN20)

01-0130-57

MM61211,0001553 -19-06APR17-11/19

850J Crawler (S.N. 130886—311988) 012820 PN=99

Track System

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

T125872B —UN—16NOV99

CAUTION: Use only the handles on the retaining collar to thread it against end plate. DO NOT place hands on threaded push rod between retaining collar and end plate. 19. Carefully reach in access door and thread the retaining collar away from spring compressor end plate until it is tight against the disc. 20. Slowly release pressure in hydraulic rams. Retaining Collar Adjustment

21. Fully retract hydraulic rams. Spring should now be completely decompressed.

4— Retaining Collar

22. Replace parts as required. 23. Disassemble track adjuster cylinder. See Track Adjuster Cylinder Disassemble and Assemble. (Group 0130.)

11 10

2 13 1

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

8— Piston 9— Spring 10— Plate 11— Rod Nut 12— Retaining Ring (2 used) 13— Plate

5 8

T210132 —UN—29JUN05

1— Cap Screw 2— Relief Valve 3— Check Valve 4— Cylinder 5— Wiper Seal 6— Wear Ring (2 used) 7— Seal Kit

Track Adjuster Cylinder and Recoil Spring Continued on next page

TM1731 (28JAN20)

01-0130-58

MM61211,0001553 -19-06APR17-12/19

850J Crawler (S.N. 130886—311988) 012820 PN=100

Track System

Specification Track Adjuster Cylinder and Recoil Spring—Weight (approximate)................................................................................ 245 kg 539 lb

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

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

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

2— Track Adjuster Cylinder and Recoil Spring

MM61211,0001553 -19-06APR17-13/19

2. Install 50.8 mm (2.00 in) wide JT07368-4 Spacer (19) between track adjuster cylinder and recoil spring and disc (3) as shown. 4— Retaining Collar 19— JT07368-4 Spacer

T210146A —UN—05APR05

2— Track Adjuster Recoil Spring Assembly 3— Disc

Spring Compressor Length Adjustment MM61211,0001553 -19-06APR17-14/19

3. With hydraulic rams (5) fully retracted, thread adjustment collar (6) toward hydraulic rams until collar is tight and there is no end play in the spring compressor. T125919B —UN—16NOV99

4. Apply only enough hydraulic pressure to hydraulic rams to hold spring assembly in position. 5. Remove lifting strap and close protective shields on spring compressor. 5— Hydraulic Ram (2 used)

6— Adjustment Collar

Adjustment Collar Position Continued on next page

TM1731 (28JAN20)

01-0130-59

MM61211,0001553 -19-06APR17-15/19

850J Crawler (S.N. 130886—311988) 012820 PN=101

Track System

T125867B —UN—16NOV99

IMPORTANT: Monitor hydraulic pressure in cylinder to be sure assembly is not binding while compressing spring. Pressure should gradually increase and rod guide should slowly extend through hole in end plate while compressing spring. 6. Increase pressure in hydraulic rams to begin compressing spring. Extend hydraulic rams (5) 101.6 mm (4 in) as shown. 5— Hydraulic Ram (2 used) Hydraulic Rams Extended for Spring Travel

MM61211,0001553 -19-06APR17-16/19

T125872B —UN—16NOV99

CAUTION: Use only the handles on the retaining collar to thread it against end plate. DO NOT place hands on threaded push rod between retaining collar and end plate. 7. Carefully reach in access door and thread the retaining collar (4) tight against the end plate as shown. 4— Retaining Collar

Retaining Collar Adjustment MM61211,0001553 -19-06APR17-17/19

8. Fully retract hydraulic rams (5) and thread adjustment collar (6) towards hydraulic rams until collar is tight and there is no end play in the spring compressor. 6— Adjustment Collar T125919B —UN—16NOV99

5— Hydraulic Ram (2 used)

Adjustment Collar Adjustment Continued on next page

TM1731 (28JAN20)

01-0130-60

MM61211,0001553 -19-06APR17-18/19

850J Crawler (S.N. 130886—311988) 012820 PN=102

Track System

9. Increase pressure in hydraulic rams to allow enough threaded length to install rod nut onto shaft (7). 10. Apply grease to threads of rod nut and install. T210147A —UN—05APR05

11. Thread rod nut onto shaft until retaining rings (9) can be installed. 12. Back rod nut off until top of rod nut is flush with top of retaining rings. Retaining rings fit into recess in rod nut. 13. Slowly release hydraulic pressure in spring compressor and fully retract hydraulic rams. 14. Remove track adjuster cylinder and recoil spring from spring compressor. 7— Shaft 8— Rod Nut

Recoil Spring Tension Nut

9— Retaining Ring (2 used)

MM61211,0001553 -19-06APR17-19/19

TM1731 (28JAN20)

01-0130-61

850J Crawler (S.N. 130886—311988) 012820 PN=103

Track System

Track Adjuster Cylinder Disassemble and Assemble

11 10

2 13

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

1 4

2. Remove guard (13), relief valve (2), and check valve (3).

T210132 —UN—29JUN05

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

CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device. Specification Track Adjuster Cylinder Piston Rod—Weight (approximate).................................................................................. 54 kg 119 lb.

3. Remove piston rod (8) from cylinder (4). 4. Remove wiper seal (5) and wear rings (6).

8 Track Adjuster Cylinder and Recoil Spring Components 1— Cap Screw 2— Relief Valve 3— Check Valve 4— Cylinder 5— Wiper Seal 6— Wear Ring (2 used) 7— Seal Kit

8— Piston Rod 9— Spring 10— Plate 11— Nut 12— Retaining Ring (2 used) 13— Guard

5. Remove retaining ring from inner seal kit (7) to remove seal. 6. Replace parts as required. 7. Install relief valve (2) and tighten to specification.

Specification Relief Valve—Torque............................................................. 49—68 N·m 36—50 lb-ft

8. Install guard (13). MM61211,0001554 -19-08JUL14-1/4

9. Install wear rings (6) into cylinder.

T211282A —UN—11MAY05

6— Wear Ring (2 used)

Wear Ring Continued on next page

TM1731 (28JAN20)

01-0130-62

MM61211,0001554 -19-08JUL14-2/4

850J Crawler (S.N. 130886—311988) 012820 PN=104

Track System

10. Install inner seal (15) with retaining ring groove facing outward. 11. Install retaining ring (16) into groove of inner seal. 16— Retaining Ring T211284A —UN—11MAY05

15— Inner Seal

Inner Seal Kit MM61211,0001554 -19-08JUL14-3/4

12. Install wiper seal (5) with lip facing outward. Use JDG840-4 Seal Installer (17) from JDG840 Hydraulic Cylinder Piston Installation Kit.

T211285A —UN—11MAY05

IMPORTANT: Add grease before installing piston rod to completely bleed air from cylinder. 13. Add 296 ml (10 oz.) of grease into cylinder cavity. 14. Apply grease to piston rod (8) and install into cylinder (4). 15. Compress piston rod until grease comes out of check valve hole. Outer Seal Installation

16. Install check valve and apply grease until piston moves 13 mm (0.51 in.).

17— JDG840-4 Seal Installer

17. Loosen check valve and completely compress piston. 18. Tighten check valve to specification. Specification Check Valve—Torque.................................................................58.5 N·m 43 lb-ft MM61211,0001554 -19-08JUL14-4/4

TM1731 (28JAN20)

01-0130-63

850J Crawler (S.N. 130886—311988) 012820 PN=105

Track System

Track Frame Remove and Install 1. Remove pushbeam and blade assembly (Outside Dozer). See Outside Dozer Push Beams Remove and Install. (Group 3240.)

T205099A —UN—04DEC04

CAUTION: Prevent possible injury from unexpected track movement. Raise the machine off the ground and support with 20-Ton Floor Stands. Tracks must be free to rotate in either direction. 2. Raise machine off the ground and support with 20-Ton Floor Stands. Lower blade to ground. CAUTION: Prevent possible injury from unexpected crossbar and track frame movement. Track frame on opposite side will pivot down. Before removing track frame always block track frame on opposite side. 3. Remove track chain. See Lubricated Track Chain Remove and Install. (Group 0130.)

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

4— Washer (2 used) 5— Cap Screw (2 used)

MM61211,0001555 -19-02NOV17-1/13

4. Remove two sprocket sections (1). Rotate final drive so inner guard will clear planetary housing. 2— Cap Screw

T210009A —UN—07APR05

1— Sprocket Section

Two Sprocket Sections Removed Continued on next page

TM1731 (28JAN20)

01-0130-64

MM61211,0001555 -19-02NOV17-2/13

850J Crawler (S.N. 130886—311988) 012820 PN=106

Track System

T210010A —UN—31MAR05

5. Disconnect crossbar lube line from track frame.

Crossbar Lube Line MM61211,0001555 -19-02NOV17-3/13

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

6. Support track frame with hoist.

T210011A —UN—31MAR05

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

MM61211,0001555 -19-02NOV17-4/13

7. Remove pivot shaft cover and track frame retainers.

T210013A —UN—31MAR05

1— Track Frame Retainers (2 used)

Track Frame Retainers Continued on next page

TM1731 (28JAN20)

01-0130-65

MM61211,0001555 -19-02NOV17-5/13

850J Crawler (S.N. 130886—311988) 012820 PN=107

Track System

8. Remove crossbar-to-track frame pivot pin. 9. Remove track frame.

T210015A —UN—31MAR05

10. Inspect pivot shaft for wear or damage. Repair or replace as necessary. See Pivot Shaft Remove and Install. (Group 0130.) 11. Inspect track frame bushings and seal for wear or damage. Replace if necessary. 12. Inspect crossbar self-aligning bushing for wear or damage. Replace if necessary. See Crossbar Remove and Install. (Group 0130.) See Crossbar Disassemble and Assemble. (Group 0130.)

crossbar-to-track frame pivot pin

13. Apply TY24425 Special Purpose HD Water Resistant Grease to track frame bushings before assembling onto pivot shaft. MM61211,0001555 -19-02NOV17-6/13

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

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

T210011A —UN—31MAR05

MM61211,0001555 -19-02NOV17-7/13

15. Apply petroleum jelly to track frame retainers (1) and install on pivot shaft. 16. Apply PM38656 Thread Lock and Sealer (high strength) to pivot shaft cover. T210013A —UN—31MAR05

17. Apply PM37479 Thread Lock and Sealer (high strength) to pivot shaft cover cap screws. 1— Track Frame Retainer (2 used)

Track Frame Retainers Continued on next page

TM1731 (28JAN20)

01-0130-66

MM61211,0001555 -19-02NOV17-8/13

850J Crawler (S.N. 130886—311988) 012820 PN=108

Track System

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

1— Pivot Shaft Cover 2— Washer (7 used)

T210014A —UN—31MAR05

Specification Pivot Shaft Cover Cap Screw—Torque............................................................................130 N·m 96 lb-ft 3— Cap Screw (7 used)

Pivot Shaft Cover MM61211,0001555 -19-02NOV17-9/13

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

T210015A —UN—31MAR05

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

Crossbar-To-Track Frame Pivot Pin MM61211,0001555 -19-02NOV17-10/13

T210010A —UN—31MAR05

20. Connect crossbar lube line to track frame.

Crossbar lube Line Continued on next page

TM1731 (28JAN20)

01-0130-67

MM61211,0001555 -19-02NOV17-11/13

850J Crawler (S.N. 130886—311988) 012820 PN=109

Track System

T210018A —UN—31MAR05

21. Remove fill plug cover and fill plug.

T210019A —UN—31MAR05

Track Frame Oil Fill Plug Cover

Track Frame Oil Fill Plug MM61211,0001555 -19-02NOV17-12/13

T210020A —UN—31MAR05

22. Add recommended oil until oil reaches top of oil fill plug hole. (See See Track Rollers, Front Idler, Carrier Roller, and Track Frame Pivot Oil. (Operators Manual.) See Check Track Frame Pivot Shaft Bushing Oil. (Operators Manual.) 23. Apply PM37397 Pipe Sealant with Teflon to track frame oil fill pipe plug. Install fill plug and fill plug cover. 24. Install sprocket segments. See Sprocket Segment Remove and Install. (Group 0130.) 25. Connect track chain. See Lubricated Track Chain Remove and Install. (Group 0130.) 26. Lower machine to ground and adjust track sag. See Adjust Track Sag. (Operators Manual.)

Track Frame Oil Fill

27. Install pushbeam and blade assembly (Outside Dozer). See Outside Dozer Push Beams Remove and Install. (Group 3240.) MM61211,0001555 -19-02NOV17-13/13

TM1731 (28JAN20)

01-0130-68

850J Crawler (S.N. 130886—311988) 012820 PN=110

Track System

Front Idler Wear Inspection NOTE: For additional information, see 755K, 850J, 850J-II, 850K Front Idler Flange Height. (SP326.)

T96419 —UN—27OCT88

100% worn is the maximum allowable height of flange for rebuilding wear surface. Measure height of flange using a depth gauge such as JT05521 Ruler 200 mm (8 in.), JT05534 Right Angle Attachment, and D05231ST Ruler 300 mm (12 in.) from JT05518A Undercarriage Inspection Kit. Specification Front Idler Flange—Height (new)................................................................ 22.0 mm 0.87 in. Front Idler Flange—Height (100% worn).......................................................................................... 30.6 mm 1.20 in.

Measure Front Idler Wear

RM58335,000141F -19-01FEB19-1/1

Front Idler Remove and Install 175 kg 385 lb.

Track Chain Tension Adjuster-to-Idler Cap Screw Torque

500—600 N·m 369—443 lb.-ft.

Dirt Cover-to-Idler Cap Screw Torque

110 N·m 80 lb.-ft.

Idler Tension Adjusting Screws Torque

115 N·m 85 lb.-ft.

T-bar Bracket Cap Screws Torque

500—600 N·m 369—443 lb.-ft.

T209871A —UN—28MAR05

SPECIFICATIONS Front Idler Weight (approximate)

Front Idler Side Plate 1— Cap Screw (3 used) 2— T-bar Bracket

OTHER MATERIAL Loctite® 271™ Threadlocker (high strength)

3— Idler

1. Disconnect track chain. See Lubricated Track Chain Remove and Install. (Group 0130.) NOTE: Make sure track frame is level before removing front idler. 2. Remove side plate cap screws (1) and T-bar bracket (2). Loctite and its related brand marks are trademarks of Henkel Corporation Continued on next page

TM1731 (28JAN20)

01-0130-69

MM61211,0001557 -19-08JUN06-1/14

850J Crawler (S.N. 130886—311988) 012820 PN=111

Track System

3. Pull idler out of track frame until you can loosen tension adjusting cap screw (9). 10— Washer (4 used) T210065A —UN—05APR05

9— Cap Screw (4 used)

Front Idler Tension Adjusting Cap Screws MM61211,0001557 -19-08JUN06-2/14

4. Pull idler out farther to remove cover (6). 6— Cover

T209872A —UN—28MAR05

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

Front Idler Dirt Cover MM61211,0001557 -19-08JUN06-3/14

CAUTION: Front idler is heavy and can cause injury if not moved properly. Use adequate lifting device to move front idler. T209873A —UN—28MAR05

Specification Front Idler—Weight (approximate)................................................................................ 175 kg 385 lb.

5. Attach idler to hoist using chain.

Attach Front Idler to Hoist Continued on next page

TM1731 (28JAN20)

01-0130-70

MM61211,0001557 -19-08JUN06-4/14

850J Crawler (S.N. 130886—311988) 012820 PN=112

Track System

6. Remove cap screws (7) holding idler to track spring adjuster. 7. Remove idler. 8— Washer (4 used)

T209874A —UN—28MAR05

7— Cap Screw (4 used)

Front Idler Mounting Cap Screws MM61211,0001557 -19-08JUN06-5/14

CAUTION: Front idler is heavy and can cause injury if not moved properly. Use adequate lifting device to move front idler. T210055A —UN—31MAR05

Specification Front Idler—Weight (approximate)................................................................................ 175 kg 385 lb.

8. Attach idler to hoist using chain.

Attach Front Idler to Hoist Continued on next page

TM1731 (28JAN20)

01-0130-71

MM61211,0001557 -19-08JUN06-6/14

850J Crawler (S.N. 130886—311988) 012820 PN=113

Track System

9. Use a C-clamp (1) to secure middle wear bar (2) to track frame. 2— Middle Wear Bar

T210057A —UN—31MAR05

T210056A —UN—31MAR05

1— C-Clamp

Middle Wear Bar MM61211,0001557 -19-08JUN06-7/14

10. Use tie wraps (3) to secure upper wear bar (4) to bracket. 4— Upper Wear Bar T210059A —UN—31MAR05

3— Tie Wrap

Upper Wear Bar Continued on next page

TM1731 (28JAN20)

01-0130-72

MM61211,0001557 -19-08JUN06-8/14

850J Crawler (S.N. 130886—311988) 012820 PN=114

Track System

T209873A —UN—28MAR05

11. Carefully guide idler into track frame.

MM61211,0001557 -19-08JUN06-9/14

12. Apply Loctite® 271™ Threadlocker (high strength) to track chain tension adjuster-to-idler cap screws and install. Tighten to specification.

7— Cap Screw (4 used)

T209874A —UN—28MAR05

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

8— Washer (4 used) Front Idler Mounting Cap Screws

Loctite and its related brand marks are trademarks of Henkel Corporation MM61211,0001557 -19-08JUN06-10/14

Specification Dirt Cover-to-Idler Cap Screw—Torque............................................................................ 110 N·m 80 lb.-ft. 4— Cap Screw (4 used) 5— Washer (4 used)

6— Dirt Cover

Continued on next page

TM1731 (28JAN20)

01-0130-73

T209872A —UN—28MAR05

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

MM61211,0001557 -19-08JUN06-11/14

850J Crawler (S.N. 130886—311988) 012820 PN=115

Track System

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

T210065A —UN—05APR05

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

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

10— Washer (4 used)

MM61211,0001557 -19-08JUN06-12/14

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

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

T209871A —UN—28MAR05

Specification T-bar Bracket Cap Screws—Torque................................................................ 500—600 N·m 369—443 lb.-ft. 3— Idler

Front Idler Side Plate MM61211,0001557 -19-08JUN06-13/14

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

1— Grease Fitting 2— Relief Valve

T206819C —UN—28JAN05

18. Connect track chain. See Lubricated Track Chain Remove and Install. (Group 0130.) 3— Check Valve

Track Adjuster Check Valve MM61211,0001557 -19-08JUN06-14/14

TM1731 (28JAN20)

01-0130-74

850J Crawler (S.N. 130886—311988) 012820 PN=116

Track System

Front Idler Disassemble and Assemble Front Idler Disassembly

22 21

22 21 12 11

2 8

19 4 13 24

15 16 16

23 24

TX1123707 —UN—08OCT12

23 25

TX1123707 Front Idler Exploded View 1— Idler 2— Shaft 3— O-ring (2 used) 4— O-ring (2 used) 5— O-ring 6— Plug 7— Bracket (left) 8— Bushing Cover (2 used) 9— Bushing (2 used) 10— Dowel Pin (2 used)

11— Lock Washer (12 used) 12— Cap Screw (12 used) 13— Metal Face Seal (2 used) 14— Bracket (right) 15— Wear Strip (lower) (2 used) 16— Shim (as required)

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

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

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

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

2. Remove cap screws (22) and washers (21).

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

3. Loosen nut (18). Strike head of nut to dislodge lock (17).

Continued on next page

TM1731 (28JAN20)

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TE14778,00000D3 -19-26APR17-1/11

850J Crawler (S.N. 130886—311988) 012820 PN=117

Track System

6. Remove bracket (7 or 14) using puller.

T211338A —UN—19MAY05

7. Remove cap screws (12) and washers (11).

TE14778,00000D3 -19-26APR17-2/11

8. Remove shaft (2) and bushing cover (8) from idler using a 2 inch disk from D01045AA Bushing, Bearing, and Seal Driver Set and a press. 9. Remove shaft from bushing case. Remove O-rings from shaft and bushing case. NOTE: Tape metal face seals together to keep them in matched sets. 10. Remove metal face seals (13) and tape together.

12. Remove cap screws (12) and washers (11) from second bushing case. 13. Turn idler over. Use a 4 inch disk to remove second bushing case from idler. Remove O-ring from bushing case. NOTE: Tape metal face seals together to keep them in matched sets.

T211339A —UN—19MAY05

11. Lift second bracket off idler.

14. Remove metal face seals (13) and tape together. 15. Inspect all parts for excessive wear or damage. Replace if necessary. Continued on next page

TM1731 (28JAN20)

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TE14778,00000D3 -19-26APR17-3/11

850J Crawler (S.N. 130886—311988) 012820 PN=118

Track System

T210217 —UN—07APR05

Front Idler Assembly

T210217 1— Idler 2— Shaft 3— O-ring (2 used) 4— O-ring (2 used) 5— O-ring 6— Plug 7— Bracket (left) 8— Bushing Cover (2 used) 9— Bushing (2 used) 10— Dowel Pin (2 used)

11— Lock Washer (12 used) 12— Cap Screw (12 used) 13— Metal Face Seal (2 used) 14— Bracket (right) 15— Wear Strip (lower) (2 used) 16— Shim (as required)

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

Continued on next page

TM1731 (28JAN20)

01-0130-77

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

TE14778,00000D3 -19-26APR17-4/11

850J Crawler (S.N. 130886—311988) 012820 PN=119

Track System

NOTE: Track roller and front idler procedures are similar. Track roller shown where noted. 1. Cool bushing (1) and heat bushing case (3) to specification. Specification Bushing—Temperature.................................................................... -18°C 0°F Specification Bushing Case—Temperature............................................................................................... 121°C 250°F

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

4. When bushing case cools, install O-ring (5) on bushing case. 1— Bushing 2— Dowel Pin 3— Bushing Case

4— Disk (4 inch diameter) 5— O-Ring 6— Alignment Mark

T210063A —UN—31MAR05

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

TE14778,00000D3 -19-26APR17-5/11

5. Install bushing case (1) using aligning studs (2), 4 inch diameter disk (4), and a press. 6. Remove aligning studs. Install cap screws and lock washers. Tighten cap screws to specification. Specification Front Idler Bushing Case Cap Screw —Torque.......................................................... 40.2—47 N·m 30—35 lb-ft

7. Turn idler over and carefully install shaft.

9. Remove studs. Install cap screws and lock washers. Tighten cap screws to specification. Specification Front Idler Bushing Case —Torque............................................................................. 40.2—47 N·m 30—35 lb-ft 1— Bushing Case 2— Stud

3— Front Idler 4— Disk (3 9/16 inch diameter) Continued on next page

TM1731 (28JAN20)

T211330A —UN—19MAY05

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

01-0130-78

TE14778,00000D3 -19-26APR17-6/11

850J Crawler (S.N. 130886—311988) 012820 PN=120

Track System

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

T6018BA —UN—26OCT88

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

O-Ring (Track Roller Shown)

T80574 —UN—26OCT88

TE14778,00000D3 -19-26APR17-7/11

TE14778,00000D3 -19-26APR17-8/11

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

1— Seal Ring Flange 2— JDG205 Seal Installation Tool

T6077AV —UN—26OCT88

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

Continued on next page

TM1731 (28JAN20)

01-0130-79

TE14778,00000D3 -19-26APR17-9/11

850J Crawler (S.N. 130886—311988) 012820 PN=121

Track System

1— JDG205 Seal Installation Tool

T80577 —UN—26OCT88

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

Seal Installation (Track Roller Shown) TE14778,00000D3 -19-26APR17-10/11

16. Wipe metal seal rings dry with a lint free tissue. 17. Apply a thin film of oil, as used in the idler, to the shiny sealing area on metal seal rings. 18. Be sure the rubber seals are free of oil. T80578 —UN—26OCT88

19. Install bracket. 20. Install dowel pin (17), washer (19), and nut (18). Tighten nut to specification. Specification Front Idler Shaft Lock Nut —Torque............................................................................ 140—180 N·m 103—133 lb-ft

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

NOTE: Perform Front Idler Leakage Test BEFORE installing plug. 23. Perform Front Idler Oil Leakage Test. (Group 0130.)

Metal Seal Rings (Track Roller Shown)

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

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

24. Install plug. Tighten to specification. Specification Front Idler Oil Plug —Torque............................................................................ 152—190 N·m 112—140 lb-ft

TE14778,00000D3 -19-26APR17-11/11

TM1731 (28JAN20)

01-0130-80

850J Crawler (S.N. 130886—311988) 012820 PN=122

Track System

Front Idler Adjustment

SPECIFICATIONS 1.5 mm 0.059 in.

Idler Tension Adjusting Screw Torque

115 N·m 85 lb.-ft.

Front Idler Rise Distance

15—18 mm 0.59—0.71 in.

Middle Wear Plate (minimum thickness)

13.5 mm 0.53 in.

TX1124309 —UN—17OCT12

Idler Vertical Movement (maximum)

IMPORTANT: If front idler vertical gap is excessive, the ability to finish grade with the crawler is affected. Also track adjuster damage may result. Front Idler Vertical Movement Adjustment

This adjustment is done to remove excess free play between the front idler and track frame. The idler should always be snug on the track frame.

Plate (idler) 1— Scribed Line 2— Plate

NOTE: All quantities listed are for one side of the idler bracket assembly only. 1. With machine sitting on a flat concrete floor scribe a line (1) to mark the position of plate (2) on track frame as shown.

3— Track Grouser (block position)

3. Check the scribed line (1) position in relation to plate (2).

2. Drive crawler onto a wood block so the front idler is centered on top of the block. TE14778,00000E7 -19-15JAN15-1/4

4. If the measurement (or movement) is more than specified maximum movement, remove one washer (2) from under each cap screw (1). Install cap screws and tighten to specification. Repeat procedure until measurement (or movement) meets specification.

1 1 2

Specification

5. If the maximum measurement is not attainable, meaning idler is not in contact with the track frame when removing washers from adjusting cap screws, an idler wear plate replacement is necessary. See Lubricated Track Chain Remove and Install and see Front Idler Remove and Install. (Group 0130.)

TX1124338 —UN—18OCT12

Idler Vertical Movement—Distance (maximum)................................................................................... 1.5 mm 0.059 in. Idler Tension Adjusting Screw—Torque............................................................................ 115 N·m 85 lb.-ft.

Front Idler Assembly (part of track frame removed for clarity) 1— Cap Screw (2 used)

2— Washer (8 used)

Front Idler Position Adjustment This adjustment establishes position of the front idler in relation to the front roller (plane) and determines if the middle wear plate is in need of replacement.

NOTE: All quantities listed are for one side of the idler bracket assembly only. Continued on next page

TM1731 (28JAN20)

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TE14778,00000E7 -19-15JAN15-2/4

850J Crawler (S.N. 130886—311988) 012820 PN=123

Track System

1. Place machine on a level concrete floor and position track grouser directly under center line (4) of the front idler shaft for proper testing as shown in the graphic. NOTE: Measurements of distances (1 and 2) must be taken directly under the center line of front idler shaft and front roller as shown. 2. With pry bar (6) positioned in front of the track and centered under front idler, raise track assembly and check distance (1) between top surface of track chain and concrete floor (5).

TX1123850 —UN—17OCT12

3. Check distance (2) between top surface of track chain and concrete floor (5).

4. Subtract distance (2) from distance (1) to determine front idler rise. 5. Compare front idler rise distance to specification. Specification Front Idler Rise—Distance.......................................................................15—18 mm 0.59—0.71 in.

6. If distance is less than specification disconnect track chain. Replace wear plates as necessary. See Lubricated Track Chain Remove and Install and see Front Idler Remove and Install. (Group 0130.)

Front Idler-to-Front Roller (edge to edge plane) Measurement 1— Front Idler—Track Chain-to-Floor Distance 2— Front Roller—Track Chain-to-Floor Distance 3— Front Roller Shaft Center Line

4— Front Idler Shaft Center Line 5— Concrete Floor 6— Pry Bar (medium length)

TE14778,00000E7 -19-15JAN15-3/4

7. Inspect middle wear plate (4) for minimum thickness. If middle wear plate thickness is less than specification, install new wear plate. Add shims (6), upper wear plate (2), and lower wear plate (5) only if necessary.

1— Bracket 2— Upper Wear Plate 3— Track Frame Assembly 4— Middle Wear Plate (bar)

5— Lower Wear Plate 6— Shim (4 used) 7— Cap Screw (4 used) (washers not shown)

1 2 TX1124339 —UN—18OCT12

Specification Middle Wear Plate (part of track frame removed for clarity)—Minimum Thickness................................................................................... 13.5 mm 0.53 in.

3 4 5 6

7 Front Idler and Wear Plates

TE14778,00000E7 -19-15JAN15-4/4

TM1731 (28JAN20)

01-0130-82

850J Crawler (S.N. 130886—311988) 012820 PN=124

Track System

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

3. Turn idler several times to seat metal face seals. 4. Assemble test equipment as shown. 5. Pressurize idler with air to specification. Specification Front Idler Leakage Test—Air Pressure............................................................ 107—127 kPa 0.8—1.2 bar 14—20 psi T211345A —UN—19MAY05

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

1— Pressure Gauge 0—689 kPa (0—6.89 bar) (0—100 psi) 2— Adapter 3— JT03456 O-Ring Face Seal (2 used) (17/16 -20 M JIC x 11/16-16 F ORFS)

4— Shut-Off Valve 5— Regulator 6— 38H1030 Tee (-6 F ORFS x -6 M ORFS x -6 M ORFS) Parker No. (6R6LOS)

TE14778,00000D4 -19-27APR17-1/1

TM1731 (28JAN20)

01-0130-83

850J Crawler (S.N. 130886—311988) 012820 PN=125

Track System

Sprocket Segment Remove and Install SPECIFICATIONS Sprocket Segment Cap Screw (zinc-plated) Torque (dry)

712 N·m 525 lb·ft

Sprocket Segment Nut Torque (dry)

850 N·m 627 lb·ft

OTHER MATERIAL Loctite® 277™ Threadlocker (high strength)

T210009A —UN—07APR05

NOTE: Final drives come equipped with cap screws or nuts depending on machine configuration. Cap screw procedure is shown here. Procedure using nuts is similar. REMOVAL 1. Raise machine off the ground. See Machine Supporting Procedure. (Group 9026-25.) 2. Remove track. See Lubricated Track Chain Remove and Install. (Group 0130.) 3. Rotate sprocket to locate sprocket segment (1) being removed and stop engine.

Sprocket Segment 1— Sprocket Segment (5 used)

2— Cap Screw (25 used)

4. Remove cap screws (2) and sprocket segment. NOTE: If the machine is driven in one direction the majority of the time, most of the wear occurs on one side of the teeth. To extend life, the sprockets can be switched from one side of the machine to the other, which causes the chain to wear on the opposite face of the teeth. 5. Remove all paint, oil, grease, and other foreign material from the mounting surface of the sprocket and planetary housing. 6. Clean and inspect parts. Repair or replace parts as necessary.

• Apply Loctite® 277™ Threadlocker (high strength) to threads of cap screws.

• Install sprocket segment and cap screws. Tighten cap screws to specification.

Specification Sprocket Segment Cap Screw (zincplated)—Torque (dry)..................................................................712 N·m 525 lb·ft

• If equipped with sprocket segment with nuts, tighten nuts to specification.

Installation is the reverse of removal procedure.

Specification Sprocket Segment Nut—Torque (dry)........................................................................850 N·m 627 lb·ft

• Thoroughly clean bolt holes before installing cap screws.

• Repeat the procedure until all sprocket segments have

INSTALLATION

IMPORTANT: Loose or broken hardware can cause segments to wear excessively. Install new cap screws or nuts during installation. Do not reuse old cap screws or nuts.

been replaced.

Loctite and its related brand marks are trademarks of Henkel Corporation SJ25320,00003C5 -19-06MAR19-1/1

TM1731 (28JAN20)

01-0130-84

850J Crawler (S.N. 130886—311988) 012820 PN=126

Section 02 Axles and Suspension Systems Contents Page

Group 0201—Drive Axle Housing and Support Final Drive Remove and Install.................. 02-0201-1 Group 0250—Axle Shaft, Bearings and Reduction Gears Planet Carrier Remove and Install.............. 02-0250-1 Planet Carrier Disassemble and Assemble............................................... 02-0250-2 Ring Gear and Hub Remove and Install ..................................................... 02-0250-3 Ring Gear and Hub Disassemble and Assemble........................................ 02-0250-4 Final Drive Metal Face Seal Remove and Install................................ 02-0250-5 Inner Final Drive Housing Remove and Install ............................................ 02-0250-21 Inner Final Drive Housing Cover Disassemble and Assemble ................ 02-0250-23 Final Drive Seal Leakage Check ............. 02-0250-28

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850J Crawler (S.N. 130886—311988) 012820 PN=1

Contents

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850J Crawler (S.N. 130886—311988) 012820 PN=2

Group 0201

Drive Axle Housing and Support Final Drive Remove and Install SPECIFICATIONS Final Drive Weight (approximate)

794 kg 1750 lb

Hydrostatic Motor Weight (approximate)

88 kg 194 lb

Cap Screw (1 and 2) Torque

620 N·m 457 lb·ft

Cap Screw (4) Torque

620 N·m 457 lb·ft

Cap Screw (3) Torque

320 N·m 236 lb·ft

SERVICE EQUIPMENT AND TOOLS DFT1260 Final Drive Lifting Fixture DFT1250 Lifting Bracket T211662A —UN—07JUN05

OTHER MATERIAL Loctite® 7649™ Primer N™ Cure Primer Loctite® 277™ Threadlocker (high strength) Loctite® 243® Threadlocker (medium strength)

REMOVAL 1. Remove rear attachment if equipped.

Final Drive (shown removed)

• See Additional Rear Counterweight Remove and

1— Cap Screw (10 used) 2— Cap Screw (2 used)

Install—If Equipped. (Group 1749.)

• See Ripper Remove and Install—If Equipped.

3— Cap Screw (4 used) 4— Cap Screw (9 used)

(Group 4200.)

CAUTION: Prevent possible injury from unexpected track movement. Machine must be raised off the ground and supported with 20-ton floor stands. Tracks must be free to rotate in either direction. 2. Raise machine off the ground and support with 20-ton floor stands. See Machine Supporting Procedure. (Group 9026-25.) 3. Disconnect track chain. See Lubricated Track Chain Remove and Install. (Group 0130.) 4. Remove rear transmission access cover and bottom main frame access covers. See Bottom Guards Remove and Install. (Group 1746.) 5. Drain inner and outer final drive housing oil. See Drain and Refill Inner and Outer Final Drive Oil. (Operator's Manual.) 6. Remove sprocket segments. See Sprocket Segment Remove and Install. (Group 0130.) 7. Remove cap screws (1) from inner final drive housing exterior to main frame. Loctite and its related brand marks are trademarks of Henkel Corporation Continued on next page

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AB06447,0000BE9 -19-26JUN19-1/3

850J Crawler (S.N. 130886—311988) 012820 PN=129

Drive Axle Housing and Support

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

TX1246022A —UN—20OCT17

8. Attach DFT1260 Final Drive Lifting Fixture (5) using M16 cap screws (6) to final drive housing (7). For more information, see DFT1260 Final Drive Lifting Fixture. (Group 9900.) Specification Final Drive—Weight (approximate)................................................................................ 794 kg 1750 lb

9. Attach DFT1250 Lifting Bracket to appropriate lifting device. For more information, see DFT1250 Lifting Bracket. (Group 9900.)

DFT1260 Final Drive Lifting Fixture 5— DFT1260 Final Drive Lifting Fixture 6— M16 Cap Screw (2 used) Continued on next page

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7— Final Drive Housing

AB06447,0000BE9 -19-26JUN19-2/3

850J Crawler (S.N. 130886—311988) 012820 PN=130

Drive Axle Housing and Support

10. Attach DFT1250 Lifting Bracket to DFT1260 Final Drive Lifting Fixture using M20 cap screws. 11. Remove cap screws (4). T211666A —UN—25MAY05

CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device. 12. Using appropriate lifting device, support hydrostatic motor. Specification Hydrostatic Motor—Weight (approximate).................................................................................. 88 kg 194 lb

13. Remove cap screws (3). 14. Remove hydraulic integrated circuit (HIC) valve (port BRK)-to-final drives line from final drive. See Park Brake System Component Location. (Group 9026-10.) 15. Pry motor away from park brake (inward). 16. Remove cap screws (2). 17. Pry inner final drive housing away from main frame. CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device.

DFT1250 Lifting Bracket

• Apply Loctite® 7649™ Primer N™ Cure Primer and

Loctite® 277™ Threadlocker (high strength) on mating surfaces of final drive and main frame. • Tighten cap screws (1, 2, and 4) evenly to specification.

Specification Cap Screw (1 and 2)—Torque...................................................................................620 N·m 457 lb·ft Cap Screw (4)—Torque...............................................................620 N·m 457 lb·ft

• Replace O-ring on hydrostatic motor flange with new O-ring.

• Apply Loctite® 243® Threadlocker (medium strength) to threads of cap screws (3) and install.

18. Remove final drive.

IMPORTANT: Prevent damage to hydrostatic motor O-ring from misalignment. Ensure that all hydrostatic motor cap screws are tightened evenly until flange gap is flush with park brake housing.

Specification Final Drive—Weight (approximate)................................................................................ 794 kg 1750 lb

19. Clean and inspect parts. Repair or replace parts as necessary.

• Align hydrostatic motor output shaft with final drive

splines. Install motor evenly to park brake housing. Tighten cap screws (3) to specification.

INSTALLATION Installation is reverse of removal procedure.

• Thoroughly clean final drive housing and main frame surfaces.

Specification Cap Screw (3)—Torque...............................................................320 N·m 236 lb·ft

Loctite and its related brand marks are trademarks of Henkel Corporation AB06447,0000BE9 -19-26JUN19-3/3

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850J Crawler (S.N. 130886—311988) 012820 PN=131

Drive Axle Housing and Support

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850J Crawler (S.N. 130886—311988) 012820 PN=132

Group 0250

Axle Shaft, Bearings and Reduction Gears Planet Carrier Remove and Install SPECIFICATIONS Planet Carrier Assembly Weight (approximate)

146 kg 322 lb

Planet Carrier Cap Screw (1 and 4) Torque

130 N·m 96 lb·ft

Drain Plug (5) Torque

73 N·m 54 lb·ft

Fill Plug (3) Torque

73 N·m 54 lb·ft

REMOVAL 1. Position crawler so oil level line (2) is parallel to ground and drain plug (5) is at lowest position.

TX1245013A —UN—03OCT17

2. Remove drain plug (5), then remove fill plug (3) to drain oil from planet housing. See Drain and Refill Inner and Outer Final Drive Oil. (Operator’s Manual.) NOTE: Cap screws (4) must remain installed until instructed to remove. Cap screws (4) secure the planet carrier until appropriate lifting device can be attached. 3. Remove cap screws (1) from planet carrier (6). Do not remove cap screws (4) at this time. Planet Carrier (850K shown)

4. Loosen cap screws (4) enough to pull planet carrier far enough away from planet housing to attach appropriate lifting device. CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device. 5. Attach appropriate lifting device to planet carrier assembly. Remove cap screws (4). Carefully remove planet carrier and O-ring from housing. Specification Planet Carrier Assembly—Weight (approximate)................................................................................ 146 kg 322 lb

6. Clean and inspect components. Repair or replace as necessary.

1— Cap Screw (38 used) 2— Oil Level Line 3— Fill Plug

4— Cap Screw (2 used) 5— Drain Plug 6— Planet Carrier

• Tighten cap screws (1 and 4) and plugs (3 and 5) to specification.

Specification Planet Carrier Cap Screw (1 and 4)—Torque.......................................................................130 N·m 96 lb·ft Drain Plug (5)—Torque..................................................................73 N·m 54 lb·ft Fill Plug (3)—Torque......................................................................73 N·m 54 lb·ft

• If repairs have been made to final drive components,

perform Final Drive Seal Leakage Check. (Group 0250.)

• Fill planet housing with recommended oil to bottom

INSTALLATION

edge of fill plug (3) hole. See Drain and Refill Inner and Outer Final Drive Oil. (Operator’s Manual.)

Installation is reverse of removal procedure.

• Check O-ring installed on planet carrier housing. IMPORTANT: O-rings must be seated in groove of plugs (3 and 5) to prevent leakage. Check condition and position before installing. JP80587,000002C -19-16JAN18-1/1

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Axle Shaft, Bearings and Reduction Gears

TX1245014A —UN—03OCT17

Planet Carrier Disassemble and Assemble

Planet Carrier 1— Fill Plug 2— Drain Plug 3— O-Ring (2 used) 4— Planet Pinion Carrier

5— O-Ring 6— Planet Pinion (3 used) 7— Bearing (3 used)

DISASSEMBLE

8— Planet Pinion Pin (3 used) 9— Planet Pin Cap Screw (3 used)

Assemble components as shown.

Remove and disassemble components as shown.

• Remove planet pinion pins (8) using puller. • Slide planet pinions (6) partially out of planet pinion

carrier (4). Install tie wraps to bearings (7) and planet pinions to secure bearings to planet pinions when removing from planet pinion carrier.

Weight Specifications CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device. Specification Planet Carrier—Weight (approximate)................................................................................ 146 kg 322 lb

• Install O-rings (3) in grooves of plugs (1 and 2). • Slide planet pinions and bearings into planet pinion carrier.

• Install planet pinion pins (8) using press. • Planet pinions should rotate freely. Torque Specifications Specification Planet Pin Cap Screw (9)—Torque.................................................................................320 N·m 235 lb·ft Fill Plug—Torque...........................................................................73 N·m 54 lb·ft Drain Plug—Torque.......................................................................73 N·m 54 lb·ft

ASSEMBLE JP80587,000002D -19-12DEC17-1/1

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850J Crawler (S.N. 130886—311988) 012820 PN=134

Axle Shaft, Bearings and Reduction Gears

Ring Gear and Hub Remove and Install SPECIFICATIONS Ring Gear and Hub Weight (approximate)

59 kg 130 lb

REMOVAL 1. Remove final drive metal face seal. See Final Drive Metal Face Seal Remove and Install. (Group 0250.)

TX1245016A —UN—04OCT17

CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device. 2. Attach appropriate lifting device to ring gear and hub (9). Specification Ring Gear and Hub—Weight (approximate).................................................................................. 59 kg 130 lb

3. Remove cap screws (5), washers (6), and ring gear and hub from planet carrier housing (10). 4. Clean and inspect parts. Repair or replace parts as necessary. See Ring Gear and Hub Disassemble and Assemble. (Group 0250.)

Ring Gear and Hub 5— Cap Screw (2 used) 6— Washer (2 used)

9— Ring Gear and Hub 10— Planet Carrier Housing

INSTALLATION Installation is reverse of removal procedure. RM58335,0001459 -19-08FEB18-1/1

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Axle Shaft, Bearings and Reduction Gears

Ring Gear and Hub Disassemble and Assemble SPECIFICATIONS Ring Gear Weight (approximate)

29 kg 64 lb

Hub Weight (approximate)

25 kg 55 lb

TX1245017A —UN—04OCT17

DISASSEMBLE 1. Remove bearing cone (4) from hub (2) using puller. CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device. 2. Using appropriate lifting device, remove snap ring (3) holding hub to ring gear (1). Remove hub from ring gear. Specification Ring Gear—Weight (approximate).................................................................................. 29 kg 64 lb Hub—Weight (approximate).................................................................................. 25 kg 55 lb

3. Clean and inspect parts. Repair or replace as necessary.

Ring Gear and Hub (exploded view) 1— Ring Gear 2— Hub

3— Snap Ring 4— Bearing Cone

ASSEMBLE Assemble components as shown.

JP80587,000002E -19-21NOV17-1/1

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850J Crawler (S.N. 130886—311988) 012820 PN=136

Axle Shaft, Bearings and Reduction Gears

Final Drive Metal Face Seal Remove and Install Toric Seal (Earlier Version) TX1246384A —UN—26OCT17

NOTE: The metal face seals were manufactured in two versions. This procedure applies to the toric seal (earlier version). If the metal face seal used is the square bore seal (later version), see the square bore seal (later version) procedure. SPECIFICATIONS Planetary Carrier Housing Weight (approximate)

258 kg 569 lb

Ring Gear With Hub Weight (approximate)

59 kg 130 lb

Retaining Plate Cap Screw Initial Torque

20 N·m 177 lb·in

Retaining Plate Cap Screw Final Torque

130 N·m 96 lb·ft

Planetary Carrier Housing Rotation

3.5 rpm (1 revolution per 17 seconds)

Planetary Carrier Housing (without metal face seals installed) Rolling Drag Torque (new bearings)

11—21 N·m 97—186 lb·in

Planetary Carrier Housing (without metal face seals installed) Rolling Drag Torque (used bearings)

5—11 N·m 44—97 lb·in

Metal Face Seal Protrusion (maximum difference)

1 mm 0.039 in

Face Seal Protrusion (maximum difference)

1 mm 0.039 in

Outer Trash Guard Cap Screw Torque

130 N·m 96 lb·ft

Sprocket Segment 3— Retaining Plate Cap Screw (12 used) 4— Retaining Plate

18— Sprocket Segment (5 used)

ESSENTIAL TOOLS DFT1261 Rolling Torque Measurement Tool JDG10081 Seal Installation Tool OTHER MATERIAL Dow Corning® 738 Electrical Sealant (T244737) Loctite® 277™ Threadlocker (high strength) Loctite® 242® Threadlocker (medium strength)

REMOVAL 1. Remove planet carrier. See Planet Carrier Remove and Install. (Group 0250.) NOTE: With planet carrier removed, planetary carrier housing (1) can be rotated by hand to remove all sprocket segments (18). 2. Remove sprocket segments (18) from planetary carrier housing. See Sprocket Segment Remove and Install. (Group 0130.) Dow Corning is a trademark of Dow Corning Continued on next page

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850J Crawler (S.N. 130886—311988) 012820 PN=137

Axle Shaft, Bearings and Reduction Gears Loctite and its related brand marks are trademarks of Henkel Corporation BS40810,000026B -19-08FEB18-2/29

3. Install cap screws (17) and flat washers (16) to secure ring gear and hub (2) in planetary carrier housing (1). CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device. 4. Attach appropriate lifting device to planetary carrier housing. TX1246559A —UN—01NOV17

Specification Planetary Carrier Housing—Weight (approximate)................................................................................ 258 kg 569 lb

NOTE: Original shim pack can be reused if bearing cups or cones are not replaced and if shims are not damaged. Planetary Carrier Housing With Ring Gear and Hub

5. Remove cap screws (3), retaining plate (4), and the shims located behind retaining plate.

1— Planetary Carrier Housing 2— Ring Gear and Hub 13— Inner Final Drive Housing Cover

6. Mark ring gear and hub (2) and inner final drive housing cover (13) with center punch marks (14) to aid in installation.

14— Center Punch Mark (2 used) 16— Flat Washer (2 used) 17— Cap Screw (2 used) BS40810,000026B -19-08FEB18-3/29

NOTE: The metal face seals were manufactured in two versions. The outer trash guards (if equipped) (20) shown are used with the toric metal face seals. If the outer trash guards differ from those shown, see the square bore seal (later version) procedure. 7. Remove outer trash guards (if equipped) (20). 8. Remove planetary carrier housing (1). 20— Trash Guard (2 used, if equipped)

TX1249803A —UN—10JAN18

19— Cap Screw (2 used)

Outer Trash Guards (if equipped) Continued on next page

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850J Crawler (S.N. 130886—311988) 012820 PN=138

Axle Shaft, Bearings and Reduction Gears

NOTE: The metal face seals were manufactured in two versions. The metal face seal is visible with the planetary carrier housing removed. This procedure applies to the toric seal (earlier version) (21). If the metal face seal used is the square bore seal (later version) (22), see the square bore seal (later version) procedure.

9. Determine the version of metal face seal used. This procedure applies to the toric seal (earlier version) (21). If the metal face seal used is the square bore seal (later version) (22), see the square bore seal (later version) procedure. 10. Remove and discard metal face seal with O-ring from planetary housing.

TX1250629 —UN—17JAN18

CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device. 11. Remove cap screws (17), flat washers (16), and ring gear and hub from planetary carrier housing. Specification Ring Gear With Hub—Weight (approximate).................................................................................. 59 kg 130 lb Metal Face Seals

12. Remove and discard metal face seal with O-ring from inner final drive housing.

21— Toric Seal (earlier version)

13. Clean and inspect parts. Repair or replace parts as necessary.

22— Square Bore Seal (later version)

INSTALLATION

e. Install planetary carrier housing.

NOTE: If installing new bearings or shims, perform retainer plate shimming procedure to determine shim pack.

f. Install original shims, retaining plate, and cap screws. Tighten cap screws to specification.

1. If replacing bearings, perform retainer plate shimming procedure: a. Install ring gear with hub into planetary carrier housing.

Specification Retaining Plate Cap Screw—Initial Torque....................................................................20 N·m 177 lb·in

g. Rotate planetary carrier housing 4 revolutions in one direction. Tighten retaining plate cap screws to specification. Repeat the two steps above until retaining plate cap screw torque stays at specification.

b. Install two cap screws (17) and flat washers (16) to planetary carrier housing. NOTE: Bearings must have light coating of oil to get correct rolling drag torque. c. Apply a light coating of oil to bearings. d. Align punch marks on hub with inner final drive housing cover.

Specification Retaining Plate Cap Screw—Final Torque...................................................................130 N·m 96 lb·ft Continued on next page

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850J Crawler (S.N. 130886—311988) 012820 PN=139

Axle Shaft, Bearings and Reduction Gears

TX1034552A —UN—09JAN08

h. Install DFT1261 Rolling Torque Measurement Tool to planetary carrier housing (1) with cap screw centered with sun pinion shaft. To make measurement tool, see DFT1261 Rolling Torque Measurement Tool. (Group 9900.) IMPORTANT: To obtain an accurate rolling drag torque, planetary carrier housing must be rotated at speed according to specifications or machine damage may result. i. Rotate planetary carrier housing using a torque wrench in one direction at approximately 3.5 rpm (1 revolution per 17 seconds). Rolling drag torque must be within specification.

Rolling Drag Measurement

Specification Planetary Carrier Housing—Rotation....................... 3.5 rpm (1 revolution per 17 seconds) Planetary Carrier Housing (without metal face seals installed)—Rolling Drag Torque (new bearings)........................................................... 11—21 N·m 97—186 lb·in Planetary Carrier Housing (without metal face seals installed)—Rolling Drag Torque (used bearings)........................................................... 5—11 N·m 44—97 lb·in

1— Planetary Carrier Housing

j. If rolling drag torque is not within specification, add or remove shims until rolling drag torque is within specification. k. Remove DFT1261 Rolling Drag Measurement Tool from planetary carrier housing. l. Attach appropriate lifting device to planetary carrier housing. Remove cap screws, retaining plate, and shims. m. Remove planetary carrier housing assembly from final drive.

NOTE: Installing a 0.15 mm (0.006 in) shim decreases rolling drag by approximately 20 N·m (177 lb·in). BS40810,000026B -19-08FEB18-6/29

n. Remove cap screws (17), flat washers (16), and ring gear with hub from planetary carrier housing.

TX1034531A —UN—09JAN08

Specification Ring Gear With Hub—Weight (approximate).................................................................................. 59 kg 130 lb

o. Place planetary carrier housing on a stable, flat surface with seal bore facing up. IMPORTANT: Seal bores must be clean and free of all rust, oil, dirt, and debris before installing seals or machine damage may result.

Planetary Carrier Housing With Ring Gear and Hub

2. Clean seal bores using denatured or 99% isopropyl alcohol and lint-free cloth.

1— Planetary Carrier Housing 2— Ring Gear and Hub

16— Flat Washer (2 used) 17— Cap Screw (2 used)

3. Clean one spacer using denatured or 99% isopropyl alcohol. Continued on next page

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850J Crawler (S.N. 130886—311988) 012820 PN=140

Axle Shaft, Bearings and Reduction Gears

NOTE: The Dow Corning® 738 Electrical Sealant (6) should be stored at or below 32°C (90°F) for a longer shelf life. Check use by date on tube. If out of date, do not use. No other sealant should be substituted for this product. Four drops of sealant are applied to spacer to prevent spacer from falling out of final drive housing seal bore. 4. Apply a drop of Dow Corning® 738 Electrical Sealant (6) in four places on spacer (5) as shown. TX1249772A —UN—10JAN18

NOTE: Rounded outer edge of spacer must be installed toward housing, and flat surface (with yellow paint spot) toward metal face seal O-ring. 5. Install spacer into planetary carrier housing seal bore with the spacer’s flat surface facing toward the metal face seal O-ring. 5— Spacer

6— Dow Corning® 738 Electrical Sealant

Seal Spacer

Dow Corning is a trademark of Dow Corning BS40810,000026B -19-08FEB18-8/29

6. Clamp JDG10081 Seal Installation Tool (7) onto metal face seal (9). Make sure that tool lip (8) is fully inserted around entire seal.

T194164A —UN—18AUG03

NOTE: To aid with metal face seal installation, lubricate O-ring using denatured or 99% isopropyl alcohol. Install seal before alcohol evaporates. 7. Clean metal face seal and seal O-ring using denatured or 99% isopropyl alcohol and a clean, lint-free cloth. 7— JDG10081 Seal Installation Tool 8— Tool Lip

9— Metal Face Seal JDG10081 Seal Installation Tool

BS40810,000026B -19-08FEB18-9/29

8. Install metal face seal (9) by pushing evenly and firmly on installation tool until tool bottoms out all the way around housing. 9— Metal Face Seal TX1249773A —UN—10JAN18

7— JDG10081 Seal Installation Tool

Metal Face Seal Installation Continued on next page

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850J Crawler (S.N. 130886—311988) 012820 PN=141

Axle Shaft, Bearings and Reduction Gears

TX1035743A —UN—30JAN08

IMPORTANT: Do not install or adjust seal without using essential installation tool. If face seal protrudes above specification, remove seal and reinstall as done in previous step. If these procedures are not followed, machine damage may result. 9. Using a caliper, measure several places around circumference of metal face seal (9) to ensure that seal is evenly installed in planetary carrier housing (1). Metal face seal must be level within 1 mm (0.039 in). Specification Metal Face Seal—Protrusion (maximum difference)...................................................................... 1 mm 0.039 in

Metal Face Seal Measurement 1— Planetary Carrier Housing

9— Metal Face Seal BS40810,000026B -19-08FEB18-11/29

10. Thoroughly clean spacer (5) using denatured or 99% isopropyl alcohol. Place spacer on a flat surface with rounded outer edge facing up. NOTE: The Dow Corning® 738 Electrical Sealant should be stored at or below 32°C (90°F) for a longer shelf life. Check use by date on tube. If out of date, do not use. No other sealant should be substituted for this product. Four drops of sealant are applied to spacer to prevent spacer from falling out of final drive housing seal bore.

5— Spacer

TX1249772A —UN—10JAN18

11. Apply a drop of Dow Corning® 738 Electrical Sealant (6) in four places on second spacer (5) as shown. 6— Dow Corning® 738 Electrical Sealant

Seal Spacer Dow Corning is a trademark of Dow Corning Continued on next page

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850J Crawler (S.N. 130886—311988) 012820 PN=142

Axle Shaft, Bearings and Reduction Gears

NOTE: Rounded outer edge of spacer must be installed toward housing, and flat surface (with yellow paint spot) toward metal face seal O-ring. TX1249775A —UN—10JAN18

12. Install spacer (5) into inner final drive housing cover (13) bore with spacer’s flat surface facing toward the metal face seal O-ring. NOTE: To aid with metal face seal installation, lubricate O-ring using denatured or 99% isopropyl alcohol. Install seal before alcohol evaporates. 13. Clean metal face seal and seal O-ring using denatured or 99% isopropyl alcohol and a clean, lint-free cloth. 5— Spacer

Inner Final Drive Housing Cover

13— Inner Final Drive Housing Cover BS40810,000026B -19-08FEB18-13/29

14. Install metal face seal into inner final drive housing cover (13) bore using JDG10081 Seal Installation Tool (7). 13— Inner Final Drive Housing Cover

TX1249776A —UN—10JAN18

7— JDG10081 Seal Installation Tool

Metal Face Seal Installation Continued on next page

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850J Crawler (S.N. 130886—311988) 012820 PN=143

Axle Shaft, Bearings and Reduction Gears

IMPORTANT: Do not install or adjust seal without using essential installation tool. If face seal protrudes above specification, remove seal and reinstall as done in previous step. If this procedure is not followed, machine damage may result. 15. Using a caliper, measure several places around circumference of metal face seal to ensure that seal is evenly installed in inner final drive housing cover (13). Metal face seal must be level within 1 mm (0.039 in).

TX1249777A —UN—10JAN18

Specification Face Seal—Protrusion (maximum difference)...................................................................... 1 mm 0.039 in

16. Apply a light coat of clean oil to both metal faces of seal using a clean, lint-free cloth. Make sure not to get any oil on seal O-rings. 13— Inner Final Drive Housing Cover Metal Face Seal Installation Check

BS40810,000026B -19-08FEB18-15/29

TX1249778A —UN—10JAN18

IMPORTANT: To prevent metal face seal from leaking, excess sealant must be removed from sealing surfaces of metal face seal. Apply a light coat of clean oil to sealing surfaces with a clean, lint-free cloth. 17. Apply a bead of Dow Corning® 738 Electrical Sealant (6) all the way around the metal face seal (9) O-ring to planetary carrier housing (1) joint. Excess sealant must be removed from sealing surfaces of metal face seal. 9— Metal Face Seal Sealant Application

TX1249779A —UN—10JAN18

1— Planetary Carrier Housing 6— Dow Corning® 738 Electrical Sealant

Cross Section View Continued on next page

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Axle Shaft, Bearings and Reduction Gears

6— Dow Corning® 738 Electrical Sealant 9— Metal Face Seal

TX1249780A —UN—10JAN18

18. Apply a 6 to 8 mm (0.236 to 0.315 in) bead of Dow Corning® 738 Electrical Sealant around metal face seal (9) O-ring to inner final drive housing cover (13) joint. Excess sealant must be removed from sealing surfaces of metal face seal. 13— Inner Final Drive Housing Cover

Sealant Application BS40810,000026B -19-08FEB18-17/29

19. Insert spacer ring (25) into inner final drive housing cover bore. Press firmly then rotate 45 degrees.

TX1066540A —UN—20OCT09

25— Spacer Ring

Spacer Ring Installation BS40810,000026B -19-08FEB18-18/29

20. Install ring gear with hub (2), flat washers (16), and cap screws (17) into planetary carrier housing (1). 21. Attach appropriate lifting device to planetary carrier housing and align center punch marks (14) on hub with inner final drive housing cover (13).

1— Planetary Carrier Housing 2— Ring Gear and Hub 13— Inner Final Drive Housing Cover

TX1246559A —UN—01NOV17

Specification Planetary Carrier Housing—Weight (approximate)................................................................................ 258 kg 569 lb 14— Center Punch Mark (2 used) 16— Flat Washer (2 used) 17— Cap Screw (2 used)

Planetary Carrier Housing With Ring Gear and Hub Continued on next page

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Axle Shaft, Bearings and Reduction Gears

22. Apply Loctite® 277™ Threadlocker (high strength) to threads of retaining plate cap screws (3).

TX1246384A —UN—26OCT17

23. Install shim pack, retaining plate (4), and cap screws (3). Tighten cap screws evenly until planetary carrier housing assembly is seated on inner final drive housing cover. Tighten retaining plate cap screws to specification. Specification Retaining Plate Cap Screw—Initial Torque....................................................................20 N·m 177 lb·in

24. Rotate planetary carrier housing 3 revolutions in one direction. Ensure that cap screws (3) are to specification. Repeat until cap screw torques stay at specification.

Retaining Plate

Specification Retaining Plate Cap Screw—Final Torque...................................................................130 N·m 96 lb·ft

3— Retaining Plate Cap Screw (12 used) 4— Retaining Plate

18— Sprocket Segment (5 used)

Loctite and its related brand marks are trademarks of Henkel Corporation Continued on next page

TM1731 (28JAN20)

02-0250-14

BS40810,000026B -19-08FEB18-20/29

850J Crawler (S.N. 130886—311988) 012820 PN=146

Axle Shaft, Bearings and Reduction Gears

25. Install outer trash guards (if equipped) (20). Apply Loctite® 242® Threadlocker (medium strength) to threads of outer trash guard cap screws (19) and tighten to specification. Specification Outer Trash Guard Cap Screw—Torque............................................................................130 N·m 96 lb·ft

NOTE: With planet carrier removed, planetary carrier housing (1) can be rotated by hand to remove all sprocket segments (18). TX1249803A —UN—10JAN18

26. Install sprocket segments (18) onto planetary carrier housing. See Sprocket Segment Remove and Install. (Group 0130.) 27. Install planet carrier. See Planet Carrier Remove and Install. (Group 0250.) 28. Before filling with oil, perform Final Drive Seal Leakage Check. (Group 0250.) Outer Trash Guards (if equipped)

Square Bore Seal (Later Version) NOTE: The metal face seals were manufactured in two versions. This procedure applies to the square bore seal (later version). If the metal face seal used is the toric seal (earlier version), see the toric seal (earlier version) procedure.

19— Cap Screw (2 used)

20— Trash Guard (2 used, if equipped)

ESSENTIAL TOOLS DFT1261 Rolling Torque Measurement Tool

SPECIFICATIONS Planetary Carrier Housing Weight (approximate)

230 kg 507 lb

Ring Gear With Hub Weight (approximate)

59 kg 130 lb

Loctite® 242® Threadlocker (medium strength)

Retaining Plate Cap Screw Initial Torque

20 N·m 177 lb·in

REMOVAL

Retaining Plate Cap Screw Final Torque

130 N·m 96 lb·ft

1. Remove planet carrier. See Planet Carrier Remove and Install. (Group 0250.)

Planetary Carrier Housing Rotation

3.5 rpm (1 revolution per 17 seconds)

Planetary Carrier Housing (without metal face seals installed) Rolling Drag Torque (new bearings)

11—21 N·m 97—186 lb·in

Planetary Carrier Housing (without metal face seals installed) Rolling Drag Torque (used bearings)

5—11 N·m 44—97 lb·in

Outer Trash Guard Cap Screw Torque

130 N·m 96 lb·ft

OTHER MATERIAL Loctite® 277™ Threadlocker (high strength)

Loctite and its related brand marks are trademarks of Henkel Corporation Continued on next page

TM1731 (28JAN20)

02-0250-15

BS40810,000026B -19-08FEB18-21/29

850J Crawler (S.N. 130886—311988) 012820 PN=147

Axle Shaft, Bearings and Reduction Gears

NOTE: With planet carrier removed, planetary carrier housing (1) can be rotated by hand to remove all sprocket segments (18).

3— Retaining Plate Cap Screw (12 used) 4— Retaining Plate

TX1246384A —UN—26OCT17

2. Remove sprocket segments (18) from planetary carrier housing. See Sprocket Segment Remove and Install. (Group 0130.) 18— Sprocket Segment (5 used)

Sprocket Segment BS40810,000026B -19-08FEB18-22/29

Specification Planetary Carrier Housing—Weight (approximate)................................................................................ 230 kg 507 lb

NOTE: Original shim pack can be reused if bearing cups or cones are not replaced and if shims are not damaged. Planetary Carrier Housing With Ring Gear and Hub

5. Remove cap screws (3), retaining plate (4), and the shims located behind retaining plate. 6. Mark ring gear and hub (2) and inner final drive housing cover (13) with center punch marks (14) to aid in installation.

1— Planetary Carrier Housing 2— Ring Gear and Hub 13— Inner Final Drive Housing Cover Continued on next page

TM1731 (28JAN20)

02-0250-16

14— Center Punch Mark (2 used) 16— Flat Washer (2 used) 17— Cap Screw (2 used) BS40810,000026B -19-08FEB18-23/29

850J Crawler (S.N. 130886—311988) 012820 PN=148

Axle Shaft, Bearings and Reduction Gears

NOTE: The metal face seals were manufactured in two versions. The outer trash guards (if equipped) (20) shown are used with the square bore metal face seals. If the outer trash guards differ from those shown, see the toric seal (earlier version) procedure. 7. Remove outer trash guards (if equipped) (20). 8. Remove planetary carrier housing (1). 20— Trash Guard (2 used, if equipped)

TX1248974A —UN—18DEC17

19— Cap Screw (9 used)

Outer Trash Guards (if equipped) BS40810,000026B -19-08FEB18-24/29

NOTE: The metal face seals were manufactured in two versions. The metal face seal is visible with the planetary carrier housing removed. This procedure applies to the square bore seal (later version) (22). If the metal face seal used is the toric seal (earlier version) (21), see the toric seal (earlier version) procedure.

9. Determine the version of metal face seal used. This procedure applies to the square bore seal (later version) (22). If the metal face seal used is the toric seal (earlier version) (21), see the toric seal (earlier version) procedure. 22— Square Bore Seal (later version)

TX1250629 —UN—17JAN18

21— Toric Seal (earlier version)

Metal Face Seals Continued on next page

TM1731 (28JAN20)

02-0250-17

BS40810,000026B -19-08FEB18-25/29

850J Crawler (S.N. 130886—311988) 012820 PN=149

Axle Shaft, Bearings and Reduction Gears

IMPORTANT: Avoid damage to metal face seals. When handling and removing seals, avoid contact with metal sealing surface. Do not remove elastomer rings from metal seal. 10. Remove final drive metal face seals (12 and 13) and elastomer rings from inner and outer housings. Keep metal face seals together as a matched set with seal ring faces together to protect surfaces. CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device. TX1250083A —UN—10JAN18

11. Remove cap screws (17), flat washers (16), and ring gear and hub from planetary carrier housing. Specification Ring Gear With Hub—Weight (approximate).................................................................................. 59 kg 130 lb

12. Clean and inspect parts. Repair or replace parts as necessary.

Inner Final Drive Housing Cover

INSTALLATION Installation is reverse of removal procedure. NOTE: If installing new bearings or shims, perform retainer plate shimming procedure to determine shim pack.

• If replacing bearings, perform retainer plate shimming procedure:

TX1250008A —UN—10JAN18

a. Install ring gear with hub into planetary carrier housing. b. Install two cap screws (17) and flat washers (16) to planetary carrier housing. NOTE: Bearings must have light coating of oil to get correct rolling drag torque. c. Apply a light coating of oil to bearings.

Planetary Carrier Housing

d. Align punch marks on hub with inner final drive housing cover.

12— Metal Face Seal

13— Metal Face Seal

e. Install planetary carrier housing. f. Install original shims, retaining plate, and cap screws. Tighten cap screws to specification.

to specification. Repeat the two steps above until retaining plate cap screw torque stays at specification.

Specification Retaining Plate Cap Screw—Initial Torque....................................................................20 N·m 177 lb·in

Specification Retaining Plate Cap Screw—Final Torque...................................................................130 N·m 96 lb·ft

g. Rotate planetary carrier housing 4 revolutions in one direction. Tighten retaining plate cap screws Continued on next page

TM1731 (28JAN20)

02-0250-18

BS40810,000026B -19-08FEB18-26/29

850J Crawler (S.N. 130886—311988) 012820 PN=150

Axle Shaft, Bearings and Reduction Gears

TX1034552A —UN—09JAN08

Rolling Drag Measurement

1— Planetary Carrier Housing

NOTE: Installing a 0.15 mm (0.006 in) shim decreases rolling drag by approximately 20 N·m (177 lb·in). Continued on next page

TM1731 (28JAN20)

02-0250-19

BS40810,000026B -19-08FEB18-27/29

850J Crawler (S.N. 130886—311988) 012820 PN=151

Axle Shaft, Bearings and Reduction Gears

n. Remove cap screws (17), flat washers (16), and ring gear with hub from planetary carrier housing.

TX1034531A —UN—09JAN08

Specification Ring Gear With Hub—Weight (approximate).................................................................................. 59 kg 130 lb

o. Place planetary carrier housing on a stable, flat surface with seal bore facing up. IMPORTANT: Avoid damage to metal face seals. When handling and installing seals, avoid contact with metal sealing surface. Use 99% isopropyl alcohol to clean and assist with seal installation.

Planetary Carrier Housing With Ring Gear and Hub 1— Planetary Carrier Housing 2— Ring Gear and Hub

Ensure that seals are seated evenly in seal cavities of inner housing cover and outer housing.

16— Flat Washer (2 used) 17— Cap Screw (2 used)

as lubricant. Push evenly on the seal until seal bottoms out evenly in the planetary carrier housing (1). • Install inner seal using 99% isopropyl alcohol as lubricant. Push evenly on the seal until seal bottoms out evenly in the inner housing cover. • Apply a light coat of clean oil to both the metal faces of seal using a clean, lint free cloth. Make sure not to get any oil on elastomer. • Apply Loctite® 277™ Threadlocker (high strength) to threads of retaining plate cap screws (3). • Apply Loctite® 242® Threadlocker (medium strength) to threads of outer trash guard cap screws (19). • If equipped, tighten outer trash guard cap screws to specification.

TX1246557A —UN—01NOV17

• Install outer metal face seal using 99% isopropyl alcohol

Metal Face Seal Installation 1— Planetary Carrier Housing

Specification Outer Trash Guard Cap Screw—Torque............................................................................130 N·m 96 lb·ft TX1035747A —UN—30JAN08

• Install shim pack, retaining plate (4), and cap screws

(3). Tighten cap screws evenly until planetary carrier housing assembly is seated on inner final drive housing cover. • Tighten retaining plate cap screws to specification.

Specification Retaining Plate Cap Screw—Initial Torque....................................................................20 N·m 177 lb·in

Planetary Carrier Housing Installation

• Rotate planetary carrier housing 3 revolutions in one

direction. Ensure that cap screws (3) are to specification. Repeat until cap screw torques stay at specification.

3— Retaining Plate Cap Screw (12 used)

4— Retaining Plate

Specification Retaining Plate Cap Screw—Final Torque...................................................................130 N·m 96 lb·ft

• Before filling with oil, perform Final Drive Seal Leakage Check. (Group 0250.)

Continued on next page

TM1731 (28JAN20)

02-0250-20

BS40810,000026B -19-08FEB18-28/29

850J Crawler (S.N. 130886—311988) 012820 PN=152

Axle Shaft, Bearings and Reduction Gears Loctite and its related brand marks are trademarks of Henkel Corporation BS40810,000026B -19-08FEB18-29/29

Inner Final Drive Housing Remove and Install Inner Final Drive Housing Cover Weight (approximate)

225 kg 496 lb

Cap Screw (3) Torque

320 N·m 236 lb·ft

Final Drive Housing Drain Plug Torque

73 N·m 54 lb·ft

Final Drive Housing Fill Plug Torque

73 N·m 54 lb·ft

T206849A —UN—24JAN05

SPECIFICATIONS

SERVICE EQUIPMENT AND TOOLS

Final Drive Plugs

JT01748 Lifting Bracket 1— Fill Plug

OTHER MATERIAL

2— Drain Plug

Loctite® 7649™ Primer N™ Cure Primer Loctite® 277™ Threadlocker (high strength)

3. Remove park brake. See Park Brake Remove and Install. (Group 1100.)

REMOVAL

4. Remove final drive metal face seal. See Final Drive Metal Face Seal Remove and Install. (Group 0250.)

1. Remove fill plug (1) and drain plug (2) to drain inner final drive housing. See Drain and Refill Inner and Outer Final Drive Oil. (Operator's Manual.) 2. Remove final drive. See Final Drive Remove and Install. (Group 0201.) Loctite and its related brand marks are trademarks of Henkel Corporation

Continued on next page

TM1731 (28JAN20)

02-0250-21

DA93471,00000E8 -19-12DEC17-1/2

850J Crawler (S.N. 130886—311988) 012820 PN=153

Axle Shaft, Bearings and Reduction Gears

5. Clean threaded holes on back side of inner final drive housing (6). Install M16 x 50 jack screws (4) to remove inner final drive housing cover (5). CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device. 6. Attach appropriate lifting device to inner final drive housing cover. TX1245927A —UN—19OCT17

Specification Inner Final Drive Housing Cover—Weight (approximate)................................................................................ 225 kg 496 lb

7. Remove cap screws (3). 8. Using the two jack screws to separate cover from housing, remove inner final drive housing cover. 9. Clean and inspect parts. Repair or replace as necessary. For more information, see Inner Final Drive Housing Cover Disassemble and Assemble. (Group 0250.)

Inner Final Drive Housing Assembly 3— Inner Final Drive Cap Screw (22 used) 4— M16 x 50 Jack Screw (2 used)

5— Inner Final Drive Housing Cover 6— Inner Final Drive Housing

INSTALLATION

• Install drain plug and fill plug with new O-rings. Tighten

Installation is reverse of removal procedure.

• Apply Loctite® 7649™ Primer N™ Cure Primer and

Loctite® 277™ Threadlocker (high strength) to housing and cover. • Install cap screws and tighten to specification. Specification Cap Screw (3)—Torque...............................................................320 N·m 236 lb·ft

plugs to specification.

Specification Final Drive Housing Drain Plug—Torque.................................................................................73 N·m 54 lb·ft Final Drive Housing Fill Plug—Torque.................................................................................73 N·m 54 lb·ft

IMPORTANT: O-rings must be seated in groove of plugs (1 and 2) to prevent leakage. Check condition and position before installing. Loctite and its related brand marks are trademarks of Henkel Corporation DA93471,00000E8 -19-12DEC17-2/2

TM1731 (28JAN20)

02-0250-22

850J Crawler (S.N. 130886—311988) 012820 PN=154

Axle Shaft, Bearings and Reduction Gears

Inner Final Drive Housing Cover Disassemble and Assemble

OTHER MATERIAL Loctite® 243™ Threadlocker (medium strength)

SPECIFICATIONS Cap Screw (13) Initial Torque

40 N·m 30 lb·ft

Cap Screw (13) Second Torque

40 N·m 30 lb·ft

Cap Screw (13) Final Torque

73 N·m 54 lb·ft

Input Pinion Gear Shaft End Play

0.025—0.10 mm 0.001—0.004 in

6 7 5

4 3 8

10 9

14 17 16 8

4 TX1245647 —UN—23OCT17

11 4 8 TX1245647 Inner Final Drive Housing Cover Assembly Continued on next page

TM1731 (28JAN20)

02-0250-23

DA93471,00000E1 -19-12DEC17-1/8

850J Crawler (S.N. 130886—311988) 012820 PN=155

Axle Shaft, Bearings and Reduction Gears 1— Inner Final Drive Housing Cover 2— Sun Pinion Shaft 3— Oil Seal 4— Bearing Cone (4 used) 5— Retaining Ring

6— Bull Gear 7— Snap Ring 8— Bearing Cup (4 used) 9— Washer (22 used) 10— Cap Screw (22 used) 11— Input Pinion Gear Shaft

12— Input Pinion Gear Shaft Quill 16— Shim (as required) 13— Cap Screw (8 used) 17— Shim (as required) 14— Inner Final Drive Housing 15— Shim (as required)

1. Remove snap ring (7). Remove sun pinion shaft (2) using a press.

2. Remove bull gear (6).

Loctite and its related brand marks are trademarks of Henkel Corporation DA93471,00000E1 -19-12DEC17-2/8

3. Remove cap screws (13), input pinion gear shaft quill (12), and input pinion gear shaft (11).

TX1246177A —UN—25OCT17

4. Remove bearing cup (8) from input pinion gear shaft quill. 5. Remove retaining ring (5). 6. Remove oil seal (3), bearing cups (8), and bearing cones (4) from inner final drive housing cover (1) using a driver. 7. Remove bearing cup (8) from hole in inner final drive housing cover. Input Pinion Gear Shaft

8. Remove bearing cones (4) from input pinion gear shaft. 9. Clean and inspect parts. Repair or replace parts as necessary.

4— Bearing Cone (2 used)

11— Input Pinion Gear Shaft DA93471,00000E1 -19-12DEC17-3/8

10. Install bearing cup (8) tight against shoulder in inner final drive housing cover.

TX1246178A —UN—25OCT17

11. Install oil seal (3) 6 mm (0.24 in) below bearing bore with lip (spring side) toward bearing. 12. Install cup (8), two bearing cones (4), and cup (8) into cover (1) using a press. 13. Install retaining ring (5). 3— Oil Seal 4— Bearing Cone (2 used)

5— Retaining Ring 8— Bearing Cup (3 used) Bearing Cups Continued on next page

TM1731 (28JAN20)

02-0250-24

DA93471,00000E1 -19-12DEC17-4/8

850J Crawler (S.N. 130886—311988) 012820 PN=156

Axle Shaft, Bearings and Reduction Gears

14. Install bearing cones (4) tight against shoulders on input pinion gear shaft (11) using press. 11— Input Pinion Gear Shaft TX1246177A —UN—25OCT17

4— Bearing Cone (2 used)

Input Pinion Gear Shaft DA93471,00000E1 -19-12DEC17-5/8

15. Install bearing cup (8) into input pinion gear shaft quill (12). 16. Install input pinion gear shaft. 17. Install shims (15—17) removed initially and add an additional 0.508 mm (0.020 in) shim to ensure input pinion gear shaft end play. 15— Shim (as required) 16— Shim (as required) 17— Shim (as required)

TX1246154A —UN—25OCT17

8— Bearing Cup 11— Input Pinion Gear Shaft 12— Input Pinion Gear Shaft Quill

Input Pinion Gear Shaft Quill Continued on next page

TM1731 (28JAN20)

02-0250-25

DA93471,00000E1 -19-12DEC17-6/8

850J Crawler (S.N. 130886—311988) 012820 PN=157

Axle Shaft, Bearings and Reduction Gears

18. Install input pinion gear shaft quill (12) and cap screws (13). Tighten cap screws to specification. Specification Cap Screw (13)—Initial Torque...........................................................................................40 N·m 30 lb·ft

19. Rotate input pinion gear shaft 3 revolutions in one direction. Ensure that cap screws (13) are to specification. Repeat until cap screw torque stays at specification. Specification Cap Screw (13)—Second Torque...........................................................................................40 N·m 30 lb·ft

20. Push and rotate input pinion gear shaft to seat rollers in bearing. TX1246179A —UN—25OCT17

21. Measure input pinion gear shaft end play with dial indicator. Record measurement. 22. Remove shims as required to get input pinion gear shaft to end play specification. Apply Loctite® 243™ Threadlocker (medium strength) to cap screws. Tighten cap screws to specification. Specification Cap Screw (13)—Final Torque...........................................................................................73 N·m 54 lb·ft Input Pinion Gear Shaft—End Play.............................................................0.025—0.10 mm 0.001—0.004 in

Input Pinion Gear Shaft Assembly 11— Input Pinion Gear Shaft 12— Input Pinion Gear Shaft Quill

13— Cap Screw (8 used)

Loctite and its related brand marks are trademarks of Henkel Corporation Continued on next page

TM1731 (28JAN20)

02-0250-26

DA93471,00000E1 -19-12DEC17-7/8

850J Crawler (S.N. 130886—311988) 012820 PN=158

Axle Shaft, Bearings and Reduction Gears

23. Install bull gear (6) with lip side of gear toward bearings. NOTE: Support bull gear hub while pressing sun pinion shaft into position. TX1246181A —UN—25OCT17

24. Install sun pinion shaft (2) through bearing assembly into bull gear using a press. 25. Install snap ring (7). 26. Use a soft-faced hammer to set bearings. Tap on bull gear side of sun pinion shaft until snap ring is pushed up tightly against bull gear. 27. Rotate input pinion gear shaft. Shaft must rotate freely. 7— Snap Ring

TX1246182A —UN—25OCT17

2— Sun Pinion Shaft 6— Bull Gear

Lip Side of Bull Gear

Bull Gear Installed DA93471,00000E1 -19-12DEC17-8/8

TM1731 (28JAN20)

02-0250-27

850J Crawler (S.N. 130886—311988) 012820 PN=159

Axle Shaft, Bearings and Reduction Gears

Final Drive Seal Leakage Check 27.6 kPa 0.276 bar 4 psi

Outer Final Drive Leakage Test Time

2 minutes

Outer Final Drive Leakage Check Pressure (maximum loss)

1.4 kPa 0.014 bar 0.2 psi

Inner Final Drive Seal Leakage Check Pressure

27.6 kPa 0.276 bar 4 psi

Inner Final Drive Seal Leakage Check Time

2 minutes

Inner Final Drive Seal Leakage Check Pressure (maximum loss)

1.4 kPa 0.014 bar 0.2 psi TX1246377A —UN—26OCT17

SPECIFICATIONS Outer Final Drive Leakage Test Pressure

SERVICE EQUIPMENT AND TOOLS DFT1302 Final Drive Pressure Test Adapter

Perform this check after all final drive repairs to test if seals are seated properly. 1. Remove fill plugs (4 and 5). Outer Planet Carrier (850K shown) 5— Fill Plug

TX1246329A —UN—01NOV17

4— Fill Plug

Inner Final Drive Fill Port (850K shown) Continued on next page

TM1731 (28JAN20)

02-0250-28

JP80587,0000030 -19-03JAN18-1/2

850J Crawler (S.N. 130886—311988) 012820 PN=160

Axle Shaft, Bearings and Reduction Gears

2. Install DFT1302 Final Drive Pressure Test Adapter (1), pressure gauge (2), and air pressure regulator (3) into outer final drive fill port. TX1026442A —UN—14AUG07

IMPORTANT: Prevent possible damage to lip seal. Air pressure must not exceed 27.6 kPa (0.276 bar) (4 psi). 3. Pressurize final drive housing to specification. Do not exceed specified pressure. Specification Outer Final Drive Leakage Test—Pressure........................................................................... 27.6 kPa 0.276 bar 4 psi Outer Final Drive Leakage Test—Time..................................................................2 minutes

4. Monitor the pressure. If outer final drive housing is sealed properly, pressure holds as specified. If pressure loss exceeds specification, check for leakage. Repair leaks as required. Specification Outer Final Drive Leakage Check—Pressure (maximum loss)............................................................................ 1.4 kPa 0.014 bar 0.2 psi

5. Remove DFT1302 Final Drive Pressure Test Adapter, pressure gauge, and air pressure regulator. 6. Install DFT1302 Final Drive Pressure Test Adapter, pressure gauge, and air pressure regulator into inner final drive fill port. 7. Pressurize inner final drive housing to specification.

Outer Final Drive Leakage Check (850K shown) 1— DFT1302 Final Drive Pressure Test Adapter 2— Pressure Gauge

3— Air Pressure Regulator

Inner Final Drive Seal Leakage Check—Time..............................................................2 minutes

8. Monitor the pressure. If inner final drive housing is sealed properly, pressure holds as specified. If pressure loss exceeds specification, check for leakage. Repair leaks as required. Specification Inner Final Drive Seal Leakage Check—Pressure (maximum loss)............................................................................ 1.4 kPa 0.014 bar 0.2 psi

9. Remove DFT1302 Final Drive Pressure Test Adapter, pressure gauge, and air pressure regulator. 10. Install fill plugs.

Specification Inner Final Drive Seal Leakage Check—Pressure....................................................................... 27.6 kPa 0.276 bar 4 psi JP80587,0000030 -19-03JAN18-2/2

TM1731 (28JAN20)

02-0250-29

850J Crawler (S.N. 130886—311988) 012820 PN=161

Axle Shaft, Bearings and Reduction Gears

TM1731 (28JAN20)

02-0250-30

850J Crawler (S.N. 130886—311988) 012820 PN=162

Contents

Section 03 Transmission

Page

Group 0300—Remove and Install Hydrostatic Pump Remove and Install ..................................................... 03-0300-1 Hydrostatic Motor Remove and Install ..................................................... 03-0300-7 Group 0315—Control Linkage Transmission Control Lever (TCL) Remove and Install................................ 03-0315-1 Transmission Control Lever (TCL) Disassemble and Assemble .................. 03-0315-2 Group 0360—Hydrostatic System Hydrostatic Pump Disassemble................. 03-0360-1 Charge Pump Disassemble and Assemble............................................... 03-0360-7 Pump Displacement Control Valve (PDCV) Disassemble and Assemble............................................. 03-0360-11 Multi-Function Valve Remove and Install ................................................... 03-0360-12 Multi-Function Valve Disassemble and Assemble...................................... 03-0360-12 Hydrostatic Pump Assemble ................... 03-0360-14 Hydrostatic Motor Disassemble............... 03-0360-31 Hydrostatic Motor Assemble.................... 03-0360-37 Hydraulic Integrated Circuit (HIC) Valve Remove and Install .................... 03-0360-51 Hydraulic Integrated Circuit (HIC) Valve Disassemble and Assemble............................................. 03-0360-53 Hydrostatic Reservoir Remove and Install ................................................... 03-0360-55 Hydraulic Fan Motor Remove and Install ................................................... 03-0360-57 Hydraulic Fan Pump Remove and Install ................................................... 03-0360-58 Hydraulic Fan Reversing Valve Remove and Install.............................. 03-0360-59 Hydraulic Fan Reversing Valve Disassemble and Assemble ................ 03-0360-60

TM1731 (28JAN20)

03-1

850J Crawler (S.N. 130886—311988) 012820 PN=1

Contents

TM1731 (28JAN20)

03-2

850J Crawler (S.N. 130886—311988) 012820 PN=2

Group 0300

Remove and Install Hydrostatic Pump Remove and Install

pressure in the system before disconnecting or connecting hydraulic or other lines. Tighten all connections before applying pressure.

SPECIFICATIONS Hydrostatic Reservoir Capacity

105.6 L 27.9 gal

850J Dual Hydrostatic Pump Assembly Approximate Weight

197 kg 435 lb

Hydrostatic Pump-to-Flywheel Housing Cover Cap Screw (Oiled) Torque

396 N·m 292 lb·ft

Dampener Hub-to-Hydrostatic Pump Shaft Set Screw Torque

120 N·m 88 lb·ft

Flywheel Housing Cover Plate Cap Screw Torque

57 N·m 42 lb·ft

Hydrostatic Reservoir Capacity

105.6 L 27.9 gal

2. Stop engine. Operate all hydraulic controls to release pressure in hydraulic system. 3. Turn battery disconnect switch to OFF position. 4. Drain or apply vacuum to reservoir. Specification Hydrostatic Reservoir—Capacity.................................................................... 105.6 L 27.9 gal

5. Tilt cab or ROPS.

1. Lower all equipment to the ground.

T211198A —UN—11MAY05

CAUTION: To avoid injury from escaping fluid under pressure, stop engine and relieve the

1— Line (hydraulic suction) 2— Line (hydraulic pressure) 3— Line (hydraulic case drain) 4— Line (hydraulic load sense) 5— Hydraulic Pump

6— Line (hydraulic left lift cylinder) 7— Line (fuel) 8— Pressure Control Pilot (PCP) Connector (2 used) 9— Line (hydrostatic suction) (2 used)

Disconnect lines (1-4) from hydraulic pump (5). Close all openings using caps and plugs.

7. Cut tie wraps from fuel line (7) and move line off to the side.

10— Line (hydrostatic closed loop) (4 used) 11— Line (charge pump-to-HIC valve) (2 used) 12— Line (HIC valve-to-pump) (2 used)

8. Disconnect Pressure Control Pilot (PCP) connectors (8) from front and rear pumps. 9. Disconnect lines (9-14) from hydrostatic pumps.

Continued on next page

TM1731 (28JAN20)

13— Line (hydrostatic pump case drain) 14— Line (hydrostatic motor case drain

03-0300-1

OUO1020,000156E -19-07NOV17-1/11

850J Crawler (S.N. 130886—311988) 012820 PN=165

Remove and Install

10. Remove cap screws (4) from hydraulic pump and remove pump. OUO1020,000156E -19-07NOV17-2/11

NOTE: For ease of removal and installation of pumps, tie lines together and pull up and out of the way. 11. Disconnect hydrostatic pump case supply line (15). 15— Line (hydrostatic pump case supply)

T211199A —UN—11MAY05

12— Line (HIC valve-to-pump) (2 used)

OUO1020,000156E -19-07NOV17-3/11

12. Remove cap screws (1 and 2) and remove rear pump mounting bracket. 2— Cap Screws (rear mounting bracket-to-main frame) (4 used) T211299A —UN—11MAY05

1— Cap Screws (hydrostatic pump-to-rear mounting bracket) (4 used)

Continued on next page

TM1731 (28JAN20)

03-0300-2

OUO1020,000156E -19-07NOV17-4/11

850J Crawler (S.N. 130886—311988) 012820 PN=166

Remove and Install

IMPORTANT: Damage to pump may occur if eyebolt interferes with components in pump. Ensure that eye bolt threads are no longer than case drain fitting threads. T210872A —UN—28APR05

13. Drill and tap two 1-1/16 plugs to accommodate a 1/2 in eye bolt. Remove case drain fittings and install eyebolts as shown. 14. Connect hydrostatic pumps to hoist using lifting chains. CAUTION: Dual hydrostatic pump assembly is heavy. Use adequate lifting device to move pump assembly.

16. Carefully remove pumps from machine.

Specification 850J Dual Hydrostatic Pump Assembly—Approximate Weight........................................................................................... 197 kg 435 lb

17. Remove hydraulic lines and fittings from pumps. Identify lines and mark orientation of fittings to aid in reassembly.

15. Remove flywheel housing cover cap screws and pull pumps back far enough for dampener hub to clear flywheel dampener. OUO1020,000156E -19-07NOV17-5/11

T118271B —UN—08JAN99

18. Remove cap screws (1) and separate pumps. 1— Cap Screw (4 used)

Continued on next page

TM1731 (28JAN20)

03-0300-3

OUO1020,000156E -19-07NOV17-6/11

850J Crawler (S.N. 130886—311988) 012820 PN=167

Remove and Install

19. Loosen set screw (2) and remove dampener hub (3) from pump drive shaft.

20. If flywheel housing cover was removed with pumps, remove four pump mounting cap screws holding flywheel housing cover (1) to pumps.

22. If flywheel housing cover was removed with pumps, install cover onto pump. Dip cap screws threads in oil, install and tighten cap screws to specification.

Specification Hydrostatic Pumpto-Flywheel Housing Cover Cap Screw (Oiled)—Torque...........................................................................396 N·m 292 lb·ft

23. Position dampener hub (3) with spline away from pump. Slide hub onto shaft until snap ring contacts end of shaft. 24. Tighten dampener hub set screws (2) to specification.

T211211 —UN—10MAY05

21. Clean and inspect all parts for wear or damage. Replace parts as necessary.

1— Flywheel Housing Cover 2— Set Screw (2 used)

3— Dampener Hub

Specification Dampener Hub-toHydrostatic Pump Shaft Set Screw—Torque.....................................................................120 N·m 88 lb·ft OUO1020,000156E -19-07NOV17-7/11

25. Assemble pumps using four cap screws (1). T118271B —UN—08JAN99

26. Install hydraulic lines in position as marked during removal. 27. Install hydrostatic pumps. Adjust lifting chains as necessary when installing pumps to align dampener hub with dampener. Tighten cap screws to specification. Specification Flywheel Housing Cover Plate Cap Screw—Torque..............................................................................57 N·m 42 lb·ft

1— Cap Screw (4 used)

28. Remove lift eyes from pumps and install fittings.

Continued on next page

TM1731 (28JAN20)

03-0300-4

OUO1020,000156E -19-07NOV17-8/11

850J Crawler (S.N. 130886—311988) 012820 PN=168

Remove and Install

29. Install rear pump mount bracket and tighten cap screws (1 and 2). 2— Cap Screws (rear mounting bracket-to-main frame) (4 used) T211299A —UN—11MAY05

1— Cap Screws (hydrostatic pump-to-rear mounting bracket) (4 used)

OUO1020,000156E -19-07NOV17-9/11

30. Connect hydrostatic pump case flushing line (15). 15— Line (hydrostatic pump case flushing)

T211199A —UN—11MAY05

12— Line (HIC valve-to-charge pump) (2 used)

Continued on next page

TM1731 (28JAN20)

03-0300-5

OUO1020,000156E -19-07NOV17-10/11

850J Crawler (S.N. 130886—311988) 012820 PN=169

T211198A —UN—11MAY05

Remove and Install

1— Line (hydraulic suction) 2— Line (hydraulic pressure) 3— Line (hydraulic case drain) 4— Line (hydraulic load sense) 5— Hydraulic Pump

6— Line (hydraulic left lift cylinder) 7— Line (fuel) 8— Pressure Control Pilot (PCP) Connector (2 used) 9— Line (hydrostatic suction) (2 used)

31. Connect lines (9-14).

10— Line (hydrostatic closed loop) (4 used) 11— Line (charge pump-to-HIC valve) (2 used) 12— Line (HIC valve-to-charge pump) (2 used)

13— Line (hydrostatic pump case drain) 14— Line (hydrostatic motor case drain

32. Connect Pressure Control Pilot (PCP) connectors (8) onto front and rear pumps.

Specification Hydrostatic Reservoir—Capacity.................................................................... 105.6 L 27.9 gal

33. Route fuel line to original location and secure with tie wraps.

37. Return cab or ROPS to operating position.

34. Connect lines (1-6) onto hydraulic pumps.

38. Turn battery disconnect switch to ON position.

35. Install access plate on bottom of hydrostatic reservoir compartment.

39. Perform Hydrostatic Pump and Motor Initial Start-Up Procedure. (Group 9026-25.)

36. Fill hydrostatic reservoir. See Transmission and Hydraulic Reservoir Oil. (Operators Manual.) Also Change Hydrostatic Transmission Oil and Replace Hydrostatic Charge and Fan Oil Filters. (Operators Manual.)

40. Calibrate transmission controller. See Transmission Control Unit (TCU) Calibration. (Group 9015-20.)

OUO1020,000156E -19-07NOV17-11/11

TM1731 (28JAN20)

03-0300-6

850J Crawler (S.N. 130886—311988) 012820 PN=170

Remove and Install

Hydrostatic Motor Remove and Install 1. Lower all equipment to the ground.

T211388A —UN—19MAY05

CAUTION: To avoid injury from escaping fluid under pressure, stop engine and relieve the pressure in the system before disconnecting or connecting hydraulic or other lines. Tighten all connections before applying pressure. 2. Stop engine. Operate all hydraulic controls to release pressure in hydraulic system. 3. Turn battery disconnect switch to OFF position. 4. Drain or apply a vacuum to reservoir.

1— Case Drain Hose 2— Forward Direction Hose 3— Reverse Direction Hose 4— Diagnostic Hose (2 used)

Specification Hydrostatic Reservoir—Capacity.................................................................... 105.6 L 27.9 gal

5— Motor Shift Solenoid Connector 6— Motor Speed Sensor Connector 7— Cap Screw (4 used) 8— Washer (4 used)

5. Remove rear access cover or optional rear mounted equipment from machine. 6. Identify hoses and mark locations to aid in assembly. 7. Disconnect case drain hose (1), diagnostic hoses (4) and forward and reverse hoses (2 and 3).

8. Close all openings using caps and plugs. 9. Disconnect harness connectors from motor shift solenoid (5) and motor speed sensor (6). Continued on next page

TM1731 (28JAN20)

03-0300-7

OUO1020,000156F -19-19MAY06-1/2

850J Crawler (S.N. 130886—311988) 012820 PN=171

Remove and Install

CAUTION: Hydrostatic Motor is heavy. Use adequate lifting device to move hydrostatic motor.

T211467A —UN—15JUN05

Specification Hydrostatic Motor Approximate—Weight..................................................................... 94 kg 207 lb

10. Attach DFT1243 Lifting Bracket Extension (1) to DFT1250 Lifting Bracket (2) using M20 x 2.5 x 130 cap screws, washers, and nuts (3). Attach tool to hoist. See DFT1250 Lifting Bracket. (Group 9900.) See DFT1243 Lifting Bracket Extension. (Group 9900.) 1— DFT1243 Lifting Bracket Extension 2— DFT1250 Lifting Bracket

11. Attach DFT1137 Hydrostatic Motor Removal and Installation Tool (4) to motor. See DFT1137 Hydrostatic Motor Removal and Installation Tool. (Group 9900.)

3— Cap Screws, Washers, and Nuts (2 used) 4— DFT1137 Hydrostatic Motor Removal and Installation Tool

12. Attach DFT1243 to eyebolt in DFT1137. 13. Remove four cap screws and washers from motor mounting flange. 14. Carefully pry motor away from mounting plate.

22. Remove hydrostatic motor removal and installation tools.

15. Remove motor.

23. Connect hydrostatic lines and harness connectors as marked.

16. Repair or replace motor. See Hydrostatic Motor Disassemble and see Hydrostatic Motor Assemble. (Group 0360.)

24. Install rear access plate or optional rear mounted equipment. 25. Replace bottom access plates if removed.

17. Install aligning studs to aid assembly. 18. Apply petroleum jelly to new O-ring and install on transmission motor pilot.

26. Fill reservoir to proper level. See Hydrostatic Transmission Oil and Replace Hydrostatic Charge and Fan Oil Filters. (Operators Manual.)

19. Guide hydrostatic motor through frame opening.

27. Turn battery disconnect switch to ON position.

20. Position motor on aligning studs. Align splines in coupler and slide motor into position.

28. Perform Hydrostatic Pump and Motor Initial Start-Up Procedure. (Group 9026-25.)

21. Apply PM37509 Cure Primer and PM37477 Thread Lock and Sealer (Medium Strength) to threads of cap screws. Install and tighten to specification.

29. Calibrate machine. See Transmission Control Unit (TCU) Calibration. (Group 9015-20.)

Specification Hydrostatic Motor Mounting Cap Screws—Torque..........................................................................320 N·m 236 lb-ft OUO1020,000156F -19-19MAY06-2/2

TM1731 (28JAN20)

03-0300-8

850J Crawler (S.N. 130886—311988) 012820 PN=172

Group 0315

Control Linkage Transmission Control Lever (TCL) Remove and Install 1. Turn battery disconnect switch to the OFF position. NOTE: Mark electrical connectors to aid in assembly. 2. Disconnect rotary sensors (1 and 3) and neutral start switch (2). 3. Disconnect harness connectors (4 and 5) to transmission speed control switch and horn button. 4— Harness to Horn Switch 5— Harness to Transmission Switch

T199271A —UN—16APR04

1— Steer Sensor 2— Neutral Start Switch 3— FNR Sensor

CED,TX03543,2276 -19-12JUL05-1/2

4. Remove four hex flange screws and transmission control lever (TCL) assembly. 5. Install transmission control lever (TCL) assembly using four hex flange screws. 6. Connect rotary sensors (1 and 3) and neutral start switch (2). 7. Turn battery disconnect switch to the ON position.

9. Recalibrate transmission controller. See Transmission Control Unit (TCU) Calibration. (Group 9015-20.) 1— Hex Flange Screw

T199276A —UN—16APR04

8. Adjust transmission control lever (TCL). See Transmission Control Lever (TCL) Adjustment. (Group 9015-20.)

CED,TX03543,2276 -19-12JUL05-2/2

TM1731 (28JAN20)

03-0315-1

850J Crawler (S.N. 130886—311988) 012820 PN=173

Control Linkage

T199250 —UN—15APR04

Transmission Control Lever (TCL) Disassemble and Assemble

T199250 Transmission Control Lever (TCL)

Continued on next page

TM1731 (28JAN20)

03-0315-2

CED,OUTX547,108 -19-28MAY09-1/30

850J Crawler (S.N. 130886—311988) 012820 PN=174

Control Linkage 1— Transmission Control Lever (TCL) 2— (TCL) Harness, Switch and Cover 3— Switch Cover 4— Cap Screw (4 used) 5— Screw kit For Handle 6— Not Used 7— Spring Pin (3 used) 8— Cable Clamp 9— Tie Band 10— Not Used 11— Not Used 12— Not Used 13— Not Used 14— Not Used 15— Ball Joint 16— Nut 17— Nut (2 used) 18— Spring 19— Spacer (2 used)

20— Spring 21— Stepped Washer (2 used) 22— Spring 23— Spring 24— Spring Pack Assembly 25— Linkage 26— Ball Joint 27— Nut (2 used) 28— Ball Joint 29— Rotary Sensor Kit 30— Not Used 31— Cap Screw (2 used) 32— O-Ring 33— Bearing (3 used) 34— Washer (2 used) 35— Plate 36— Washer 37— Socket Head Screw 38— Cap Screw (2 used) 39— Detent Lever Assembly

40— O-Ring (2 used) 41— Cap Screw (6 used) 42— Socket Head Cap Screw 43— Spacer 44— Spacer 45— Spring 46— Nut (2 used) 47— Detent Shaft 48— Neutral Cam 49— Cam Cover 50— SLC Body 51— O-Ring 52— Neutral Start Switch 53— Spring Plate 54— Seal Plug (2 used) 55— Shaft 56— Needle Bearing (2 used) 57— Lip Seal (2 used) 58— Bracket Assembly

59— Lip Seal (2 used) 60— Bearing Block 61— Shaft 62— Needle Bearing 63— Mounting Post (4 used) Longer Threaded Post Shown 64— Mounting Plate And FNR Label 65— Boot Assembly 66— Not Used 67— Not Used 68— Not Used 69— Not Used 70— Screw (4 used) 71— Not Used 72— Transmission Control Lever (TCL) Assembly

CED,OUTX547,108 -19-28MAY09-2/30

T199273A —UN—16APR04

1. Remove transmission control lever (TCL) from side console. See Transmission Control Lever (TCL) Remove and Install. (Group 0315.)

Continued on next page

TM1731 (28JAN20)

03-0315-3

CED,OUTX547,108 -19-28MAY09-3/30

850J Crawler (S.N. 130886—311988) 012820 PN=175

Control Linkage

• Separate boot from plate using a screwdriver. • Remove tie bands (1). • Put identification marks (2) on both sides of wire lead to aid in assembly.

T124645B —UN—17SEP99

T124638B —UN—17SEP99

• Remove clamp (3) from wire lead. • Remove screws (1, 2 and 3) and boot from SLC.

SLC Assembly With Speed In Grip Shown

Continued on next page

TM1731 (28JAN20)

03-0315-4

CED,OUTX547,108 -19-28MAY09-4/30

850J Crawler (S.N. 130886—311988) 012820 PN=176

Control Linkage

• Split grip halves (1) to remove switch (2). Boot (3) on switch can be replaced, if necessary. 3— Clamp

1— Screw (2 used) 2— Screw

3— Screw with nut (2 used)

1— Grip 2— Switch

3— Boot

T124646B —UN—17SEP99

1— Tie Bands 2— Identification Marks

Speed In Grip Switch CED,OUTX547,108 -19-28MAY09-5/30

2. Loosen lock nut (1). 3. Remove steer shaft (2) from rod end (3). 4. Remove two socket head cap screws (4) and remove steer shaft assembly from body. 3— Rod End 4— Socket Head Cap Screw (2 used) T119639B —UN—19JAN99

1— Lock Nut 2— Steer Shaft

Continued on next page

TM1731 (28JAN20)

03-0315-5

CED,OUTX547,108 -19-28MAY09-6/30

850J Crawler (S.N. 130886—311988) 012820 PN=177

Control Linkage

5. Remove rod end lock nut (8). NOTE: Use two wrenches to loosen spring end lock nuts (1).

6. Remove one spring end lock nut (1), spring guide (2), spacer (3), spring (4) or (7) and spring seat (5) from one side of steering plate (6). 7. Place steer shaft (9) in soft jaw vise and remove spring end lock nut (1), spring guide (2), spacer (3), spring (4) or (7) and spring seat (5) from other side of steering plate. 6— Steering Plate 7— Springs (gold) 8— Rod End Lock Nut 9— Steer Shaft

T119642B —UN—19JAN99

1— Spring End Lock Nut (2 used) 2— Spring Guide (2 used) 3— Spacer (2 used) 4— Springs (chrome) 5— Spring Seat (2 used)

T119641B —UN—19JAN99

NOTE: Springs are color coded to aid in assembly.

CED,OUTX547,108 -19-28MAY09-7/30

8. Remove two socket head cap screws (1), retaining plate (2) and detent spring (3). 9. Remove nut (4), socket head cap screw (8), spacer (5), washer (7) and detent lever (9). 10. Remove tube (6) from detent lever. 6— Tube 7— Washer 8— Socket Head Cap Screw 9— Detent Lever

T119643B —UN—19JAN99

1— Socket Head Cap Screws (2 used) 2— Retaining Plate 3— Detent Spring 4— Nut 5— Spacer

Continued on next page

TM1731 (28JAN20)

03-0315-6

CED,OUTX547,108 -19-28MAY09-8/30

850J Crawler (S.N. 130886—311988) 012820 PN=178

Control Linkage

11. Remove socket head cap screws from steer sensor (1) and forward/reverse sensor (2). Remove sensors and O-rings.

3— Cover 4— Neutral Start Switch

T119645B —UN—19JAN99

1— Steer Sensor 2— Forward/Reverse Sensor

T119644B —UN—19JAN99

12. Remove cover (3) and neutral start switch (4).

CED,OUTX547,108 -19-28MAY09-9/30

13. Disconnect forward/reverse rod end (1) and remove steer rod end (2) from bracket assembly (3). 3— Bracket Assembly T119646B —UN—19JAN99

1— Forward/Reverse Rod 2— Steer Rod

Continued on next page

TM1731 (28JAN20)

03-0315-7

CED,OUTX547,108 -19-28MAY09-10/30

850J Crawler (S.N. 130886—311988) 012820 PN=179

Control Linkage

NOTE: Care should be taken to avoid damaging bearing block, bearings and seals.

T119649B —UN—19JAN99

14. Remove two seal plugs and using a 1/4 in. punch with rounded edges, drive pivot pin (1) from bracket assembly. Remove bracket. 1— Pivot Pin

CED,OUTX547,108 -19-28MAY09-11/30

15. Remove steer sensor shaft (2) and bearing block (1). 2— Steer Sensor Shaft

T119650B —UN—19JAN99

1— Bearing Block

CED,OUTX547,108 -19-28MAY09-12/30

NOTE: When driving pin out of detent plate, support assembly to prevent damage to bearings and seals. 16. With the detent placed at the furthest reverse position, drive spring pin (1) out until detent plate (2) can be rotated around detent shaft (3).

T119651B —UN—18JAN99

17. Remove detent shaft (3) by pulling on cam (5). Be sure to catch detent plate (2) with rod end assembly and two spacers (4) when removing detent shaft. 18. Remove rod end assembly from detent plate, if replacement is required. 19. Remove cam (5) from detent shaft (3) by driving out spring pin, if replacement is required. 20. Remove pin (1) from detent plate. 1— Spring Pin 2— Detent Plate 3— Detent Shaft

4— Spacers (2 used) 5— Cam

Continued on next page

TM1731 (28JAN20)

03-0315-8

CED,OUTX547,108 -19-28MAY09-13/30

850J Crawler (S.N. 130886—311988) 012820 PN=180

Control Linkage

21. Remove yoke pivot pin seals (1) and steer shaft seals (3) using a pick.

23. Remove steer shaft bearings (4) and detent shaft bearings (5) using JDG1303-1 Bearing Driver and JDG1303-2 or JDG1303-3 Sleeve from JDG1303 Bearing Driver Kit. 24. Clean and inspect parts. 4— Steer Shaft Bearing (2 used) 5— Detent Shaft Bearing (2 used)

T121379B —UN—11MAY99

T121378B —UN—11MAY99

1— Yoke Pivot Pin Seal (2 used) 2— Yoke Pivot Pin Bearing (2 used) 3— Steer Shaft Seal (2 used)

T121377B —UN—11MAY99

22. Remove yoke pivot pin bearings (2) using a punch.

Continued on next page

TM1731 (28JAN20)

03-0315-9

CED,OUTX547,108 -19-28MAY09-14/30

850J Crawler (S.N. 130886—311988) 012820 PN=181

Control Linkage

25. Install yoke pivot pin bearing (3) using JDG1303-4 Driver Disk and JDG1303-5 Driver Rod. Drive bearing until driver disk is fully seated on yoke, this will set bearing to proper depth. 26. Repeat step 28 for installing other yoke pivot pin bearing. IMPORTANT: Lip side of seal must face away from bearing. 27. Apply petroleum jelly to seal and install seal (5) on JDG1303-7 Driver Disk (4) with lip of seal facing toward driver disk.

T121380B —UN—11MAY99

IMPORTANT: Drive bearing from lettered side of bearing only.

29. Repeat steps 30 and 31 for installing other yoke pivot pin seals. 1— JDG1305-5 Driver Rod 2— JDG1303-4 Driver Disk 3— Yoke Pivot Pin Bearing (2 used)

4— JDG1303-7 Driver Disk 5— Yoke Pivot Pin (2 used)

Continued on next page

TM1731 (28JAN20)

03-0315-10

T121381B —UN—11MAY99

28. Place seal and driver disk square on yoke. Insert JDG1303-5 Driver Rod and drive seal until driver disk is fully seated on yoke.

CED,OUTX547,108 -19-28MAY09-15/30

850J Crawler (S.N. 130886—311988) 012820 PN=182

Control Linkage

30. Install steer shaft cap bearing (3) using JDG1303-1 Bearing Driver (1) and JDG1303-3 Sleeve (2). Drive bearing until driver is fully seated, this will set bearing to proper depth. 31. Install steer shaft bearing (4) using JDG1303-1 Bearing Driver. Drive bearing until driver is fully seated, this will set bearing to proper depth. IMPORTANT: Lip side of seal must face away from bearing.

T121382B —UN—11MAY99

IMPORTANT: Drive bearing from lettered side of bearing only.

32. Apply petroleum jelly to seals install seal (5) on JDG1303-6 Driver Disk with lip of seal facing toward driver disk.

T121383B —UN—11MAY99

33. Place seal and driver disk square in opening and firmly press with finger pressure to install seal. Press disk driver until fully seated. 34. Repeat steps to install other steer shaft seals. 4— Steer Shaft Bearing 5— Steer Shaft Seal (2 used)

T121384B —UN—11MAY99

1— JDG1303-1 Bearing Driver 2— JDG1303-3 Sleeve 3— Steer Shaft Cap Bearing

Continued on next page

TM1731 (28JAN20)

03-0315-11

CED,OUTX547,108 -19-28MAY09-16/30

850J Crawler (S.N. 130886—311988) 012820 PN=183

Control Linkage

IMPORTANT: Drive bearing from lettered side of bearing only.

T121385B —UN—11MAY99

35. Install detent shaft bearing (3) from the stepped recess side (yellow) opening. Using JDG1303-1 Bearing Driver (1) and JDG1303-2 Sleeve (2), drive bearing through until bearing driver is fully seated. This will set bearing to proper depth. 36. Install detent shaft bearing (4) using JDG1303-1 Bearing Driver. Drive bearing until bearing driver is fully seated, this will set bearing to proper depth. 3— Detent Shaft Bearing 4— Detent Shaft Bearing

T121386B —UN—11MAY99

1— JDG1303-1 Bearing Driver 2— JDG1303-2 Sleeve

CED,OUTX547,108 -19-28MAY09-17/30

37. Install rod on detent plate, if removed. Tighten nut to specifications. Single Lever Control—Specification Detent Plate Rod Ball Joint Nut—Torque..........................................................................19 N·m 168 lb-in.

NOTE: When driving pin in detent plate, support assembly to prevent damage to bearings and seals. 39. While holding detent plate (2) and spacers (4) in place, install detent shaft (3) as shown with spring pin holes for plate and cam in line. Install spring pin (1) in detent plate. 1— Spring Pin 2— Detent Plate 3— Detent Shaft

4— Spacers (2 used) 5— Cam

Continued on next page

TM1731 (28JAN20)

T119651B —UN—18JAN99

38. Install cam (5) on detent shaft and install spring pin.

03-0315-12

CED,OUTX547,108 -19-28MAY09-18/30

850J Crawler (S.N. 130886—311988) 012820 PN=184

Control Linkage

NOTE: Align pin bore in bearing block and sensor shaft. 40. Install bearing block (1) and steer sensor shaft (2). 2— Steer Sensor Shaft T119650B —UN—19JAN99

1— Bearing Block

CED,OUTX547,108 -19-28MAY09-19/30

NOTE: Care should be taken to avoid damaging bearing block, bearings and seals.

T119649B —UN—19JAN99

41. Install lever assembly, and using a 1/4 in. punch with rounded edges, drive pivot pin (1) into bracket assembly. Pin should protrude equally on both ends. 42. Install seal plugs. 1— Pivot Pin

CED,OUTX547,108 -19-28MAY09-20/30

T119646B —UN—19JAN99

43. Apply cure primer and thread lock and sealer (medium strength) to threads of rod ends. Connect forward/reverse rod end (1) and install steer rod end (2) on bracket assembly (3). Tighten ball joint nuts to specifications. Single Lever Control—Specification Forward/Reverse Rod Ball Joint Nut—Torque...................................................................14 N·m 124 lb-in. Steer Rod Ball Joint Nut—Torque....................................................................................9 N·m 80 lb-in.

1— Forward/Reverse Rod 2— Steer Rod Continued on next page

TM1731 (28JAN20)

03-0315-13

3— Bracket Assembly

CED,OUTX547,108 -19-28MAY09-21/30

850J Crawler (S.N. 130886—311988) 012820 PN=185

Control Linkage

NOTE: Steer sensor and forward/reverse sensors are interchangeable.

T119644B —UN—19JAN99

44. Install sensors (1 and 2) and O-rings. Tighten cap screws to specifications. Single Lever Control—Specification Steer Sensor Mounting Cap Screws—Torque......................................................................5 N·m 44 lb-in. Forward/Reverse Sensor Mounting Cap Screws—Torque..............................................................................5 N·m 44 lb-in.

45. Install neutral start switch (4) and tighten to specifications.

T119645B —UN—19JAN99

Single Lever Control—Specification Neutral Start Switch—Torque.............................................................................14 N·m 124 lb-in.

46. Install cover (3) and tighten cap screws to specifications. Single Lever Control—Specification Neutral Start Switch Cover Cap Screws—Torque..............................................................................5 N·m 44 lb-in.

1— Steer Sensor 2— Forward/Reverse Sensor

3— Cover 4— Neutral Start Switch CED,OUTX547,108 -19-28MAY09-22/30

47. Install tube (6), washer (7), spacer (5), socket head cap screw (8) and nut (4). Tighten cap screw first and then nut, to specifications. Single Lever Control—Specification Detent Lever Socket Head Cap Screw and Nut—Torque..................................................................................19 N·m 168 lb-in.

Single Lever Control—Specification Detent Spring Retaining Plate Cap Screws—Torque..............................................................................5 N·m 44 lb-in. 1— Socket Head Cap Screws (2 used) 2— Retaining Plate 3— Detent Spring 4— Nut 5— Spacer

6— Tube 7— Washer 8— Socket Head Cap Screw 9— Detent Lever

Continued on next page

TM1731 (28JAN20)

03-0315-14

T119643B —UN—19JAN99

48. Install detent spring (3), retaining plate (2) and socket head cap screws (1). Tighten cap screws to specifications.

CED,OUTX547,108 -19-28MAY09-23/30

850J Crawler (S.N. 130886—311988) 012820 PN=186

Control Linkage

49. Place steering shaft in soft jaw vise. Install steering plate (6), spring seat (5), spring (4) or (7), spacer (3) spring guide (2) and spring end lock nut (1). Repeat steps for opposite end, then tighten spring end lock nuts (1) to specifications. Single Lever Control—Specification Steer Shaft Spring End Lock Nuts—Torque..........................................................................8 N·m 71 lb-in.

T119641B —UN—19JAN99

NOTE: Steering plate (6) must be installed so that the flat side faces chrome spring (4).

50. Install rod end lock nut (8). 6— Steering Plate 7— Springs (gold) 8— Rod End Lock Nut 9— Steer Shaft T119642B —UN—19JAN99

1— Spring End Lock Nut (2 used) 2— Spring Guide (2 used) 3— Spacer (2 used) 4— Springs (chrome) 5— Spring Seat (2 used)

CED,OUTX547,108 -19-28MAY09-24/30

51. Install steer shaft assembly and two socket head cap screws (4). Tighten cap screws to specifications.

52. Screw steer shaft into rod end (3) and tighten lock nut (1). 1— Lock Nut 2— Steer Shaft

3— Rod End 4— Socket Head Cap Screw (2 used)

Continued on next page

TM1731 (28JAN20)

03-0315-15

T119639B —UN—19JAN99

Single Lever Control—Specification Steer Shaft Assembly Mounting Cap Screws—Torque............................................................................34 N·m 25 lb-ft

CED,OUTX547,108 -19-28MAY09-25/30

850J Crawler (S.N. 130886—311988) 012820 PN=187

Control Linkage

T124646B —UN—17SEP99

53. If removed, install boot (3) and switch (2) in grip (1).

CED,OUTX547,108 -19-28MAY09-26/30

T124645B —UN—17SEP99

54. Install and tighten screws (1—3).

Continued on next page

TM1731 (28JAN20)

03-0315-16

CED,OUTX547,108 -19-28MAY09-27/30

850J Crawler (S.N. 130886—311988) 012820 PN=188

Control Linkage

IMPORTANT: Tie bands MUST be installed and wire lead MUST be positioned in clamp between assembly marks to provide a loop in wiring harness for steering. 55. Install tie bands (1) on wire harness.

T124638B —UN—17SEP99

56. Install clamp (3).

CED,OUTX547,108 -19-28MAY09-28/30

57. Install four socket head cap screws (1) and tighten to specification. Specification Transmission Control Lever (TCL) Top Plate Socket Head Cap Screws—Torque..............................................................................9 N·m 6.6 lb ft

58. Install boot (2).

T199277A —UN—16APR04

1— Socket Head Cap Screw (4 used)

Continued on next page

TM1731 (28JAN20)

03-0315-17

CED,OUTX547,108 -19-28MAY09-29/30

850J Crawler (S.N. 130886—311988) 012820 PN=189

Control Linkage

59. Install transmission control lever (TCL) assembly inside console. See Transmission Control Lever (TCL) Remove and Install. (Group 0315.) Install four cap screws (1) and tighten to specification. Specification Transmission Control Lever (TCL) Top Plate Cap Screws—Torque....................................................................37 N·m 27 lb ft

61. Recalibrate transmission controller. See Transmission Control Unit (TCU) Calibration. (Group 9015-20.)

T199276A —UN—16APR04

60. Adjust single lever control. See Transmission Control Lever (TCL) Adjustment. (Group 9015-20.)

CED,OUTX547,108 -19-28MAY09-30/30

TM1731 (28JAN20)

03-0315-18

850J Crawler (S.N. 130886—311988) 012820 PN=190

Group 0360

Hydrostatic System Hydrostatic Pump Disassemble

T8492AC —UN—05FEB15

IMPORTANT: If only shaft and/or shaft seal are being replaced, major disassembly of pump or removal of speed sensor is not required. Pump must be positioned with the shaft up to prevent damage to sensor or speed ring. 1. Remove four socket head screws (3) and pressure control pilot (PCP) from pump displacement control valve. PCP is serviced as an assembly. Do not disassemble. NOTE: Displacement control valve can be disassembled for cleaning only. (See procedure in this group.)

Hydrostatic Pump

2. Remove six socket head screws (1) and pump displacement control valve from housing.

T100315 —UN—05FEB15

IMPORTANT: After the seal carrier is removed, the shaft and bearing assembly are free in housing. Do not remove shaft unless it is positioned with the shaft up. If pump is positioned horizontally when the shaft is removed, the cylinder block will move out of place, making shaft installation difficult. 3. Remove retainer plate screws (2). 4. Remove retainer plate. A spring inside the rotate group will try to overcome the friction from the O-ring on the seal carrier OD. If seal carrier does not move from its bore, use a rubber hammer and tap on top of shaft. Spring inside rotating group will move seal carrier upward from bore.

O-Ring 1— Socket Head Screw (6 used) 2— Retainer Plate Screw

3— Socket Head Screw (4 used) 4— O-Ring

7. Remove and install seal using a press.

5. Remove O-ring (4) from carrier. 6. Inspect seal carrier and seal for wear or damage. NOTE: Apply PM37477 Thread Lock and Sealer (medium strength) to outside diameter of seal prior to installation. RM58335,0001442 -19-16JUN11-1/16

T8464AC —UN—14JUN95

9. Remove retaining ring and press shaft out of bearing.

Pump Shaft Continued on next page

TM1731 (28JAN20)

03-0360-1

T8464AD —UN—14JUN95

8. Remove the shaft and bearing assembly from the housing. The bearing outside diameter is a slip fit in the housing bore.

Rear Pump Shaft RM58335,0001442 -19-16JUN11-2/16

850J Crawler (S.N. 130886—311988) 012820 PN=191

Hydrostatic System

10. Place pump with auxiliary mounting flange up. 11. Remove end cap to pump housing socket head screws (1). 12. Remove large socket head screws (2) and mounting flange. 2— Large Socket Head Screw

T8493AB —UN—05FEB15

1— Pump Housing Socket Head Screw

Cap Screws RM58335,0001442 -19-16JUN11-3/16

13. Remove end cap from housing. Remove end cap gasket and swash plate leveling spring shims from the spring pockets. NOTE: The two long swash plate leveler springs are nested, with the smaller spring installed into the larger spring.

Swash Plate Leveling Spring Shims

T8464AI —UN—14JUN95

T8464AH —UN—14JUN95

IMPORTANT: Note quantity of swash plate leveling spring shims removed from end cap spring pockets. The same quantity must be used for assembly.

End Cap

14. Remove two long swash plate leveler springs and one short swash plate hold down spring. Continued on next page

TM1731 (28JAN20)

03-0360-2

RM58335,0001442 -19-16JUN11-4/16

850J Crawler (S.N. 130886—311988) 012820 PN=192

T8464AJ —UN—14JUN95

Hydrostatic System

T8464AL —UN—14JUN95

Pins and Valve Plate

Side Cover and Swash Plate Leveler

15. Remove the alignment pins and valve plate. Note the direction of the arrows on the valve plate for assembly.

17. Remove side cover and swash plate leveler (T-bar) assembly from housing. 18. Remove spring seats from swash plate leveler.

Scribe Line on Side Cover and Housing Continued on next page

TM1731 (28JAN20)

03-0360-3

T8464AN —UN—14JUN95

T8464AM —UN—14JUN95

16. Scribe a line on the side cover and the housing.

Spring Seats

RM58335,0001442 -19-16JUN11-5/16

850J Crawler (S.N. 130886—311988) 012820 PN=193

Hydrostatic System

19. Remove guide posts (B) and sealing nuts holding leveler to side cover (A).

D—Wear Strip (2 used) E—O-Ring

T8464CL —UN—14JUN95

A—Side Cover B—Guide Post (2 used) C—Swash Plate Leveler (T-bar)

T8464AO —UN—14JUN95

20. Remove swash plate leveler (C) and O-ring (E) from side cover.

Lever

T100196 —UN—05FEB15

Side Cover

Cover Lever Assembly RM58335,0001442 -19-16JUN11-6/16

21. Scribe a line on each servo cylinder and the housing to identify each servo cylinder with its respective side of the housing.

23. Carefully pry each cylinder from the housing using a screwdriver in the groove of the cylinder. The servo piston will remain in the housing. 24. Remove the cylinder block through the housing end cap opening. The swash plate and piston assembly will remain in the housing.

Servo Cylinder

T8464AT —UN—14JUN95

T8464AS —UN—14JUN95

22. Remove cap screws from each servo piston.

Cylinder Block RM58335,0001442 -19-16JUN11-7/16

25. Remove the swash plate bearing cage link pin from the housing through the control opening.

Swash Plate Bearing Cage Link Pin Continued on next page

TM1731 (28JAN20)

03-0360-4

T8464AV —UN—14JUN95

T8464AU —UN—14JUN95

26. Remove the bearing cage locator link from the swash plate through the control opening. Inspect link for wear or damage and replace as necessary.

Bearing Cage Locator Link

RM58335,0001442 -19-16JUN11-8/16

850J Crawler (S.N. 130886—311988) 012820 PN=194

Hydrostatic System

28. Remove the servo piston and slider block from housing.

Swash Plate and Pistons

T8464AX —UN—14JUN95

T8464AW —UN—14JUN95

27. Remove swash plate and pistons through the housing side cover. Disengage the servo arm from the slider block located in the servo piston as the assembly is removed.

Servo Piston and Slider Block RM58335,0001442 -19-16JUN11-9/16

29. Remove the swash plate cradle bearing cage.

T8464AY —UN—14JUN95

T8464AZ —UN—14JUN95

30. Remove the bearing races. The bearing races are a loose fit on two locating pins in the housing.

Swash Plate Cradle Bearing Cage

Bearing Races RM58335,0001442 -19-16JUN11-10/16

T8464BB —UN—14JUN95

31. Remove four cap screws holding the slipper guide hold down mechanism to the swash plate.

Cap Screws RM58335,0001442 -19-16JUN11-11/16

32. Remove the piston assemblies from the slipper guide. T8464BE —UN—14JUN95

33. After disassembly, all parts should be thoroughly cleaned. Replace all O-rings, gaskets, and the shaft seal. Inspect all parts for damage, nicks, or unusual or excessive wear or discoloration. If the end cap journal bearing needs replacement (as evidenced by large amounts of the metal back of the bearing being visible through the plastic bearing material), replace end cap. Remove Piston Assemblies Continued on next page

TM1731 (28JAN20)

03-0360-5

RM58335,0001442 -19-16JUN11-12/16

850J Crawler (S.N. 130886—311988) 012820 PN=195

Hydrostatic System

T8464BF —UN—05JUL95

34. Clean threaded holes in swash plate that attach slipper guide of all retaining compound prior to assembly.

Clean Threaded Holes in Swash Plate RM58335,0001442 -19-16JUN11-13/16

T8500AB —UN—05FEB15

NOTE: Servo arm and swash plate guide are both retained with the same special locking screw. Servo arm alignment is critical to proper pump operation. For this reason, removal of the servo arm from the swash plate is not recommended. Swash plate is serviced as an assembly. 35. Inspect servo arm (4) and swash plate guide (2) for wear. Replace as necessary. 36. Inspect headed roll pin and washer (1) for the bearing cage locator link. 37. Remove cap screw securing feedback link (3) and inspect for wear or damage. Clean cap screw threads with PM37509 Cure Primer. Apply PM38654 Thread Lock and Sealer (high strength) to threads. Install feedback link. Tighten cap screw to specification.

Servo Arm and Swash Plate Guide 1— Headed Roll Pin and Washer 2— Swash Plate Guide

3— Feedback Link 4— Servo Arm

Specification Feedback Link Cap Screw—Torque...........................................................................54.2 N·m 40 lb.-ft. RM58335,0001442 -19-16JUN11-14/16

T8464BI —UN—14JUN95

39. Install new expander O-rings and seal rings into the grooves of the servo piston. 40. Lubricate seal rings and carefully slide the servo piston into the servo cylinder. Allow the assembly to sit 5—10 minutes to allow the seal rings to return to their original size. Remove servo piston. Servo Piston and Sealing Rings Continued on next page

TM1731 (28JAN20)

T8464BJ —UN—14JUN95

38. Inspect servo piston and sealing rings for wear or damage. Replace as necessary.

03-0360-6

Servo Piston and Sealing Rings RM58335,0001442 -19-16JUN11-15/16

850J Crawler (S.N. 130886—311988) 012820 PN=196

Hydrostatic System

T8492AA —UN—14JUN95

41. Compress the cylinder block spring and remove the spiral retaining ring, retainer, spring and spring seat. Clean cylinder block components and reassemble.

Cylinder Block Components RM58335,0001442 -19-16JUN11-16/16

Charge Pump Disassemble and Assemble IMPORTANT: Absolute cleanliness is essential when working on hydrostatic components.

1— Socket Head Screw (4 used)

T199994A —UN—17MAY04

1. Remove socket head screws (1), flange adapter (2) and O-ring. 2— Flange Adapter

Remove Adapter Plate RM58335,0001443 -19-31JUL19-1/10

2. Remove cap screws (3) and retaining plate (4). 4— Retaining Plate

T199995A —UN—17MAY04

3— Cap Screw (6 used)

Pump Retaining Screws Continued on next page

TM1731 (28JAN20)

03-0360-7

RM58335,0001443 -19-31JUL19-2/10

850J Crawler (S.N. 130886—311988) 012820 PN=197

Hydrostatic System

IMPORTANT: Wear patterns develop between pump gerotor assembly and eccentric ring. Components must be installed in proper position with original orientation. T199996A —UN—17MAY04

3. Mark visible side of pump gerotor assembly (5) and eccentric ring (6) to aid in proper assembly. 4. Remove parts (1—8). 5. Remove bushing from charge pump cover (1). 6. Clean and inspect all parts for wear or damage. Replace as necessary. Charge Pump Cover-to-Port Layout

7. Apply clean hydraulic oil to all internal parts before assembling.

1— Charge Pump Cover 2— Auxiliary Drive Coupling 3— Charge Pump Shaft 4— Key

5— Charge Pump Gerotor 1 Assembly 1 6— Eccentric Ring 7— Alignment Pin 8— Port Plate

Serviced as an assembly RM58335,0001443 -19-31JUL19-3/10

IMPORTANT: Charge pump rotation is determined by the orientation of eccentric ring in the gerotor assembly, and the location of the alignment pin. Incorrect assembly will not provide charge oil to the pump and will result in damage to the pump. NOTE: One of the large socket head screws and four washers must be installed in the end cap, as illustrated, before assembling the charge pump. T199997A —UN—17MAY04

8. Install charge pump alignment pin (1) in the rotation hole as illustrated. 9. Install port plate (2). 1— Alignment Pin

2— Port Plate

Install Alignment Pin Continued on next page

TM1731 (28JAN20)

03-0360-8

RM58335,0001443 -19-31JUL19-4/10

850J Crawler (S.N. 130886—311988) 012820 PN=198

Hydrostatic System

IMPORTANT: Wear patterns develop between pump gerotor gears and eccentric ring. Components must be installed in proper position with original orientation. 10. Install the eccentric ring (1) making sure alignment pin (2) is correctly installed. 11. Install the gerotor gears (3). 3— Gerotor Gears

T119171B —UN—07JAN99

1— Eccentric Ring 2— Alignment Pin

Eccentric Ring Alignment Pin and Gears RM58335,0001443 -19-31JUL19-5/10

12. Install charge pump shaft (1) with key (2) aligned with slot in gerotor gear. 2— Key T199993A —UN—17MAY04

1— Pump Shaft

Charge Pump Shaft and Key RM58335,0001443 -19-31JUL19-6/10

13. Install auxiliary drive coupling (1).

T119593B —UN—15JAN99

1— Auxiliary Drive Coupling

Auxiliary Drive Coupling Continued on next page

TM1731 (28JAN20)

03-0360-9

RM58335,0001443 -19-31JUL19-7/10

850J Crawler (S.N. 130886—311988) 012820 PN=199

Hydrostatic System

14. Install bushing in charge pump cover (2). 15. Install charge pump cover making sure hole (1) aligns correctly with alignment pin (3). 3— Alignment Pin

T119172B —UN—07JAN99

1— Hole in Cover 2— Charge Pump Cover

Charge Pump Cover, Hole & Alignment Pin RM58335,0001443 -19-31JUL19-8/10

16. Install retaining plate (1) and cap screws (2). Tighten to specifications.

T119594B —UN—22JAN99

Specification Charge Pump Retaining Plate Cap Screws—Torque............................................................................14 N·m 120 lb.-in.

17. Lubricate O-ring (4) with petroleum jelly and install. 18. Remove socket head screw and washers (3). 1— Retaining Plate 2— Cap Screw (6 used)

3— Socket Head Screw and Washers 4— O-Ring

Retaining Plate

Continued on next page

TM1731 (28JAN20)

03-0360-10

RM58335,0001443 -19-31JUL19-9/10

850J Crawler (S.N. 130886—311988) 012820 PN=200

Hydrostatic System

19. Install flange adapter (2). 20. Install socket head screws and washers (1). Tighten to specifications. T199994A —UN—17MAY04

Specification Flange Adapter-to-Pump Socket Head Screw—Torque............................................................................298 N·m 220 lb-ft

21. Install pumps and calibrate transmission control unit (TCU). See Transmission Control Unit (TCU) Calibration. (Group 9015.) Double Pump Adapter Plate 1— Socket Head Screw and Washer (4 used)

2— Flange Adapter

RM58335,0001443 -19-31JUL19-10/10

Pump Displacement Control Valve (PDCV) Disassemble and Assemble IMPORTANT: Do not disassemble the pump displacement control valve (PDCV) housing, piston and barrel assembly (9). Correct backlash and neutral adjustment cannot be obtained if disassembled. NOTE: The PDCV is serviced as an assembly and should only be disassembled for cleaning. 1. Disassemble the PDCV as shown. Do not disassemble the PDCV housing, piston and barrel assembly (9). 2. Clean and inspect all parts for wear or damage. Replace parts as necessary. 3. Assemble PDCV as shown.

T102089 —UN—23JUL96

4. Perform Pump Displacement Control Valve (PDCV) Neutral (Null) Adjustment. (Group 9026-25.) IMPORTANT: Calibrate transmission controller whenever a sensor or transmission component is adjusted or replaced. 5. Perform Transmission Control Unit (TCU) Calibration. (Group 9015-20.) 1— Outer Spring 2— Inner Spring 3— Spacer and O-Ring 4— Linkage Identification Stamp (13 used) 5— Feedback Link

6— Chamfered Side of Guide 7— Guide 8— Null Adjustment Screw 9— PDCV Housing, Piston and Barrel Assembly

Pump Displacement Control Valve

RM58335,0001444 -19-26APR11-1/1

TM1731 (28JAN20)

03-0360-11

850J Crawler (S.N. 130886—311988) 012820 PN=201

Hydrostatic System

Multi-Function Valve Remove and Install 1. Remove multi-function valve from hydrostatic pump housing. 2. Inspect valve for wear or damage. Replace valve if necessary. 3. Install and tighten valve to specification.

Specification Multi-Function Valve—Torque.............................................................................210 N·m 155 lb.-ft.

4. If valve was disassembled for any reason or a new valve is installed, perform Multi-Function Relief Valve Test. (Group 9026-25.) OUO1020,0001573 -19-17JUL14-1/1

Multi-Function Valve Disassemble and Assemble TX1015964A —UN—27DEC06

NOTE: Multi-function valve is serviced as an assembly. This procedure is for inspection and cleaning only. 1. Secure multi-function valve in vise (as shown). 2. Using screwdriver (18), remove poppet housing (17), by carefully prying free from tangs (8) on valve body (6) as shown. Be careful not to drop poppet housing. 3. Remove parts (9—15) from poppet housing (17) and valve body (6) (as shown). Multi-Function Valve (assembled)

4. Remove dust cap (1). 5. Remove locking nut (2). 6. Remove end cap (3) and spring guide (4).

10— Spring Guide 11— Guide 12— Washer 13— Spring 14— Relief Valve Poppet 15— Check Valve Poppet 16— O-Ring 17— Poppet Housing 18— Screwdriver

Multi-Function Valve (in Vise)

TX1015963A —UN—04JAN07

1— Dust Cap 2— Locking Nut 3— End Cap 4— Spring Guide 5— O-Ring 6— Valve Body 7— O-Ring 8— Tang 9— Spring

TX1015966A —UN—27DEC06

7. Clean and inspect all parts for wear and damage. Replace valve if necessary.

Multi-Function Valve (exploded view) Continued on next page

TM1731 (28JAN20)

03-0360-12

RM58335,0001446 -19-01FEB19-1/2

850J Crawler (S.N. 130886—311988) 012820 PN=202

Hydrostatic System

8. Install new O-rings (5,7, and 16).

TX1015964A —UN—27DEC06

9. Assemble poppet housing (17), check valve poppet (15), relief valve poppet (14), spring (13), washer (12), guide (11) and valve body (6). Place assembled parts, in vertical position with poppet housing up, on a sturdy flat surface. Firmly strike the poppet housing with a soft faced hammer, with a downward blow. This will seat the poppet housing (17) on the tangs (8) of the valve body (6). 10. Assemble remaining parts as shown. 11. After multi-function valve is installed on machine, perform Multi-Function Relief Valve Test. (Group 9026-25.) 10— Spring Guide 11— Guide 12— Washer 13— Spring 14— Relief Valve Poppet 15— Check Valve Poppet 16— O-Ring 17— Poppet Housing 18— Screwdriver

TX1015966A —UN—27DEC06

1— Dust Cap 2— Locking Nut 3— End Cap 4— Spring Guide 5— O-Ring 6— Valve Body 7— O-Ring 8— Tang 9— Spring

Multi-Function Valve (assembled)

TX1015963A —UN—04JAN07

Multi-Function Valve (in vise)

Multi-Function Valve (exploded view) RM58335,0001446 -19-01FEB19-2/2

TM1731 (28JAN20)

03-0360-13

850J Crawler (S.N. 130886—311988) 012820 PN=203

Hydrostatic System

Hydrostatic Pump Assemble SPECIFICATIONS 13.5 N·m 120 lb·in

Servo Cylinder Cap Screw Torque

32 N·m 24 lb·in

Pump Guide Post Nut Torque

23 N·m 204 lb·in

Swash Plate Angle Side-to-Side Maximum Depth Difference

0.025 mm 0.001 in

Swash Plate Cover Cap Screw—Through Hole Torque

50 N·m 37 lb·in

Swash Plate Cover Cap Screw—Blind Hole Torque

64 N·m 47 lb·in

4.5 mm (0.177 in) Pocket Depth Quantity

One shim each pocket

6 mm (0.24 in) Pocket Depth Quantity

Add enough shims to get 3.5—4 mm (0.14—0.16 in) pocket depth.

7 or 7.5 mm (0.28 or 0.29 in) Pocket Depth Quantity

One shim each pocket

Pump End Cap—Large Cap Screw Torque

298 N·m 220 lb·in

Pump End Cap—Small Cap Screw Torque

38 N·m 28 lb·in

Retaining Plate Cap Screw Torque

35.3 N·m 26 lb·ft

PDCV Cap Screw Torque

16 N·m 142 lb·in

PCP Cap Screw Torque

4 N·m 35 lb·in

TX1074902A —UN—30MAR10

Bearing Plate Cap Screws Torque

First Bearing Plate Installation 1— Cap Screw (2 used) 2— Bearing Plate 3— Flat Washer (2 used)

4— Spacer (2 used) 5— Slipper Guide

2. Install the piston assemblies into the slipper guide. 3. Apply clean hydrostatic oil on slippers. Center the pistons and guide on the swash plate. IMPORTANT: For correct assembly and to prevent premature wear, slipper guide bearing must be installed as shown. The split between the slipper guide bearing plates must be located in line with the swash plate arm. The TEFLON® surface side of slipper guide bearing must be installed against the slipper guide. 4. Install bearing plate (2) with TEFLON® surface against the slipper guide (5) as shown.

ESSENTIAL TOOLS JDG920-1 Swash Plate Leveling Tool

Loctite® 242® Threadlocker (medium strength)

NOTE: Inspect the flat washers for raised edges or burrs. The smooth side of the flat washers must be installed next to the bearing plates.

IMPORTANT: Damage to polished surfaces can cause premature pump failure. Be careful when handling parts with polished surfaces to prevent nicks or scratches.

IMPORTANT: To prevent premature pump failure, new slipper guide bearing plate cap screws must be installed. Install new cap screws whenever slipper guide bearing plates are removed.

NOTE: Either side of slipper guide can be installed against slippers. Flip slipper guide if excessive wear is on top bearing surface.

5. Apply Loctite® 242® Threadlocker (medium strength) on cap screw threads. Install new cap screws (1) and flat washers (3) through the slipper guide bearing and spacers (4). Finger tighten the cap screws into the swash plate.

OTHER MATERIAL

1. Inspect slipper guide surface. Install smoothest side away from slippers. NOTE: Apply clean hydrostatic oil to all internal parts before assembly. Loctite and its related brand marks are trademarks of Henkel Corporation TEFLON is a trademark of Du Pont Co.

Continued on next page

TM1731 (28JAN20)

03-0360-14

RM58335,0001447 -19-18JUL19-1/31

850J Crawler (S.N. 130886—311988) 012820 PN=204

Hydrostatic System

6. Install bearing plate (6).

TX1125506A —UN—28NOV12

6— Bearing Plate

Bearing Plate RM58335,0001447 -19-18JUL19-2/31

7. Tighten cap screws to specification. Check movement of the assembly by hand. The slipper guide and piston slippers must slide freely on the swash plate. Specification Bearing Plate Cap Screws—Torque.........................................................................13.5 N·m 120 lb·in

TX1125507A —UN—28NOV12

7— Cap Screw (4 used)

Slipper Guide and Slippers Continued on next page

TM1731 (28JAN20)

03-0360-15

RM58335,0001447 -19-18JUL19-3/31

850J Crawler (S.N. 130886—311988) 012820 PN=205

Hydrostatic System

NOTE: The pistons and bores are not selectively fitted; specific piston and bore orientation is not required. 8. Lubricate the pistons and cylinder block bores. Install the assembled swash plate (8) into the cylinder block (9) as shown. 9— Cylinder Block

TX1125508A —UN—28NOV12

8— Swash Plate

Pistons and Cylinder Block RM58335,0001447 -19-18JUL19-4/31

9. Confirm pins (10) are secure in housing (11). 11— Housing

TX1125509A —UN—28NOV12

10— Pin (2 used)

Swash Plate Bearing Race Locating Pins Continued on next page

TM1731 (28JAN20)

03-0360-16

RM58335,0001447 -19-18JUL19-5/31

850J Crawler (S.N. 130886—311988) 012820 PN=206

Hydrostatic System

IMPORTANT: The locating pins are offset in the housing to ensure proper assembly. Use petroleum jelly to retain the races in position while assembling. 10. Install races (12); use the locating pins as a guide.

TX1125510A —UN—28NOV12

12— Race (2 used)

Swash Plate Bearing Races RM58335,0001447 -19-18JUL19-6/31

11. Lubricate and install bearing cage (13).

TX1125511A —UN—28NOV12

13— Bearing Cage

Bearing Cage Continued on next page

TM1731 (28JAN20)

03-0360-17

RM58335,0001447 -19-18JUL19-7/31

850J Crawler (S.N. 130886—311988) 012820 PN=207

Hydrostatic System

12. Install slider block (14) on the swash plate servo arm.

TX1125512A —UN—28NOV12

14— Slider Block

Slider Block RM58335,0001447 -19-18JUL19-8/31

13. Position the servo piston (15) in the housing.

TX1125514A —UN—28NOV12

15— Servo Piston

Servo Piston Continued on next page

TM1731 (28JAN20)

03-0360-18

RM58335,0001447 -19-18JUL19-9/31

850J Crawler (S.N. 130886—311988) 012820 PN=208

Hydrostatic System

TX1125516A —UN—28NOV12

NOTE: A cap screw (approximately 229 mm [9 in.] long), two flat washers (64 mm [2.5 in.] OD), and a nut can be used to assist in lowering cylinder block into housing. 14. Carefully lower the swash plate assembly (16) into the housing (17). 16— Swash Plate Assembly

17— Housing

TX1125517A —UN—28NOV12

Cylinder Block Installation

Cylinder Block Installation Continued on next page

TM1731 (28JAN20)

03-0360-19

RM58335,0001447 -19-18JUL19-10/31

850J Crawler (S.N. 130886—311988) 012820 PN=209

Hydrostatic System

15. Hold the cylinder block and swash plate assembly approximately 13 mm (0.5 in.) above the cradle bearing. Properly position the feedback link (18) in the control opening.

TX1125520A —UN—28NOV12

18— Feedback Link

Feedback Link Assembly RM58335,0001447 -19-18JUL19-11/31

16. Move the servo piston (19) on the slider block. All parts must slide freely. 17. Lower the cylinder block and swash plate assembly until the swash plate is properly positioned on the cradle bearings.

TX1125521A —UN—28NOV12

19— Servo Piston

Servo Piston Continued on next page

TM1731 (28JAN20)

03-0360-20

RM58335,0001447 -19-18JUL19-12/31

850J Crawler (S.N. 130886—311988) 012820 PN=210

Hydrostatic System

NOTE: If an assembly tool was used to install cylinder block, remove nut and washer and allow cap screw and washer to fall through the shaft opening of the housing. 18. Install new O-rings (20) on servo cylinders (21). Hold the servo piston in position and install the servo cylinders. NOTE: Be sure to assemble the correct servo cylinder on each side of the housing.

TX1125523A —UN—28NOV12

19. Install and tighten servo cylinder cap screws to specification. Specification Servo Cylinder Cap Screw—Torque..............................................................................32 N·m 24 lb·ft 20— O-Ring (2 used)

21— Servo Cylinder (2 used)

Servo Cylinder RM58335,0001447 -19-18JUL19-13/31

20. Align the slot in the swash plate bearing cage with the spring pin (22) in the swash plate and the pin hole (23) in the housing. Hook the cage locator link over the spring pin, between the washer and the swash plate. Rotate the link into the slot in the bearing cage. 23— Pin Hole TX1125524A —UN—28NOV12

22— Spring Pin

Linkage Assembly Continued on next page

TM1731 (28JAN20)

03-0360-21

RM58335,0001447 -19-18JUL19-14/31

850J Crawler (S.N. 130886—311988) 012820 PN=211

Hydrostatic System

21. Align the hole in the locator link with the hole in the housing and install the link anchor pin (24) though the link and into the housing.

TX1125525A —UN—28NOV12

24— Link Anchor Pin

Locator Link RM58335,0001447 -19-18JUL19-15/31

22. Push the swash plate assembly (25) toward the control side of the housing until the swash plate guide contacts the bearing race. Check for clearance between the servo arm and the slider block. If no clearance is present, check the assembly of the bearing cage and races.

TX1125527A —UN—28NOV12

25— Swash Plate Assembly

Swash Plate Assembly Continued on next page

TM1731 (28JAN20)

03-0360-22

RM58335,0001447 -19-18JUL19-16/31

850J Crawler (S.N. 130886—311988) 012820 PN=212

Hydrostatic System

26— Side Cover 27— Guide Post (2 used) 28— Swash Plate Leveler (T-Bar)

TX1125529A —UN—28NOV12

23. Install wear strips (29) and position the swash plate leveler (T-bar) (28) on the side cover (26). Install a new O-ring (30). Note the orientation of the leveler and the cover. 29— Wear Strip (2 used) 30— O-Ring

Cover Assembly RM58335,0001447 -19-18JUL19-17/31

24. Apply Loctite® 242® Threadlocker (medium strength) to guide posts (27). Install leveler, guide posts, and sealing nuts. Tighten nuts to specification.

TX1125530A —UN—28NOV12

Specification Pump Guide Post Nut—Torque..................................................................................23 N·m 204 lb·in 27— Guide Post (2 used)

Guide Posts Loctite and its related brand marks are trademarks of Henkel Corporation Continued on next page

TM1731 (28JAN20)

03-0360-23

RM58335,0001447 -19-18JUL19-18/31

850J Crawler (S.N. 130886—311988) 012820 PN=213

Hydrostatic System

IMPORTANT: Tabs of T-bar must be positioned on top of swash plate or damage to tabs will occur. 25. Install spring seats (31). Install side cover and swash plate leveler (T-bar). Rotate the side cover to align the marks on the cover and housing that were made at disassembly.

TX1125531A —UN—28NOV12

31— Spring Seat (2 used)

Leveler Spring Seats RM58335,0001447 -19-18JUL19-19/31

26. Apply Loctite® 242® Threadlocker (medium strength) to cap screws. Install a cap screw (32) finger tight to each side of swash plate cover while checking the zero angle position.

TX1125534A —UN—28NOV12

32— Cap Screw (2 used)

Swash Plate Cover Loctite and its related brand marks are trademarks of Henkel Corporation Continued on next page

TM1731 (28JAN20)

03-0360-24

RM58335,0001447 -19-18JUL19-20/31

850J Crawler (S.N. 130886—311988) 012820 PN=214

Hydrostatic System

27. Install nested swash plate leveling springs (one small spring and one large spring on each side), servo arm link spring (single short spring), and JDG920-1 Swash Plate Leveling Tool (33).

28. Locate the swash plate on its bearings. Using a depth micrometer, measure the distance from the pump housing to the top of swash plate. Take a second measurement on the opposite side of the swash plate. These measurements must not vary by more than specification. Rotate the side cover (which will also rotate the leveler and swash plate) until the zero angle position is established, as determined by the depth measurement.

TX1125535A —UN—28NOV12

NOTE: Depth gauge must be located on swash plate and not on piston retainer plate.

33— Swash Plate Leveling Tool

When zero angle position has been established, tighten the two side cap screws. Specification Swash Plate Angle Side-to-Side Maximum—Depth Difference................................................................................. 0.025 mm 0.001 in RM58335,0001447 -19-18JUL19-21/31

29. Apply Loctite® 242® Threadlocker (medium strength) to screws. Install and tighten remaining cap screws to specification.

34— Through Hole (2 used)

TX1125528A —UN—28NOV12

Specification Swash Plate Cover Cap Screw—Through Hole—Torque................................................................................50 N·m 37 lb·ft Swash Plate Cover Cap Screw—Blind Hole—Torque................................................................................64 N·m 47 lb·ft 35— Blind Hole (4 used)

Cover Holes Loctite and its related brand marks are trademarks of Henkel Corporation Continued on next page

TM1731 (28JAN20)

03-0360-25

RM58335,0001447 -19-18JUL19-22/31

850J Crawler (S.N. 130886—311988) 012820 PN=215

Hydrostatic System

30. Install end cap alignment pins (36) into housing. NOTE: The arrow cutouts in the valve plate must point in the direction of pump rotation when viewed from the shaft end. 31. Apply hydrostatic oil on running surface of cylinder block and install valve plate on alignment pins.

TX1125536A —UN—28NOV12

36— End Cap Alignment Pin (2 used)

End Cap Alignment Pins RM58335,0001447 -19-18JUL19-23/31

32. Install new gasket (37) on housing. Be careful that gasket does not get caught on dowel pins. IMPORTANT: Use hardened swash plate leveler spring shims only. Using other shimming materials could cause damage to pump.

TX1125540A —UN—28NOV12

NOTE: Thickness of a new shim is 0.5 mm (0.20 in.). 33. Lubricate end cap journal bearings. Install shims (38) into end cap pockets as removed during disassembly. Retain shims using petroleum jelly. If quantity of shims removed is unknown, consult specifications to determine number of shims needed. Specification 4.5 mm (0.177 in.) Pocket Depth—Quantity................................................... One shim each pocket 6 mm (0.24 in.) Pocket Depth—Quantity.............................Add enough shims to get 3.5—4 mm (0.14—0.16 in.) Pocket Depth. 7 or 7.5 mm (0.28 or 0.29 in.) pocket depth—Quantity................................................... One shim each pocket

End Cap Gasket 37— Gasket

Continued on next page

TM1731 (28JAN20)

03-0360-26

38— Shim

RM58335,0001447 -19-18JUL19-24/31

850J Crawler (S.N. 130886—311988) 012820 PN=216

Hydrostatic System

34. Position springs into pockets in end cap and install end cap (39).

TX1125541A —UN—28NOV12

39— End Cap

End Cap RM58335,0001447 -19-18JUL19-25/31

35. Install cap screws (40). Tighten cap screws to specification. Specification Pump End Cap—Large Cap Screw—Torque....................................................................298 N·m 220 lb·ft

TX1125544A —UN—28NOV12

40— Cap Screw (4 used)

Torque Continued on next page

TM1731 (28JAN20)

03-0360-27

RM58335,0001447 -19-18JUL19-26/31

850J Crawler (S.N. 130886—311988) 012820 PN=217

Hydrostatic System

36. Install cap screws (41). Tighten cap screws to specification. Specification Pump End Cap—Small Cap Screw—Torque......................................................................38 N·m 28 lb·ft

TX1125545A —UN—28NOV12

41— Cap Screw (2 used)

Torque RM58335,0001447 -19-18JUL19-27/31

37. Install shaft assembly (42).

TX1125546A —UN—28NOV12

42— Shaft Assembly

Shaft Assembly Continued on next page

TM1731 (28JAN20)

03-0360-28

RM58335,0001447 -19-18JUL19-28/31

850J Crawler (S.N. 130886—311988) 012820 PN=218

Hydrostatic System

38. Install new O-ring (43) and seal carrier (44). 44— Seal Carrier

TX1125547A —UN—28NOV12

43— O-Ring

O-Ring RM58335,0001447 -19-18JUL19-29/31

39. Install retaining plate. Tighten cap screws (45) to specification.

45— Cap Screw (4 used) 46— Cap Screw (4 used)

TX1125549A —UN—28NOV12

Specification Retaining Plate Cap Screw—Torque...........................................................................35.3 N·m 26 lb·ft 47— Cap Screw (4 used)

Assembly Continued on next page

TM1731 (28JAN20)

03-0360-29

RM58335,0001447 -19-18JUL19-30/31

850J Crawler (S.N. 130886—311988) 012820 PN=219

Hydrostatic System

IMPORTANT: If system has been contaminated with debris, the screen filters (52) must be removed for cleaning of associated parts. Screen filters are not reusable; replace after removal. See parts catalog for replacement parts. 40. Inspect and clean screen filters (52) before installing displacement control valve (49). 41. Install new gasket (48) and displacement control valve on housing. Engage the feedback linkage pin (50) in the mating hole in the feedback link (51) attached to the swash plate. Install and tighten pump displacement control valve (PDCV) cap screws (46) to specification. Specification PDCV Cap Screw—Torque..............................................................................16 N·m 142 lb·in TX1166014A —UN—17JUL14

42. Install four new O-rings and pressure control pilot (PCP). Install and tighten cap screws (47) to specification. Specification PCP Cap Screw—Torque............................................................................... 4 N·m 35 lb·in 48— Gasket 49— Displacement Control Valve 50— Feedback Linkage Pin

51— Feedback Link 52— Screen Filter (3 used)

Control Valve, Pin and Feedback Link

RM58335,0001447 -19-18JUL19-31/31

TM1731 (28JAN20)

03-0360-30

850J Crawler (S.N. 130886—311988) 012820 PN=220

Hydrostatic System

Hydrostatic Motor Disassemble 2

22 38 23

39 7 5

20 8

13 15 17 4

35 37

28 27

25 12 21

TX1090664 —UN—13APR11

10 23 9 TX1090664

22 Hydrostatic Motor Exploded View

1— Socket Head Cap Screw (3 used) 2— Guard 3— Solenoid Valve 4— Socket Head Cap Screw (4 used) 5— Servo Cover 6— Gasket 7— Spool Valve 8— O-Ring (2 used) 9— Plug Fitting 10— O-Ring 12— Shuttle Cartridge

13— Spring Seat 14— Spring 15— Spring Retainer 16— Spring 17— Spring Guide 18— Socket Head Cap Screw (4 used) 19— Socket Head Cap Screw (4 used) 20— End Cap Housing 21— Gasket 22— Plug Fitting (2 used)

23— O-Ring (2 used) 24— Spring and Seat (2 used) 25— Flushing Valve Spool 26— Socket Head Cap Screw (4 used) 27— Cover 28— O-Ring 29— O-Ring 30— Piston Assembly 31— Ring 32— O-Ring 33— Lever

34— Socket Head Cap Screw 35— Spacer 36— Set Screw 37— Set Screw 38— Shaft 39— O-Ring 40— Operating Charge Relief Valve 41— O-Ring 42— O-Ring

1. Thoroughly clean external surface of motor prior to disassembly. Continued on next page

TM1731 (28JAN20)

03-0360-31

RM58335,0001448 -19-12FEB15-1/7

850J Crawler (S.N. 130886—311988) 012820 PN=221

Hydrostatic System

2. Scribe a line on end cap housing (20) and rotating group housing (58) to aid in assembly. 3. Remove eight socket head cap screws (18 and 19) and remove end cap housing from rotating group housing. 4. Remove guard (2) from servo cover (5). 5. Mark position of solenoid valve (3) on servo cover to aid in assembly. 6. Remove solenoid valve from servo cover. 7. Remove socket head cap screws (4) and servo cover from end cap housing. 58— Rotating Group Housing

TX1060918 —UN—19JUN09

20— End Cap Housing

Hydrostatic Motor Continued on next page

TM1731 (28JAN20)

03-0360-32

RM58335,0001448 -19-12FEB15-2/7

850J Crawler (S.N. 130886—311988) 012820 PN=222

Hydrostatic System

7 1

5 3

6 TX1034626 —UN—16JAN08

12 20 10

TX1034626

9 Motor Shift Solenoid Valve Assembly

1— Socket Head Cap Screw (3 used) 2— Guard 3— Solenoid Valve

4— Socket Head Cap Screw (4 used) 5— Servo Cover 6— Gasket

8. Disassemble motor shift solenoid valve components (9—12) as shown.

7— Spool Valve 8— O-Ring (2 used) 9— Plug Fitting 10— O-Ring

9. Clean and inspect components. Replace as required. Continued on next page

TM1731 (28JAN20)

12— Shuttle Cartridge 20— End Cap Housing

03-0360-33

RM58335,0001448 -19-12FEB15-3/7

850J Crawler (S.N. 130886—311988) 012820 PN=223

Hydrostatic System

38 23

39 24 30 33

35 37

28 27

17 34 20

25 24

TX1090665 —UN—26APR11

23 TX1090665

22 Hydrostatic Motor End Cap Exploded View

13— Spring Seat 14— Spring 15— Spring Retainer 16— Spring 17— Spring Guide 18— Socket Head Cap Screw (4 used) 19— Socket Head Cap Screw (4 used)

20— End Cap Housing 21— Gasket 22— Plug Fitting (2 used) 23— O-Ring (2 used) 24— Spring and Seat (2 used) 25— Flushing Valve Spool 26— Socket Head Cap Screw (4 used)

10. Disassemble end cap assembly components (13—42) as shown.

27— Cover 28— O-Ring 29— O-Ring 30— Piston Assembly 31— Ring 32— O-Ring 33— Lever 34— Socket Head Cap Screw 35— Spacer 36— Set Screw

11. Clean and inspect components. Replace as required.

Continued on next page

TM1731 (28JAN20)

37— Set Screw 38— Shaft 39— O-Ring 40— Operating Charge Relief Valve 41— O-Ring 42— O-Ring

03-0360-34

RM58335,0001448 -19-12FEB15-4/7

850J Crawler (S.N. 130886—311988) 012820 PN=224

Hydrostatic System

55 52 57 51 59 56 72 64

71 70 67

63 61

62 60

T210518

T210518 —UN—28APR05

Rotating Group Assembly 50— Socket Head Cap Screw (8 used) 51— Flange 52— O-Ring 53— Seal 54— O-Ring 55— Shaft Assembly 56— Piston Ring Seal (9 used)

57— Speed Ring 58— Rotating Group Housing 59— Dowel Pin (2 used) 60— Socket Head Cap Screw (2 used) 61— Guard 62— Socket Head Cap Screw

IMPORTANT: To prevent damage to the hydrostatic motor, special attention should be given to the orientation of the valve segment (65) with end cap housing (20) and rotating group housing (58). On earlier motors, the semicircular recess on valve segment will need to be located on the opposite side as the speed sensor.

63— Motor Speed Sensor 64— O-Ring 65— Valve Segment 66— Plate 67— Bearing 68— Dowel Pin (2 used) 69— Cylinder Block

70— Synchronizer Shaft 71— Support Pin (2 used) 72— Roller (6 used)

15. Remove old seal (53) from flange. Once removed, the seal is not reusable.

12. Remove socket head cap screw (62) and motor speed sensor (63) from rotating group housing (58). 13. Scribe a line on rotating group housing and flange (51) to aid in assembly.

NOTE: Record orientation of valve segment (65) during disassembly. On earlier hydrostatic motors, the semicircular recess on valve segment must be located on the opposite side as the speed sensor. On later motors, the semicircular recess can be located on either side. 16. Remove hydrostatic motor parts (59—72). Record orientation of valve segment (65) during removal to aid in assembly.

14. Remove socket head cap screws (50) and flange from rotating group housing. Continued on next page

TM1731 (28JAN20)

03-0360-35

RM58335,0001448 -19-12FEB15-5/7

850J Crawler (S.N. 130886—311988) 012820 PN=225

Hydrostatic System

17. Pull shaft assembly (55) out of rotating group housing (58), taking care to not damage shaft assembly (55) and speed ring (57). DO NOT damage pistons. Use attachments from D01173AA 17-1/2 Ton Puller Set and JT01800 Driver Set.

T199010A —UN—01APR04

18. Remove piston ring seals (56) from pistons using a small retaining ring pliers and an O-ring pick.

Shaft Assembly RM58335,0001448 -19-12FEB15-6/7

NOTE: Remove speed ring ONLY if replacement is necessary.

TX1061876A —UN—17JUL09

IMPORTANT: To prevent damage to the sealing surface of the cylinder block, use a hammer and a brass drift to remove the speed ring. 19. If required, remove speed ring (57) from shaft assembly by gently tapping on ring using a hammer and brass drift. 20. Clean and inspect components. Replace as required. 57— Speed Ring

Shaft Assembly RM58335,0001448 -19-12FEB15-7/7

TM1731 (28JAN20)

03-0360-36

850J Crawler (S.N. 130886—311988) 012820 PN=226

Hydrostatic System

Hydrostatic Motor Assemble End Cap Assembly

22 19 38

23 18

30 94

35 37

34 20

28 27

25 24

TX1008261 —UN—24MAY06

TX1008261

22 Hydrostatic Motor Control Valve

18— Socket Head Cap Screw (4 24— Spring and Seat (2 used) used) 25— Flushing Valve Spool 19— Socket Head Cap Screw (4 26— Socket Head Cap Screw (4 used) used) 20— End Cap Housing 27— Cover 21— Gasket 28— O-Ring 22— Flushing Valve Plug (2 used) 29— O-Ring 23— O-Ring (2 used) 30— Piston Assembly 31— Ring

NOTE: Apply clean hydraulic oil to all internal parts prior to assembly.

32— O-Ring 33— Lever 34— Socket Head Cap Screw 35— Spacer 36— Set Screw 37— Set Screw 38— Shaft 39— O-Ring 40— Operating Charge Relief Valve 41— O-Ring

42— O-Ring 91— Spring Seat 92— Spring 93— Spring Retainer 94— Spring (2 used) 95— Spring Retainer 96— Spring Guide

Specification Flushing Valve Plug—Torque.................................................................................35 N·m 26 lb.-ft.

1. Install flushing valve spool (25), spring and seat (24), O-ring (23), and flushing valve plug (22) into end cap housing (20). Tighten flushing valve plug to specification.

3. Install O-ring (41) onto operating charge relief valve (40).

Specification Flushing Valve Plug—Torque.................................................................................35 N·m 26 lb.-ft.

4. Install poppet valve, spring, and operating charge relief valve plug into operating charge relief valve housing. Tighten operating charge relief valve plug to specification.

2. Repeat installation of similar spring and seat, O-ring, and flushing valve plug on other side. Tighten flushing valve plug to specification.

Specification Operating Charge Relief Valve Plug—Torque.......................................................................35 N·m 26 lb.-ft.

Continued on next page

TM1731 (28JAN20)

03-0360-37

TF85550,0989894 -19-19MAR13-1/15

850J Crawler (S.N. 130886—311988) 012820 PN=227

Hydrostatic System

5. Install O-ring (42) onto operating charge relief valve housing. Install operating charge relief valve into end cap and tighten to specification.

6. Install spring guide (96), springs (92 and 94), retainers (93 and 95), and spring seat (91), into end cap housing (20).

Specification Operating Charge Relief Valve—Torque...............................................................................52 N·m 38 lb.-ft. Continued on next page

TM1731 (28JAN20)

03-0360-38

TF85550,0989894 -19-19MAR13-2/15

850J Crawler (S.N. 130886—311988) 012820 PN=228

Hydrostatic System

7 1

5 3

6 TX1034626 —UN—16JAN08

12 20 10

TX1034626

9 Motor Shift Solenoid Valve Assembly

1— Socket Head Cap Screw (3 used) 2— Guard 3— Solenoid Valve

4— Socket Head Cap Screw (4 used) 5— Servo Cover 6— Gasket

7— Spool Valve 8— O-Ring (2 used) 9— Plug Fitting 10— O-Ring

NOTE: Later shuttle cartridge (12) is a one piece design and requires higher torque when installing.

12— Shuttle Cartridge 20— End Cap Housing

11. Assemble guard (2) with socket head cap screws (1) and tighten to specification.

7. Install shuttle cartridge (12). Tighten to specification. Specification Shuttle Cartridge Set Screw Two Piece Design—Torque.............................................................................. 8 N·m 71 lb.-in. Shuttle Cartridge Set Screw One Piece Design—Torque..................................................................... 12—16 N·m 106—142 lb.-in.

8. Install O-ring (10) onto plug fitting (9). Install plug fitting into housing. 9. Install solenoid valve (3) in servo cover (5). Tighten to specification. Specification Solenoid Valve—Torque................................................................30 N·m 22 lb.-ft.

Specification Guard Socket Head Cap Screw—Torque............................................................................. 15 N·m 133 lb.-in.

12. Install O-rings (8) onto spool valve (7). Install spool valve into end cap housing (20). 13. Install servo cover and gasket (6) onto end cap housing with socket head cap screws (4). Tighten screws to specification. Specification Solenoid Valve Housing-to-End Cap Socket Head Cap Screw—Torque............................................................................ 110 N·m 81 lb.-ft.

10. Install solenoid valve coil in position as marked during removal. Install cap. Continued on next page

TM1731 (28JAN20)

03-0360-39

TF85550,0989894 -19-19MAR13-3/15

850J Crawler (S.N. 130886—311988) 012820 PN=229

Hydrostatic System

22 19 38

23 18

30 33

35 37

34 20

28 27

25 24

TX1008261 —UN—24MAY06

TX1008261

22 Hydrostatic Motor Control Valve

18— Socket Head Cap Screw (4 used) 19— Socket Head Cap Screw (4 used) 20— End Cap Housing 21— Gasket 22— Plug (2 used) 23— O-Ring (2 used) 24— Spring and Seat (2 used)

25— Flushing Valve Spool 26— Socket Head Cap Screw (4 used) 27— Cover 28— O-Ring 29— O-Ring 30— Piston Assembly 31— Ring 32— O-Ring 33— Lever

14. Lubricate and place O-ring (39) on shaft (38) and install shaft in end cap housing (20). 15. Install parts (31—37) onto piston assembly (30).

34— Socket Head Cap Screw 35— Spacer 36— Set Screw 37— Set Screw 38— Shaft 39— O-Ring 40— Operating Charge Relief Valve 41— O-Ring 42— O-Ring

16. Install O-rings (28 and 29) and place cover (27) on end cap housing. Install and tighten socket head cap screws (26). Continued on next page

TM1731 (28JAN20)

91— Spring Seat 92— Spring 93— Spring Retainer 94— Spring (2 used) 95— Spring Retainer 96— Spring Guide

03-0360-40

TF85550,0989894 -19-19MAR13-4/15

850J Crawler (S.N. 130886—311988) 012820 PN=230

Hydrostatic System Rotating Group Assembly

55 52 57 51 59 56 72 64

71 70 67

63 61

62 60

T210518

T210518 —UN—28APR05

Rotating Group Assembly 50— Socket Head Cap Screw (8 used) 51— Flange 52— O-Ring 53— Seal 54— O-Ring 55— Shaft Assembly 56— Piston Ring Seal (9 used)

57— Speed Ring 58— Rotating Group Housing 59— Dowel Pin (2 used) 60— Socket Head Cap Screw (2 used) 61— Guard 62— Socket Head Cap Screw

63— Motor Speed Sensor 64— O-Ring 65— Valve Segment 66— Bearing Plate 67— Bearing 68— Dowel Pin (2 used) 69— Cylinder Block

Continued on next page

TM1731 (28JAN20)

03-0360-41

70— Synchronizer Shaft 71— Support Pin (2 used) 72— Roller (6 used)

TF85550,0989894 -19-19MAR13-5/15

850J Crawler (S.N. 130886—311988) 012820 PN=231

TX1132121 —UN—01MAR13

Hydrostatic System

Piston Ring Seals 2— Identification Mark 3— Spherical Surface

4— Piston (9 used) 56— Piston Ring Seal (9 used)

IMPORTANT: Prevent incorrect assembly of piston ring seal (56). When installing new piston ring seals, the spherical surface (3) MUST conform to the shape of the piston (4). A radial identification mark (2) is provided on the outer edge of the piston ring seal.

NOTE: Shaft assembly, with exception to the piston ring seals, is serviced as an assembly. 1. Install new piston ring seals (56) on pistons (4). The ends of each piston ring seal MUST NOT overlap each other. Continued on next page

TM1731 (28JAN20)

03-0360-42

TF85550,0989894 -19-19MAR13-6/15

850J Crawler (S.N. 130886—311988) 012820 PN=232

Hydrostatic System

2. Inspect bronze surface of bearing plate (66) for damage and excessive wear. The sealing surfaces must be free of scratches and nicks. The locating pin holes must not be worn. Replace the bearing plate if damaged or worn.

3. Inspect valve segment (65) sealing surfaces and spindle (73) for damage or wear. Check that the spindle is located correctly in the valve segment by measuring dimension A. If this dimension is not within specification, the spindle has moved in the valve segment and the assembly must be replaced. Specification Valve Segment Spindle Dimension A—Length......................................................43.8—44.6 mm 1.72—1.76 in.

4. Inspect cylinder block (69) for wear or damage. The piston bores must be smooth. The bearing plate surface must be free of scratches or nicks, and the holes for the bearing plate locating pins must not be worn. The races for the synchronizing shaft rollers must not be worn. 5. Inspect cylinder block bearing (67). If it requires replacement, remove bearing using a suitable puller. DO NOT damage the bearing plate surface of the cylinder block.

Press a new bearing (if removed) into the cylinder block until it is located the proper distance (dimension B) below the bearing plate. Specification Cylinder Block Bearing Dimension B—Depth........................................................18.5—19.0 mm 0.73—0.75 in.

IMPORTANT: To prevent damage to the sealing surface of the cylinder block, use a suitable puller to remove bearing. 6. Place cylinder block on a clean, soft surface (cardboard or shop towel) to replace speed ring. Be careful NOT to damage sealing surface of cylinder block.

7. Place new speed ring on piston side of shaft assembly. 73— Spindle A—Dimension A B—Dimension B T210535 —UN—19APR05

65— Valve Segment 66— Bearing Plate 67— Cylinder Block Bearing 69— Cylinder Block

T210535 Valve Segment Spindle Continued on next page

TM1731 (28JAN20)

03-0360-43

TF85550,0989894 -19-19MAR13-7/15

850J Crawler (S.N. 130886—311988) 012820 PN=233

Hydrostatic System

IMPORTANT: To prevent damage to speed ring, use installation tool JDG1332 Speed Ring Installer.

TX1061876A —UN—17JUL09

8. Carefully place JDG1332 Speed Ring Installer over shaft assembly pistons. Alternately tap edge of installer using a rubber mallet to seat speed ring. Speed ring will be located correctly when installer is bottomed on shaft assembly. 57— Speed Ring

Speed Ring Shown Installed Continued on next page

TM1731 (28JAN20)

03-0360-44

TF85550,0989894 -19-19MAR13-8/15

850J Crawler (S.N. 130886—311988) 012820 PN=234

Hydrostatic System

NOTE: Apply clean hydrostatic oil to all internal parts prior to assembly. 9. Position shaft assembly (55) in motor housing (58). Align scribe mark between motor housing and flange (51). Install flange over shaft assembly as far as possible. Install two cap screws used for mounting end cap housing 180° apart on flange. Alternately tighten screws until bottomed to seat flange and shaft assembly. Remove two end cap housing screws and repeat procedure using 50 mm (1.97 in.) screws. Remove screws. Install eight socket head cap screws (50). Alternately tighten screws to seat shaft assembly and flange against motor housing. Tighten flange-to-motor housing cap screws to specification. Specification Flange-to-Motor Housing Cap Screw—Torque....................................................................174 N·m 128 lb.-ft. 54— O-Ring 55— Shaft Assembly 58— Motor Housing

T210536 —UN—26APR05

50— Socket Head Cap Screw (8 used) 51— Flange 53— Seal

Shaft Assembly Continued on next page

TM1731 (28JAN20)

03-0360-45

TF85550,0989894 -19-19MAR13-9/15

850J Crawler (S.N. 130886—311988) 012820 PN=235

Hydrostatic System

10. Install synchronizing shaft support pin (71) into shaft assembly (55) and retain with petroleum jelly. 11. Install synchronizing shaft rollers (72) on the journals of synchronizing shaft (70) and retain with petroleum jelly. Position each roller with its outside edge even with end of synchronizing shaft journal. IMPORTANT: To prevent damage to the hydrostatic motor, install synchronizing shaft correctly. The cylinder block end of the shaft is larger than the shaft assembly end. 12. Install synchronizing shaft (70) and rollers (72) into motor shaft (55).

13. Rollers must enter races in motor shaft insert, and recess in end of synchronizing shaft must engage support pin. Tip and rotate synchronizing shaft in all directions to check for binding. Synchronizing shaft rollers must move freely in races in motor shaft insert. 55— Shaft Assembly 70— Synchronizing Shaft

71— Support Pin 72— Rollers (6 used)

T210569 —UN—25APR05

Synchronizer Shaft Continued on next page

TM1731 (28JAN20)

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TF85550,0989894 -19-19MAR13-10/15

850J Crawler (S.N. 130886—311988) 012820 PN=236

Hydrostatic System

T210583 —UN—25APR05

T210583 Cylinder Block 55— Shaft Assembly 70— Synchronizing Shaft

72— Roller

71— Support Pin (2 used)

14. Position synchronizing shaft (55) in housing as shown. Tip the three pistons closest to the highest side of housing. TF85550,0989894 -19-19MAR13-11/15

15. Install the second synchronizing shaft support pin (71) into recess of cylinder block and retain with petroleum jelly.

T210592A —UN—25APR05

IMPORTANT: To prevent damage to the hydrostatic motor, install cylinder block correctly. The cylinder block must be positioned so the synchronizing shaft rollers will enter their races in the block, while each piston enters its corresponding bore in the block. 16. With the synchronizing shaft supported in the shaft assembly, install the cylinder block and its synchronizing shaft support pin (71) onto the pistons and synchronizing shaft.

Support Pin 69— Cylinder Block

Continued on next page

TM1731 (28JAN20)

03-0360-47

71— Synchronizing Shaft Support Pin (2 used) TF85550,0989894 -19-19MAR13-12/15

850J Crawler (S.N. 130886—311988) 012820 PN=237

Hydrostatic System

NOTE: A brass rod may be inserted through the cylinder block to guide the pistons into position.

T200222A —UN—20MAY04

17. Start with the six pistons closest to the lower part of the end cap mounting surface. After the six pistons enter their bores, tilt cylinder block so synchronizing shaft rollers (72) enter their races in cylinder block, and the support pin enters its recess in synchronizing shaft. NOTE: Apply clean hydrostatic oil to all cylinder block bores. 18. Lift cylinder block slightly and guide the three remaining pistons into their bores.

Cylinder Block Assembly

T200223A —UN—20MAY04

After the last piston is in position, check position of rollers at highest side of housing. Maintain an inward force on cylinder block and carefully push it toward highest part of housing to check that all synchronizing shaft rollers are in position. If cylinder block is properly assembled, there will be very little (if any) rotational free play between block and motor shaft.

Cylinder Block Assembly Continued on next page

TM1731 (28JAN20)

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TF85550,0989894 -19-19MAR13-13/15

850J Crawler (S.N. 130886—311988) 012820 PN=238

Hydrostatic System Final Assembly 1. Install alignment pins (68) into cylinder block. The longer end of each shouldered pin is installed into block. 2. Install bearing plate (66) on cylinder block with steel side facing toward block. Lubricate bronze side of plate with clean hydrostatic oil. 3. Install end cap alignment pins (59) and gasket (21). Carefully locate cylinder block against highest part of housing. IMPORTANT: To prevent damage to the hydrostatic motor, DO NOT allow the pistons or synchronizing shaft rollers to fall out of position. Apply clean hydrostatic oil to all parts while assembling. NOTE: On earlier hydrostatic motors, the semicircular recess on valve segment must be located on the opposite side as the speed sensor. On later motors, semicircular recess can be located on either side. 4. Apply petroleum jelly to mating surfaces of valve segment and end cap housing. Install valve segment (65), with semicircular recess (74) in the same position as during disassembly, into end cap housing (20) so spindle engages, setting lug in servo piston. Locate valve segment and servo piston in the approximate center of its travel. On earlier hydrostatic motors, valve segment must be installed with semicircular recess (74) on the opposite side as the speed sensor. IMPORTANT: To prevent damage to hydrostatic motor, DO NOT force end cap into position on housing. Apply clean hydrostatic oil to all parts while assembling. 5. Apply clean hydrostatic oil to valve segment and bearing plate mating surfaces. Install end cap assembly and valve segment. Spindle must engage bearing in cylinder block. 66— Bearing Plate 68— Alignment Pin (2 used) 74— Semicircular Recess

T210575 —UN—25APR05

20— End Cap Housing 21— Gasket 59— Alignment Pin (2 used) 65— Valve Segment

Bearing Plate Continued on next page

TM1731 (28JAN20)

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TF85550,0989894 -19-19MAR13-14/15

850J Crawler (S.N. 130886—311988) 012820 PN=239

Hydrostatic System

IMPORTANT: To prevent damage to hydrostatic motor, DO NOT allow pistons or synchronizing shaft rollers to fall out of position. Apply clean hydrostatic oil to all parts while assembling. NOTE: On newer model motors, all eight cap screws used to mount end cap are same length due to change in end cap dimensions. 6. Install socket head cap screws (18 and 19). NOTE: The internal spring in the motor shaft should hold the end cap a short distance away from the housing. 7. Tighten socket head cap screws by hand in sequence shown while rotating motor shaft to ensure proper positioning of synchronizing shaft rollers. 8. Tighten screws using sequence shown to approximately 1/2 final torque value. Repeat sequence and tighten to final torque. TX1060916 —UN—19JUN09

Specification Motor End Cap-toHousing Screw—Torque.................................................... 192—234 N·m 142—173 lb.-ft.

9. Rotate shaft 360° to check final assembly. 19— Socket Head Cap Screw (4 used)

End Cap Assembly & Valve Segment

T8506AQ —UN—10JUL95

18— Socket Head Cap Screw (4 used)

Screw Torque Sequence TF85550,0989894 -19-19MAR13-15/15

TM1731 (28JAN20)

03-0360-50

850J Crawler (S.N. 130886—311988) 012820 PN=240

Hydrostatic System

Hydraulic Integrated Circuit (HIC) Valve Remove and Install Hydraulic Integrated Circuit (HIC) Valve Removal T212453A —UN—05JUL05

1. Turn battery disconnect switch to OFF. 2. Tilt cab/ROPS. See Cab or ROPS Tilting Procedure. (Operator's Manual.) IMPORTANT: If pump vacuum is used to control oil leakage, do not remove cartridge valves with manifold in place. The vacuum can cause o-ring and back-up rings to be pulled off cartridge valve and lodge in passages. 1— Cap Screw (3 used) 2— Hydraulic Integrated Circuit (HIC) Valve

3. Drain hydrostatic reservoir or apply vacuum. See Change Hydrostatic Transmission Oil and Replace Hydrostatic Charge and Fan Oil Filters. (Operator's Manual.) Specification Hydrostatic Reservoir—Capacity.................................................................... 105.6 L 27.9 gal

6. Disconnect transmission harness (3) connectors from HIC valve. CAUTION: HIC Valve is heavy and can cause injury if not moved properly. Use adequate lifting device to move HIC Valve.

4. Label hydraulic lines and electrical harness connections to aid assembly. CAUTION: To avoid injury from escaping fluid under pressure, relieve the pressure in the system before disconnecting or connecting hydraulic or other lines. Tighten all connections before applying pressure. 5.

3— Transmission Harness

Specification HIC Valve—Approximate Weight.......................................................................................... 29.5 kg 65 lb

7. Remove HIC valve mounting cap screws (1). Remove HIC valve (2) using hoist.

Disconnect hydraulic lines from HIC valve. Close all openings using caps and plugs. Continued on next page

TM1731 (28JAN20)

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TE14778,00000DF -19-26APR17-1/2

850J Crawler (S.N. 130886—311988) 012820 PN=241

Hydrostatic System Hydraulic Integrated Circuit (HIC) Valve Installation

T212453A —UN—05JUL05

CAUTION: HIC Valve is heavy and can cause injury if not moved properly. Use adequate lifting device to move HIC Valve. Specification HIC Valve—Approximate Weight.......................................................................................... 29.5 kg 65 lb

1. Set Hydraulic Integrated Circuit (HIC) Valve (2) on frame using hoist. Apply oil to HIC valve mounting cap screws (1) and install. Torque to specification. Specification HIC Valve Installation—Torque.....................................................................104 N·m 77 lb-ft

2. Connect transmission harness (3) connectors as marked during removal. 3. Connect hydraulic lines as marked during removal. 4. Remove vacuum if used. Fill reservoir to specification. See Change Hydrostatic Transmission Oil and Replace Hydrostatic Charge and Fan Oil Filters. (Operator's Manual.)

1— Cap Screw (3 used) 2— Hydraulic Integrated Circuit (HIC) Valve

3— Transmission Harness

5. Lower cab/ROPS to normal operating position. See Cab or ROPS Tilting Procedure. (Operator's Manual.) 6. Turn battery disconnect switch to ON. 7. Start engine and check for leaks. Repair as necessary.

See Hydraulic and Hydrostatic Oil. (Operator's Manual.) TE14778,00000DF -19-26APR17-2/2

TM1731 (28JAN20)

03-0360-52

850J Crawler (S.N. 130886—311988) 012820 PN=242

Hydrostatic System

Hydraulic Integrated Circuit (HIC) Valve Disassemble and Assemble 10 16

8 13

12 17

TX1063241 —UN—09SEP09

18 9

TX1063241

Hydraulic Integrated Circuit (HIC) Valve 2— Ball Shuttle Valve 8— Hydrostatic Oil Temperature Sensor 9— Park Brake Solenoid 1 10— Park Brake Solenoid 2 11— Hydrostatic Oil Cooler Bypass Solenoid 12— Hydrostatic Oil Cooler Bypass Valve

13— Hydrostatic Oil Reservoir 18— Hydrostatic Charge Oil Filter 24— Hand Pump Tilt Relief Valve Bypass Solenoid 19— Neutral Charge Relief Valve 39— Hydraulic Integrated Circuit 14— Hydrostatic Oil Reservoir 20— Hand Pump Park Brake (HIC) Valve Bypass Valve Relief Valve 51— Brake Pressure Sensor 16— Hydrostatic Charge Oil Filter 21— Hand Pump 52— Hydrostatic Charge Bypass Valve 22— Hand Pump Selector Valve 1 Pressure Sensor 17— Hydrostatic Charge Oil Filter 23— Hand Pump Selector Valve 2 Restriction Switch

Item

Name

Torque Value

Ball Shuttle Valve

33.9 N·m 25 lb.-ft.

Hydrostatic Oil Temperature Sensor

24 N·m 18 lb.-ft.

Park Brake Solenoid 1

Cartridge: 33.9 N·m Cartridge: 25 lb.-ft. Coil Nut: 8.1 N·m Coil Nut: 72 lb.-in.

Park Brake Solenoid 2

Cartridge: 47.5 N·m Cartridge: 35 lb.-ft. Coil Nut: 11.5 N·m Coil Nut: 102 lb.-in.

Hydrostatic Oil Cooler Bypass Solenoid

Mounting Screw: 3.5 N·m Mounting Screw: 31.2 lb.-in.

Hydrostatic Oil Cooler Bypass Valve

95 N·m 70 lb.-ft.

Hydrostatic Oil Reservoir Bypass Solenoid

Cartridge: 23.5 N·m Cartridge: 208 lb.-in. Coil Nut: 6.1 N·m Coil Nut: 54 lb.-in.

Hydrostatic Oil Reservoir Bypass Valve

95 N·m 70 lb.-ft. Continued on next page

TM1731 (28JAN20)

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TE14778,00000D2 -19-26APR17-1/4

850J Crawler (S.N. 130886—311988) 012820 PN=243

Hydrostatic System Item

Name

Torque Value

Hydrostatic Charge Oil Filter Bypass Valve

162.7 N·m 120 lb.-ft.

Hydrostatic Charge Oil Filter Restriction Switch

37 N·m 27 lb.-ft.

Neutral Charge Relief Valve

Cartridge: 67.8 N·m Cartridge: 50 lb.-ft.

Hand Pump Park Brake Relief Valve

27.1 N·m 20 lb.-ft.

Hand Pump

35.3 N·m 26 lb.-ft.

Hand Pump Selector Valve 1

25.8 N·m 228 lb.-in.

Hand Pump Selector Valve 2

35.3 N·m 26 lb.-ft.

Hand Pump Tilt Relief Valve

27.1 N·m 20 lb.-ft.

Brake Pressure Sensor

24 N·m 18 lb.-ft.

Hydrostatic Charge Pressure Sensor

24 N·m 18 lb.-ft.

Hydraulic Integrated Circuit (HIC) Valve Component Torque Values

The HIC valve contains components for four different hydraulic circuits. For more information on the HIC valve see Hydraulic Integrated Circuit (HIC) Valve Operation. (Group 9026-05.)

For information on the park brake circuit, see Park Brake Valve Operation. (Group 9026-05.)

For information on the charge oil circuit, see Charge Pump Operation. (Group 9026-05.) Also, see Hydrostatic Charge Oil Filter Operation. (Group 9026-05.)

For information on hand pump operation, see the Operator's Manual. For more HIC valve information see Hydrostatic System Schematic—Neutral (Park Brake On). (Group 9026-15.)

For information on the hydrostatic oil cooling circuit, see Oil Cooler and Reservoir Bypass Operation. (Group 9026-05.) TE14778,00000D2 -19-26APR17-2/4

HIC Valve Threaded Insert Remove and Install

T212511A —UN—05JUL05

IMPORTANT: If pump vacuum is used to control oil leakage, do not remove cartridge valves with manifold in place. The vacuum can cause O-ring and backup rings to be pulled off cartridge valve and lodge in passages. 1. Remove hydrostatic charge oil filter. 2. Remove threaded insert using JDG10011 Internal Pipe Wrench. 3. Clean HIC valve manifold and threaded insert mating surfaces with PM37509 Cure Primer. 4. Apply a thin continuous line of PM37485 Retaining Compound (Maximum Strength) around bottom third threads.

JDG10011 Internal Pipe Wrench 1— Threaded Insert 2— HIC Valve Manifold Continued on next page

TM1731 (28JAN20)

03-0360-54

3— JDG10011 Internal Pipe Wrench TE14778,00000D2 -19-26APR17-3/4

850J Crawler (S.N. 130886—311988) 012820 PN=244

Hydrostatic System

5. Install threaded insert into HIC valve manifold with beveled edge (4) facing inward, until shoulder hits.

T212549 —UN—06JUL05

4— Beveled Edge

4 Threaded Insert Cross Section

TE14778,00000D2 -19-26APR17-4/4

Hydrostatic Reservoir Remove and Install 1. Turn battery disconnect switch to OFF.

T207457A —UN—26JAN05

2. Tilt cab/ROPS. See Cab or ROPS Tilting Procedure. (Operator's Manual.) 3. Remove left and rear fenders. 4. Remove left service door. 5. Drain reservoir. See Change Hydrostatic Transmission Oil and Replace Hydrostatic Charge and Fan Oil Filters. (Operator's Manual.) Specification Hydrostatic Reservoir—Capacity.................................................................... 105.6 L 27.9 gal

1— Filler Plug 3— Hydraulic Fan Oil Filter

6. Remove twist ties from windshield washer hoses and harness. Remove washer reservoir cap screws and move washer reservoir out of the way.

4— Hydrostatic Charge Oil Filter 5— Hydrostatic Reservoir Oil Level Sight Glass

7. Disconnect hoses from hydraulic fan oil filter (3). Close all openings using caps and plugs. Continued on next page

TM1731 (28JAN20)

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TE14778,0000089 -19-26APR17-1/2

850J Crawler (S.N. 130886—311988) 012820 PN=245

Hydrostatic System

8. Disconnect reservoir drain hose (1), hydrostatic pump suction hoses (6 and 3), hydraulic fan pump suction hose (4), Hydraulic Integrated Circuit (HIC) hose (5), and hand pump suction hose (2) from reservoir. 9. Disconnect hydraulic filter restriction switch harness from switch. 10. Support hydrostatic reservoir with hoist. CAUTION: Hydrostatic reservoir is heavy and can cause injury if not moved properly. Use adequate lifting device to move reservoir. Specification Hydrostatic Reservoir—Approximate Weight........................................................................................... 176 kg 388 lb

T212245A —UN—20JUN05

11. Remove cap screws and remove reservoir using hoist. NOTE: For cleanout cover repair procedure see Hydraulic Reservoir Cleanout Cover Remove and Install. (Group 3260.) 12. Install reservoir with cap screws. Tighten to specification. Specification Hydrostatic Reservoir Mounting Cap Screw—Torque............................................................................319 N·m 235 lb-ft

13. Connect suction and return hoses.

1— Hydrostatic Reservoir Drain Hose 2— Hand Pump Suction Hose 3— Hydrostatic Pump Suction Hose

14. Install windshield washer bottle. 15. Route hoses and wiring harnesses back to their original locations. Replace all tie bands that were removed. 16. Install left service door and fenders. 17. Fill reservoir to specification. See Change Hydrostatic Transmission Oil and Replace Hydrostatic Charge and Fan Oil Filters. (Operator's Manual.)

4— Hydraulic Fan Pump Suction Hose 5— Hydraulic Integrated Circuit (HIC) Valve Suction and Return Hose 6— Hydrostatic Pump Suction Hose

18. Lower cab/ROPS to normal operating position. See Cab or ROPS Tilting Procedure. (Operator's Manual.) 19. Turn battery disconnect switch to ON. 20. Start engine and check for leaks. Repair as necessary.

See Hydraulic and Hydrostatic Oil. (Operator's Manual.) TE14778,0000089 -19-26APR17-2/2

TM1731 (28JAN20)

03-0360-56

850J Crawler (S.N. 130886—311988) 012820 PN=246

Hydrostatic System

Hydraulic Fan Motor Remove and Install Hydraulic Fan Motor Removal 1. Turn battery disconnect switch to OFF. 2. Open grille door and label front of fan to aid assembly. Remove fan. CAUTION: To avoid injury from escaping fluid under pressure, relieve the pressure in the system before disconnecting or connecting hydraulic or other lines. Tighten all connections before applying pressure. Disconnect forward pressure line (1).

T212454A —UN—05JUL05

4. Remove cap screws (7). 5. Disconnect reverse pressure line (2) and case drain line (3). Close all openings with caps and plugs. 6. Disconnect fan drive harness (4) connector from motor. 7. Remove motor assembly. 1— Forward Pressure Line 2— Reverse Pressure Line 3— Case Drain Line 4— Harness 5— Fan Motor Mounting Bracket

6— Fan Motor Hub 7— Mounting Bracket Cap Screw (4 used) 8— Fan Motor Mounting Cap Screw (2 used) 9— Nut TE14778,00000E1 -19-26APR17-1/3

8. Remove fan hub (1) from fan motor (2) using puller (3). 9. Remove mounting bracket (5). 3— Puller

T212461A —UN—05JUL05

1— Fan Motor Hub 2— Fan Motor

Continued on next page

TM1731 (28JAN20)

03-0360-57

TE14778,00000E1 -19-26APR17-2/3

850J Crawler (S.N. 130886—311988) 012820 PN=247

Hydrostatic System Hydraulic Fan Motor Installation 1. Install mounting bracket (5) onto fan motor. 2. Apply T43512 Thread Lock and Sealer (Medium Strength) to hydraulic fan motor shaft threads. 3. Install fan motor hub and nut. Tighten nut to specification. Specification Fan Motor HubTo-Hydraulic Fan Motor—Torque.............................................................................129 N·m 95 lb-ft T212454A —UN—05JUL05

4. Connect reverse pressure line (2) and case drain line (3). 5. Connect fan drive harness (4) connector from motor. 6. Install fan motor and bracket assembly onto frame using cap screws (7). 7. Connect forward pressure line (1). 8. Install fan as marked during disassembly. 9. Fill reservoir to specification. See Change Hydrostatic Transmission Oil and Replace Hydrostatic Charge and Fan Oil Filters. (Operator's Manual.) See Hydraulic and Hydrostatic Oil. (Operator's Manual.)

1— Forward Pressure Line 2— Reverse Pressure Line 3— Case Drain Line 4— Harness 5— Hydraulic Fan Motor Mounting Bracket

6— Fan Motor Hub 7— Mounting Bracket Cap Screw (4 used) 8— Motor Mounting Cap Screw (2 used) 9— Nut

10. Turn battery disconnect switch to ON. 11. Start engine and check for leaks. Repair as necessary. TE14778,00000E1 -19-26APR17-3/3

Hydraulic Fan Pump Remove and Install 1. Turn battery disconnect switch to OFF.

T212466A —UN—05JUL05

2. Apply vacuum to hydrostatic reservoir. CAUTION: To avoid injury from escaping fluid under pressure, relieve the pressure in the system before disconnecting or connecting hydraulic or other lines. Tighten all connections before applying pressure. 3.

Disconnect suction line (1) and high pressure line (2). Close all openings with caps and plugs.

Fan Pump Remove and Install (850J shown)

4. Remove socket head cap screws and washers (4). 1— Suction Line 2— High Pressure Line

5. Remove fan pump (3) and gasket. 6. Install gasket and fan pump (3) onto engine using socket head cap screws and washers (4).

See Hydraulic and Hydrostatic Oil. (Operator's Manual.)

7. Connect suction line (1) and high pressure line (2). 8. Remove vacuum if used. Fill reservoir to specification. See Change Hydrostatic Transmission Oil and Replace Hydrostatic Charge and Fan Oil Filters. (Operator's Manual.)

3— Fan Pump 4— Hex Socket Head Cap Screw and Washer

9. Turn battery disconnect switch to ON. 10. Start engine and check for leaks. Repair as necessary. TE14778,00000E3 -19-26APR17-1/1

TM1731 (28JAN20)

03-0360-58

850J Crawler (S.N. 130886—311988) 012820 PN=248

Hydrostatic System

Hydraulic Fan Reversing Valve Remove and Install Hydraulic Fan Reversing Valve Removal 1. Turn battery disconnect switch to OFF. 2. Apply vacuum to hydrostatic reservoir. 3. Label hydraulic lines and electrical harness connections to aid assembly.

T212469A —UN—05JUL05

CAUTION: To avoid injury from escaping fluid under pressure, relieve the pressure in the system before disconnecting or connecting hydraulic or other lines. Tighten all connections before applying pressure. Disconnect harness connectors from proportional solenoid (6) and reversing solenoid (7).

5. Disconnect hydraulic lines (2—5) from fan reversing valve. Close all openings using caps and plugs. 6. Remove mounting cap screws, washers, and nuts (8). Remove reversing valve assembly.

1— Hydraulic Fan Reversing Valve 2— Reverse Pressure Line 3— Forward Pressure Line 4— Return Line

5— High Pressure Line (from fan pump) 6— Proportional Solenoid 7— Reversing Solenoid 8— Cap Screws, Washers, and Nuts TE14778,00000E5 -19-27APR17-1/2

Hydraulic Fan Reversing Valve Installation 1. Install fan reversing valve onto main frame using cap screws, washers, and nuts (8). 2. Connect hydraulic lines (2—5) to fan reversing valve as marked during removal.

4. Remove vacuum if used. Fill reservoir to specification. See Change Hydrostatic Transmission Oil and Replace Hydrostatic Charge and Fan Oil Filters. (Operator's Manual.) See Hydraulic and Hydrostatic Oil. (Operator's Manual.) 5. Turn battery disconnect switch to ON. 6. Start engine and check for leaks. Repair as necessary. 1— Hydraulic Fan Reversing Valve 2— Reverse Pressure Line 3— Forward Pressure Line 4— Return Line

5— High Pressure Line (from fan pump) 6— Proportional Solenoid 7— Reversing Solenoid 8— Cap Screws, Washers, and Nuts

T212469A —UN—05JUL05

3. Connect harness connectors to proportional solenoid (6) and reversing solenoid (7).

TE14778,00000E5 -19-27APR17-2/2

TM1731 (28JAN20)

03-0360-59

850J Crawler (S.N. 130886—311988) 012820 PN=249

Hydrostatic System

Hydraulic Fan Reversing Valve Disassemble and Assemble 4— Proportional Solenoid 5— Check Valve (4 used) 6— Cap Screws, Washers, and Nuts

T212474A —UN—05JUL05

1— Fan Reversing Valve Block 2— Reversing Solenoid 3— Directional Valve

Item

Name

Torque Value

Reversing Solenoid

27 N·m (20 lb-ft) Coil Nut: 6.8 N·m (60 lb-in.)

Directional Valve

Cartridge: 68 N·m (50 lb-ft)

Proportional Solenoid

Cartridge: 34 N·m (25 lb-ft) Coil Nut: 6.1 N·m (54 lb-in.)

Check Valve

Cartridge: 27 N·m (20 lb-ft)

For more information hydraulic fan reversing valve information see Hydraulic Reversing Fan Drive Operation. (Group 9026-05.)

For more information see Hydrostatic System Schematic—Neutral (Park Brake On). (Group 9026-15.) TE14778,00000E6 -19-08MAY08-1/1

TM1731 (28JAN20)

03-0360-60

850J Crawler (S.N. 130886—311988) 012820 PN=250

Section 04 Engine Contents Page

Group 0400—Removal and Installation Engine Remove and Install........................ 04-0400-1 Oil Pan Remove and Install ..................... 04-0400-12 Flywheel Remove and Install................... 04-0400-19 Engine Mounts Remove and Install ................................................... 04-0400-22

TM1731 (28JAN20)

04-1

850J Crawler (S.N. 130886—311988) 012820 PN=1

Contents

TM1731 (28JAN20)

04-2

850J Crawler (S.N. 130886—311988) 012820 PN=2

Group 0400

Removal and Installation Engine Remove and Install 1. Lower all equipment to the ground. 2. Turn key switch to the ON position but do not start engine.

TX1008348A —UN—30MAY06

3. Set hydraulic enable switch to enable position (front half of switch pressed down). 4. Cycle each function several times until accumulator pressure has been discharged. 5. Turn key switch to the OFF position. NOTE: Battery disconnect switch is located inside the right rear service door. 6. Turn battery disconnect switch to the OFF position.

Hydrostatic Pump and PCP Wiring Harness Connectors

7. Raise cab/ROPS. See Cab or ROPS Tilting Procedure. (Operator's Manual.) 8. Remove engine side shields. See Engine Side Shields Remove and Install. (Group 1910.)

1— Engine Wiring Harness 2— PCP Wiring Harness Connector

3— PCP Wiring Harness Connector

9. Remove hood. See Hood Remove and Install. (Group 1910.) 10. Remove bottom guards. See Bottom Guards Remove and Install. (Group 1746.) CAUTION: Prevent possible injury. Do not drain engine coolant until it cools below operating temperature. Then slowly loosen cylinder block drain valve to relieve any pressure. 11. Drain cooling system. See Draining the Cooling System. (Operator's Manual.) Specification Cooling System—Capacity....................................................................................................... 38 L 10 gal.

12. Disconnect plastic line from bottom of starting aid, if equipped. 13. Remove muffler. 14. Remove hood support with air cleaner. See Hood Support Remove and Install. (Group 1910.) 15. Disconnect engine wiring harness (1). See Engine Harness (W10) Component Location. (Group 9015-10.) NOTE: Identify PCP wiring harness connectors for ease of installation. 16. Disconnect PCP wiring harness connectors (2 and 3). See Transmission Harness (W11) Component Location. (Group 9015-10.) Continued on next page

TM1731 (28JAN20)

04-0400-1

CP94658,000018B -19-04FEB11-1/16

850J Crawler (S.N. 130886—311988) 012820 PN=253

Removal and Installation

17. Disconnect reversing fan valve wiring harness connectors (4 and 5), if equipped. See Engine Harness (W10) Component Location. (Group 9015-10.) 5— Reversing Fan Valve Wiring Harness Connector

TX1008350A —UN—30MAY06

4— Reversing Fan Valve Wiring Harness Connector

Reversing Fan Valve CP94658,000018B -19-04FEB11-2/16

18. Disconnect wiring harness connectors from horn (6) and front lights (7). See Engine Harness (W10) Component Location. (Group 9015-10.) 7— Front Lights Wiring Harness Connector (2 used)

TX1008352A —UN—30MAY06

6— Horn Wiring Harness Connector

Front Lights and Horn CP94658,000018B -19-04FEB11-3/16

19. Disconnect wiring harness connectors from quick-drop valve (8), if equipped. See Engine Harness (W10) Component Location. (Group 9015-10.) TX1008353A —UN—30MAY06

8— Quick-Drop Valve Wiring Harness Connector (outside dozers only)

Quick-Drop Valve Continued on next page

TM1731 (28JAN20)

04-0400-2

CP94658,000018B -19-04FEB11-4/16

850J Crawler (S.N. 130886—311988) 012820 PN=254

Removal and Installation

20. Disconnect positive battery cable (9) and ground strap (10) from starter. 10— Ground Strap TX1008363A —UN—05JUN06

9— Positive Battery Cable

Starter CP94658,000018B -19-04FEB11-5/16

21. Remove rear access cover and close fuel shutoff valve (11). See Fuel Drain and Shutoff Valve. (Operator's Manual.) TX1008365A —UN—05JUN06

11— Fuel Shutoff Valve

Fuel Shutoff Valve Continued on next page

TM1731 (28JAN20)

04-0400-3

CP94658,000018B -19-04FEB11-6/16

850J Crawler (S.N. 130886—311988) 012820 PN=255

Removal and Installation

22. Disconnect fuel supply line (12) and return line (13). Close all openings using plugs and caps. 13— Fuel Return Line

TX1008880A —UN—05JUN06

12— Fuel Supply Line

Fuel Supply and Return Lines—Tier 3/Stage IIIA 9.0L

TX1054845 —UN—09FEB09

Fuel Supply and Return Lines—Tier 2/Stage II 8.1L Continued on next page

TM1731 (28JAN20)

04-0400-4

CP94658,000018B -19-04FEB11-7/16

850J Crawler (S.N. 130886—311988) 012820 PN=256

Removal and Installation

TX1054848A —UN—06FEB09

CAUTION: Escaping fluid under pressure can penetrate the skin causing serious injury. Avoid the hazard by relieving pressure before disconnecting hydraulic or other lines. 23. Drain or pull vacuum on hydraulic oil tank. 24. Disconnect hoses from hydraulic fan drive pump (14). Close all openings using plugs and caps. 25. Remove charge air hoses and tube (15). 26. Remove serpentine belt (16). 27. Remove radiator hoses. Disconnect heater hoses (29), if equipped. Close all openings using plugs and caps.

Left Side of Engine Shown—Tier 3/Stage IIIA 9.0L

28. Disconnect wiring harness connector from air conditioning compressor. See Engine Harness (W10) Component Location. (Group 9015-10.) Remove air conditioning compressor (17) leaving refrigerant lines (18) attached and set off to the side.

14— Hydraulic Fan Drive Pump 15— Charge Air Hose and Tube 16— Serpentine Belt

TX1054849A —UN—09FEB09

29. Disconnect alternator wire harness from right side rail support and disconnect starter wire harness from left side rail support. See Engine Harness (W10) Component Location. (Group 9015-10.) 17— Air Conditioning Compressor 18— Refrigerant Line (2 used) 29— Heater Hose

Left Side of Engine Shown—Tier 2/Stage II 8.1L CP94658,000018B -19-04FEB11-8/16

NOTE: Certain lifting brackets may require a spacer to be placed between the lifting bracket and engine to keep lifting brackets parallel.

Specification Engine—Tier 3/Stage IIIA—Weight (approximate) ............................................................................ 952.5 kg 2100 lb. Engine—Tie r2/Stage II—Weight (approximate) ..................................................................................................... 907 kg 2000 lb. 19— Lifting Bracket (2 used)

Lifting Brackets and Load Leveler

20— Load Leveler Continued on next page

TM1731 (28JAN20)

TX1008896A —UN—07JUN06

30. Install lifting brackets (19) to engine. Attach lifting brackets (19) to load leveler (20) and appropriate lifting device.

04-0400-5

CP94658,000018B -19-04FEB11-9/16

850J Crawler (S.N. 130886—311988) 012820 PN=257

Removal and Installation

31. Support hydrostatic pump using JT07184 Pump Support Bracket (21) and a ratchet lifting device (22). 22— Ratchet Lifting Device

TX1008385A —UN—05JUN06

21— JT07184 Pump Support Bracket

Pump Support CP94658,000018B -19-04FEB11-10/16

32. Remove hydrostatic pump-to-flywheel cap screws (23).

TX1008361A —UN—05JUN06

23— Hydrostatic Pump-toFlywheel Cap Screw (4 used)

Hydrostatic Pump Continued on next page

TM1731 (28JAN20)

04-0400-6

CP94658,000018B -19-04FEB11-11/16

850J Crawler (S.N. 130886—311988) 012820 PN=258

Removal and Installation

CAUTION: Prevent possible crushing injury from heavy component. Use an appropriate lifting device to remove engine and mounting hardware. 33. Remove engine mount hardware (24—26).

34. Remove engine. Specification Engine—Tier 3/Stage IIIA—Weight (approximate) ............................................................................ 952.5 kg 2100 lb. Engine—Tier 2/Stage II—Weight (approximate) ..................................................................................................... 907 kg 2000 lb.

25 28

25 TX1008366

TX1008366 —UN—05JUN06

Engine Cradle

35. Install engine and engine mount hardware (24—26). Tighten to specification.

TX1008361A —UN—05JUN06

Specification Engine Mount Cap Screw—Torque............................................................................346 N·m 255 lb-ft

36. Install hydrostatic pump-to-flywheel cap screws (23). Tighten to specification. Remove all lifting and supporting devices from engine and hydrostatic pump. Specification Hydrostatic Pumpto-Flywheel Cap Screw—Torque............................................................................396 N·m 292 lb-ft

37. Install air conditioning compressor. Install starter and alternator wiring harnesses to engine rail supports. See Engine Harness (W10) Component Location. (Group 9015-10.)

Hydrostatic Pump 23— Hydrostatic Pump-toFlywheel Cap Screw (4 used) 24— Engine Mount Cap Screw (6 used) 25— Washer (14 used)

Continued on next page

TM1731 (28JAN20)

04-0400-7

26— Engine Mount Cap Screw (8 used) 27— Right Rail Support 28— Left Rail Support

CP94658,000018B -19-04FEB11-12/16

850J Crawler (S.N. 130886—311988) 012820 PN=259

Removal and Installation

38. Connect wiring harness connectors (1—7), if equipped. See Engine Harness (W10) Component Location. (Group 9015-10.) 5— Reversing Fan Valve Wiring Harness Connector 6— Horn Wiring Harness Connector 7— Front Lights Wiring Harness Connector (2 used)

TX1008348A —UN—30MAY06

1— Engine Wiring Harness 2— PCP Wiring Harness Connector 3— PCP Wiring Harness Connector 4— Reversing Fan Valve Wiring Harness Connector

TX1008350A —UN—30MAY06

Hydrostatic Pump and PCP Wiring Harness Connectors

TX1008352A —UN—30MAY06

Reversing Fan Valve

Front Lights and Horn Continued on next page

TM1731 (28JAN20)

04-0400-8

CP94658,000018B -19-04FEB11-13/16

850J Crawler (S.N. 130886—311988) 012820 PN=260

Removal and Installation

39. Install charge air hoses and tube and install serpentine belt.

TX1054848A —UN—06FEB09

40. Install radiator hoses. Connect heater hoses, if equipped. 41. Connect hydraulic hoses to fan drive pump. Remove vacuum or fill hydraulic oil tank to specification. See Check Hydraulic Oil Level. (Operator's Manual.) Specification Hydraulic Oil Level—Capacity........................................................................... 105.6 L 27.9 gal. Left Side of Engine Shown—Tier 3/Stage IIIA 9.0L 17— Air Conditioning Compressor 18— Refrigerant Line (2 used) 29— Heater Hose

TX1054849A —UN—09FEB09

14— Hydraulic Fan Drive Pump 15— Charge Air Hose and Tube 16— Serpentine Belt

Left Side of Engine Shown—Tier 2/Stage II 8.1L Continued on next page

TM1731 (28JAN20)

04-0400-9

CP94658,000018B -19-04FEB11-14/16

850J Crawler (S.N. 130886—311988) 012820 PN=261

Removal and Installation

42. Connect fuel supply line and return line. 43. Open fuel shutoff valve and install rear access cover. 13— Fuel Return Line

TX1008880A —UN—05JUN06

11— Fuel Shutoff Valve 12— Fuel Supply Line

Fuel Supply and Return Lines—Tier 3/Stage IIIA 9.0L

TX1054845 —UN—09FEB09

TX1008365A —UN—05JUN06

Fuel Supply and Return Lines—Tier 2/Stage II 8.1L

Fuel Shutoff Valve Continued on next page

TM1731 (28JAN20)

04-0400-10

CP94658,000018B -19-04FEB11-15/16

850J Crawler (S.N. 130886—311988) 012820 PN=262

Removal and Installation

44. Connect positive battery cable and ground strap to starter.

TX1008363A —UN—05JUN06

45. Install hood support with air cleaner. See Hood Support Remove and Install. (Group 1910.) 46. Install muffler. Connect plastic line to bottom of starting aid, if equipped. 47. Fill cooling system. See Filling the Cooling System. (Operator's Manual.) Specification Cooling System—Capacity....................................................................................................... 38 L 10 gal.

48. Install bottom guards. See Bottom Guards Remove and Install. (Group 1746.) 49. Install hood. See Hood Remove and Install. (Group 1910.) 50. Install engine side shields. See Engine Side Shields Remove and Install. (Group 1910.)

Starter 9— Positive Battery Cable

10— Ground Strap

51. Lower cab or ROPS. See cab/ROPS Tilting Procedure. (Operator's Manual.) 52. Turn battery disconnect switch to the ON position. CP94658,000018B -19-04FEB11-16/16

TM1731 (28JAN20)

04-0400-11

850J Crawler (S.N. 130886—311988) 012820 PN=263

Removal and Installation

Oil Pan Remove and Install 1. Remove front oil pan bottom guard. See Bottom Guards Remove and Install. (Group 1746.) 2. Drain engine oil into a suitable container for storage or disposal. See Change Engine Oil and Filter. (Operator's Manual.) Specification Engine Oil—Capacity........................................................................ 28 L 7.4 gal.

TX1056042A —UN—17FEB09

CAUTION: Explosive release of fluids from pressurized cooling system can cause serious burns. Shut off engine. Only remove cap when cool enough to touch with bare hands. Slowly loosen cap to relieve pressure before removing completely. 3. Drain cooling system into a suitable container for storage or disposal. See Draining the Cooling System. (Operator's Manual.) Specification Coolant— Tier 3/Stage III A 9.0L Engine—Capacity.............................................................................. 35 L 9.2 gal. Coolant— Tier 2/Stage II 8.1L Engine—Capacity...................................................................... 38 L 10 gal.

Hood and Exhaust Stack 30— Air Pre-Cleaner (if equipped) 31— Exhaust Stack

32— Hood

4. Remove engine side shields. See Engine Side Shields Remove and Install. (Group 1910.) 5. Remove hood (32). Continued on next page

TM1731 (28JAN20)

04-0400-12

CP94658,000018A -19-04FEB11-1/9

850J Crawler (S.N. 130886—311988) 012820 PN=264

Removal and Installation

6. Loosen clamp (28) and disconnect air cleaner hose (27). 7. Remove cap screws (25) and remove air cleaner (26). 8. Raise cab/ROPS. See Cab or ROPS Tilting Procedure. (Operator's Manual.) 9. Disconnect plastic line from bottom of starting aid, if equipped.

25 27— Air Cleaner Hose 28— Clamp

27 28

TX1058276 —UN—15APR09

25— Cap Screw (4 used) 26— Air Cleaner

Air Cleaner Continued on next page

TM1731 (28JAN20)

04-0400-13

CP94658,000018A -19-04FEB11-2/9

850J Crawler (S.N. 130886—311988) 012820 PN=265

Removal and Installation

20 18 15

19 21

22 23

13 14

TX1058273 —UN—15APR09

TX1058273 Charged Air Hoses and Radiator Hoses 13— Lower Charged Air Hose 14— Clamp 15— Cap Screw 16— Bracket

17— Clamp 18— Upper Charged Air Hose 19— Clamp 20— Upper Radiator Hose

21— Engine-to-Coolant Surge Tank Hose 22— Clamp 23— Clamp

10. Disconnect upper radiator hose (20) and lower radiator hose (24).

24— Lower Radiator Hose

12. Remove cap screw (15) and disconnect lower charged air hose from bracket (16).

11. Disconnect upper charged air hose (18) and lower charged air hose (13). CP94658,000018A -19-04FEB11-3/9

CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device. NOTE: For proper clearance during oil pan removal, the engine must be raised slightly.

TX1058274A —UN—15APR09

13. Disconnect engine mounts and install lifting sling at three lifting points: two at engine and one at hydraulic oil pump. 29— Lifting Sling

Lifting Sling Continued on next page

TM1731 (28JAN20)

04-0400-14

CP94658,000018A -19-04FEB11-4/9

850J Crawler (S.N. 130886—311988) 012820 PN=266

Removal and Installation

14. Lift engine assembly approximately 100 mm (4 in.). Support engine with blocks of wood at engine mounting points. Specification Engine—Tier 3/Stage IIIA—Weight (approximate) ............................................................................ 952.5 kg 2100 lb. Engine—Tier 2/Stage II—Weight (approximate) ..................................................................................................... 907 kg 2000 lb. TX1058277 —UN—15APR09

Specification Engine—Height (approximate).............................................................................. 100 mm 4 in.

Engine Assembly CP94658,000018A -19-04FEB11-5/9

15. Remove cap screws (11) and engine oil pan guard (12). 12— Engine Oil Pan Guard

TX1058278 —UN—15APR09

11— Cap Screw (4 used)

Engine Oil Pan Guard Continued on next page

TM1731 (28JAN20)

04-0400-15

CP94658,000018A -19-04FEB11-6/9

850J Crawler (S.N. 130886—311988) 012820 PN=267

Removal and Installation

16. Remove cap screws (33 and 34) and fly wheel cover (35). 35— Flywheel Cover

TX1058275 —UN—15APR09

33— Cap Screw (2 used) 34— Cap Screw (2 used)

Flywheel Cover Continued on next page

TM1731 (28JAN20)

04-0400-16

CP94658,000018A -19-04FEB11-7/9

850J Crawler (S.N. 130886—311988) 012820 PN=268

TX1054847 —UN—09FEB09

Removal and Installation

Oil Pan Removal 1— Oil Pan 4— Cap Screw M8 x 50 (8 used) 2— Gasket 5— Cap Screw M10 x 25 (3 used) 3— Cap Screw M10 x 50 (18 used)

6— Drain Valve 7— O-Ring (3 used) 8— Drain Plug (2 used)

9— Gasket 10— Cover

17. Remove cap screws (3 and 4) from engine oil pan (1). IMPORTANT: Do not pry or gouge the sealing surface of engine oil pan. Tap engine oil pan with a rubber mallet in order to remove. 18. Remove engine oil pan.

CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device. 26. Remove blocks of wood and lower engine assembly. Specification Engine—Tier 3/Stage IIIA—Weight (approximate) ............................................................................ 952.5 kg 2100 lb. Engine—Tier 2/Stage II—Weight (approximate) ..................................................................................................... 907 kg 2000 lb.

19. Remove gasket (2) from oil pan. 20. Clean mating surface of the engine oil pan and the cylinder block. 21. Apply PM38655 Flexible Form-in-Place Gasket on the sealing surface of oil pan. 22. Install new gasket.

27. Connect engine mounts and remove JDG23 Lifting Sling.

23. Install engine oil pan. Install cap screws (3 and 4). Tighten to specification. Specification Oil Pan M8 x 50 Cap Screw—Torque..............................................................................35 N·m 26 lb.-ft. Oil Pan M10 x 50 Cap Screw—Torque..............................................................................70 N·m 52 lb.-ft.

Specification Engine Mount Cap Screws—Torque..........................................................................346 N·m 255 lb.-ft.

28. Connect lower charged air hose to bracket. Install cap screw.

24. Install flywheel cover and cap screws.

29. Connect lower charged air hose and upper charged air hose.

25. Install engine oil pan guard and cap screws.

30. Connect lower radiator hose and upper radiator hose. Continued on next page

TM1731 (28JAN20)

04-0400-17

CP94658,000018A -19-04FEB11-8/9

850J Crawler (S.N. 130886—311988) 012820 PN=269

Removal and Installation II Engines or Diesel Engine Oil—Tier 3/Stage IIIA Engines. (Operator's Manual.)

31. Connect plastic line from bottom of starting aid, if equipped.

Specification Engine Oil—Capacity........................................................................ 28 L 7.4 gal.

32. Lower cab/ROPS. See Cab or ROPS Tilting Procedure. (Operator's Manual.) 33. Install air cleaner and cap screws.

39. Fill cooling system. See Filling the Cooling System. (Operator's Manual.)

34. Connect air cleaner hose and clamp. 35. Install hood. 36. Install engine side shields. See Engine Side Shields Remove and Install. (Group 1910.) 37. Install front oil pan bottom guard. See Bottom Guards Remove and Install. (Group 1746.) 38. Fill engine crankcase with correct grade and viscosity engine oil. See Diesel Engine Oil—Tier 2/Stage

Specification Coolant— Tier 3/Stage III A 9.0L Engine—Capacity.............................................................................. 35 L 9.2 gal. Coolant—Tier 2/Stage II 8.1L Engine—Capacity...................................................................... 38 L 10 gal. CP94658,000018A -19-04FEB11-9/9

TM1731 (28JAN20)

04-0400-18

850J Crawler (S.N. 130886—311988) 012820 PN=270

Removal and Installation

Flywheel Remove and Install 3 4

TX1009031 —UN—12JUN06

TX1009031 Engine/Hydraulic and Hydrostatic Pump Cradle Mount 1— Flywheel Cover 2— Flywheel Cover Cap Screw (12 used)

3— Hydraulic Pump Support Bracket 4— Hydraulic Pump Support Bracket Mounting Cap Screw M12 x 45 (4 used)

1. Lower equipment to the ground.

NOTE: Identify PCP electrical connectors for ease of installation.

NOTE: Battery disconnect switch is located inside of the right rear service door. 2. Turn battery disconnect switch to the OFF position. 3. Raise cab/ROPS. See Cab or ROPS Tilting Procedure. (Operator's Manual.) 4. Place straps around tandem hydrostatic pumps and hydraulic pump.

8. Remove cap screws (4) from hydraulic pump support bracket (3). 9. Connect a ratchet winch strap to hydraulic pump through rear access cover.

CAUTION: Prevent possible injury from crushing. Heavy component; use appropriate lifting device. 5. Using DFT1063, DFT1067, DFT1065, and a load leveler, connect lifting straps to hoist. See DF1063 Final Drive Lift Bracket, DFT1167 Final Drive Lifting Bracket Adapter Spacer, and DF1065 Final Drive and Pump Adapter Bracket. (Group 9900.) 6. Remove rear access cover and bottom guard for access to pump assembly. See Bottom Guards Remove and Install. (Group 1746.)

7. Disconnect PCP electrical connectors on hydrostatic pumps. See Transmission Harness (W11) Component Location. (Group 9015-10.)

10. Remove cap screws (2) from flywheel cover (1). 11. Use hoist and ratchet winch strap to pull pump assembly toward rear of machine. 12. Separate pump assembly from flywheel housing. 13. Remove flywheel. See Remove Flywheel . (CTM400.) 14. Install flywheel. See Install Flywheel . (CTM400.) IMPORTANT: Release ratchet strap slowly to avoid damage to flywheel coupler. 15. Install pump assembly to flywheel housing.

Continued on next page

TM1731 (28JAN20)

04-0400-19

JW40272,00001CB -19-30AUG17-1/2

850J Crawler (S.N. 130886—311988) 012820 PN=271

Removal and Installation

16. Install flywheel cover cap screws (2). Tighten to specifications. Specification Flywheel Cover Cap Screws—Torque............................................................................80 N·m 59 lb-ft

17. Install hydraulic pump support bracket cap screws (4).

18. Connect PCP electrical connectors on hydrostatic pumps. See Transmission Harness (W11) Component Location. (Group 9015-10.) 19. Install rear access cover and bottom guard. 20. Lower cab/ROPS. See Cab or ROPS Tilting Procedure. (Operator's Manual.)

Specification Hydraulic Pump support Bracket Cap Screws—Torque..........................................................................140 N·m 105 lb-ft JW40272,00001CB -19-30AUG17-2/2

TM1731 (28JAN20)

04-0400-20

850J Crawler (S.N. 130886—311988) 012820 PN=272

Removal and Installation

TM1731 (28JAN20)

04-0400-21

850J Crawler (S.N. 130886—311988) 012820 PN=273

Removal and Installation

T206114 —UN—07JAN05

Engine Mounts Remove and Install

Engine Mounts

Continued on next page

TM1731 (28JAN20)

04-0400-22

MM61211,0001551 -19-04FEB11-1/2

850J Crawler (S.N. 130886—311988) 012820 PN=274

Removal and Installation 1— Right Rail Assembly 2— Left Rail Assembly 3— Washer (16 used) 4— Cap Screw (12 used) 5— Cap Screw (2 used)

6— Flange Nut (4 used) 7— Cap Screw 8— Cap Screw (6 used) 9— Flywheel Cover 10— Cap Screw (4 used) 11— Washer (12 used)

12— Cap Screw (9 used) 13— Cap Screw (4 used) 14— Washer (4 used) 15— Nut (4 used) 16— Washer (4 used) 17— Isolator (4 used)

18— Rear Power Train/Engine Support/Cradle 19— Washer (8 used) 20— Plate (4 used)

Item

Measurement

Specification

Engine

Approximate Weight

952.5 kg 2100 lb

Item

Measurement

Specification

Engine Mount Cap Screws

Torque

346 N·m 255 lb-ft MM61211,0001551 -19-04FEB11-2/2

TM1731 (28JAN20)

04-0400-23

850J Crawler (S.N. 130886—311988) 012820 PN=275

Removal and Installation

TM1731 (28JAN20)

04-0400-24

850J Crawler (S.N. 130886—311988) 012820 PN=276

Section 05 Engine Auxiliary Systems Contents Page

Group 0505—Cold Weather Starting Aid Starting Aid Assembly Remove and Install .............................................. 05-0505-1 Group 0510—Cooling System Fan Blade Remove and Install .................. 05-0510-1 Fan Shroud Remove and Install ................ 05-0510-1 Cooling Package Remove and Install ..................................................... 05-0510-3 Group 0515—Engine Speed Control Decelerator/Brake Pedal Remove and Install .............................................. 05-0515-1 Decelerator/Brake Pedal Disassemble and Assemble .................. 05-0515-2 Group 0530—External Exhaust Systems Muffler Remove and Install........................ 05-0530-1 Group 0560—External Fuel Supply Systems Fuel Tank Remove and Install ................... 05-0560-1 Auxiliary Water Separator Fuel Filter Remove and Install—If Equipped ............................................... 05-0560-3

TM1731 (28JAN20)

05-1

850J Crawler (S.N. 130886—311988) 012820 PN=1

Contents

TM1731 (28JAN20)

05-2

850J Crawler (S.N. 130886—311988) 012820 PN=2

Group 0505

Cold Weather Starting Aid Starting Aid Assembly Remove and Install 1. Open right-side engine service door. 2. Loosen clamp and remove starting fluid container (1). 3. Disconnect starting aid solenoid electrical connector and starting aid tube (4). 4. Remove cap screws (3) and starting aid. 5. Install starting aid solenoid and cap screws. 6. Connect starting aid tube and solenoid electrical connector.

1— Starting Fluid Container 2— Starting Aid Solenoid

T211402A —UN—16MAY05

7. Install starting fluid container. Tighten clamp. 3— Cap Screw (4 used) 4— Starting Aid Tube

Starting Aid SJ25320,0000041 -19-02JUN06-1/2

8. Remove adapter (5) from intake manifold with nozzle holder (6) and nozzle (7). 9. Remove nozzle from nozzle holder. 10. Clean or replace nozzle as required.

TX1008683 —UN—31MAY06

IMPORTANT: Nozzle must be secure in holder to prevent engine damage. Do not overtighten or nozzle may break. 11. Carefully tighten nozzle in nozzle holder. 12. Apply PM37421 Thread Lock and Sealer (High Strength) to threads of nozzle holder. IMPORTANT: Arrows on nozzle holder should point toward incoming air. Nozzle and Holder Assembly

13. Install nozzle holder with nozzle toward center of air inlet, allowing fluid to spray into incoming air flow. Arrow on hex flats indicates direction of nozzle.

5— Adapter 6— Nozzle Holder

7— Nozzle

SJ25320,0000041 -19-02JUN06-2/2

TM1731 (28JAN20)

05-0505-1

850J Crawler (S.N. 130886—311988) 012820 PN=279

Cold Weather Starting Aid

TM1731 (28JAN20)

05-0505-2

850J Crawler (S.N. 130886—311988) 012820 PN=280

Group 0510

Cooling System Fan Blade Remove and Install 1. Lower blade to the ground. 2. Turn battery disconnect switch to OFF or disconnect battery ground cable. 3. Open upper grille unit. TX1008806A —UN—05JUN06

4. Remove cap screws (2) and remove fan blade (1). 5. Install brackets and cap screws. 6. Install fan blade using cap screws. 7. Close upper grille unit. 8. Turn battery switch to ON or connect battery ground cable. Fan Blade 1— Fan Blade

2— Cap Screw (6 used)

CS33148,000097D -19-18JAN12-1/1

Fan Shroud Remove and Install 1

1. Lower blade to the ground.

TX1105189 —UN—17JAN12

2. Turn battery disconnect switch to OFF or disconnect battery ground cable.

3. Remove hood and grille housing cover. See Hood Remove and Install. (Group 1910.)

CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device. Lifting heavy components incorrectly can cause severe injury or machine damage.

6 5 Upper and Lower Grill

4. Remove cap screws (2) and upper grille unit (1). 1— Upper Grille Unit 2— Cap Screw (4 used) 3— Lower Grille Unit

Specification Upper Grille Unit—Weight (approximate).................................................................................. 69 kg 152 lb.

5. Remove cap screws (6) and hose guard (5). CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device. Lifting heavy components incorrectly can cause severe injury or machine damage.

6. Remove cap screws (4) and lower grille unit (3). Specification Lower Grille Unit—Weight (approximate).................................................................................. 71 kg 157 lb.

Continued on next page

TM1731 (28JAN20)

4— Cap Screw (4 used) 5— Hose Guard 6— Cap Screw (5 used)

05-0510-1

JW40272,00000E4 -19-23JAN12-1/3

850J Crawler (S.N. 130886—311988) 012820 PN=281

Cooling System

7. Remove horn (7) and horn wiring harness (8). 7— Horn

8— Horn Wiring Harness

TX1105191 —UN—17JAN12

Horn and Horn Wiring Harness JW40272,00000E4 -19-23JAN12-2/3

8. Remove cap screws (12 and 13). Remove brackets (11). 9. Remove cap screws (10) and fan shroud (9). Replace as necessary.

13 12

11 12

11. Install brackets and cap screws. 12. Install horn and horn wiring harness.

13. Install lower grille unit and cap screws. 14. Install hose guard and cap screws. 15. Install upper grille unit and cap screws.

TX1105192

16. Install hood and grille housing cover. See Hood Remove and Install. (Group 1910.) 17. Turn battery switch to ON or connect battery ground cable.

TX1105192 —UN—18JAN12

10. Install fan shroud and cap screws.

Fan Shroud 9— Fan Shroud 10— Cap Screw (8 used) 11— Bracket (2 used)

12— Cap Screw (4 used) 13— Cap Screw (2 used)

JW40272,00000E4 -19-23JAN12-3/3

TM1731 (28JAN20)

05-0510-2

850J Crawler (S.N. 130886—311988) 012820 PN=282

Cooling System

Cooling Package Remove and Install 1. Lower blade to the ground.

T210810A —UN—25APR05

CAUTION: To avoid injury from escaping fluid under pressure, stop engine and relieve the pressure in the system before disconnecting or connecting hydraulic or other lines. Tighten all connections before applying pressure. 2. Stop engine. Operate all hydraulic controls to relieve hydraulic system pressure. 3. Turn battery disconnect switch to OFF or disconnect battery ground strap.

Quick-Drop Valve (Outside Dozers Only)

4. Remove engine side shields. See Engine Side Shields Remove and Install. (Group 1910.)

1— Quick-Drop Valve Hose 2— Quick-Drop Valve Hose

3— Quick-Drop Valve

5. Remove hood. See Hood Remove and Install. (Group 1910.) 6. Drain engine coolant. See Draining the Cooling System. (Operator's Manual.) Specification Cooling System with Recovery Tank—Capacity—Tier 3/Stage IIIA 9.0L................................................................................ 38 L 10 gal Capacity—Tier 2/Stage II 8.1L ............................................................................................... 34.5 L 9.1 gal.

7. Drain or pull a vacuum on hydrostatic reservoir. 8. Disconnect hoses from oil cooler. Close all openings using plugs and caps. 9. On Outside Dozer (OSD) machines: Remove grille housing cover for access to quick drop valve (3). 10. Disconnect quick drop valve hoses (1 and 2). Continued on next page

TM1731 (28JAN20)

05-0510-3

CP94658,0000189 -19-13FEB09-1/11

850J Crawler (S.N. 130886—311988) 012820 PN=283

Cooling System

11. Remove cap screws (27) and hydraulic hoses (28). 12. Remove hydraulic cooler (29). 29— Hydraulic Cooler

TX1008740A —UN—01JUN06

27— Cap Screw (4 used) 28— Hydraulic Hose (2 used)

Hydraulic Cooler CP94658,0000189 -19-13FEB09-2/11

13. Disconnect upper radiator hose (5), lower radiator hose and charge air cooler hose (7). 14. Remove charge air cooler tube (6). 8— Oil Cooler Hose 9— Charge Air Cooler 10— Hydrostatic Oil Cooler 11— Cap Screw (2 used) TX1008264A —UN—01JUN06

4— Radiator 5— Upper Radiator Hose 6— Charge Air Cooler Tube 7— Charge Air Cooler Hose

Cooling Package CP94658,0000189 -19-13FEB09-3/11

15. Remove front bottom guard and disconnect hoses. (12—14). Close all openings using plugs and caps. 14— Hydraulic Hose TX1008388A —UN—31MAY06

12— Hydraulic Hose 13— Hydraulic Hose

Front Bottom Guard Removed Continued on next page

TM1731 (28JAN20)

05-0510-4

CP94658,0000189 -19-13FEB09-4/11

850J Crawler (S.N. 130886—311988) 012820 PN=284

Cooling System

16. Remove cap screws (15).

TX1008387A —UN—31MAY06

15— Cap Screw (2 used)

Cap Screws CP94658,0000189 -19-13FEB09-5/11

17. Remove cap screws (11 and 30). 18. Remove bracket (31). CAUTION: Prevent possible crushing injury from heavy cooling package. Use an appropriate lifting device to install. TX1008741A —UN—01JUN06

19. Remove cooling package using an appropriate lifting strap around cooling package and removing lower mounting hardware. Specification Cooling Package Approximate—Weight................................................................... 148 kg 325 lb.

20. Remove fan shroud from coolers. 11— Cap Screw (2 used) 30— Cap Screw (4 used)

Mounting Hardware

31— Bracket (2 used)

Continued on next page

TM1731 (28JAN20)

05-0510-5

CP94658,0000189 -19-13FEB09-6/11

850J Crawler (S.N. 130886—311988) 012820 PN=285

Cooling System

21 18

TX1008390 —UN—01JUN06

TX1008390 Engine Fan and Support 16— Cap Screw (6 used) 17— Fan 18— Hub 19— Spool Washer

20— Nut 21— Lock Nut 22— Bracket 23— Cap Screw (2 used)

24— Cap Screw (4 used) 25— Cap Screw (4 used)

26— Fan Drive Support

21. Remove fan (17) and bracket (22).

25. Install fan (17) and bracket (22).

22. Remove fan drive support (26) from cooler.

26. Install fan shroud to coolers.

23. Lay coolers on side and replace as necessary. 24. Install fan drive support (26) to cooler. Continued on next page

TM1731 (28JAN20)

05-0510-6

CP94658,0000189 -19-13FEB09-7/11

850J Crawler (S.N. 130886—311988) 012820 PN=286

Cooling System

CAUTION: Prevent possible crushing injury from heavy cooling package. Use an appropriate lifting device to remove.

Specification Cooling Package Approximate—Weight................................................................... 148 kg 325 lb.

27. Install cooling package using appropriate lifting strap around cooling package and install lower mounting hardware. CP94658,0000189 -19-13FEB09-8/11

28. Install bracket (31). 29. Install cap screws (11 and 30). 30. Install cap screws (15).

11— Cap Screw (2 used) 12— Hydraulic Hose 13— Hydraulic Hose 14— Hydraulic Hose

TX1008741A —UN—01JUN06

31. Install hydraulic hoses (12—14) and front bottom guard. 15— Cap Screw (2 used) 30— Cap Screw (4 used) 31— Bracket

TX1008387A —UN—31MAY06

Mounting Hardware

TX1008388A —UN—31MAY06

Cap Screws

Front Bottom Guard Removed Continued on next page

TM1731 (28JAN20)

05-0510-7

CP94658,0000189 -19-13FEB09-9/11

850J Crawler (S.N. 130886—311988) 012820 PN=287

Cooling System

32. Install charge air cooler tube (6). 33. Connect radiator hoses and charge air cooler hose (7). 8— Oil Cooler Hose 9— Charge Air Cooler 10— Hydrostatic Oil Cooler 11— Cap Screw (2 used) TX1008264A —UN—01JUN06

4— Radiator 5— Upper Radiator Hose 6— Charge Air Cooler Tube 7— Charge Air Cooler Hose

Cooling Package CP94658,0000189 -19-13FEB09-10/11

34. Install hydraulic cooler (29) and cap screws (27). 35. Install hydraulic hoses (28) to hydraulic cooler. 36. On Outside Dozer (OSD) Machines: Connect quick drop valve hoses (1 and 2). 37. Install grille housing cover. TX1008740A —UN—01JUN06

38. Connect hoses to oil cooler. 39. Fill engine coolant Specification Cooling System with Recovery Tank—Capacity—Tier 3/Stage IIIA 9.0L................................................................................ 38 L 10 gal. Capacity—Tier 2/Stage II 8.1L ............................................................................................... 34.5 L 9.1 gal.

Hydraulic Cooler

T210810A —UN—25APR05

40. Fill hydraulic system and hydrostatic system to specifications. See Change Hydraulic System Oil and Replace Filter. (Operator's Manual.) See Change Hydrostatic Transmission Oil and Replace Hydrostatic Charge and Fan Oil Filters. (Operator's Manual.) Specification Hydraulic System—Capacity........................................................................ 105.6 L 27.9 gal Quick-Drop Valve (Outside Dozers Only)

Specification Hydrostatic System—Capacity........................................................................ 105.6 L 27.9 gal

1— Quick-Drop Valve Hose 2— Quick-Drop Valve Hose 3— Quick-Drop Valve

41. Install hood. See Hood Remove and Install. (Group 1910.) 42. Install engine side shields. See Engine Side Shields Remove and Install. (Group 1910.)

27— Cap Screw (4 used) 28— Hydraulic Hose (2 used) 29— Hydraulic Cooler

43. Turn battery disconnect switch to ON or connect battery ground strap. CP94658,0000189 -19-13FEB09-11/11

TM1731 (28JAN20)

05-0510-8

850J Crawler (S.N. 130886—311988) 012820 PN=288

Group 0515

Engine Speed Control Decelerator/Brake Pedal Remove and Install

2 1

1. Loosen mounting cap screws (1). 2. Disconnect harness to decelerator sensor (2).

T199889 —UN—12MAY04

3. Remove cap screws and assembly. 4. Inspect and replace parts as necessary. NOTE: When installing assembly, verify that the round dust seal is in place on rear of support. 5. Install assembly and tighten cap screws to specification. Specification Decelerator Mounting Cap Screws—Torque....................................................................73 N·m 54 lb-ft

1— Cap Screw (4 used)

2— Decelerator Sensor

6. Connect harness to decelerator sensor. MF82180,00001DA -19-07MAY04-1/1

TM1731 (28JAN20)

05-0515-1

850J Crawler (S.N. 130886—311988) 012820 PN=289

Engine Speed Control

T199839 —UN—17MAY04

Decelerator/Brake Pedal Disassemble and Assemble

T199839 1— Pedal 2— Shaft 3— Support 4— Spring Pin (7 used) 5— Torsion Spring 6— Nut (3 used)

7— Cap Screw (7 used) 8— Cap Screw (2 used) 9— Hex Socket Head Screw (2 used) 10— Washer (4 used)

1. Remove assembly from machine. See Decelerator/Brake Pedal Remove and Install. (Group 0515.)

11— Washer (3 used) 12— Snap Spring 13— Needle Bearing (2 used) 14— Decelerator Sensor

15— Spring 16— Stop Plate 17— Pin Fastener 18— O-Ring

3. Remove decelerator sensor (14) and O-ring (18).

2. Remove hex socket head cap screws (9) securing decelerator sensor. MF82180,00001DB -19-14JUL05-1/11

T200194A —UN—19MAY04

CAUTION: Decelerator pedal is under spring pressure. Removing stop plate without relieving spring pressure can cause bodily injury. Relieve spring pressure by slowly loosening cap screws and holding pressure against pedal. 4. Loosen cap screws (8) securing stop plate (16). 5. Remove cap screws (8), relieving tension in torsion spring (5). 4— Pin 5— Torsion Spring

8— Cap Screw (2 used) 16— Stop Plate Continued on next page

TM1731 (28JAN20)

05-0515-2

MF82180,00001DB -19-14JUL05-2/11

850J Crawler (S.N. 130886—311988) 012820 PN=290

Engine Speed Control

6. Remove pins (4) retaining pedal on shaft.

T200195A —UN—19MAY04

4— Pin (2 used)

MF82180,00001DB -19-14JUL05-3/11

7. Remove shaft (2). 11— Washer

T200196A —UN—19MAY04

2— Shaft 5— Torsion Spring

MF82180,00001DB -19-14JUL05-4/11

8. Loosen retaining nuts (6). 9. Remove cap screws (7).

6— Retaining Nut (2 used) 7— Cap Screw (2 used) 11— Washer

T200197A —UN—19MAY04

10. Apply pressure to washer (11) to compress spring (15) enough to remove snap ring (12). 12— Snap Ring 15— Spring

Continued on next page

TM1731 (28JAN20)

05-0515-3

MF82180,00001DB -19-14JUL05-5/11

850J Crawler (S.N. 130886—311988) 012820 PN=291

Engine Speed Control

11. Remove pin fastener (17) and washer (11). 12. Disassemble remaining parts as necessary. Press out roller bearings (13) if necessary. 17— Pin Fastener

T200198A —UN—19MAY04

11— Washer

MF82180,00001DB -19-14JUL05-6/11

13. Press bearings (13) into support (3) to specification.

T200199A —UN—19MAY04

Specification Bearing Placement—Distance from inside surface.......................................................................................0.0—1.0 mm 0.0—0.039 in.

14. Apply petroleum jelly to bearing rollers. 15. Install pins (4) into support (3) to specification. Specification Pin Placement—Distance from surface.........................................................................0.0—1.0 mm 0.0—0.039 in.

16. Install pin fastener (17) through washer (11) into back of support (3).

3— Support 4— Pin (4 used)

13— Roller Bearing (2 used)

MF82180,00001DB -19-14JUL05-7/11

17. Install spring (15) and washer (11) onto shaft and compress to install snap ring (12).

Specification Retaining Nuts—Torque................................................................73 N·m 54 lb-ft 6— Retaining Nut (2 used) 7— Cap Screw (2 used) 11— Washer

12— Snap Ring 15— Spring

Continued on next page

TM1731 (28JAN20)

05-0515-4

T200197A —UN—19MAY04

18. Install retaining nuts (6) onto cap screws (7). Install cap screws. Tighten nuts to specification.

MF82180,00001DB -19-14JUL05-8/11

850J Crawler (S.N. 130886—311988) 012820 PN=292

Engine Speed Control

19. Assemble torsion spring (5) onto pedal then rotate spring until spring is stopped by pin.

2— Shaft 5— Torsion Spring

T200196A —UN—19MAY04

20. Place pedal with spring and washer (11) into support and install shaft (2) through assembly. 11— Washer

MF82180,00001DB -19-14JUL05-9/11

21. Verify torsion spring is installed correctly then install pin (4) into the outer hole on shaft, between washer and pedal. Verify pin has equal length on each side of shaft.

T200195A —UN—19MAY04

22. Rotate pedal to align the hole in the pedal and shaft. Install pin (4) into hole. 4— Pin (2 used)

MF82180,00001DB -19-14JUL05-10/11

23. Secure pedal assembly and press pedal downwards. Install stop plate (16) and secure with cap screws (8). Tighten cap screws to specification.

T200194A —UN—19MAY04

Specification Stop Plate Cap Screws—Torque............................................................................37 N·m 27 lb-ft

24. Install decelerator sensor (14) with O-ring (18) onto shaft. 25. Slowly rotate sensor into position and install hex socket head cap screws (9). Tighten to specifications. Specification Sensor Hex Socket Head Cap Screws—Torque...................................................................6.1 N·m 4.5 lb-ft

4— Pin 5— Torsion Spring

8— Cap Screw (2 used) 16— Stop Plate

26. Install assembly on machine. See Decelerator/Brake Pedal Remove and Install. (Group 0515.) 27. Perform Decelerator/Brake Pedal Adjustment. (Group 9015-20.) MF82180,00001DB -19-14JUL05-11/11

TM1731 (28JAN20)

05-0515-5

850J Crawler (S.N. 130886—311988) 012820 PN=293

Engine Speed Control

TM1731 (28JAN20)

05-0515-6

850J Crawler (S.N. 130886—311988) 012820 PN=294

Group 0530

External Exhaust Systems Muffler Remove and Install 1. Remove hood. See Hood Remove and Install. (Group 1910.) 2. Loosen clamp (6). 3. Remove cap screws (3).

4. Remove muffler (4). 5. Remove and install parts as necessary. 6. Install muffler.

2 5

7. Install cap screws (3) and clamp (6).

1— Nut 2— Cap Screw 3— Cap Screw (3 used) 4— Muffler 5— Washer (4 used)

6— Clamp 7— Exhaust Stack 8— Exhaust Stack Clamp 9— Shim 10— Nut (3 used)

3 5 10

TX1008346

TX1008346 —UN—31MAY06

8. Install Hood. See Hood Remove and Install. (Group 1910.)

Muffler SJ25320,0000042 -19-12JUN06-1/1

TM1731 (28JAN20)

05-0530-1

850J Crawler (S.N. 130886—311988) 012820 PN=295

External Exhaust Systems

TM1731 (28JAN20)

05-0530-2

850J Crawler (S.N. 130886—311988) 012820 PN=296

Group 0560

External Fuel Supply Systems Fuel Tank Remove and Install 1. Remove cab/ROPS. See Cab/ROPS Remove and Install. (Group 1800.) T209431A —UN—10MAR05

2. Remove hydraulic reservoir. See Hydraulic Reservoir Remove and Install. (Group 3260.) 3. Remove hydrostatic reservoir. See Hydrostatic Reservoir Remove and Install. (Group 0360.) 4. Drain fuel from tank. Specification Fuel Tank—Capacity....................................................................... 371 L 98 gal

5. Disconnect fuel supply and return lines from fuel tank.

Fuel Tank Removal 1— Fuel Level Sensor

4— Wiring Harness (4 used)

6. Disconnect wiring from fuel level sensor (1). 7. Remove wiring harnesses (4) from bulkheads. 8. Remove cab tilt cylinder from fuel tank. Continued on next page

TM1731 (28JAN20)

05-0560-1

TX,9025,BS501 -19-12JUL05-1/2

850J Crawler (S.N. 130886—311988) 012820 PN=297

T209434 —UN—11MAR05

External Fuel Supply Systems

T209434 Fuel Tank 2— Cap Screw (8 used) 11— Sealing Washer

12— Ball 13— Plug 14— O-Ring

18— Washer (8 used)

9. Remove all ground straps from fuel tank.

15. Connect wiring to fuel level sensor.

CAUTION: Prevent possible crushing injury from heavy fuel tank. Use an appropriate lifting device. 10. Remove fuel tank mounting hardware (2 and 18) and slowly remove fuel tank. Specification Fuel Tank—Weight........................................................................ 239 kg 525 lb

11. Install fuel tank using mounting hardware (2 and 18). 12. Install cab tilt cylinder to fuel tank. 13. Install all ground straps to fuel tank.

16. Connect fuel supply and return lines to fuel tank. 17. Fill fuel tank. Specification Fuel Tank—Capacity....................................................................... 371 L 98 gal

18. Install cab/ROPS. Cab/ROPS Remove and Install. (Group 1800.) 19. Install hydrostatic reservoir. See Hydrostatic Reservoir Remove and Install. (Group 0360.) 20. Install hydraulic reservoir. See Hydraulic Reservoir Remove and Install. (Group 3260.)

14. Install wiring harnesses to bulkheads. TX,9025,BS501 -19-12JUL05-2/2

TM1731 (28JAN20)

05-0560-2

850J Crawler (S.N. 130886—311988) 012820 PN=298

External Fuel Supply Systems

Auxiliary Water Separator Fuel Filter Remove and Install—If Equipped 1. Turn battery disconnect switch to OFF position. See Battery Disconnect Switch Check. (Operators Manual.) CAUTION: Prevent possible crushing injury from heavy engine side shields. Use appropriate lifting device.

2 4

3. Open air vent (3) and drain (8) to remove fuel. Drain fuel into a suitable container and dispose of fuel waste properly.

4. Disconnect lines (1 and 4). Cap and plug all openings.

5. Remove cap screws (2) and auxiliary water separator fuel filter (6) from bracket (5).

TX1054956 —UN—10FEB09

2. Remove engine side shields. See Engine Side Shields Remove and Install. (Group 1910.)

2 9

6. Inspect and replace parts as needed. 7. Install cap screws and filter to bracket. 8. Connect lines (1 and 4). See Bleeding Fuel System. (Operator's Manual.) 9. Fill fuel filter by using air vent and priming hand pump (9). 10. Turn battery disconnect switch to ON. 11. Start engine and let it run for 1 minute. Check for leaks. 12. Install engine side shields.

Auxiliary Water Separator Fuel Filter 1— Line (to filter) 2— Cap Screw (2 used) 3— Air Vent 4— Line (from tank) 5— Bracket

6— Auxiliary Water Separator Fuel Filter 7— Heater Connector 8— Drain 9— Priming Hand Pump CP94658,0000188 -19-13FEB09-1/1

TM1731 (28JAN20)

05-0560-3

850J Crawler (S.N. 130886—311988) 012820 PN=299

External Fuel Supply Systems

TM1731 (28JAN20)

05-0560-4

850J Crawler (S.N. 130886—311988) 012820 PN=300

Contents

Section 07 Dampener Drive

Page

Group 0752—Elements Dampener Drive Remove and Install (SN 130866—135190) ................ 07-0752-1 Damper Drive Remove and Install.............. 07-0752-3

TM1731 (28JAN20)

07-1

850J Crawler (S.N. 130886—311988) 012820 PN=1

Contents

TM1731 (28JAN20)

07-2

850J Crawler (S.N. 130886—311988) 012820 PN=2

Group 0752

Elements Dampener Drive Remove and Install (SN 130866—135190)

4. Using DFT1063, DFT1067, DFT1065, and a load leveler connect lifting straps to hoist. See DFT1063 Pump Lifting Bracket, DFT1167 Spacer, and DFT1065 Pump Lifting Bracket. (Group 9900.)

1. Lower equipment to the ground. 2. Raise cab/ROPS. See Cab or ROPS Tilting Procedure. (Operator's Manual.)

5. Disconnect PCP electrical connectors on hydrostatic pumps.

T212464 —UN—08JUL05

3. Place straps around tandem hydrostatic pumps and hydraulic pump.

T212464 Power Train/Engine Cradle Mounting

Continued on next page

TM1731 (28JAN20)

07-0752-1

MR50960,0000235 -19-02MAY07-1/2

850J Crawler (S.N. 130886—311988) 012820 PN=303

T212750 —UN—15JUL05

Elements

Dampener Assembly 1— Cap Screw (8 used) 2— Washer (8 used) 3— Dampener 4— Socket Head Cap Screw

5— Internal Snap Ring 9— Flywheel Cover 10— Hydraulic Pump Bracket Mounting Cap Screws M12 x 45 (4 used)

6. Remove cap screws (10) to allow hydraulic and hydrostatic pumps to move towards rear of machine for access to flywheel. 7. Connect a ratchet winch strap to hydraulic pump through rear access cover. 8. Remove flywheel cover (9). Use hoist and winch ratchet strap to pull pump assembly towards rear of machine. 9. Remove hub (3).

18— Hydraulic Pump Support Bracket

13. Install dampener with the largest offset side of dampener away from flywheel. Apply thread lock and sealer (medium strength) to threads of cap screws (A). Install dampener cap screws with washer. Tighten cap screws to specification. Specification Dampener Cap Screws—Torque..........................................................................130 N·m 95 lb-ft

14. Install flywheel cover (9).

10. Install new hub with teeth/tangs away from pump. Slide hub on shaft until snap ring (5) contacts end of shaft.

15. Install hydraulic pump bracket cap screws (10).

11. Tighten cross clamp screw (4) to specifications.

16. Connect PCP electrical connectors on hydrostatic pumps.

Specification Isolator Cross Screw—Torque............................................................................122 N·m 90 lb-ft

17. Install rear access cover and bottom guard. 18. Lower cab/ROPS. See Cab or ROPS Tilting Procedure. (Operator's Manual.)

12. Remove cap screws (A) and dampener (C) from flywheel. MR50960,0000235 -19-02MAY07-2/2

TM1731 (28JAN20)

07-0752-2

850J Crawler (S.N. 130886—311988) 012820 PN=304

Elements

Damper Drive Remove and Install

2. Raise cab/ROPS. See Cab or ROPS Tilting Procedure. (Operator's Manual.)

SPECIFICATIONS Hub Cross Screws Torque

122 N·m 90 lb·ft

Damper Cap Screws Torque

130 N·m 95 lb·ft

3. Place straps around tandem hydrostatic pumps and hydraulic pump.

OTHER MATERIAL

1. Lower equipment to the ground.

5. Disconnect PCP electrical connectors on hydrostatic pumps.

T212464 —UN—08JUL05

Loctite Thread Lock and Sealer (Medium Strength) LOCTITE® Products

4. Using DFT1063, DFT1067, DFT1065, and a load leveler connect lifting straps to hoist. See DFT1063 Pump Lifting Bracket, DFT1167 Spacer, and DFT1065 Pump Lifting Bracket. (Group 9900.)

T212464

Continued on next page

TM1731 (28JAN20)

07-0752-3

MR50960,0000237 -19-30MAR17-1/2

850J Crawler (S.N. 130886—311988) 012820 PN=305

TX1027536 —UN—02AUG07

Elements

1— Cap Screw (8 used) 2— Bushings (8 used) 3— Damper Assembly 4— Hub Socket Head Cap Screw (2 used)

10— Hydraulic Pump Bracket Mounting Cap Screws (4 used) 18— Hydraulic Pump Support Bracket

5— Internal Snap Ring 6— Hub 7— Flywheel Disk 9— Damper Plate

13. Install damper plate (7), if necessary, with the largest offset side of damper away from flywheel. Apply Loctite thread lock and sealer (medium strength) to threads of cap screws (1). Install damper cap screws with spacers. Tighten cap screws to specification. Specification Damper Cap Screws—Torque..........................................................................130 N·m 95 lb·ft

14. Install flywheel cover (9).

10. Install new hub assembly, if necessary, with isolators from pump. Slide hub (6) on shaft until snap ring (5) contacts end of shaft. 11. Tighten cross clamp screws (4) to specifications. Specification Hub Cross Screws—Torque..........................................................................122 N·m 90 lb·ft

15. Install hydraulic pump bracket cap screws (10). 16. Connect PCP electrical connectors on hydrostatic pumps. 17. Install rear access cover and bottom guard. 18. Lower cab/ROPS. See Cab or ROPS Tilting Procedure. (Operator's Manual.)

12. Remove cap screws (1) and damper plate from flywheel if necessary. LOCTITE and its related brand marks are trademarks of Henkel Corp. MR50960,0000237 -19-30MAR17-2/2

TM1731 (28JAN20)

07-0752-4

850J Crawler (S.N. 130886—311988) 012820 PN=306

Contents

Section 11 Park Brake

Page

Group 1100—Park Brake Park Brake Remove and Install ..................11-1100-1 Group 1115—Control Linkage Park Lock Linkage Remove and Install ...................................................... 11-1115-1 Park Lock Linkage Disassemble and Assemble......................................... 11-1115-2 Group 1160—Hydraulic System Park Brake Disassemble and Assemble................................................11-1160-1

TM1731 (28JAN20)

11-1

850J Crawler (S.N. 130886—311988) 012820 PN=1

Contents

TM1731 (28JAN20)

11-2

850J Crawler (S.N. 130886—311988) 012820 PN=2

Group 1100

Park Brake Park Brake Remove and Install 61 kg 134 lb

Park Brake Mounting Cap Screw (16) Torque

102 N·m 75 lb·ft

T211631A —UN—20JUN05

SPECIFICATIONS Park Brake Weight (approximate)

REMOVAL NOTE: Park brake assembly can be removed without removing final drive. 1. If final drive is being removed, disconnect hydrostatic motor from final drive and support with blocks. Remove final drive. See Final Drive Remove and Install. (Group 0200.) If final drive is not being removed, remove hydrostatic motor. See Hydrostatic Motor Remove and Install. (Group 0300.) 2. Remove cap screws (16). CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device.

Park Brake (shown with final drive removed) 15— Washer (8 used)

16— Cap Screw (8 used)

3. Install lifting hooks and remove park brake using appropriate lifting device. Specification Park Brake—Weight (approximate).................................................................................. 61 kg 134 lb JL48493,00003CB -19-28NOV17-1/2

4. Remove O-rings (7) from housing (6). 5. Remove park brake-to-final drive housing gasket.

T211655A —UN—25MAY05

6. Clean and inspect parts. Repair or replace as necessary. See Park Brake Disassemble and Assemble. (Group 1160.) INSTALLATION Installation is reverse of removal procedure.

• Lubricate O-rings (7), park brake-to-final drive housing gasket, and cap screws (16) with oil.

• Tighten park brake mounting cap screws (16) to

Park Brake O-Rings

specification.

Specification Park Brake Mounting Cap Screw (16)—Torque....................................................................102 N·m 75 lb·ft

6— Housing

reappear. See 000116.01—Brake Pressure Low. (Group 9001-30.)

• With engine running, release park brake for 1 minute to allow brake cavity to fill with oil.

IMPORTANT: A diagnostic trouble code (DTC) may be generated while filling brake cavity. If so, remove DTC and then cycle park brake to ensure that DTC does not

7— O-Ring (2 used)

• Calibrate transmission control unit (TCU). See

Transmission Control Unit (TCU) Calibration. (Group 9015-20.) JL48493,00003CB -19-28NOV17-2/2

TM1731 (28JAN20)

11-1100-1

850J Crawler (S.N. 130886—311988) 012820 PN=309

Group 1115

Control Linkage Park Lock Linkage Remove and Install 1. Lower all equipment to ground and stop engine. 2. Turn battery disconnected switch to OFF. 3. Cut tie band and disconnect park lock lever switch connector (16) from cab harness. 4. Remove control lever knob.

T199669A —UN—04MAY04

16— Park Lock Lever Switch Connector

TE14778,000002D -19-09FEB05-1/2

5. Remove two cap screws (8) from front of left side console. 6. Remove park lock lever assembly from left side console. T208317A —UN—14APR05

7. Assemble park lock lever assembly to left side console using two cap screws (8). Tighten to specification. Specification Park Lock Lever Mounting Cap Screw—Torque..............................................................................73 N·m 54 lb-ft Park Lock Lever Remove and Install

8. Assemble control lever knob onto control lever. Tighten nut to specification.

8— Cap Screw (2 used)

Specification Control Lever Knob Nut—Torque..................................................................................23 N·m 204 lb-in.

10. Turn battery disconnect switch to ON.

9. Connect park lock lever switch connector (16) to cab harness. TE14778,000002D -19-09FEB05-2/2

TM1731 (28JAN20)

11-1115-1

850J Crawler (S.N. 130886—311988) 012820 PN=310

Control Linkage

T199655 —UN—07MAY04

Park Lock Linkage Disassemble and Assemble

T199655 1— Cotter Pin 2— Nut 3— Pin Fastener 4— Pin Fastener 5— Washer 6— Spring 7— Hex Socket Head Cap Screw (2 used)

8— Flanged Head Cap Screw (2 used) 9— Lock Nut 10— Washer 11— Washer (2 used) 12— Washer 13— Washer 14— Control Lever

1. Lower all equipment to ground and stop engine. 2. Turn battery disconnect switch to OFF. 3. Remove park lock assembly. See Park Lock Linkage Remove and Install. (Group 1115.)

15— Stud 16— Switch 17— Bracket 18— Threaded Stud 19— Threaded Stud 20— Spring Washer (5 used) 21— Knob 22— Washer (2 used)

23— Lock Nut 24— Plate (2 used) 25— Compressing Spring 26— Plate

5. Remove lock nut (23), spring washers (20), plate (24), and washer (22). 6. Loosen lock nut (9) several turns. Do not remove.

4. Remove plate (26), spring (25), and washer (10). Continued on next page

TM1731 (28JAN20)

11-1115-2

TE14778,000002C -19-04DEC09-1/3

850J Crawler (S.N. 130886—311988) 012820 PN=311

Control Linkage

CAUTION: Park lock control lever is under spring pressure. Removing control lever without relieving spring pressure can cause bodily injury. Relieve spring pressure by SLOWLY removing control lever over stops and rotating lever over center. 7. Using pry bar, lift control lever (14) and pin fastener (3) until control lever is higher than stops (27 and 28). This allows lever to rotate further and relieve spring tension. 8. Remove control lever (14), pin fastener (4), spring (6), and washer (5). T199670A —UN—04MAY04

9. Disassemble remaining parts. 10. Assemble pin fastener (4) onto control lever stud (15) using washers (11) and cotter pin (1). 11. Assemble pin fastener (3) onto threaded stud (19) using washers (13 and 12), and lock nut (9). Do not tighten lock nut. 12. Assemble plate (24) and washer (22) onto threaded stud (18).

Park Lock Lever Assembly Side View

13. Assemble washer (5) and compression spring (6) onto pin fastener (3).

3— Pin Fastener 9— Lock Nut 14— Control Lever

23— Lock Nut 27— Stop 28— Stop

14. With pin fastener (4) slid into compression spring (6), assemble control lever onto threaded stud (18). 15. Rotate control lever until lever fits over stops (27 and 28). Push into place. 16. Tighten lock nut (9) to specification.

Specification Lock Nut (M8)—Torque................................................... Tighten lock nut until solid then loosen 1/2 turn.

17. Assemble washer (22) and plate (24) onto threaded stud (18). TE14778,000002C -19-04DEC09-2/3

18. Assemble spring washers (20) as shown. Assemble lock nut (23) and tighten to specification.

19. Assemble switch (16) onto bracket using hex socket head cap screws (7). Tighten to specification. Specification Hex Socket Head Cap Screws—Torque.........................................................................10.4 N·m 92 lb.-in.

20. Assemble washer (10), and compression spring (25) onto control lever (14). 21. Assemble plate (26) onto control lever (14) with chamfer pointing away from spring.

20 23

T199665 —UN—04MAY04

Specification Lock Nut (3/8)—Torque........................................... Tighten lock nut until solid then loosen 1/2—2 turns.

Park Lock Lever Spring Washer Cross Section 20— Spring Washer (5 used)

23— Lock Nut

22. Install park lock assembly. See Park Lock Linkage Remove and Install. (Group 1115.) TE14778,000002C -19-04DEC09-3/3

TM1731 (28JAN20)

11-1115-3

850J Crawler (S.N. 130886—311988) 012820 PN=312

Group 1160

Hydraulic System Park Brake Disassemble and Assemble

NOTE: 655K, 750J, and 750K machines are composed of four separator plates (10) and four friction discs (11).

SPECIFICATIONS Cap Screw (31) Size

M10-1.5 x 40 mm

Park Brake Cover Torque

73 N·m 54 lb·ft

755K, 850J, and 850K machines are composed of six separator plates (10) and six friction discs (11).

5 6 7 8

10 15

16 T211563 —UN—08JUL05

10 14 12

11 T211563

11 Park Brake (exploded view) (750K machine shown)

1— O-Ring 2— Piston 3— O-Ring 4— Compression Spring (16 used) 5— Pressure Plate

6— Housing 7— O-Ring (2 used) 8— Gasket 9— Snap Ring 10— Separator Plate (4 used)

11— Friction Disc (4 used) 12— Hub 13— Gasket 14— Cover 15— Washer (8 used) 16— Cap Screw (8 used)

17— Washer (4 used, if equipped) 18— Cap Screw (4 used)

JL48493,00003CC -19-28NOV17-1/15

DISASSEMBLE 1. Remove cover (14). 18— Cap Screw (4 used) TX1182666A —UN—15JAN15

14— Cover 17— Washer (4 used, if equipped)

Brake Cover Continued on next page

TM1731 (28JAN20)

11-1160-1

JL48493,00003CC -19-28NOV17-2/15

850J Crawler (S.N. 130886—311988) 012820 PN=313

Hydraulic System

2. Remove brake hub (12).

T211633A —UN—25MAY05

12— Hub

Brake Hub JL48493,00003CC -19-28NOV17-3/15

NOTE: 655K, 750J, and 750K machines are composed of four separator plates (10) and four friction discs (11).

T211634A —UN—25MAY05

755K, 850J, and 850K machines are composed of six separator plates (10) and six friction discs (11). 3. Remove friction discs (11), separator plates (10), and gasket (13). 6— Housing 10— Separator Plate (4 used)

11— Friction Disc (4 used) 13— Gasket

Friction Discs and Separator Plates (750K machine shown) JL48493,00003CC -19-28NOV17-4/15

NOTE: Pressure plate (5) may need to be reoriented to line up pressure plate cap screw holes with brake housing cap screw holes.

T211635A —UN—25MAY05

4. Install two washers (30) and cap screws (31) to compress pressure plate (5) and compression springs (4). Remove snap ring (9). Specification Cap Screw (31)—Size.................................................. M10-1.5 x 40 mm 4— Compression Spring (16 used) 5— Pressure Plate 9— Snap Ring

30— Washer (2 used) 31— Cap Screw (2 used) Brake Plate Continued on next page

TM1731 (28JAN20)

11-1160-2

JL48493,00003CC -19-28NOV17-5/15

850J Crawler (S.N. 130886—311988) 012820 PN=314

Hydraulic System

5. Loosen cap screws evenly and remove pressure plate and compression springs (4). 4— Compression Spring (16 used) T211637A —UN—10JUN05

2— Piston

Brake Compression Springs JL48493,00003CC -19-28NOV17-6/15

6. Remove brake piston (2) and O-rings (1 and 3). 3— O-Ring 6— Housing

T211781A —UN—10JUN05

1— O-Ring 2— Piston

Brake Piston JL48493,00003CC -19-28NOV17-7/15

7. Remove O-rings (7) and gasket (8) from housing (6). 8. Clean and inspect all parts for wear or damage. Replace parts as necessary. 7— O-Ring (2 used)

T211655A —UN—25MAY05

6— Housing

Housing O-Rings Continued on next page

TM1731 (28JAN20)

11-1160-3

JL48493,00003CC -19-28NOV17-8/15

850J Crawler (S.N. 130886—311988) 012820 PN=315

Hydraulic System ASSEMBLE 1. Apply clean oil on O-rings (1 and 3) and install on piston (2).

1— O-Ring 2— Piston

T211781A —UN—10JUN05

2. Install piston in housing (6). 3— O-Ring 6— Housing

Brake Piston JL48493,00003CC -19-28NOV17-9/15

3. Install compression springs (4). 4— Compression Spring (16 used)

T211637A —UN—10JUN05

2— Piston

Compression Springs JL48493,00003CC -19-28NOV17-10/15

4. Install pressure plate (5), washers (30), and cap screws (31). Tighten cap screws evenly to compress pressure plate.

T211635A —UN—25MAY05

Specification Cap Screw (31)—Size.................................................. M10-1.5 x 40 mm

5. Install snap ring (9). 6. Loosen cap screws evenly and remove. 4— Compression Spring (16 used) 5— Pressure Plate 9— Snap Ring

30— Washer (2 used) 31— Cap Screw (2 used) Brake Plate Continued on next page

TM1731 (28JAN20)

11-1160-4

JL48493,00003CC -19-28NOV17-11/15

850J Crawler (S.N. 130886—311988) 012820 PN=316

Hydraulic System

7. Install hub (12).

T211633A —UN—25MAY05

12— Hub

Brake Hub JL48493,00003CC -19-28NOV17-12/15

NOTE: 655K, 750J, and 750K machines are composed of four separator plates (10) and four friction discs (11).

T211634A —UN—25MAY05

755K, 850J, and 850K machines are composed of six separator plates (10) and six friction discs (11). 8. Install separator plates (10) and friction discs (11). Start with separator plate and alternate with friction disc. 6— Housing 10— Separator Plate (4 used)

11— Friction Disc (4 used) 13— Gasket

Friction Discs and Separator Plates (750K machine shown) JL48493,00003CC -19-28NOV17-13/15

9. Install gasket (13) and cover (14). Install and carefully tighten cap screws (18) to compress springs. Tighten to specification.

14— Cover 17— Washer (4 used, if equipped)

TX1182666A —UN—15JAN15

Specification Park Brake Cover—Torque..............................................................................73 N·m 54 lb·ft 18— Cap Screw (4 used)

Brake Cover Continued on next page

TM1731 (28JAN20)

11-1160-5

JL48493,00003CC -19-28NOV17-14/15

850J Crawler (S.N. 130886—311988) 012820 PN=317

Hydraulic System

10. Apply clean oil on O-rings (7) and install on housing (6). 7— O-Ring (2 used)

T211655A —UN—25MAY05

6— Housing

Housing O-Rings JL48493,00003CC -19-28NOV17-15/15

TM1731 (28JAN20)

11-1160-6

850J Crawler (S.N. 130886—311988) 012820 PN=318

Section 15 Equipment Attaching Contents Page

Group 1511—Drawbar Extended Rigid Drawbar Remove and Install .............................................. 15-1511-1 Rigid Drawbar Remove and Install ..................................................... 15-1511-2

TM1731 (28JAN20)

15-1

850J Crawler (S.N. 130886—311988) 012820 PN=1

Contents

TM1731 (28JAN20)

15-2

850J Crawler (S.N. 130886—311988) 012820 PN=2

Group 1511

Drawbar

T205332 —UN—29DEC04

Extended Rigid Drawbar Remove and Install

Extended Rigid Drawbar

Continued on next page

TM1731 (28JAN20)

15-1511-1

TX,1511,RR5385 -19-28MAY09-1/2

850J Crawler (S.N. 130886—311988) 012820 PN=321

Drawbar 1— Extended Rigid Drawbar 2— Washer (8 used)

7— Lock Nut 8— Cap Screw

3— Quick Lock Pin 4— Retainer 5— Cap Screw (8 used)

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

2. Install extended rigid drawbar (1) to machine using cap screws (5) and washers (2). Tighten cap screws to specification.

1. Remove cap screws (5), washers (2), and extended rigid drawbar (1) from rear of machine. Specification Extended Rigid Drawbar—Weight............................................................................ 91 kg 200 lb

Specification Extended Rigid Drawbar-to-Main Frame Cap Screws—Torque......................................................... Dry 1300 N·m Dry 975 lb-ft Lubricated 1050 N·m Lubricated 750 lb-ft TX,1511,RR5385 -19-28MAY09-2/2

Rigid Drawbar Remove and Install CAUTION: Prevent possible crushing injury from heavy component. Use an appropriate lifting device.

TX1090292A —UN—04APR11

1. Remove cap screws (1), washers (2), and rigid drawbar (3) from rear of machine. Specification Rigid Drawbar—Weight................................................................... 54 kg 120 lb.

2. Install rigid drawbar (3) to machine using cap screws (1) and washers (2). Tighten cap screws to specification. Specification Rigid Drawbar-toMain Frame Cap Screws—Torque................................................................. Dry 1300 N·m Dry 975 lb-ft Lubricated 1050 N·m Lubricated 750 lb-ft

Rigid Drawbar 1— Cap Screw (4 used) 2— Washer (4 used)

3— Rigid Drawbar

FB87413,5F5E33B -19-25JAN13-1/1

TM1731 (28JAN20)

15-1511-2

850J Crawler (S.N. 130886—311988) 012820 PN=322

Section 17 Frames, Chassis, or Supporting Structure Contents Page

Group 1740—Frame Installation Welding Repair of Major Structures .............................................. 17-1740-1 Group 1746—Frame Bottom Guards Bottom Guards Remove and Install ..................................................... 17-1746-1 Group 1749—Chassis Weights Front Counterweight Remove and Install ..................................................... 17-1749-1 Rear Counterweight Remove and Install ..................................................... 17-1749-3 Additional Rear Counterweight Remove and Install (If Equipped) .............................................. 17-1749-5

TM1731 (28JAN20)

17-1

850J Crawler (S.N. 130886—311988) 012820 PN=1

Contents

TM1731 (28JAN20)

17-2

850J Crawler (S.N. 130886—311988) 012820 PN=2

Group 1740

Frame Installation Welding Repair of Major Structures IMPORTANT: Disconnect battery ground strap or turn battery disconnect switch to OFF (if applicable).

2. Use one of the following weld processes:

• AWS-E-7018 covered electrode with shielded metal arc welding (SMAW) process.

Disconnect both negative and positive battery cables and microprocessor unit (if applicable).

• AWS-ER-70S-3 wire electrode with gas metal arc welding (GMAW) process.

IMPORTANT: Have only a qualified welder do this job. Connect welder ground clamp close to each weld area so electrical current does not pass through any bearings. Remove or protect all parts that can be damaged by heat or weld splatter. CAUTION: Avoid potentially toxic fumes and dust. Hazardous fumes can be generated when paint is heated by welding, soldering, or using a torch. Do all work outside or in a well ventilated area. Dispose of paint and solvent properly. If you sand or grind paint, avoid breathing the dust. Wear an approved respirator. If you use solvent or paint stripper, remove stripper with soap and water before welding. Remove solvent or paint stripper containers and other flammable material from area. Allow fumes to disperse at least 15 minutes before welding or heating.

• AWS-E70T-1 or E71T-1 wire electrode with flux core arc welding (FCAW) process.

Welding Repair of Major Structure—Specification Weld Metal—Tensile Strength...................................................................................482.6 MPa 70,000 psi Yield Strength .........................................................................413.7 MPa 60,000 psi Elongation......................................................................................... 22%

IMPORTANT: Area to be repaired must be preheated to allow better weld penetration. 3. To repair weld metal failure, remove failed weld metal using arc or grinding equipment. Thoroughly clean area to be welded. Preheat structural assemblies to a minimum of 38°C (100°F). Preheat ground engaging tools (cutting edges, skid shoes, and teeth shanks) to 177°C (350°F). To repair base metal failure remove enough material to allow weld to penetrate to the bottom of crack. Preheat structural assemblies to a minimum of 38°C (100°F). Preheat ground engaging tools (cutting edges, skid shoes, and teeth shanks) to 177°C (350°F).

1. Remove paint before welding or heating. IMPORTANT: Electrical current traveling from the welder through the machine electrical system may damage the machine electrical system, including battery, machine information center, and pump and valve controller. Disconnect battery ground cable, machine information center, and pump and valve controller electrical connectors before welding on the machine. Have only a qualified welder do this job. Connect welder ground clamp close to each weld area so electrical current does not pass through any bearings. Remove or protect all parts that can be damaged by heat or weld splatter.

Welding Repair of Major Structure—Specification Structural Assemblies—Preheat Temperature..................................................................................... 38°C 100°F Ground Engaging Tools—Preheat Temperature................................................................................... 177°C 350°F

TX,1740,RR5420 -19-20MAY14-1/1

TM1731 (28JAN20)

17-1740-1

850J Crawler (S.N. 130886—311988) 012820 PN=325

Frame Installation

TM1731 (28JAN20)

17-1740-2

850J Crawler (S.N. 130886—311988) 012820 PN=326

Group 1746

Frame Bottom Guards Bottom Guards Remove and Install

TX1008263 —UN—24MAY06

5 11 8 14

TX1008263

5 5

Bottom Guards 5— Washer (23 used) 8— Cap Screw (23 used)

11— Front Bottom Guard 13— Oil Pan Bottom Guard 12— Transmission Bottom Guard 14— Middle Bottom Guard

CAUTION: Prevent possible crushing injury from heavy bottom guards. Use appropriate tools to remove. 1. Remove front and transmission bottom guards (11 and 12).

Specification Front and Transmission Bottom Guards Approximate—Weight..................................................................... 41 kg 90 lb

2. Clean machine of dirt and debris. 3. Install front and transmission bottom guards. SJ25320,000003F -19-05JUN06-1/1

TM1731 (28JAN20)

17-1746-1

850J Crawler (S.N. 130886—311988) 012820 PN=327

Frame Bottom Guards

TM1731 (28JAN20)

17-1746-2

850J Crawler (S.N. 130886—311988) 012820 PN=328

Group 1749

Chassis Weights

T205467 —UN—29DEC04

Front Counterweight Remove and Install

Front Counterweight 1— Front Counterweight 2— Washer (4 used)

3— Washer (4 used) 5— Cap Screw M20 x 110 (4 used) 4— Cap Screw M12 x 150 (4 used) Continued on next page

TM1731 (28JAN20)

17-1749-1

OUO1020,000156A -19-10MAY06-1/2

850J Crawler (S.N. 130886—311988) 012820 PN=329

Chassis Weights

CAUTION: Prevent possible injury from falling counterweight. Use a hoist or suitable lifting device to support weight. 1. Remove cap screws (4 and 5) along with front counterweight (1).

Specification 850J Front Counterweight—Weight................................................................ 400 kg 880 lb

2. Install front counterweight and tighten cap screws. OUO1020,000156A -19-10MAY06-2/2

TM1731 (28JAN20)

17-1749-2

850J Crawler (S.N. 130886—311988) 012820 PN=330

Chassis Weights

T205447 —UN—07JAN05

Rear Counterweight Remove and Install

Rear Counterweight 1— Rear Counterweight 2— Washer (6 used)

3— Cap Screw 1 in. x 4-1/2 in. (6 4— Cap Screw M12 x 100 (6 used) used) 5— Washer (6 used) Continued on next page

TM1731 (28JAN20)

17-1749-3

OUO1020,000156B -19-10MAY06-1/2

850J Crawler (S.N. 130886—311988) 012820 PN=331

Chassis Weights

CAUTION: Prevent possible injury from falling counterweight. Use a hoist or suitable lifting device to support weight. 1. Remove cap screws (3 and 4) along with rear counterweight (1).

Specification 850J Rear Counterweight—Weight................................................................ 448 kg 987 lb

2. Install rear counterweight and tighten cap screws. OUO1020,000156B -19-10MAY06-2/2

TM1731 (28JAN20)

17-1749-4

850J Crawler (S.N. 130886—311988) 012820 PN=332

Chassis Weights

Additional Rear Counterweight Remove and Install (If Equipped)

SPECIFICATIONS 448 kg 987 lb.

Additional Rear Counterweight Weight (approximate)

338 kg 746 lb.

Additional Rear Counterweight Cap Screw Torque

1200 N·m 885 lb.-ft.

Extended Rigid Drawbar Weight (approximate)

116 kg 256 lb.

Rigid Drawbar Weight (approximate)

54 kg 120 lb.

4 2 TX1129175 —UN—25JAN13

Rear Counterweight Weight (approximate)

1. Park machine on flat and level surface. See Park and Prepare for Service Safely. (Group 0001.) CAUTION: Prevent possible crushing injury from heavy component. Do not loosen cap screws (8) on the rear weight access doors. Once cap screws (3) are removed the rear counterweight will no longer be attached to the machine, and will be resting on the rear weight access doors.

3 Additional Rear Counterweight 1— Rear Counterweight 2— Additional Rear Counterweight 3— Cap Screw 1 in. x 7-1/2 in. (8 used)

CAUTION: Prevent possible crushing injury from heavy component. Use appropriate supporting device. 2. Support rear counterweight (1) to prevent it from sliding off rear weight access doors. Specification Rear Counterweight—Weight (approximate)............................................................................................. 448 kg 987 lb.

4— Washer (8 used) 8— Cap Screw M12 x 100 (7 used)

Specification Additional Rear Counterweight Cap Screw—Torque..........................................................................1200 N·m 885 lb.-ft.

CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device. 3. Remove cap screws (3) and additional rear counterweight (2). Specification Additional Rear Counterweight—Weight (approximate)................................................................................ 338 kg 746 lb.

4. Install additional rear counterweight and tighten cap screws to specification. Continued on next page

TM1731 (28JAN20)

17-1749-5

FB87413,5F5E341 -19-29JAN13-1/3

850J Crawler (S.N. 130886—311988) 012820 PN=333

Chassis Weights Additional Rear Counterweight (extended rigid drawbar )

1. Park machine on flat and level surface. See Park and Prepare for Service Safely. (Group 0001.) CAUTION: Prevent possible crushing injury from heavy component. Do not loosen cap screws (8) on the rear weight access doors. Once cap screws (3) and (5) are removed the rear counterweight will no longer be attached to the machine, and will be resting on the rear weight access doors.

TX1129178 —UN—25JAN13

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

2. Remove cap screws (5) and extended rigid drawbar (6).

Specification Extended Rigid Drawbar—Weight (approximate).................................................................................116 kg 256 lb.

4 Additional Rear Counterweight (extended rigid drawbar) 1— Rear Counterweight 2— Additional Rear Counterweight 3— Cap Screw 1 in. x 7-1/2 in. (2 used) 4— Washer (10 used)

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

5— Cap Screw 1 in. X 9 in. (8 used) 6— Extended Rigid Drawbar 8— Cap Screw M12 x 100 (7 used)

3. Support rear counterweight (1) to prevent it from sliding off rear weight access doors. Specification Rear Counterweight—Weight (approximate)............................................................................................. 448 kg 987 lb.

CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device. 4. Remove cap screws (3) and additional rear counterweight (2).

5. Install additional rear counterweight and cap screws (3). 6. Install extended rigid drawbar and cap screws (5). 7. Tighten all cap screws to specification. Specification Additional Rear Counterweight Cap Screw—Torque..........................................................................1200 N·m 885 lb.-ft.

Specification Additional Rear Counterweight—Weight (approximate)................................................................................ 338 kg 746 lb. Continued on next page

TM1731 (28JAN20)

17-1749-6

FB87413,5F5E341 -19-29JAN13-2/3

850J Crawler (S.N. 130886—311988) 012820 PN=334

Chassis Weights Additional Rear Counterweight (with rigid drawbar)

8 1

1. Park machine on flat and level surface. See Park and Prepare for Service Safely. (Group 0001.) CAUTION: Prevent possible crushing injury from heavy component. Do not loosen cap screws (8) on the rear weight access doors. Once cap screws (3) and (5) are removed the rear counterweight will no longer be attached to the machine, and will be resting on the rear weight access doors.

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

TX1129177 —UN—25JAN13

2. Remove cap screws (5) and rigid drawbar (7). Specification Rigid Drawbar—Weight (approximate).................................................................................. 54 kg 120 lb.

Additional Rear Counterweight (with rigid drawbar)

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

1— Rear Counterweight 2— Additional Rear Counterweight 3— Cap Screw 1 in. x 7-1/2 in. (6 used) 4— Washer (10 used)

CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device. 4. Remove cap screws (3) and additional rear counterweight (2). Specification Additional Rear Counterweight—Weight (approximate)................................................................................ 338 kg 746 lb.

5— Cap Screw 1 in. x 9 in. (4 used) 7— Rigid Drawbar 8— Cap Screw M12 x 100 (7 used)

5. Install additional rear counterweight and cap screws (3). 6. Install rigid drawbar and cap screws (5). 7. Tighten all cap screws to specification. Specification Additional Rear Counterweight Cap Screw—Torque..........................................................................1200 N·m 885 lb.-ft.

FB87413,5F5E341 -19-29JAN13-3/3

TM1731 (28JAN20)

17-1749-7

850J Crawler (S.N. 130886—311988) 012820 PN=335

Chassis Weights

TM1731 (28JAN20)

17-1749-8

850J Crawler (S.N. 130886—311988) 012820 PN=336

Contents

Section 18 Operator’s Station

Page

Group 1800—Removal and Installation Cab/ROPS Remove and Install ................. 18-1800-1 Group 1810—Operator Enclosure Remove and Install Window ...................... 18-1810-1 Remove and Install Windowpanes ........................................ 18-1810-2 Hand Pump Bleed Procedure.................... 18-1810-2 Wiper Installation .............................................18-1810-3 Group 1821—Seat and Seat Belt Disassemble and Assemble Seat.............. 18-1821-1 Group 1830—Heating and Air Conditioning R134a Refrigerant Cautions ...................... 18-1830-1 R134a Compressor Oil Charge Check .................................................... 18-1830-1 R134a Compressor Oil Removal............... 18-1830-1 R134a Component Oil Charge .................. 18-1830-2 Leakage Testing ........................................ 18-1830-3 R134a Refrigerant Recovery, Recycling and Charging Station Installation Procedure............................ 18-1830-3 Recover R134a System............................. 18-1830-4 Evacuate R134a System ........................... 18-1830-5 Charge R134a System .............................. 18-1830-6 Air Conditioner System Cleaning Procedures ............................................ 18-1830-7 Purge R134a System ................................ 18-1830-7 Flush R134a System ................................. 18-1830-8 Evaporator or Heater Core Remove and Install .............................................. 18-1830-9 Expansion Valve Remove and Install ................................................... 18-1830-11 A/C Freeze Switch Remove and Install ................................................... 18-1830-11 Upper Cab Heater Blower Motor and Heater Blower Resistor Remove and Install.............................. 18-1830-12 Cab Upper Heater Disassemble and Assemble...................................... 18-1830-14 Cab or ROPS Under Seat Heater Disassemble and Assemble ................ 18-1830-16 Receiver-Dryer Remove and Install ................................................... 18-1830-18 Condenser Remove and Install ............... 18-1830-18 Compressor Remove and Install ............. 18-1830-19 Compressor Clutch Disassemble and Assemble...................................... 18-1830-21 Clutch Hub Clearance Check .................. 18-1830-22 Compressor Manifold Inspect.................. 18-1830-22 Compressor Disassemble and Assemble............................................. 18-1830-23 TM1731 (28JAN20)

18-1

850J Crawler (S.N. 130886—311988) 012820 PN=1

Contents

TM1731 (28JAN20)

18-2

850J Crawler (S.N. 130886—311988) 012820 PN=2

Group 1800

Removal and Installation Cab/ROPS Remove and Install 1. Recover R134a System. See Recover R134a System. (Group 1830.) T208971A —UN—04MAR05

2. Tilt cab/ROPS. See Cab or ROPS Tilting Procedure. (Operator's Manual.) 3. Label and disconnect all pilot control hydraulic hoses from hydraulic control lever (1). 4. Drain coolant. See Draining the Cooling System. (Operator's Manual.) 5. Disconnect heater hoses (2 and 3). 3— Heater Hose

T208968A —UN—04MAR05

1— Hydraulic Control Lever 2— Heater Hose

Hydraulic Control Lever

Heater Hoses Continued on next page

TM1731 (28JAN20)

18-1800-1

CED,OUO1057,219 -19-28MAY09-1/4

850J Crawler (S.N. 130886—311988) 012820 PN=339

Removal and Installation

6. Disconnect air conditioning hoses from location (8 and 9). 7. Disconnect wiring harnesses (4). 9— Air Conditioning Hose Location

T208936A —UN—04MAR05

4— Wiring Harness (4 used) 8— Air Conditioning Hose Location

T208843A —UN—04MAR05

Air Conditioning Hoses

Wiring Harnesses Continued on next page

TM1731 (28JAN20)

18-1800-2

CED,OUO1057,219 -19-28MAY09-2/4

850J Crawler (S.N. 130886—311988) 012820 PN=340

Removal and Installation

8. Disconnect windshield washer hoses (5) from tank. 9. Disconnect machine ground strap (6) from cab. 10. Lower cab. 11. Remove cab tilt cylinder pin (7). 12. Remove rear cab mounting pins. CAUTION: Prevent possible crushing injury from cab/ROPS. Use an appropriate lifting device.

T208847A —UN—04MAR05

13. Install four JT05552 Lifting Eyebolts (A) in top of cab. Attach chain and slowly remove cab/ROPS. Specification Canopy/ROPS—Weight................................................................ 703 kg 1550 lb Cab/ROPS—Weight...................................................................... 953 kg 2100 lb

14. Lower cab/ROPS onto frame. 15. Install rear cab mounting pins.

Ground Strap and Windshield Washer Hoses

16. Install cab tilt cylinder pin (7). 17. Tilt cab. 18. Connect machine ground strap (6) to cab.

5— Windshield Washer Hose (2 used ) 6— Machine Ground Strap

T209059A —UN—04MAR05

19. Connect windshield washer hoses (5) to tank. 7— Cab Tilt Cylinder Pin

Cab Tilt Cylinder Pin Continued on next page

TM1731 (28JAN20)

18-1800-3

CED,OUO1057,219 -19-28MAY09-3/4

850J Crawler (S.N. 130886—311988) 012820 PN=341

Removal and Installation

20. Connect wiring harnesses (4). 21. Connect heater hoses (2 and 3). 22. Connect all pilot control hydraulic hoses to hydraulic control lever (1). 23. Connect air conditioning hoses that were previously removed. 24. Fill cooling system. See Filling the Cooling System. (Operator's Manual.) 25. Lower cab/ROPS. See Cab or ROPS Tilting Procedure. (Operator's Manual.) T208843A —UN—04MAR05

26. Evacuate R134a System. See Evacuate R134a System. (Group 1830.) 27. Charge R134a System See Charge R134a System. (Group 1830.) 1— Hydraulic Control Lever 2— Heater Hose

3— Heater Hose 4— Wiring Harness (4 used)

T208971A —UN—04MAR05

Wiring Harnesses

T208968A —UN—04MAR05

Hydraulic Control Lever

Heater Hoses CED,OUO1057,219 -19-28MAY09-4/4

TM1731 (28JAN20)

18-1800-4

850J Crawler (S.N. 130886—311988) 012820 PN=342

Group 1810

Operator Enclosure

T8499AT —UN—26JUN95

Remove and Install Window

Windows 1— Molding 2— Left Side Window

3— Front Window Pane 4— Right Side Window

5— Rear Window

Remove and install windows as shown. TX,1810,RR5410 -19-25NOV09-1/1

TM1731 (28JAN20)

18-1810-1

850J Crawler (S.N. 130886—311988) 012820 PN=343

Operator Enclosure

Remove and Install Windowpanes

2. If window frame is removable, remove frame from cab.

NOTE: Use this procedure to replace all door windowpanes and rear/front windowpanes.

3. Scrape broken glass off existing adhesive. DO NOT remove adhesive from window frame or cab.

Use a Urethane Auto Glass Adhesive Sealant to hold windowpanes in place. Also use the primers, which are recommended for the adhesive formulation which has been selected. DO NOT use any other type of adhesive other than a urethane. It is also recommended that an auto glass dealer install the windowpanes.

4. Trim existing adhesive so it has a smooth surface. 5. Inspect and clean both replacement glass and window frame. Use water with a mild detergent and allow to dry. 6. Apply primers per adhesive manufacturer's recommendations

IMPORTANT: Windowpanes must have an ultraviolet barrier around the edge of the glass since ultraviolet rays will deteriorate the adhesive. Windowpanes ordered through John Deere Parts have the ultraviolet barrier. If the windowpane is purchased through a glass dealer, the dealer must put an ultraviolet barrier on the glass. DO NOT apply paint to the border of the glass.

8. Put the new windowpane into position. Use light hand pressure to force windowpane down around the edges until even with metal frame. DO NOT over press adhesive.

If an auto glass dealer is not installing the windowpanes, use the following procedure:

9. If windowpane is installed directly on cab, use tape to hold it in place while adhesive cures.

1. Purchase urethane adhesive and appropriate primers from your local auto glass dealer.

10. Allow adhesive to cure for 24 hours before operating machine.

7. Apply a 12.5 mm (1/2 in.) bead of adhesive on top of the existing adhesive. Bead must be high enough to fill gap between frame and installed window.

CED,TX14826,12085 -19-17AUG99-1/1

Hand Pump Bleed Procedure Follow this procedure to bleed air from the hand pump/cab tilt cylinder circuit. T206573A —UN—04JAN05

IMPORTANT: For satisfactory operation of the cab tilt cylinder it is essential that all air be bled from the system. Therefore, any time air is induced into the system, the bleed procedure MUST be performed. 1. Remove test port 12 plug (1). 2. Operate hand pump (2) until all air is out of system. Hand Pump Bleed Procedure

3. Install and tighten test port 12 plug. 1— Test Port 12 Plug

2— Hand Pump KV70328,00001F9 -19-30NOV11-1/1

TM1731 (28JAN20)

18-1810-2

850J Crawler (S.N. 130886—311988) 012820 PN=344

Operator Enclosure

Wiper Arm Installation Use the following procedure when installing or reinstalling a wiper arm:

TX1271802A —UN—23JAN19

IMPORTANT: Prevent damage to wiper arm resulting from slippage against wiper shaft spline (41) during operation. Metal chips and debris accumulated in the wiper shaft spline can cause the wiper shaft (40) to slip in the wiper arm. Clear wiper shaft spline and wiper arm mounting hole of metal chips or debris before installing wiper arm. 1. Inspect wiper shaft spline (41) and wiper arm mounting hole for metal chips or debris. Clean metal chips or debris from wiper shaft spline and wiper arm mounting hole with wire brush if necessary. 2. Install wiper arm and wiper arm retaining nut. Tighten wiper arm retaining nut to specification. Wait 30 minutes and tighten to specification again.

Cleaning Wiper Shaft Spline 40— Wiper Shaft

41— Wiper Shaft Spline

Specification Wiper Arm Retaining Nut—Torque..................................................................................17 N·m 150 lb·in OUT1736,0000093 -19-07FEB19-1/1

TM1731 (28JAN20)

18-1810-3

850J Crawler (S.N. 130886—311988) 012820 PN=345

Operator Enclosure

TM1731 (28JAN20)

18-1810-4

850J Crawler (S.N. 130886—311988) 012820 PN=346

Group 1821

Seat and Seat Belt

T8388AG —UN—26JUN95

Disassemble and Assemble Seat

1— Seat Support 2— Seat Belt 3— Armrest (2 used)

4— Bracket (2 used) 5— Washer (12 used) 6— Cap Screw (12 used)

1. Remove only parts necessary to make repairs.

7— Pad (2 used) 8— Plate (2 used) 9— Washer (4 used)

2. See following illustrations in this group to disassemble and assemble seat. Continued on next page

TM1731 (28JAN20)

10— Cap Screw (4 used)

18-1821-1

T52,1821,K120 -19-25NOV09-1/6

850J Crawler (S.N. 130886—311988) 012820 PN=347

T6139AU —UN—19OCT88

Seat and Seat Belt

Seat Cushions With Tilt Latch A—Washer (4 used) B—Armrest (2 used) C—Backrest D—Nut (2 used)

E—Washer (2 used) F— Spacer (2 used) G—Screw (2 used) H—Washer (2 used)

I— Cap Screw (2 used) J— Spring (2 used) K—Seat Cushion L— Cap Continued on next page

TM1731 (28JAN20)

18-1821-2

M—Tilt Latch N—Spring O—Cap Screw (4 used) T52,1821,K120 -19-25NOV09-2/6

850J Crawler (S.N. 130886—311988) 012820 PN=348

T6139AT —UN—19OCT88

Seat and Seat Belt

Scissors Suspension Arms With Shafts A—Bar B—Lock Nut C—Cross Pivot Bearing (2 used)

D—Outer Arm E—Shaft F— End

G—Bar H—Bar Continued on next page

TM1731 (28JAN20)

18-1821-3

T52,1821,K120 -19-25NOV09-3/6

850J Crawler (S.N. 130886—311988) 012820 PN=349

T6139AS —UN—19OCT88

Seat and Seat Belt

Suspension Housing With Spring and Shock A—Height Adjustment Cap B—Lever C—Pin (3 used) D—Latch Return Spring E—Latch F— Nut (2 used) G—Bolt (4 used)

H—Upper Housing Plate I— Springs (2 used) J— Bushing (2 used) K—Shock Absorber L— Special Shoulder Bolt M—Gear and Shaft Assembly

N—Spring Pad O—Conical Spring P—Spring Washer Q—Special Washer (2 used) R—Isolator S—Gear and Shaft T— Cap Screw (2 used) Continued on next page

TM1731 (28JAN20)

18-1821-4

U—Outer Arm V—Weight Adjusting Knob W—Weight Decal

T52,1821,K120 -19-25NOV09-4/6

850J Crawler (S.N. 130886—311988) 012820 PN=350

T6139AW —UN—19OCT88

Seat and Seat Belt

Seat Adjustment Link and Side Bracket A—Right Side Bracket B—Bar C—Nut (2 used) D—Left Side Bracket

E—Washer F— Washer G—Cap Screw (2 used) H—Lock Nut (4 used)

I— Washer J— Link (2 used) K—Nut (4 used) L— Link (2 used) Continued on next page

TM1731 (28JAN20)

18-1821-5

T52,1821,K120 -19-25NOV09-5/6

850J Crawler (S.N. 130886—311988) 012820 PN=351

T6139AX —UN—19OCT88

Seat and Seat Belt

Seat Adjuster Assembly A—Lift-To-Side Cap B—Washer C—Latch Link D—Decal E—Spring Pin F— Ride Height Indicator

G—Slide Stop Bolt H—Lower Housing I— Nut (2 used) J— Right Side Latch K—Tension Spring (2 used)

L— Left Side Latch M—Cable N—Strap O—Nut P—Slide Track Q—Cap Screw R—Roller (4 used)

S—Washer (4 used) T— Plug U—Boot V—Latch Rod

T52,1821,K120 -19-25NOV09-6/6

TM1731 (28JAN20)

18-1821-6

850J Crawler (S.N. 130886—311988) 012820 PN=352

Group 1830

Heating and Air Conditioning R134a Refrigerant Cautions DO NOT heat refrigerant over 52°C (125°F) in a closed container. Heated refrigerant will develop high pressure which can burst the container.

CAUTION: DO NOT allow liquid refrigerant to contact eyes or skin. Liquid refrigerant will freeze eyes or skin on contact. Wear goggles, gloves and protective clothing.

Keep refrigerant containers away from heat sources. Store refrigerant in a cool place.

If liquid refrigerant contacts eyes or skin, DO NOT rub the area. Splash large amounts of COOL water on affected area. Go to a physician or hospital immediately for treatment.

DO NOT handle damp refrigerant container with your bare hands. Skin may freeze to container. Wear gloves.

DO NOT allow refrigerant to contact open flames or very hot surfaces such as electric welding arc, electric heating element and lighted smoking materials.

If skin freezes to container, pour COOL water over container to free the skin. Go to a physician or hospital immediately for treatment. CED,OUTX547,172 -19-21OCT98-1/1

R134a Compressor Oil Charge Check Remove compressor if R134a leakage was detected and repaired. See Compressor Remove and Install . (Group 1830.) Drain oil from the compressor and record the amount. See R134a Compressor Oil Removal. (Group 1830.) NOTE: Drain oil and save if this is a new compressor.

2. Remove, clean, but do not disassemble the valve. 3. Flush the complete system with TY16134 air conditioning flushing solvent. 4. If the compressor is serviceable, pour flushing solvent in the manifold ports and internally wash out the old oil. 5. Install a new receiver-dryer.

If the oil drained from a compressor removed from operation is very black or the amount of oil is less than specification, perform the following: Specification Compressor Oil—Volume.................................................................................. 6.0 mL 0.2 fl oz

6. Install required amount of TY22025 refrigerant oil in the compressor. See R134a Component Oil Charge. (Group 1830.) 7. Connect all components, evacuate and charge the system.

1. Remove and discard the receiver-dryer. CED,OUTX547,173 -19-05MAY04-1/1

R134a Compressor Oil Removal

4. Record measured oil and discard oil properly.

1. Remove compressor from machine. See Compressor Remove and Install. (Group 1830.) 2. Remove inlet/outlet manifold from compressor, and clutch dust cover.

5. Install new oil. See R134a Component Oil Charge. (Group 1830.) 6. Install compressor. See Compressor Remove and Install. (Group 1830.)

3. Drain oil into graduated container while rotating compressor shaft. CED,OUTX547,174 -19-09FEB05-1/1

TM1731 (28JAN20)

18-1830-1

850J Crawler (S.N. 130886—311988) 012820 PN=353

Heating and Air Conditioning

R134a Component Oil Charge CAUTION: All new compressors are charged with a mixture of nitrogen, R134a refrigerant and TY22025 (R134a) refrigerant oil. Wear safety goggles and discharge the compressor slowly to avoid possible injury.

Specification Oil, New Compressor Installation, Complete System Not Flushed—Volume................................................ Drain and return 45 mL Drain and return 1.5 fl oz

Compressors can be divided into three categories when determining the correct oil charge for the system.

• Used compressor removed from operation and oil drained. See R134a Compressor Oil Removal. (Group 1830.) Add specified amount of new oil.

• New compressor from parts depot • Used compressor removed from operation • Compressor internally washed with flushing solvent

Specification Oil, Used Compressor Installation, Complete System Not Flushed, Oil Drained—Volume....................................................................Add 45 mL Add 1.5 fl oz

Use the following procedure to determine the amount of system oil charge prior to installation of compressor on a machine. 1. When the complete system, lines, and components were flushed add the correct amount of oil as described.

• Used compressor removed from operation, oil

drained, and flushed add specified amount of new oil.

• New compressor from parts depot contains a

amount of new oil. System requires an additional amount of new oil.

Specification Oil, New Compressor Installation, Complete System Flushed—Supplied Volume......................................................................................... 230 mL 7.77 fl oz Additional Volume ........................................................................ 2.4 mL 0.08 fl oz

• Used compressor removed from operation, oil

Specification Oil, Used Compressor Installation, Complete System Not Flushed, Oil Drained, Flushed—Volume....................................................................Add 60 mL Add 2.0 fl oz

NOTE: Hoses = 3 mL per 0.3 m (0.1 fl oz per ft). Approximate total length equals 12.5 m (41.0 ft). 3. If any section of hose is removed and flushed or replaced, measure the length of hose and use the formula to determine the correct amount of oil to be added.

drained, and flushed requires specified amount of new oil.

CAUTION: DO NOT leave the system or R134a compressor oil containers open. This oil easily absorbs moisture. DO NOT spill R134a compressor oil on acrylic or ABS plastic. This oil will deteriorate these materials rapidly. Identify R134a oil containers and measures to eliminate accidental mixing of different oils.

Specification Oil, Used Compressor Installation, Complete System Flushed—Volume......................................................................... 260 mL 8.8 fl oz

2. When the complete system was not flushed add the correct amount of oil for the compressor plus the amount of oil for each component that was serviced.

• New compressor from parts depot, drain and return

Components listed below which have been removed, drained or flushed, require the removal of the compressor to determine the correct oil charge. Use the following chart as a guide for adding oil to components:

specified amount of oil to the compressor. See R134a Compressor Oil Removal. (Group 1830.)

Item

Measurement

Specification

Evaporator

Oil Charge

32.5 mL 1.1 fl oz

Condenser

Oil Charge

32.5 mL 1.1 fl oz

Receiver/Dryer

Oil Charge

30 mL 1.0 fl oz Continued on next page

TM1731 (28JAN20)

18-1830-2

CED,OUTX547,175 -19-09FEB05-1/2

850J Crawler (S.N. 130886—311988) 012820 PN=354

Heating and Air Conditioning Item

Measurement

Specification

Hoses

Oil Charge

121.2 mL approximate 4.1 fl oz approximate CED,OUTX547,175 -19-09FEB05-2/2

Leakage Testing 1. Inspect all lines, fittings, and components for oily or dusty spots. When refrigerant leaks from the system, a small amount of oil is carried out with it. 2. A soap and water solution can be sprayed on the components in the system to form bubbles at the source of the leak.

3. If a leak detector is used, move the leak detector probe under the hoses and around the connections at specified rate. 4. Some refrigerant manufacturers add dye to refrigerant to aid in leak detection.

CED,OUO1066,309 -19-09FEB05-1/1

R134a Refrigerant Recovery, Recycling and Charging Station Installation Procedure CAUTION: Do not remove high pressure relief valve (A). Air conditioning system will discharge rapidly causing possible injury. IMPORTANT: Use correct refrigerant recovery, recycling and charging stations. DO NOT mix refrigerant, hoses, fittings, components or refrigerant oils. 1. Close both high and low pressure valves on refrigerant recovery, recycling and charging station (H). 2. Remove cap from low pressure test port (G). 3. Connect low pressure blue hose (D) from refrigerant recovery, recycling and charging station (H) to low pressure test port (G) on compressor. TX1073899 —UN—24MAR10

4. Connect high pressure red hose (C) to high pressure test port (B). 5. Follow the manufacturers instructions when using the refrigerant recovery, recycling and charging station. A—High Pressure Relief Valve B—High Pressure Test Port C—Red Hose D—Blue Hose

E—High Pressure Hose F— Low Pressure Hose G—Low Pressure Test Port H—Refrigerant Recovery/Recycling and Charging Station

R134a Refrigerant Recovery, Recycling and Charging Station

CED,OUTX547,176 -19-29JUN11-1/1

TM1731 (28JAN20)

18-1830-3

850J Crawler (S.N. 130886—311988) 012820 PN=355

Heating and Air Conditioning

Recover R134a System CAUTION: Do not remove high pressure relief valve (A). Air conditioning system will discharge rapidly causing possible injury. IMPORTANT: Use correct refrigerant recovery, recycling and charging stations. DO NOT mix refrigerant, hoses, fittings, components or refrigerant oils. NOTE: Run the air conditioning system for 3 minutes to help in the recovery process. Turn air conditioning system off before proceeding with recovery steps. 1. Connect refrigerant recovery, recycling and charging station. See R134a Refrigerant Recovery, Recycling and Charging Station Installation Procedure. (Group 1830.)

A—High Pressure Relief Valve B—High Pressure Test Port C—Red Hose D—Blue Hose

TX1073899 —UN—24MAR10

2. Follow the manufacturers instructions when using the refrigerant recovery, recycling and charging station. E—High Pressure Hose F— Low Pressure Hose G—Low Pressure Test Port H—Refrigerant Recovery/Recycling and Charging Station Recover R134a System

CED,OUTX547,177 -19-29JUN11-1/1

TM1731 (28JAN20)

18-1830-4

850J Crawler (S.N. 130886—311988) 012820 PN=356

Heating and Air Conditioning

Evacuate R134a System CAUTION: Do not remove high pressure relief valve (A). Air conditioning system will discharge rapidly causing possible injury. IMPORTANT: Use correct refrigerant recovery, recycling and charging stations. DO NOT mix refrigerant, hoses, fittings, components or refrigerant oils. Do not run compressor while evacuating. 1. Connect refrigerant recovery, recycling and charging station. See R134a Refrigerant Recovery, Recycling and Charging Station Installation Procedure. (Group 1830.) 2. Open low and high pressure valves on refrigerant recovery, recycling and charging station. TX1073899 —UN—24MAR10

3. Follow the manufacturers instructions and evacuate the system. NOTE: The vacuum specifications listed are for sea level conditions. Subtract 3.4 kPa (34 mbar) (1 in. Hg) from 98 kPa (980 mbar) (29 in. Hg) for each 300 m (1000 ft) elevation above sea level. 4. Evacuate system until low pressure gauge registers specified vacuum.

Evacuate R134a System

If specified vacuum cannot be obtained in 15 minutes, test the system for leaks. See Leakage Testing. (Group 1830.) Correct any leaks. Specification Vacuum—Pressure at Sea Level...................................................................................... 98 kPa 980 mbar 29 in. Hg Pressure Above Sea Level ..................................................................... Subtract 3.4 kPa from 98 kPa for each 300 m elevation Subtract 34 mbar from 980 mbar for each 300 m elevation Subtract 1 in. Hg from 29 in. Hg for each 1000 ft elevation

5. When vacuum reaches specified level, close low-side and high-side valves. Turn vacuum pump off. 6. If the vacuum decreases more than specified amount in 5 minutes, there is a leak in the system.

A—High Pressure Relief Valve B—High Pressure Test Port C—Red Hose D—Blue Hose

E—High Pressure Hose F— Low Pressure Hose G—Low Pressure Test Port H—Refrigerant Recovery/Recycling and Charging Station

Specification Leak Present—Decrease in Vacuum..................................................................................... 3.4 kPa 34 mbar 1 in. Hg

7. Repair leak. 8. Start to evacuate. 9. Open low-side and high-side valves. 10. Evacuate system for 30 minutes after initial specified vacuum is reached. 11. Close low-side and high-side valves. Stop evacuation. 12. See Charge R134a System. (Group 1830.) CED,OUTX547,178 -19-26APR17-1/1

TM1731 (28JAN20)

18-1830-5

850J Crawler (S.N. 130886—311988) 012820 PN=357

Heating and Air Conditioning

Charge R134a System CAUTION: Do not remove high pressure relief valve (A). Air conditioning system will discharge rapidly causing possible injury. IMPORTANT: Use correct refrigerant recovery, recycling and charging stations. DO NOT mix refrigerant, hoses, fittings, components or refrigerant oils. 1. Connect JT02045 R134a refrigerant recovery, recycling and charging station. See R134a Refrigerant Recovery, Recycling and Charging Station Installation Procedure. (Group 1830.) 2. Evacuate the system. See Evacuate R134a System. (Group 1830.)

TX1073899 —UN—24MAR10

NOTE: Before beginning to charge air conditioning system, the following conditions must exist: Engine STOPPED, the pump must be capable of pulling at least 28.6 in. Hg vacuum (sea level). Subtract 3.4 kPa (34 mbar) (1 in. Hg) from 98 kPa (980 mbar) (29 in. Hg) for each 300 m (1000 ft) elevation above sea level. 3. Follow the manufacturers instructions and charge the system. Charge R134a System

4. Add refrigerant until system is charged to specification. Specification Refrigerant (Portable Charging Station)—Weight............................................................................ 1.5 kg 3.5 lb. Refrigerant (Automated Charging Station)—Weight.......................................................................... 1.47 kg 3.25 lb.

A—High Pressure Relief Valve B—High Pressure Test Port C—Red Hose D—Blue Hose

E—High Pressure Hose F— Low Pressure Hose G—Low Pressure Test Port H—Refrigerant Recovery/Recycling and Charging Station

5. Perform Air Conditioner Check. See Operational Checkout. (Group 9005-10.) MG76653,0000002 -19-26APR17-1/1

TM1731 (28JAN20)

18-1830-6

850J Crawler (S.N. 130886—311988) 012820 PN=358

Heating and Air Conditioning

Air Conditioner System Cleaning Procedures Flushing

• TY16134 Air Conditioning System Flushing Solvent Purging

Flushing the system or component is a cleaning process using a liquid solvent to remove oil and debris. Purging is always necessary after flushing to remove solvent from the system or component.

Purging the system or a component is a cleaning process using a gas to force liquid from the system. Purging alone will not remove refrigerant oil from the system.

Following is a list of situations that require a flushing procedure be done:

Following is a list of situations that require a purging procedure be done:

1. The compressor has an internal malfunction. 2. No oil remains in used compressor. 3. Oil drained from compressor appears or smells overheated. 4. System was contaminated with a mixture of refrigerant oils. 5. System was left open to the atmosphere long enough for dirt, moisture, or debris to enter the tubing or components. 6. System has an internal blockage. The following solvent is recommended for flushing air conditioner systems. Use only solvents with an equivalent MSDS.

• After flushing system with solvent, to prevent oil dilution • System was contaminated with nitrogen or two refrigerants.

• System was left open to the atmosphere and flushing could not be performed.

• Installation of new lines, condenser, or evaporator was required.

Evacuating Evacuating the system is a process to remove air and moisture from the system, creating a vacuum. See Evacuate R134a System. (Group 1830.) MF82180,00001DD -19-29JUN11-1/1

Purge R134a System IMPORTANT: Air compressors used for purging systems require a water separator. Purging without a separator adds moisture, creating hydrofluoric acid when combined with refrigerant oil. Acid is corrosive to metal tubing. 1. Connect dry nitrogen hose to gauge manifold center hose. 2. Connect gauge manifold suction hose to compressor suction port, and open valves. 3. Connect gauge manifold discharge hose to compressor discharge post, and open valve. Disconnect discharge hose from gauge manifold to allow purging nitrogen to atmosphere.

4. Open nitrogen tank valve and adjust regulator to Specification. Purge system for 2 minutes. Disconnect nitrogen supply. Specification Nitrogen Purge—Pressure................................................... 275 kPa for 2 minutes 2.75 bar for 2 minutes 40 psi for 2 minutes

5. Evacuate system. See Evacuate R134a System. (Group 1830.)

CED,TX03399,2292 -19-29JUN11-1/1

TM1731 (28JAN20)

18-1830-7

850J Crawler (S.N. 130886—311988) 012820 PN=359

Heating and Air Conditioning

Flush R134a System Add flushing solvent to system with JT02075 Air Conditioning Flusher and JT02098 Fitting Kit.

Specification Flusher Tank—Capacity...................................................................... 4 L 1 gal

NOTE: Flushing can be performed on vehicle. 1. Recover refrigerant. See Recover R134a System. (Group 1830.)

NOTE: Air pressure must be at least 620 kPa (6.2 bar) (90 psi) for flushing and purging.

2. Remove compressor and measure oil drained from both manifold ports.

9. Connect a supply line of moisture-free compressed air or dry nitrogen to flusher air valve. Adjust regulator to specification.

3. Clean compressor as follows:

Specification Regulated Air—Minimum Pressure...................................................................................... 620 kPa 6.2 bar 90 psi

a. Pour specified amount of flushing solvent into suction port and specified amount of flushing solvent into discharge port. Plug both ports in compressor manifold, using caps. Specification Compressor Flushing Solvent—Quantity in Suction Port.................................................................................. 240 mL 8 fl oz Quantity in Discharge Port .............................................................................................. 120 mL 4 fl oz

b. Turn compressor end for end and roll it side to side. c. Remove both plugs from manifold ports and drain solvent from compressor.

10. Open air valve to force flushing solvent into condenser circuit. Flusher tank is empty when hose pulsing stops. Additional flushing cycles are required if system is heavily contaminated with burned oil or metal particles. NOTE: Purging the condenser circuit takes 10—12 minutes to thoroughly remove solvent. 11. Disconnect hose from aeration nozzle to check circuit for solvent. Hold hose close to a piece of cardboard; continue purging until cardboard is dry. Flush Evaporator

d. Connect battery power to compressor clutch coil. Rotate pulley at least five revolutions to move solvent out of cylinders. e. Invert compressor, roll end for end, and side to side. Drain thoroughly.

1. If system is contaminated with burned refrigerant oil or debris, remove and bench flush evaporator. Go to step 18 to flush evaporator through expansion valve, if oil appears normal. Remove evaporator. See Evaporator or Heater Core Remove and Install. (Group 1830.) 2. Force flushing solvent through evaporator inlet with compressed air.

f. Let compressor sit inverted for 3—5 minutes. g. Repeat previous two steps at least three times.

3. Purge system until dry.

4. Remove and discard receiver-dryer.

4. Reinstall evaporator.

5. Divide system into two circuits:

Flush Evaporator Through Expansion Valve

a. Condenser, including inlet and outlet hoses.

1. Connect flusher outlet hose to connection of receiver/dryer outlet hose using JT03188 Adapter.

b. Evaporator, including inlet and outlet hoses. NOTE: DO NOT attempt to flush through compressor or receiver-dryer. Flushing through expansion valve is acceptable if refrigerant oil has normal odor and appearance.

2. Attach a hose and aerator nozzle to compressor inlet line using JT02101 Adapter. Put nozzle in a container to collect solvent. 3. Repeat Steps 8, 9 and 10 to flush evaporator.

6. To Flush/Purge Condenser: Connect flusher outlet hose to inlet end of compressor discharge line using JT02102 Adapter.

NOTE: Purging the evaporator circuit takes 12—15 minutes to thoroughly remove solvent. 4. Disconnect hose from aeration nozzle to check circuit for solvent. Hold hose close to a piece of cardboard. Continue purging until cardboard is dry.

7. Attach a return hose and aerator nozzle to outlet end of receiver/dryer inlet hose using JT03197 Adapter. Put nozzle in container to collect flushing solvent. 8. Fill flusher tank with solvent and fasten all connections.

Install a new receiver-dryer compatible with R134a refrigerant. Tighten connections and mounting bracket.

Continued on next page

TM1731 (28JAN20)

18-1830-8

CED,TX03399,2293 -19-29JUN11-1/2

850J Crawler (S.N. 130886—311988) 012820 PN=360

Heating and Air Conditioning

Add required oil. See R134a Component Oil Charge. (Group 1830.)

Connect clutch coil wire. Install drive belt. Purge system. See Purge R134a System. (Group 1830.)

Install compressor, and connect refrigerant lines to manifold.

CED,TX03399,2293 -19-29JUN11-2/2

Evaporator or Heater Core Remove and Install

1. Remove cap screws to remove access cover to air conditioning and heater assembly. 2. Recover air conditioning system. See Recover R134a System. (Group 1830.) 3.

Disconnect (1, 2, 4—6, 8 and 9).

T118219B —UN—03NOV98

NOTE: Anytime air conditioning system is discharged, a new receiver/dryer must be installed.

4. Remove cap screw (3) on both sides. 5. Remove eight cap screws (7) and remove A/C and heater assembly. 6— Expansion Valve Hose-to-Compressor 7— Cap Screw (8 used) 8— A/C Blower Fans and Switch Connector 9— Low Pressure Switch Connector

T118220B —UN—05NOV98

1— Receiver-Dryer Hose-to-Condenser 2— Receiver-Dryer Hose from Evaporator 3— Cap Screw (2 used) 4— Two Heater Hoses-to-Under the Seat Heater Core 5— A/C Harness Connector-toCab Harness Connector

CED,OUTX547,182 -19-28MAY09-1/3

Disconnect lines and bracket from expansion valve (14).

7. Remove two screw (12) and remove expansion valve T118221B —UN—03NOV98

8. Remove bracket (13). 9. Remove two cap screw and remove plate (10). 10. Remove cover (11) and remove evaporator or heater core. 10— Plate 11— Evaporator/Heater Core Cover 12— Cap Screw (2 used)

13— Bracket 14— Expansion Valve

Continued on next page

TM1731 (28JAN20)

18-1830-9

CED,OUTX547,182 -19-28MAY09-2/3

850J Crawler (S.N. 130886—311988) 012820 PN=361

Heating and Air Conditioning

11. Install evaporator or heater core. 12. Install (11, 10, 13, and 14). Tighten cap screws.

14. Connect hoses (1 and 2). 15. Install access cover and tighten cap screws. 16. Install new receiver/dryer. 17. Apply refrigerant oil to new O-rings and immediately connect lines.

T118221B —UN—03NOV98

13. Connect (4—6, 8 and 9). Tighten cap screws (3 and 7).

18. Add oil. See R134a Component Oil Charge. (Group 1830.)

8— A/C Blower Fans and Switch Connector 9— Low Pressure Switch Connector 10— Plate 11— Evaporator/Heater Core Cover 12— Cap Screw (2 used) 13— Bracket 14— Expansion Valve

T118219B —UN—03NOV98

T118220B —UN—05NOV98

19. Evacuate and charge the air conditioning system. See Evacuate R134a System and see Charge R134a System. (Group 1830.)

CED,OUTX547,182 -19-28MAY09-3/3

TM1731 (28JAN20)

18-1830-10

850J Crawler (S.N. 130886—311988) 012820 PN=362

Heating and Air Conditioning

Expansion Valve Remove and Install NOTE: Anytime air conditioning system is discharged, a new receiver-dryer must be installed. T200241A —UN—20MAY04

1. Open Access cover 2. Recover the air conditioning system. See Recover R134a System. (Group 1830.) 3. Disconnect hoses (1 and 3) and remove cap screw and bracket (2). 4. Remove two screws on expansion valve and remove valve. 5. Install expansion valve and cap screw. Tighten cap screw to specification. Specification Cap Screw—Torque............................................................ 5.2—6.2 N·m 46—55 lb-in.

6. Install bracket and connect hoses. Install new receiver-dryer. See Receiver-Dryer Remove and Install. (Group 1830.)

Expansion Valve 1— Expansion Valve Hose-to-Compressor 2— Cap Screw and Bracket

3— Expansion Valve Hose-to-Receiver/Dryer

9. Evacuate and charge the air conditioning system. See Evacuate R134a System and See Charge R134a System. (Group 1830.)

7. Apply refrigerant oil to new O-rings and immediately connect lines. 8. Add oil. See R134a Component Oil Charge. (Group 1830.) SK44377,00002B4 -19-01DEC14-1/1

A/C Freeze Switch Remove and Install 1. Disconnect connector (1).

3. Remove cap screws (3). 1— Connector 2— Sensor

3— Cap Screw (2 used)

T118417B —UN—16NOV98

2. Remove sensor (2) from evaporator.

CED,TX03399,5071 -19-09FEB05-1/1

TM1731 (28JAN20)

18-1830-11

850J Crawler (S.N. 130886—311988) 012820 PN=363

Heating and Air Conditioning

Upper Cab Heater Blower Motor and Heater Blower Resistor Remove and Install 1. Remove A/C and heater access cover. T118407B —UN—16NOV98

2. Remove blower motor cover (for blower motor only). 3. Disconnect blower motor connectors (3). Remove cap screws (1 and 2). 4. Remove blower motor. 5. Disconnect leads (5) and cap screw (4) to remove heater resistor. 6. Install new resistor and connect leads and install cap screw (4). 7. Install blower motor and connect connectors. 8. Install covers.

1— Cap Screw (4 used) 2— Cap Screw 3— Blower Motor Connector (2 used)

4— Resistor Cap Screw 5— Resistor Wire Lead (3 used)

CED,TX03399,5066 -19-09FEB05-1/1

TM1731 (28JAN20)

18-1830-12

850J Crawler (S.N. 130886—311988) 012820 PN=364

Heating and Air Conditioning

TM1731 (28JAN20)

18-1830-13

850J Crawler (S.N. 130886—311988) 012820 PN=365

Heating and Air Conditioning

T117712 —UN—15DEC98

Cab Upper Heater Disassemble and Assemble

Continued on next page

TM1731 (28JAN20)

18-1830-14

CED,TX03399,5025 -19-09FEB05-1/2

850J Crawler (S.N. 130886—311988) 012820 PN=366

Heating and Air Conditioning 1— Top Cover 2— Cap Screw (24 used) 3— Evaporator Core 4— Heater Core 5— Cap Screw (10 used) 6— Bracket 7— Grommet (2 used) 8— Gasket Kit 9— Switch Knob (2 used)

10— Nut (2 used) 11— Rotary Switch 12— Heater Switch 13— Heater Control Switch 14— Recirculation Filter 15— Fresh Air Filter 16— Main Housing 17— Cap Screw (4 used)

18— Grommet 19— Mount Plate 20— O-Ring 21— Cap Screw (2 used) 22— Thermal Expansion Valve 23— O-Ring 24— Plate 25— Bracket 26— Freeze Control Switch 27— Blower Fan

28— Wiring Harness 29— Resistor 30— Motor Support Retainer 31— Motor Retainer 32— Bracket 33— A/C Back Cover 34— Upper Heater Assembly

CED,TX03399,5025 -19-09FEB05-2/2

TM1731 (28JAN20)

18-1830-15

850J Crawler (S.N. 130886—311988) 012820 PN=367

Heating and Air Conditioning

T117713 —UN—03DEC98

Cab or ROPS Under Seat Heater Disassemble and Assemble

Continued on next page

TM1731 (28JAN20)

18-1830-16

CED,TX03399,5024 -19-26APR17-1/3

850J Crawler (S.N. 130886—311988) 012820 PN=368

Heating and Air Conditioning 1— Heater Base 2— Heater Assembly 3— Heater Tray 4— Gasket Kit

5— Blower Motor Bulkhead 6— Heater Core 7— Support 8— Wiring Harness (Not Shown) with Grommet

1. Drain engine coolant. See 850J-II Drain and Refill Capacities for amount. (Operator's Manual.) 2. Remove floor mat and floor access plate.

9— Backing Plate 10— Cap Screw (10 used) 11— Blower 12— Cap Screw (2 used)

13— Switch

3. For machines equipped with a toolbox, pull out drawer and remove cap screw holding toolbox in place. Remove toolbox. CED,TX03399,5024 -19-26APR17-2/3

4. Remove four cap screws (A) from around seat box bottom.

6. Remove two cap screws from knee pad (E) on both sides of seat (if equipped). 7. On units equipped with rear screen or cab, tilt back of seat forward. 8. Tilt seat up as far as possible with jack screw (D) located in left rear corner of seat box.

T116758B —UN—03SEP98

5. Remove shoulder cap screws (C) from seat box under armrest (B) on both sides of seat.

9. Disconnect blower wire connector and heater hoses. 10. Remove heater/blower assembly

12. Assemble parts and lower seat. 13. Install floor access plate and floor mat. 14. Fill engine coolant. See 850J-II Drain and Refill Capacities. (Operator's Manual.) D—Jack Screw E—Knee Pad

T200435A —UN—27MAY04

A—Cap Screws Around Seat Box Bottom (4 used) B—Armrest C—Shoulder Cap Screws (2 used)

T116757B —UN—21AUG98

11. Remove part as necessary.

CED,TX03399,5024 -19-26APR17-3/3

TM1731 (28JAN20)

18-1830-17

850J Crawler (S.N. 130886—311988) 012820 PN=369

Heating and Air Conditioning

Receiver-Dryer Remove and Install NOTE: Anytime air conditioning system is discharged, a new receiver-dryer must be installed. T118142B —UN—02NOV98

1. Remove left hand side cover. 2. Recover the air conditioning system. See Recover R134a System. (Group 1830.) 3. Disconnect hoses (1 and 3) and remove four cap screws (2) and remove receiver-dryer. 4. Install new receiver-dryer, and bracket. Tighten cap screws. 5. Apply refrigerant oil to new O-rings and immediately connect lines. 6. Add oil. See R134a Component Oil Charge. (Group 1830.)

1— Receiver/Dryer Hose-to-Condenser 2— Receiver/Dryer Hose-from-Evaporator

3— Receiver/Dryer Bracket Cap Screw (4 used)

7. Evacuate and charge the air conditioning system. See Evacuate R134a System and see Charge R134a System. (Group 1830.) CED,OUTX547,181 -19-28MAY09-1/1

Condenser Remove and Install NOTE: Anytime air conditioning system is discharged, a new receiver-dryer must be installed. T118149B —UN—02NOV98

If servicing the condenser fans do not disconnect condenser hoses. Remove condenser and lay to the side. 1. Remove bottom cover. 2. Recover the air conditioning system. See Recover R134a System. (Group 1830.) 3. Disconnect hoses (1 and 3) and remove six cap screws (2) and remove condenser. 1— From Receiver-Dryer-toCondenser Hose 2— Cap Screw (6 used)

4. Install condenser. Tighten cap screws. 5. Connect lines (1 and 3). 6. Install a new receiver-dryer. See Receiver-Dryer Remove and Install. (Group 1830.) 7. Apply refrigerant oil to new O-rings connect lines.

3— Condenser-to-Compressor Hose

9. Evacuate and charge the air conditioning system. See Evacuate R134a System and see Charge R134a System. (Group 1830.)

8. Add compressor oil. See R134a Component Oil Charge. (Group 1830.) CED,OUTX547,183 -19-28MAY09-1/1

TM1731 (28JAN20)

18-1830-18

850J Crawler (S.N. 130886—311988) 012820 PN=370

Heating and Air Conditioning

T117702 —UN—22OCT98

Compressor Remove and Install

1— Compressor 2— Spring Pin (2 used) 3— Bracket 4— Support

5— Spacer 6— Sleeve 7— Pulley 8— Cap Screw 9— Washer (6 used)

10— Cap Screw 11— Cap Screw (3 used) 12— Nut (3 used) 13— Washer (2 used)

1. Remove refrigerant from the system. See Recover R134a System. (Group 1830.)

Support Bracket-toEngine Block Cap Screw—Torque............................................................................120 N·m 89 lb-ft Compressor Bracket to Engine Block Cap Screws—Torque............................................................................70 N·m 52 lb-ft Idler pulley-to-fan drive cap screw—Torque........................................................................50 N·m 37 lb-ft

2. Loosen belt adjuster and remove belt. 3. Disconnect wiring lead, suction and discharge lines. 4. Remove four cap screws and compressor. 5. Repair or replace compressor. See Compressor Disassemble and Assemble. (Group 1830.) 6. Install compressor and tighten cap screws. Air Conditioning Compressor Remove and Install—Specification Compressor-to-Bracket Cap Screws—Torque....................................................................35 N·m 26 lb-ft

7. Connect suction and discharge lines and wiring lead. 8. Install belt. 9. Install a new receiver/dryer.

Continued on next page

TM1731 (28JAN20)

14— Cap Screw (2 used) 15— Cap Screw

18-1830-19

CED,TX03399,5020 -19-09FEB05-1/2

850J Crawler (S.N. 130886—311988) 012820 PN=371

Heating and Air Conditioning

10. Evacuate and charge the air conditioning system. See Evacuate R134a System and see Charge R134a System. (Group 1830.)

avoid possible high pressure discharge of extra refrigerant oil that is in all new compressors.

IMPORTANT: When turning air conditioning on for the first time, set the engine rpm at slow idle to CED,TX03399,5020 -19-09FEB05-2/2

TM1731 (28JAN20)

18-1830-20

850J Crawler (S.N. 130886—311988) 012820 PN=372

Heating and Air Conditioning

T114965 —UN—29APR98

Compressor Clutch Disassemble and Assemble

1. Mount compressor on D01006AA Bench Mounted Holding Fixture or DFRW20 Compressor Holding Fixture using two 6 in. x 1/4 in. eye bolts with nuts as illustrated. 2. Remove dust cover. 3. Hold the clutch hub using JDG747 Compressor Clutch Spanner (A) and remove the clutch shaft bolt (B). 4. Remove the clutch hub (C). Remove the shims (H) from the clutch hub and save for installation.

RW21157 —UN—24JUN92

5. Remove and discard snap ring (D). Remove the pulley (E) using a plastic hammer or JDG220 Puller, JDG748 Jaws and JDG771 Forcing Screw. 6. Disconnect the clutch coil lead wire. Remove and discard the snap ring (F) and remove the clutch coil (G). NOTE: The bearing in the pulley is not serviceable. 7. Check pulley bearing operation. Replace pulley and bearing as required. 8. Install the clutch coil and new snap ring with flat side of the snap ring down. Connect the clutch coil lead wire. 9. Install the pulley and new snap ring with the flat side of the snap ring down. Apply grease to the shims (H) and install to the clutch hub.

A—JDG747 Compressor Clutch Spanner B—Clutch Shaft Bolt C—Clutch Hub D—Pulley Snap Ring

E—Pulley F— Clutch Coil Snap Ring G—Clutch Coil H—Shims

10. Install clutch hub and shaft bolt and tighten. Specification Compressor Hub Retaining Nut—Torque..................................................................14 N·m 124 lb-in. TX,18,RB761 -19-09FEB05-1/1

TM1731 (28JAN20)

18-1830-21

850J Crawler (S.N. 130886—311988) 012820 PN=373

Heating and Air Conditioning

Clutch Hub Clearance Check NOTE: The clutch coil is not polarity sensitive. 1. Check pulley-to-clutch hub clearance using a dial indicator. Mount the gauge to the pulley as illustrated and connect a set of jumper wires from the compressor to a 12V battery. 2. Rotate the pulley and check clearance in three equally spaced locations around the clutch hub. Add or remove shims to obtain specified clearance. Specification Air Conditioning Clutch Hub-toPulley—Clearance............................................................0.35—0.65 mm 0.014—0.026 in.

Specification Air Conditioning Clutch Shaft Bolt—Torque .......................................................................14 N·m 124 lb-in.

RW21159 —UN—24JUN92

3. Tighten clutch shaft bolt to specification after correct clearance is obtained.

TX,18,RB762 -19-09FEB05-1/1

Compressor Manifold Inspect 1. Remove cap screws (A) and the manifold (B). 2. Remove and discard seal (C). Inspect porting surfaces. 3. Lubricate and install a new seal (C). 4. Install manifold and tighten cap screws. Specification Manifold Through Bolt—Torque..................................................................................26 N·m 19 lb-ft C—Manifold Seal RW21160 —UN—24JUN92

A—Manifold Cap Screw B—Manifold

TX,18,RB763 -19-09FEB05-1/1

TM1731 (28JAN20)

18-1830-22

850J Crawler (S.N. 130886—311988) 012820 PN=374

Heating and Air Conditioning

RW21161 —UN—24JUN92

Compressor Disassemble and Assemble

A—Rear Pins B—Rear Housing C—Rear Gasket D—Rear Discharge Reed Valve E—Rear Valve Plate

F— Rear Suction Reed Valve G—Rear O-Ring H—Front O-Ring I— Front Suction Reed Valve J— Front Valve Plate

K—Front Discharge Reed Valve L— Front Gasket M—Snap Ring N—Lip Seal O—Washer P—Through Bolt Continued on next page

TM1731 (28JAN20)

18-1830-23

Q—Felt Holder R—Felt S—Front Housing T— Front Pins

TX,18,RB764 -19-09FEB05-1/3

850J Crawler (S.N. 130886—311988) 012820 PN=375

Heating and Air Conditioning

1. Clean the compressor using solvent before disassembly. Mount compressor on holding fixture and remove clutch. See Compressor Clutch Disassemble and Assemble. (Group 1830.) IMPORTANT: When removing front and rear housing, be careful not to damage the sealing surfaces. 2. Disassemble the compressor as illustrated and discard the O-rings, gaskets, lip seal, snap ring, and through bolt washers. Replace parts from service kits.

RW21162 —UN—24JUN92

NOTE: The valve plates, reed valves, cylinders, and cylinder housings are not serviceable. Some cylinder scuffing (light scratches) is normal. 3. Inspect the valves for an even wear pattern and the cylinders for scoring or excessive wear. Replace compressor as required. 4. Remove the shaft seal snap ring (M). Turn the housing over and remove the felt holder (Q) and felt (R) from the front housing (S). 5. Remove the shaft lip seal (N) from the front housing (S) using a small tool with 5/8 in. OD. 6. Wash all parts in clean solvent and dry before assembly. IMPORTANT: Lubricate O-rings, gaskets, and lip seal using only TY22025 (R134a) refrigerant oil during assembly. Other oils could damage the compressor. 7. Apply R134a oil to the bore of the front housing and install new lip seal (N) to the bottom of the bore using a socket. Install new snap ring (M) flat side down. RW21163 —UN—24JUN92

IMPORTANT: Bushing spacer (U) must be in position before assembling the compressor. 8. Install pins (A) and new O-ring (G) in the rear cylinder. NOTE: The rear valve plate is marked with an “R” and is installed face up. 9. Install parts (F—D) over the pins on the rear cylinder. 10. Install a new gasket (C) flat side down and the rear housing (B) on the rear cylinder. Mount the compressor onto the holding fixture.

C—Rear Gasket D—Rear Discharge Reed Valve E—Rear Valve Plate

F— Rear Suction Reed Valve U—Pump Body

11. Install pins (T) and new O-ring (H) in the front cylinder. 15. Partially tighten the through bolts and then tighten to specification.

NOTE: The front valve plate is marked with an “F” and is installed face up. 12. Install parts (I—K) over the pins on the front cylinder. 13. Install a new gasket (L) flat side down. Put JDG746 lip seal protector on the shaft and lubricate with R134a oil. 14. Install the front housing (S) on the front cylinder and remove the lip seal protectors. Install through bolts (P) and new washers (O).

Specification Air Conditioning Compressor Through Bolt—Torque..................................................................................26 N·m 230 lb-in.

16. Install the felt (R) and felt holder (Q) using the clutch hub. Continued on next page

TM1731 (28JAN20)

18-1830-24

TX,18,RB764 -19-09FEB05-2/3

850J Crawler (S.N. 130886—311988) 012820 PN=376

Heating and Air Conditioning

17. Install the pulley-clutch hub and check clearance. See Clutch Hub Clearance Check. (Group 1830.) TX,18,RB764 -19-09FEB05-3/3

TM1731 (28JAN20)

18-1830-25

850J Crawler (S.N. 130886—311988) 012820 PN=377

Heating and Air Conditioning

TM1731 (28JAN20)

18-1830-26

850J Crawler (S.N. 130886—311988) 012820 PN=378

Contents

Section 19 Sheet Metal

Page

Group 1910—Hood and Engine Enclosures Hood Remove and Install .......................... 19-1910-1 Engine Side Shields Remove and Install ..................................................... 19-1910-3 Hood Support Remove and Install.............. 19-1910-4

TM1731 (28JAN20)

19-1

850J Crawler (S.N. 130886—311988) 012820 PN=1

Group 1910

Hood and Engine Enclosures Hood Remove and Install

9 7 4

7 4 7

5 6

8 2 6

1 6

6 TX1008310 —UN—24MAY06

TX1008310

Hood

Continued on next page

TM1731 (28JAN20)

19-1910-1

SJ25320,000003E -19-31MAY06-1/3

850J Crawler (S.N. 130886—311988) 012820 PN=380

Hood and Engine Enclosures 1— Hood 2— Hinge 4— Cap Screw (4 used)

5— Cap Screw (10 used) 6— Washer (10 used)

7— Washer (4 used) 8— Service Door 9— Grille Housing Cover SJ25320,000003E -19-31MAY06-2/3

1. Remove clamp (10) and exhaust stack (11). CAUTION: Prevent possible injury from heavy hood. Use an appropriate lifting device. 2. Remove hood (1) and grille housing cover (9). Specification Hood—Weight................................................................................. 73 kg 160 lb

3. Install hood and grille housing cover.

10— Clamp

TX1008656A —UN—31MAY06

4. Install exhaust stack and clamp. 11— Exhaust Stack

Exhaust Stack SJ25320,000003E -19-31MAY06-3/3

TM1731 (28JAN20)

19-1910-2

850J Crawler (S.N. 130886—311988) 012820 PN=381

Hood and Engine Enclosures

T209552 —UN—15MAR05

Engine Side Shields Remove and Install

T209552 Engine Side Shields 1— Grommet (2 used) 2— Washer (14 used) 3— Washer (8 used) 4— Cap Screw (14 used)

5— Guide (8 used) 6— Washer (4 used) 7— Cap Screw (4 used) 8— Lock Nut (4 used)

9— Left Hand Side Shield 10— Right Hand Side Shield 11— Nut 12— Door Latch

CAUTION: Prevent possible crushing injury from heavy engine side shields. Use appropriate lifting device. 1. Remove engine side shields.

13— Latch 14— Hinge 15— Rivet (4 used) 16— Washer

Specification Engine Side Shields—Weight.............................................................................. 27 kg 65 lb

2. Install engine side shields. BR81691,0000012 -19-11MAR05-1/1

TM1731 (28JAN20)

19-1910-3

850J Crawler (S.N. 130886—311988) 012820 PN=382

Hood and Engine Enclosures

Hood Support Remove and Install

9. Remove cap screws and washers (9 and 10) and hood support (11).

1. Turn battery disconnect switch to the OFF position. See Battery Disconnect Switch. (Operator's Manual.) 2. Remove hood. See Hood Remove and Install. (Group 1910.) 3. Remove engine side shields. See Engine Side Shields Remove and Install. (Group 1910.) 4. Tilt cab/ROPS. See Cab or ROPS Tilting Procedure. (Operator's Manual.) 5. Remove starting aid tube (1) from starting aid solenoid (2). 6. Remove ECU wire harness connectors (3) from ECU (4). See Engine Control Unit (ECU) Remove and Install. (Group 9015-20.) 7. Remove intake air temperature sensor wiring harness connector (5) and air filter restriction switch wiring harness connector (6). NOTE: Removal of air cleaner assembly is not necessary for removal of hood support. 8. Disconnect air intake tube (7) from turbocharger inlet (8).

Specification Hood Support—Approximate—Weight................................................................................. 43 kg 95 lb

10. Install hood support. 11. Install air intake tube to turbocharger inlet. 12. Install air filter restriction switch wiring harness connector and intake air temperature sensor wiring harness connector. 13. Install ECU wire harness connectors. See Engine Control Unit (ECU) Remove and Install. (Group 9015-20.) 14. Install starting aid tube. 15. Lower cab/ROPS. See Cab or ROPS Tilting Procedure. (Operator's Manual.) 16. Install engine side shields. See Engine Side Shields Remove and Install. (Group 1910.) 17. Install hood. See Hood Remove and Install. (Group 1910.) 18. Turn battery disconnect switch to the ON position.

CAUTION: Prevent possible crushing injury from heavy hood support. Use an appropriate lifting device when removing and installing.

Continued on next page

TM1731 (28JAN20)

19-1910-4

MH66O88,0000150 -19-26APR17-1/2

850J Crawler (S.N. 130886—311988) 012820 PN=383

Hood and Engine Enclosures 7— Air Intake Tube 8— Turbocharger Inlet 9— Cap Screw (6 used) 10— Washer (6 used) 11— Hood Support

TX1008271A —UN—02JUN06

1— Starting Aid Tube 2— Starting Aid Solenoid 3— ECU Wire Harness Connector (3 used) 4— Engine Control Unit (ECU) 5— Intake Air Temperature Sensor Wiring Harness connector 6— Air Filter Restriction Switch Wiring Harness Connector

TX1008792A —UN—02JUN06

Hood Support

TX1008623

TX1008623 —UN—02JUN06

Hood Support MH66O88,0000150 -19-26APR17-2/2

TM1731 (28JAN20)

19-1910-5

850J Crawler (S.N. 130886—311988) 012820 PN=384

Section 20 Safety, Convenience and Miscellaneous Contents Page

Group 2004—Horn and Warning Devices Remove and Install Reverse Alarm ..................................................... 20-2004-1 Adjust Reverse Warning Alarm Volume................................................... 20-2004-1

TM1731 (28JAN20)

20-1

850J Crawler (S.N. 130886—311988) 012820 PN=1

Contents

TM1731 (28JAN20)

20-2

850J Crawler (S.N. 130886—311988) 012820 PN=2

Group 2004

Horn and Warning Devices Remove and Install Reverse Alarm 1. Remove rear access panel (A). 2. Disconnect wiring leads to alarm.

A—Rear Access Panel

T8507AI —UN—19JUN95

3. Remove alarm (B). B—Alarm

TX,9025,BS516 -19-23APR96-1/1

Adjust Reverse Warning Alarm Volume IMPORTANT: The reverse warning alarm is set on low volume at the factory. It may be necessary to adjust the volume to meet local regulations. NOTE: Alarm removed from machine for clarity of photograph. 1. To change alarm to high volume, remove nuts from terminals (B and C). 2. Attach shorting bar (A) to terminals (B and C). C—Terminal

T8429AX —UN—02MAR95

A—Shorting Bar B—Terminal

TX,9025,BS515 -19-23APR96-1/1

TM1731 (28JAN20)

20-2004-1

850J Crawler (S.N. 130886—311988) 012820 PN=387

Horn and Warning Devices

TM1731 (28JAN20)

20-2004-2

850J Crawler (S.N. 130886—311988) 012820 PN=388

Contents

Section 32 Bulldozer

Page

Group 3201—Blade Cutting Edges and End Bits Remove and Install................................ 32-3201-1 Blade Remove and Install.......................... 32-3201-2 Blade Remove and Install—Mechanical Angle Blade ..................................................... 32-3201-3 Group 3240—Frames Outside Dozer Push Beams Remove and Install................................ 32-3240-1 C-Frame Remove and Install................... 32-3240-14 Pushbeams Remove and Install—Mechanical Angle Blade ................................................... 32-3240-15 Group 3260—Hydraulic System Hydraulic Pump Remove and Install ..................................................... 32-3260-1 Hydraulic Pump Disassemble and Assemble............................................... 32-3260-3 Hydraulic Pump Control Valve Disassemble and Assemble .................. 32-3260-4 Hydraulic Reservoir Remove and Install ..................................................... 32-3260-5 Hydraulic Reservoir Cleanout Cover Remove and Install ..................... 32-3260-7 Hydraulic Control Valve Remove and Install ............................................ 32-3260-10 Hydraulic Control Valve Disassemble and Assemble ................ 32-3260-11 Hydraulic Control Valve Disassemble and Assemble—IGC................................... 32-3260-14 Pilot Control Valve Remove and Install ................................................... 32-3260-17 Pilot Control Valve Disassemble and Assemble ............................................................. 32-3260-18 Integrated Grade Control (IGC) Lever Remove and Install (S.N. 130886—)............................................ 32-3260-19 Integrated Grade Control (IGC) Lever Disassemble and Assemble (S.N. 130886—).................. 32-3260-22 Quick-Drop Valve Remove and Install ................................................... 32-3260-23 Power Angle Tilt (PAT) Cylinder Remove and Install.............................. 32-3260-24 Angle Cylinder (PAT) Remove and Install ................................................... 32-3260-24 Hydraulic Cylinder Repair........................ 32-3260-25

TM1731 (28JAN20)

32-1

850J Crawler (S.N. 130886—311988) 012820 PN=1

Contents

TM1731 (28JAN20)

32-2

850J Crawler (S.N. 130886—311988) 012820 PN=2

Group 3201

Blade Cutting Edges and End Bits Remove and Install

31 29 29 3 29

T212231 —UN—23JUN05

5 29 7

T212231

29 Cutting Edges and End Bits

3— Cutting Edge (2 used) 5— Cutting Edge

6— Washer (28 used) 7— Nut (28 used)

29— Cap Screw (28 used) 30— End Bit

1. Block frame securely with cutting edge above ground level. CAUTION: Prevent possible crushing injury from heavy cutting edges. Use an appropriate lifting device to remove and install cutting edges. 2. Remove cutting edges (3 and 5) and end bits (30 and 31).

31— End Bit

Specification Cutting Edge (5)—Weight..................................................................................... 41 kg 90 lb Cutting Edge (3)—Weight..................................................................................... 32 kg 70 lb

3. Inspect parts and replace as necessary. 4. Install cutting edges (3 and 5) and end bits (30 and 31). TX,3201,SS2516 -19-11JUL95-1/1

TM1731 (28JAN20)

32-3201-1

850J Crawler (S.N. 130886—311988) 012820 PN=391

Blade

T212340 —UN—30JUN05

Blade Remove and Install

T212340 Blade—PAT Machine Shown

Continued on next page

TM1731 (28JAN20)

32-3201-2

CED,TX14826,12131 -19-25APR13-1/2

850J Crawler (S.N. 130886—311988) 012820 PN=392

Blade 3— Cutting Edge (2 used) 4— Pin 5— Cutting Edge 6— Washer (28 used) 7— Nut (28 used)

8— Half Shell Bearings (2 used) 11— Pin (3 used) 12— Plate (4 used) 16— Bushing (2 used)

1360 kg 3000 lb.

Pivot Ball Cap Screws Torque (lubricated)

691 N·m 510 lb.-ft.

26— Lubrication Fitting 29— Cap Screw (28 used) 30— End Bit 31— End Bit

6. Remove blade.

SPECIFICATIONS Blade Approximate Weight

17— Screw (4 used) 21— Socket 22— Shim (8 used) 24— Cap Screw (6 used) 25— Washer (6 used)

Specification Blade—Approximate Weight......................................................................................... 1360 kg 3000 lb.

7. Install cylinders to blade using cylinder pins (4 and 11).

NOTE: This procedure is written using a Power Angle Tilt (PAT) machine.

8. Install pivot ball cap screws (24) and half shell bearings (8).

1. Lower blade. 2. Relieve hydraulic system pressure. 3. Connect hoist chain to blade lifting points (32). 4. Remove pivot ball cap screws (24) and half shell bearings (8).

Specification Pivot Ball Cap Screws—Torque (lubricated)..................................................................................691 N·m 510 lb.-ft.

9. Disconnect hoist chains from blade lifting points (32).

5. Remove cylinder pins (4 and 11) to separate blade from cylinders. CAUTION: Prevent possible crushing injury from heavy dozer blade. Use an appropriate lifting device to remove and install. CED,TX14826,12131 -19-25APR13-2/2

Blade Remove and Install—Mechanical Angle Blade 2499 kg 5509 lb.

Blade-to-Ground Height (approximate)

1067 mm 42 in.

Cylinder Length (fully retracted)

1038 mm 40-7/8 in.

Cylinder Length (fully extended)

1184 mm 46-5/8 in.

X9811 —UN—23AUG88

SPECIFICATIONS Mechanical Angle Blade Assembly Weight (approximate)

High-Pressure Fluids

For pushbeam installation, see Pushbeams Remove and Install—Mechanical Angle Blade. (Group 3240.)

2. Relieve hydraulic system pressure.

Blade and Strut Remove

3. Remove cap screws and washers and open grille.

1. Stop engine.

4. Disconnect hydraulic hoses from bulkhead fittings. Close all openings with caps and plugs.

CAUTION: To avoid injury from escaping fluid under pressure, stop engine and relieve pressure in system before disconnecting or connecting hydraulic or other lines. Tighten all connections before applying pressure.

5. Close grille and secure with cap screws and washers.

Continued on next page

TM1731 (28JAN20)

32-3201-3

KK70125,0000038 -19-30JUN14-1/9

850J Crawler (S.N. 130886—311988) 012820 PN=393

Blade

CAUTION: Avoid personal injury from heavy component. Use appropriate lifting device. Specification Mechanical Angle Blade Assembly—Weight (approximate).............................................................................. 2499 kg 5509 lb.

TX1159702 —UN—01MAY14

6. Attach slings to blade and strut lifting points as shown in illustration.

Blade and Struts Lifting Points KK70125,0000038 -19-30JUN14-2/9

7. Remove cotter pin (27) and retainer pin (26) from ball stud (28). 27— Cotter Pin 28— Ball Stud TX1159938A —UN—06MAY14

25— Right Lower Strut 26— Retainer Pin

Strut-to-Pushbeam Assembly (right side shown from the front) KK70125,0000038 -19-30JUN14-3/9

8. Remove cap screws (20), lock washers (21), and pin retainer (19) from swivel pin (18). 9. Repeat procedure for opposite side.

5— Right Pushbeam Assembly 18— Swivel Pin 19— Pin Retainer

TX1159677A —UN—14MAY14

10. Remove blade and struts from pushbeams. Raise or lower strut to remove blade swivel pin from pushbeam pivot housing. 20— Cap Screw 3/4 x 3-1/2 in. (3 used) 21— Lock Washer (3 used)

Swivel Pin Continued on next page

TM1731 (28JAN20)

32-3201-4

KK70125,0000038 -19-30JUN14-4/9

850J Crawler (S.N. 130886—311988) 012820 PN=394

Blade Blade and Strut Installation CAUTION: Avoid personal injury from heavy component. Use appropriate lifting device. Specification Mechanical Angle Blade Assembly—Weight (approximate).............................................................................. 2499 kg 5509 lb.

1. Attach slings to blade and strut lifting points as shown in illustration. TX1159702 —UN—01MAY14

2. Keep both slings attached on one side and adjust sling attached to top of blade on opposite side. Provide sufficient slack so raising will elevate strut end and pitch top of blade forward without raising blade off ground. 3. Maneuver pushbeam into blade. Raise or lower strut to allow blade swivel pin to enter pushbeam pivot housing. 4. Secure swivel pin (18) to right pushbeam assembly (5) with pin retainer (19), cap screws (20), and lock washers (21). 20— Cap Screw 3/4 x 3-1/2 in. (3 used) 21— Lock Washer (3 used)

TX1159677A —UN—14MAY14

5— Right Pushbeam Assembly 18— Swivel Pin 19— Pin Retainer

Blade and Struts Lifting Points

Swivel Pin KK70125,0000038 -19-30JUN14-5/9

5. Align right lower strut (25) with pushbeam center brackets.

TX1159938A —UN—06MAY14

6. Install ball stud (28) through brackets and secure with retainer pin (26) and cotter pin (27). 7. Repeat procedure for opposite side. 8. Remove slings from blade and struts. 25— Right Lower Strut 26— Retainer Pin

27— Cotter Pin 28— Ball Stud

Strut-to-Pushbeam Assembly (right side shown from the front) Continued on next page

TM1731 (28JAN20)

32-3201-5

KK70125,0000038 -19-30JUN14-6/9

850J Crawler (S.N. 130886—311988) 012820 PN=395

Blade

X9811 —UN—23AUG88

High-Pressure Fluids

TX1159964 —UN—05MAY14

KK70125,0000038 -19-30JUN14-7/9

Hydraulic Plumbing Components 30— Hydraulic Hose 31— Hydraulic Hose 32— Hydraulic Hose 33— Hydraulic Hose

34— Hydraulic Hose 36— 90° Swivel Elbow Fitting (2 used) 37— Junction Block (left side)

11. Connect hydraulic hoses to bulkhead fittings.

38— Junction Block (right side) 41— O-Ring (8 used) 39— Split Flange Clamp (16 used) 40— Cap Screw M10 x 30 (32 used)

12. Close grille and secure with cap screws and washers. Continued on next page

TM1731 (28JAN20)

32-3201-6

KK70125,0000038 -19-30JUN14-8/9

850J Crawler (S.N. 130886—311988) 012820 PN=396

Blade Blade Adjustment NOTE: Strut length of 1667 mm (65-5/8 in.) is a starting dimension. Further adjustment to this length may be needed if center pin travel does not fall within 38.1 mm (1-1/2 in.) of travel range when blade is tilted from level to full tilt in either direction. 1. Check position of center pin using dimension (35). a. Measure from center of ball stud (28) to center of pin (29) in lower yoke assembly.

TX1159788 —UN—02MAY14

b. If necessary, adjust length of lower strut assembly to 1667 mm (65-5/8 in.) by rotating lower yoke assembly. 2. Lift blade off ground so ends will not collide with anything when tilted. Specification Blade-to-Ground—Height (approximate)............................................................................ 1067 mm 42 in.

Swivel Pin Travel Dimension

3. Fully tilt blade each direction and hold in tilted position for 15 seconds each cycle to fill lines and cylinders.

TX1159945A —UN—06MAY14

CAUTION: Escaping fluid under pressure can have sufficient force to penetrate skin, causing serious personal injury. Hydraulic fluid can be pressurized from mechanical leverage on cylinders, ambient temperature rise, and machine system pressure. Before disconnecting fittings, be sure to relieve all pressure. 4. If cylinders do not reach maximum stroke measurements, open lines between rod end of cylinders briefly to bleed air. Close lines and repeat cycle.

Strut Measuring Points (right side strut shown) 28— Ball Stud 29— Pin

Specification Cylinder—Length (fully retracted)................................................................................... 1038 mm 40-7/8 in. Cylinder—Length (fully extended)...................................................................................1184 mm 46-5/8 in.

When blade is not tilted, pin is pulled forward toward blade. When blade is at full tilt, pin will move back about 25.4 mm (1 in.). For correct setup, adjust the length of lower strut so 25.4 mm (1 in.) of travel falls within 38.1 mm (1-1/2 in.) range allowed. Make sure that the pin does not bottom out in either direction.

IMPORTANT: Avoid damage to surface of swivel pin and blade assembly. Adjust lower strut assembly correctly to prevent pin from bottoming out in either direction, causing binding between surface of swivel pin and blade assembly. NOTE: The center swivel pin of the pushbeam is designed to move in and out of the pushbeam pivot housing. It has a travel range of 38.1 mm (1-1/2 in.).

35— 38.1 mm (1-1/2 in.)

5. Tilt blade fully in both directions and check that swivel pin does not bottom out in either direction. 6. If swivel pin does bottom out, adjust the length of lower strut by rotating lower yoke assemblies so 25.4 mm (1 in.) of travel falls within 38.1 mm (1-1/2 in.) range allowed. KK70125,0000038 -19-30JUN14-9/9

TM1731 (28JAN20)

32-3201-7

850J Crawler (S.N. 130886—311988) 012820 PN=397

Blade

TM1731 (28JAN20)

32-3201-8

850J Crawler (S.N. 130886—311988) 012820 PN=398

Group 3240

Frames Outside Dozer Push Beams Remove and Install 680 kg 1500 lb.

Push Beam Trunnion Weight (approximate)

70 kg 155 lb.

Trunnion Mounting Cap Screw Torque

620 N·m 457 lb.-ft.

Trunnion Bushing Clearance (maximum)

1.0 mm 0.04 in.

Trunnion Cap-to-Pushbeam Socket Cap Screw Torque

1200 N·m 885 lb.-ft.

Center Pivot Mounting Cap Screw Torque

435 N·m 320 lb.-ft.

Hydraulic Hose to Elbow Fitting Torque

75 N·m 55 lb.-ft.

Elbow Fitting to Fitting Bracket Nut Torque

93 N·m 69 lb.-ft.

X9811 —UN—23AUG88

SPECIFICATIONS Push Beam Weight (approximate)

pressure in the system before disconnecting or connecting hydraulic or other lines. Tighten all connections before applying pressure. 2. Relieve hydraulic system pressure by cycling hydraulic functions with switched power ON and hydraulic enable switch ON.

Remove

3. Turn battery disconnect switch to the OFF position.

1. Lower all equipment to ground. Stop engine.

4. Hang a "DO NOT OPERATE" tag in operator station.

CAUTION: To avoid injury from escaping fluid under pressure, stop engine and relieve the Continued on next page

TM1731 (28JAN20)

32-3240-1

TX,3240,SS2521 -19-26SEP13-1/18

850J Crawler (S.N. 130886—311988) 012820 PN=399

TX1015730 —UN—03MAR10

Frames

Continued on next page

TM1731 (28JAN20)

32-3240-2

TX,3240,SS2521 -19-26SEP13-2/18

850J Crawler (S.N. 130886—311988) 012820 PN=400

Frames 1— Cap Screw (4 used) 2— Nut (8 used) 3— Cap Screw (6 used) 4— Cap Screw (2 used) 5— Cap Screw (2 used) 6— Cap Screw (20 used) 7— Washer (36 used) 8— Pitch Jack Rod

9— Pitch Jack Rod 10— Pitch Jack Turnbuckle 11— Lubrication Fitting (3 used) 12— Left Push Beam 13— Self-Aligning Bushing (2 used) 14— Trunnion Seat Cap (2 used) 15— Ring (4 used)

CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device. Specification Push Beam—Weight (approximate)................................................................................ 680 kg 1500 lb.

16— Pin Fastener 17— Pivot 18— Snap Ring (2 used) 19— Self-Aligning Bushing 20— Trunnion (2 used) 21— Blade-to-Push Beam Link 22— Lock Nut (4 used) 23— Pin Fastener (2 used)

Push Beam Trunnion—Weight (approximate).................................................................................. 70 kg 155 lb.

5. Remove parts as shown 6. Repair or replace parts as necessary

Continued on next page

TM1731 (28JAN20)

24— Plate (2 used) 25— Bushing (4 used) 26— Cap (2 used) 27— Bushing (2 used) 28— Plate (4 used) 29— Plate (20 used) 30— Right Push Beam

32-3240-3

TX,3240,SS2521 -19-26SEP13-3/18

850J Crawler (S.N. 130886—311988) 012820 PN=401

Frames

TX1015730 —UN—03MAR10

Install

Continued on next page

TM1731 (28JAN20)

32-3240-4

TX,3240,SS2521 -19-26SEP13-4/18

850J Crawler (S.N. 130886—311988) 012820 PN=402

Frames 1— Cap Screw (4 used) 2— Nut (8 used) 3— Cap Screw (6 used) 4— Cap Screw (2 used) 5— Cap Screw (2 used) 6— Cap Screw (20 used) 7— Washer (36 used) 8— Pitch Jack Rod

9— Pitch Jack Rod 10— Pitch Jack Turnbuckle 11— Lubrication Fitting (3 used) 12— Left Push Beam 13— Self-Aligning Bushing (2 used) 14— Trunnion Seat Cap (2 used) 15— Ring (4 used)

16— Pin Fastener 17— Pivot 18— Snap Ring (2 used) 19— Self-Aligning Bushing 20— Trunnion (2 used) 21— Blade-to-Push Beam Link 22— Lock Nut (4 used) 23— Pin Fastener (2 used)

24— Plate (2 used) 25— Bushing (4 used) 26— Cap (2 used) 27— Bushing (2 used) 28— Plate (4 used) 29— Plate (20 used) 30— Right Push Beam

1. Relieve hydraulic system pressure by cycling hydraulic functions with switched power ON and hydraulic enable switch ON.

TX,3240,SS2521 -19-26SEP13-5/18

2. Install trunnion (1) to track frame (2) using cap screws (3) and washers. Tighten cap screws to specification. T206734A —UN—06JAN05

Specification Trunnion Mounting Cap Screw—Torque............................................................................620 N·m 457 lb.-ft.

CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device. 3. Attach hoist to left pushbeam.

Trunnion Installation

Keep pushbeam level to allow for proper alignment with trunnion.

1— Trunnion 2— Track Frame

3— Cap Screw (10 used)

TX,3240,SS2521 -19-26SEP13-6/18

4. Align pushbeam socket (5) with trunnion ball. 5. Install pushbeam, bushing (27), and trunnion cap (4) without shims and tighten cap screws (6). TX1144602A —UN—25SEP13

Measure distance between trunnion cap and pushbeam. Insert enough shims to fill distance plus one thin (1 mm [0.04 in.]) shim. Clearance between trunnion and trunnion bushing (27) should be within specification. Specification Trunnion Bushing—Clearance (maximum)................................................................................... 1.0 mm 0.04 in.

6. Tighten cap screws (6) to specification. Specification Trunnion Cap-toPushbeam Socket Cap Screw—Torque..........................................................................1200 N·m 885 lb.-ft.

Trunnion Cap Installation 4— Trunnion Cap 5— Pushbeam Socket 6— Cap Screw (2 used) 7— Lock Nut (2 used)

Continued on next page

TM1731 (28JAN20)

32-3240-5

8— Shim (thick) (as required) 9— Shim (thin) (as required) 27— Bushing

TX,3240,SS2521 -19-26SEP13-7/18

850J Crawler (S.N. 130886—311988) 012820 PN=403

Frames

7. Install center pivot (10) to left pushbeam (11) using cap screw (12), washer, and nut (13). NOTE: Do not tighten at this point. T206740A —UN—06JAN05

8. Keep front of installed pushbeam supported. (approximately 10 in.) 9. Install right pushbeam (14) to opposite side. Ensure to insert alignment pin (15) through center pivot and into left pushbeam. 10— Center Pivot 11— Left Pushbeam 12— Cap Screw (6 used)

13— Nut (6 used) 14— Right Pushbeam 15— Alignment Pin

Center Pivot Installation and Pushbeam Alignment

TX,3240,SS2521 -19-26SEP13-8/18

10. Center pushbeam with blade. Measure distance from grill housing (18) to inside of pushbeam (19). Adjust until distances between grill housing and inside of pushbeam are within 10 mm (3/8 in.) on each side. Tighten center pivot hardware to specification.

18— Grill Housing

T191174A —UN—15MAY03

Specification Center Pivot Mounting Cap Screw—Torque....................................................................435 N·m 320 lb.-ft. 19— Inside of Pushbeam

Pushbeam Alignment TX,3240,SS2521 -19-26SEP13-9/18

11. Install pitch jack (21) to left pushbeam. Insert one bushing (22) on each side of pitch jack yoke. Install pin (23) and secure with pin retainer and cap screw.

21— Pitch Jack 22— Bushing

T206784A —UN—06JAN05

12. Tip pitch jack back toward machine. 23— Pin

Pitch Jack Installation Continued on next page

TM1731 (28JAN20)

32-3240-6

TX,3240,SS2521 -19-26SEP13-10/18

850J Crawler (S.N. 130886—311988) 012820 PN=404

Frames

13. Remove fitting cover from front of machine. 14. Mark left fitting (20) (as if in operators seat) with white paint and right fitting (19) with red paint. 20— Left Fitting (white) T206781A —UN—06JAN05

19— Right Fitting (red)

Front Fitting Identification TX,3240,SS2521 -19-26SEP13-11/18

X9811 —UN—23AUG88

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. 15. Remove caps from elbow fittings. 16. Connect hydraulic hoses to fittings. 17. Install cable to fitting cover using clamps and washers. 18. Install cordura sleeves over hoses and cables. Keep cable on bottom of hoses. Secure cordura sleeve into place using clamps.

19. Install fitting cover to front of machine. Continued on next page

TM1731 (28JAN20)

32-3240-7

TX,3240,SS2521 -19-26SEP13-12/18

850J Crawler (S.N. 130886—311988) 012820 PN=405

T206887 —UN—28JAN05

Frames

Tilt Cylinder Hydraulic Plumbing Exploded View

Continued on next page

TM1731 (28JAN20)

32-3240-8

TX,3240,SS2521 -19-26SEP13-13/18

850J Crawler (S.N. 130886—311988) 012820 PN=406

Frames 1— Cable Clamp (4 used) 2— Washer (8 used) 3— Hydraulic Hose (2 used) 4— Guard 5— Cap Screw (2 used) 6— Washer (2 used)

7— O ring 15— 90° Bulkhead Fitting (2 used) 21— Lubrication Fitting (2 used) 8— Cap Screw (2 used) 16— O ring 22— Cordura Sleeve 10— Hose Guard 17— Hydraulic Hose 23— Isolator 11— Hose Clamp (5 used) 18— Hydraulic Cylinder 24— Cordura Sleeve 12— Cable 19— Nut (2 used) 13— 90° Bulkhead Fitting (2 used) 20— Hydraulic Hose 14— Bulkhead Nut (2 used)

20. Install 90° elbow fittings (15) into head and rod end ports of hydraulic tilt cylinder. 21. Connect hydraulic hose (20) to head end elbow fitting and mark both ends with white paint. 22. Connect hydraulic hose (17) to rod end elbow fitting and mark both ends with red paint.

Specification Hydraulic Hose to Elbow Fitting—Torque..............................................................................75 N·m 55 lb.-ft.

23. Install cordura sleeve (24) over hoses and secure in place with clamps (11). Continued on next page

TM1731 (28JAN20)

32-3240-9

TX,3240,SS2521 -19-26SEP13-14/18

850J Crawler (S.N. 130886—311988) 012820 PN=407

Frames

24. Install fitting cover (16) to tilt cylinder (18) using cap screws (17). 25. Install hydraulic tilt cylinder to right pushbeam with one bushing on each side of tilt cylinder head end yoke. Install pin and secure with pin retainer and cap screw. 26. Tip cylinder back toward machine. 27. Install link (24) to pushbeam ear with cap screw (25), washer, and nut. CAUTION: Prevent possible crushing injury from heavy component. Use appropriate lifting device 28. Lift blade and align with bottom pushbeam clevises. Install pins and secure with cap screws and pin retainers.

T206779A —UN—06JAN05

29. Connect rod end of tilt cylinder to blade with one bushing on each side of yoke and secure with pin, cap screw, and pin retainer. 30. Connect pitch jack to blade using one bushing on each side of yoke and secure with pin, cap screw, and pin retainer. 31. Connect link to blade using a cap screw, washer, and nut. Tilt Cylinder Cover 24— Link 25— Cap Screw

T206785A —UN—06JAN05

16— Fitting Cover 17— Cap Screw (2 used) 18— Tilt Cylinder

Link to Pushbeam Continued on next page

TM1731 (28JAN20)

32-3240-10

TX,3240,SS2521 -19-26SEP13-15/18

850J Crawler (S.N. 130886—311988) 012820 PN=408

Frames

32. Install bulkhead elbow fittings (26) to fitting bracket (27) on blade using washers and nuts.

T206788A —UN—06JAN05

Specification Elbow Fitting to Fitting Bracket Nut—Torque.....................................................................93 N·m 69 lb.-ft.

33. Connect hoses from machine hydraulic ports to elbow fittings (26). Install hose marked with red paint to top fitting and hose with white paint to bottom fitting. 34. Connect cable to bracket on blade using clamps and washers.

Fittings To Blade 26— Bulkhead Elbow Fittings

27— Fitting Bracket TX,3240,SS2521 -19-26SEP13-16/18

35. Install molding (28) to support bracket (29) on blade. 36. Route hoses from tilt cylinder (30) through support bracket on blade and connect painted hoses to corresponding elbow fittings.

28— Molding 29— Support Bracket

T206789A —UN—06JAN05

37. Install fitting cover to blade using cap screws and nuts. 30— Hoses From Tilt Cylinder

Hose Wrap Continued on next page

TM1731 (28JAN20)

32-3240-11

TX,3240,SS2521 -19-26SEP13-17/18

850J Crawler (S.N. 130886—311988) 012820 PN=409

Frames

38. Remove cap screws (31) and lift cylinder support brackets (32). Install cap screws (31) into lift cylinder swivel joint and sheet metal. 39. Start machine and extend lift cylinders until they align with clevises on blade. Install pins, pin retainers, and cap screws. 40. Operate machine to ensure proper function. 32— Lift Cylinder Support Bracket

T206790A —UN—06JAN05

31— Cap Screws (2 used)

Lift Cylinder Support Bracket TX,3240,SS2521 -19-26SEP13-18/18

TM1731 (28JAN20)

32-3240-12

850J Crawler (S.N. 130886—311988) 012820 PN=410

Frames

TM1731 (28JAN20)

32-3240-13

850J Crawler (S.N. 130886—311988) 012820 PN=411

Frames

T205979 —UN—14JAN05

C-Frame Remove and Install

C-Frame

Continued on next page

TM1731 (28JAN20)

32-3240-14

BR81691,0000019 -19-25APR12-1/2

850J Crawler (S.N. 130886—311988) 012820 PN=412

Frames 1— Lock Nut M8 (2 used) 6— Washer (4 used) 2— Cap Screw M20 x 45 (4 used) 7— Frame 3— Cap Screw M20 x 110 (4 used) 8— Pivot Ball 4— Cap Screw M8 x 100 (2 used) 9— Pitch Link Mount 5— Cap Screw M12 x 16 (2 used) 10— Step 11— Step 12— Pitch Strut Assembly 13— Bushing (2 used)

14— Snap Ring (4 used) 15— Lubrication Fitting (2 used) 16— Quick Lock Pin (2 used) 17— Washer (4 used) 18— Strap (2 used) 19— Pin (4 used)

NOTE: C-Frame must be supported with blocks during procedure.

20— Pin (2 used) 21— Plate (2 used) 22— Pin Fastener (2 used) 23— Pin Fastener (4 used) 24— Pin

Specification C-Frame Without Blade—Approximate Weight........................................................................................... 770 kg 1700 lb

1. Remove blade. Perform Blade Remove and Install. (Group 3201.) 2. Remove lift cylinder rod end pins (19) using a slide hammer.

6. Install C-frame. 7. Install C-Frame pins (22) and cap screws (2).

3. Disconnect hydraulic hoses from tee fittings on C-Frame and from tilt cylinder.

8. Connect hydraulic hoses to tee fittings on C-Frame and to tilt cylinder.

4. Remove cap screws (2) and C-Frame pins (22).

9. Install lift cylinder rod end pins (19). CAUTION: Prevent possible crushing injury from heavy C-frame. Use an appropriate lifting device to remove and install C-frame.

10. Install blade. Perform Blade Remove and Install. (Group 3201.)

5. Remove C-frame. BR81691,0000019 -19-25APR12-2/2

Pushbeams Remove and Install—Mechanical Angle Blade Pushbeam Assembly Weight (approximate)

1760 kg 3880 lb.

Left Pushbeam Assembly Weight (approximate)

910 kg 2006 lb.

Right Pushbeam Assembly Weight (approximate)

850 kg 1874 lb.

Trunnion Weight (approximate)

35 kg 77 lb.

Trunnion Mounting Cap Screws Torque

620 N·m 457 lb.-ft.

Pushbeam Flange Cap Screws Torque

1830 N·m 1350 lb.-ft.

Trunnion Step Cap Mounting Cap Screws Torque

1119 N·m 825 lb.-ft.

X9811 —UN—23AUG88

SPECIFICATIONS

High-Pressure Fluids

pressure in system before disconnecting or connecting hydraulic or other lines. Tighten all connections before applying pressure. 3. Remove blade and strut assembly. See Blade Remove and Install—Mechanical Angle Blade. (Group 3201.)

Pushbeams Remove 1. Park machine on firm, level surface. 2. Stop engine. CAUTION: To avoid injury from escaping fluid under pressure, stop engine and relieve

Continued on next page

TM1731 (28JAN20)

32-3240-15

KK70125,0000039 -19-16JUN14-1/9

850J Crawler (S.N. 130886—311988) 012820 PN=413

Frames

4. Disconnect lift cylinders from pushbeams: a. Lower pushbeams and support with appropriate blocking. TX1159670A —UN—01MAY14

b. Remove cap screws (17), flags (16), and pins (15). c. Start machine and retract lift cylinders to protect cylinder rods, if necessary. Stop engine. CAUTION: Avoid personal injury from heavy component. Use appropriate lifting device. 5. Support pushbeam ends at trunnions. Lift Cylinder Rod End (left lift cylinder shown)

Specification Pushbeam Assembly—Weight (approximate).............................................................................. 1760 kg 3880 lb.

15— Pin 16— Flag

17— Cap Screw M12 x 16

KK70125,0000039 -19-16JUN14-2/9

6. Remove trunnion step caps (9) to remove pushbeams from trunnions. 12— Spacer (2 used) 13— Shim (as needed) TX1159669A —UN—06MAY14

9— Trunnion Step Cap 10— Cap Screw 1 x 7-1/2 in. (2 used) 11— Lock Nut 1 in. (2 used)

Pushbeam Removal (right side shown) Continued on next page

TM1731 (28JAN20)

32-3240-16

KK70125,0000039 -19-16JUN14-3/9

850J Crawler (S.N. 130886—311988) 012820 PN=414

Frames

7. If width over track shoes is wider than inside width of pushbeam assembly, separate left and right pushbeams to remove pushbeams from machine. CAUTION: Avoid personal injury from heavy component. Use appropriate lifting device. 8. Remove nuts (8), lock washers (7), and cap screws (6).

TX1159701 —UN—01MAY14

Specification Left Pushbeam Assembly—Weight (approximate)................................................................................ 910 kg 2006 lb. Right Pushbeam Assembly—Weight (approximate)................................................................................ 850 kg 1874 lb.

9. Remove pushbeams from machine. 10. Remove bearings from left and right trunnion bases on the end of each pushbeam assembly arm. Replace bearings if worn or damaged. 7— Lock Washer (16 used) 8— Nut 1-1/4 in. (16 used)

TX1159668A —UN—01MAY14

4— Left Pushbeam Assembly 5— Right Pushbeam Assembly 6— Cap Screw 1-1/4 x 4 in. (16 used)

Pushbeam Lifting Points (right pushbeam assembly shown)

Left and Right Pushbeam Assemblies KK70125,0000039 -19-16JUN14-4/9

CAUTION: Avoid personal injury from heavy component. Use appropriate lifting device.

TX1159667A —UN—01MAY14

11. If needed, remove trunnions (1) from left and right track frames. Specification Trunnion—Weight (approximate).................................................................................. 35 kg 77 lb. 1— Trunnion 2— Cap Screw M20 x 70 (8 used)

3— Washer (8 used) Trunnion Removal (right side shown) Continued on next page

TM1731 (28JAN20)

32-3240-17

KK70125,0000039 -19-16JUN14-5/9

850J Crawler (S.N. 130886—311988) 012820 PN=415

Frames Pushbeam Install 1. Park machine on firm, level surface.

TX1159667A —UN—01MAY14

2. Stop engine. CAUTION: Avoid personal injury from heavy component. Use appropriate lifting device. 3. If needed, install trunnions (1) to left and right track frames with cap screws (2) and washers (3). Tighten cap screws to specification. Specification Trunnion—Weight (approximate).................................................................................. 35 kg 77 lb. Trunnion Mounting Cap Screws—Torque..........................................................................620 N·m 457 lb.-ft.

Trunnion Installation (right side shown) 1— Trunnion 2— Cap Screw M20 x 70 (8 used)

3— Washer (8 used)

KK70125,0000039 -19-16JUN14-6/9

CAUTION: Avoid personal injury from heavy component. Use appropriate lifting device. Specification Left Pushbeam Assembly—Weight (approximate)................................................................................ 910 kg 2006 lb. Right Pushbeam Assembly—Weight (approximate)................................................................................ 850 kg 1874 lb.

TX1159701 —UN—01MAY14

NOTE: If width over track shoes is wider than inside width of pushbeam assembly, attach pushbeam halves to dozer trunnions first and then assemble bolt flanges. Perform steps 7—10 then proceed with steps 4—6. 4. Attach appropriate lifting device and position left and right pushbeam assemblies (4 and 5) with bolt flanges together. 5. Install cap screws (6), lock washers (7), and nuts (8) finger tight.

Pushbeam Half Lifting Points

6. Align outer edges of both pushbeam flanges and tighten cap screws to specification.

4— Left Pushbeam Assembly 5— Right Pushbeam Assembly 6— Cap Screw 1-1/4 x 4 in. (16 used)

TX1159668A —UN—01MAY14

Specification Pushbeam Flange Cap Screws—Torque........................................................................1830 N·m 1350 lb.-ft.

7— Lock Washer (16 used) 8— Nut 1-1/4 in. (16 used)

Left and Right Pushbeam Assemblies Continued on next page

TM1731 (28JAN20)

32-3240-18

KK70125,0000039 -19-16JUN14-7/9

850J Crawler (S.N. 130886—311988) 012820 PN=416

Frames

NOTE: Block positioning at each arm should match bearing to trunnion on machine.

TX1159669A —UN—06MAY14

7. Position pushbeam with blocks under each arm and under the center below the swivel pin. 8. Install bearings to left and right trunnion bases on the end of each pushbeam assembly arm. 9. Maneuver machine into pushbeam with trunnions against pushbeam bearings. 10. Install pushbeam to trunnions: a. Install trunnion step caps (9), without any shims, to pushbeam bearing with cap screws (10) and lock nuts (11). Tighten cap screws evenly. b. Measure gap between trunnion base and step cap. c. Remove cap screws, lock nuts, and trunnion step caps. NOTE: Shims (13) should be used to fill gap between trunnion base and step cap with spacers (12) plus one additional shim. d. Install trunnion step caps (9) to pushbeam bearing with cap screws (10), lock nuts (11), spacers (12), and enough shims (13) to fill gaps plus one additional shim. Tighten cap screws to specification.

Pushbeam-to-Trunnion Installation (right side shown) 9— Trunnion Step Cap 10— Cap Screw 1 x 7-1/2 in. (2 used) 11— Lock Nut 1 in. (2 used)

12— Spacer (2 used) 13— Shim (as needed)

Specification Trunnion Step Cap Mounting Cap Screws—Torque........................................................................ 1119 N·m 825 lb.-ft.

KK70125,0000039 -19-16JUN14-8/9

11. Connect lift cylinders to pushbeam: a. Start machine and extend lift cylinders until they align with clevises on pushbeams. TX1159670A —UN—01MAY14

b. Secure lift cylinder rods to pushbeam with pins (15), flags (16), and cap screws (17). c. Remove blocks from under pushbeams. d. Slowly raise and lower pushbeam fully, checking clearance to tracks and trunnion ensuring no binding. 12. Install blade and strut assembly. See Blade Remove and Install—Mechanical Angle Blade. (Group 3201.) 15— Pin 16— Flag

Lift Cylinder Rod End (left lift cylinder shown)

17— Cap Screw M12 x 16

KK70125,0000039 -19-16JUN14-9/9

TM1731 (28JAN20)

32-3240-19

850J Crawler (S.N. 130886—311988) 012820 PN=417

Frames

TM1731 (28JAN20)

32-3240-20

850J Crawler (S.N. 130886—311988) 012820 PN=418

Group 3260

Hydraulic System Hydraulic Pump Remove and Install

109 200 201

129 199 131 129

130

132

T202385 —UN—20NOV04

131

104

T202385 104— Hydraulic Pump 109— Pressure Reducing Valve 129— Control Valve-to-Pressure Reducing Valve Hose

130— Hydraulic Reservoir-to199— Hydraulic Pump Case Hydraulic Pump Inlet Hose Drain Hose 131— Load Sense Hose 200— Control Valve-to-Hydraulic 132— Hydraulic Pump-to-Control Filter Hose Valve Inlet Hose 201— Pressure Reducing Valve-to-Hydraulic Reservoir Return Hose

1. Lower all equipment to ground.

NOTE: Applying vacuum to hydrostatic reservoir will help reduce leaking of hydrostatic oil from hydrostatic drain case lines once hydraulic pump is removed.

2. Relieve all hydraulic pressure in system. 3. Turn battery disconnect switch to OFF. 4. Tilt cab/ROPS. See Cab or ROPS Tilting Procedure. (Operator's Manual.)

5. Apply vacuum to hydrostatic reservoir.

Continued on next page

TM1731 (28JAN20)

32-3260-1

JG81906,000012B -19-04APR13-1/2

850J Crawler (S.N. 130886—311988) 012820 PN=419

Hydraulic System

6. Drain hydraulic reservoir.

10. Install hydraulic pump with O-ring to rear hydrostatic pump using cap screws.

Specification Hydraulic Reservoir—Capacity.................................................................... 105.6 L 27.9 gal

11. Fill hydraulic pump with oil through case drain port to avoid air pockets in system. 12. Connect all hydraulic hoses (130, 131, 132, and 199).

7. Label all hoses connected to hydraulic pump.

13. Fill reservoir to specification. 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. 8. Disconnect hoses (130, 131, 132, and 199). Cap and plug all openings. CAUTION: Prevent possible crushing injury from hydraulic pump. Use an appropriate lifting device. 9. Install lifting strap around hydraulic pump. Connect strap to the end of DFT1243, DFT1065, DFT1167, and DFT1063. Remove cap screws along with hydraulic pump. See DFT1243 Lifting Bracket Extension. See DF1065 Final Drive and Pump Adapter Bracket. See DFT1167 Spacer. See DF1063 Pump Lifting Bracket. (Group 9900.) Specification Hydraulic Pump—Weight................................................................................ 41 kg 90 lb

Specification Hydraulic Reservoir—Capacity.................................................................... 105.6 L 27.9 gal

14. Remove vacuum from hydrostatic reservoir. 15. Start engine and check for leaks. NOTE: Replacement 100 cm3 pump is the same for J- and K-series machines. Pump cutoff pressure must be set to correct specification for applicable machine. 16. If installing a replacement 100 cm3 hydraulic pump, adjust pump cutoff pressure to correct specification.

• See Pump Load Sense Differential and System

Pressure (Pump Cutoff) Test and Adjustment. (Group 9025-25.) • See Pump Load Sense Differential and System Pressure Test and Adjustment—IGC. (Group 9025-25.)

17. Tilt cab/ROPS. See Cab or ROPS Tilting Procedure. (Operator's Manual.) JG81906,000012B -19-04APR13-2/2

TM1731 (28JAN20)

32-3260-2

850J Crawler (S.N. 130886—311988) 012820 PN=420

Hydraulic System

TX1121959 —UN—13SEP12

Hydraulic Pump Disassemble and Assemble

Hydraulic Pump 1— Cap Screw (4 used) 2— Control Valve

3— O-Ring (4 used) 4— Hydraulic Pump

5— Seal 6— Snap Ring

6. Cover pump input shaft in tape to prevent damage to seal when installing.

SPECIFICATIONS Control Valve Cap Screw Torque

15.5 N·m 137 lb.-in.

7. Install new O-rings and snap ring.

1. Remove snap ring (6).

8. Remove tape from input shaft.

2. Remove seal (5).

9. Install control valve and new gasket. Install cap screws and tighten to specification.

3. Remove cap screws (1) and control valve (2).

Specification Control Valve Cap Screw—Torque...........................................................................15.5 N·m 137 lb.-in.

4. Remove O-rings (3). 5. Inspect and replace parts as necessary. IMPORTANT: Cover pump input shaft to prevent seal damage during installation.

TX,3260,SS2327 -19-13SEP12-1/1

TM1731 (28JAN20)

32-3260-3

850J Crawler (S.N. 130886—311988) 012820 PN=421

Hydraulic System

Hydraulic Pump Control Valve Disassemble and Assemble

NOTE: Pump control is serviced as complete assembly or a seal kit only.

1 22

IMPORTANT: When removing adjusting screws and O-rings make note to retain current settings. 1. Remove complete adjustment screw assemblies by removing fittings (4 & 23) with all adjusting parts in place. Replace O-ring (5 & 21). Install adjustment assemblies in housing. Tighten in housing (14) port. 2. Remove adjustment covers (1) for load sense and high pressure cut off screws (3). 3. Remove lock nuts (22) and O-rings (2) being careful not to lose current settings. Replace O-rings.

3 23 4 5

4. Install lock nuts, O-rings and adjustment covers.

7 17

5. Install control on hydraulic pump housing.

1— Cap (adjustment screw) 2— O-rings (4 used) 3— Adjustment Screw (2 used) 4— Fitting 5— O-Ring 6— Spring 7— Spring 8— Guide 9— Spool—Load Sense 10— Plug 11— Plug 12— Cap Screw (4 used)

13— Plug (2 used) 14— Control Housing 15— Spool—High Pressure Cut-Off 16— Guide 17— Spring 18— Spring 19— Spacer 20— Spacer 21— O-Ring 22— Hex Nut (2 used) 23— Fitting

8 16 9 15

T211883 —UN—23JUN05

6. Perform Pump Load Sense Differential and System Pressure (Pump Cutoff) Test and Adjustment. (Group 9025-25.)

Pump Control Exploded View BR81691,000001C -19-25APR12-1/1

TM1731 (28JAN20)

32-3260-4

850J Crawler (S.N. 130886—311988) 012820 PN=422

Hydraulic System

Hydraulic Reservoir Remove and Install

109 200 201

129 199 131 129

130

132

T202385 —UN—20NOV04

131

104

T202385 Hydraulic Reservoir 104— Hydraulic Pump 109— Pressure Reducing Valve 129— Control Valve-to-Pressure Reducing Valve Hose

1. Lower all equipment to the ground.

Specification Hydraulic Reservoir—Capacity.................................................................... 105.6 L 27.9 gal

2. Relieve all hydraulic system pressure. 3. Turn battery disconnect switch to OFF. 4. Tilt cab/ROPS. See Cab or ROPS Tilting Procedure. (Operator's Manual.) 5. Drain hydraulic reservoir.

6. Remove right rear service door. 7. Disconnect hydraulic hose (200) from hydraulic filter assembly. Continued on next page

TM1731 (28JAN20)

32-3260-5

TX,3260,SS2328 -19-28MAY09-1/3

850J Crawler (S.N. 130886—311988) 012820 PN=423

Hydraulic System

8. Disconnect hydraulic hoses (130, 199, and 201.) TX,3260,SS2328 -19-28MAY09-2/3

CAUTION: Prevent possible crushing injury from heavy rear fender. Use an appropriate lifting device. T209325A —UN—04MAR05

9. Remove rear fender (2). Specification Rear Fender—Weight..................................................................... 30 kg 65 lb

10. Remove right rear fender (1). 11. Disconnect wiring eyelets from backup alarm. Rear Fenders

CAUTION: Prevent possible crushing injury from heavy fuel tank guard. Use an appropriate lifting device.

1— Right Rear Fender 2— Rear Fender

3— Fuel Tank Guard

12. Remove fuel tank guard (3). Specification Fuel Tank Guard—Weight................................................................................ 32 kg 70 lb

17. Connect wiring eyelets to backup alarm. 18. Install right rear fender (1). CAUTION: Prevent possible crushing injury from heavy rear fender. Use an appropriate lifting device.

13. Remove reservoir mounting cap screws. CAUTION: Prevent possible crushing injury from heavy component. Use an appropriate lifting device.

19. Install rear fender (2).

14. Remove hydraulic reservoir. Specification Hydraulic Reservoir—Weight........................................................................ 131 kg 288 lb

15. Install hydraulic reservoir on mounting pads and loosely install hardware. Align right side of hydraulic reservoir with right side of frame. Tighten cap screws. CAUTION: Prevent possible crushing injury from heavy fuel tank guard. Use an appropriate lifting device. 16. Install fuel tank guard (3).

Specification Rear Fender—Weight..................................................................... 30 kg 65 lb

20. Connect hydraulic hoses (130, 199, and 201.) 21. Connect hydraulic hose (200) to hydraulic filter assembly. 22. Install right rear service door. 23. Fill hydraulic reservoir to specification. Specification Hydraulic Reservoir—Capacity.................................................................... 105.6 L 27.9 gal

24. Lower cab/ROPS. See Cab or ROPS Tilting Procedure. (Operator's Manual.)

Specification Fuel Tank Guard—Weight................................................................................ 32 kg 70 lb

25. Start engine and check for leaks. Repair as necessary. TX,3260,SS2328 -19-28MAY09-3/3

TM1731 (28JAN20)

32-3260-6

850J Crawler (S.N. 130886—311988) 012820 PN=424

Hydraulic System

Hydraulic Reservoir Cleanout Cover Remove and Install 1. Drain reservoir. T197423A —UN—02FEB04

Specification 750J and 850J Hydraulic Reservoir—Capacity.................................................................... 105.6 L 27.9 gal

2. Remove components as necessary to adequately access cleanout cover. IMPORTANT: Prevent fluid contamination. Remove paint and debris from sealing edge of cleanout cover prior to removal.

Hydraulic Reservoir Cleanout Cover 1— Hydraulic Reservoir 2— Cap Screw

3. Remove paint from sealing edge of hydraulic reservoir cleanout cover (3).

3— Hydraulic Reservoir Cleanout Cover

NOTE: Do not fully remove cap screw (2) from inner plate. 6. Inspect and remove paint build-up and debris from reservoir exterior wall.

4. Loosen cap screw (2) enough to remove cleanout cover assembly.

Inspect locator tabs in reservoir to verify that they are perpendicular to reservoir wall.

IMPORTANT: Avoid fluid contamination. Paint may be chipped if cleanout cover drops into reservoir. Clean all debris from reservoir before installing cleanout cover.

NOTE: Cap screw should turn into weld nut without resistance. If resistance is felt, inspect weld nut for debris in threads and clean as necessary.

5. Inspect gasket and cover plates for any cuts or loose material that could lead to contamination. Repair or replace parts as necessary. IMPORTANT: Avoid fluid contamination. Do not allow paint or debris to enter reservoir. Thoroughly clean if debris enters reservoir. Continued on next page

TM1731 (28JAN20)

32-3260-7

BT40170,000000B -19-27JUN05-1/4

850J Crawler (S.N. 130886—311988) 012820 PN=425

Hydraulic System

IMPORTANT: Avoid possible fluid leak. Verify O-ring is installed under head of cap screw before assembly. NOTE: To ease installation, do not thread cap screw all the way into weld nut. Orient as shown. 7. Loosely assemble cleanout cover with gasket and inner plate.

T198245B —UN—02MAR04

4— Inner Plate Tabs

BT40170,000000B -19-27JUN05-2/4

IMPORTANT: Inner plate must seat flush against reservoir wall. Damage will result to locator tabs (5 and 6) if inner plate is installed incorrectly.

T198238B —UN—02MAR04

NOTE: Install inner plate with tabs (4) facing towards top of reservoir. Inner plate must be located between upper (5) and lower (6) locator tabs. 8. Install cleanout cover assembly starting with one corner of inner plate upper tabs. Rest one tab of inner plate on locator tab (5) and rotate inner plate around until entirely inside reservoir. Pull back on cap screw to seat inner plate against reservoir wall between locator tabs (5 and 6). 4— Inner Plate Tab (2 used) 5— Upper Locator Tab (2 used) Continued on next page

TM1731 (28JAN20)

32-3260-8

6— Lower Locator Tab (2 used) 7— Inner Plate BT40170,000000B -19-27JUN05-3/4

850J Crawler (S.N. 130886—311988) 012820 PN=426

Hydraulic System

9. Hand tighten cap screw (2) while prying out on gasket and outer plate as shown to ensure that inner plate stays seated between locator tabs (5 and 6). IMPORTANT: Do not use impact gun to tighten cap screw. Damage will result to cleanout cover assembly. 10. Tighten cap screw to specification. Specification Hydraulic Reservoir Cleanout Cover Cap Screw—Torque..............................................................................47 N·m 35 lb-ft

11. Paint affected areas using TY6522 spray paint. 12. Install components removed to access cleanout cover.

Specification 750J and 850J Hydraulic Reservoir—Capacity.................................................................... 105.6 L 27.9 gal 2— Cap Screw 5— Upper Locator Tab (2 used)

6— Lower Locator Tab (2 used)

T198239B —UN—02MAR04

13. Fill reservoir.

BT40170,000000B -19-27JUN05-4/4

TM1731 (28JAN20)

32-3260-9

850J Crawler (S.N. 130886—311988) 012820 PN=427

Hydraulic System

Hydraulic Control Valve Remove and Install

T208751A —UN—03MAR05

NOTE: The photos show both standard hydraulic control valve configuration and integrated grade control (IGC). Although the hose routing and connections are different, the remove and install procedure is similar, except where noted. 1. Lower all equipment to the ground. 2. Relieve all hydraulic pressure in system. 3. Turn battery disconnect switch to OFF. 4. Drain oil from hydraulic reservoir or pull a vacuum pump on reservoir.

Hydraulic Control Valve (Standard Configuration)

Specification Hydraulic Reservoir—Capacity (approximate).................................................................................. 106 L 28 gal

TX1008887A —UN—07JUN06

5. Tilt cab/ROPS. See Cab or ROPS Tilting Procedure. (Operator's Manual.) 6. For IGC equipped machines, label and disconnect wire harness connectors. Remove wire harness support bracket. 7. Label and disconnect all control valve hoses. Close all openings using caps and plugs. Hydraulic Control Valve (IGC)

CAUTION: Prevent possible crushing injury from heavy control valve. Use an appropriate lifting device.

13. Fill hydraulic reservoir to specification or remove vacuum.

Specification Hydraulic Control Valve—Weight (approximate).................................................................................. 39 kg 85 lb

8. Support control valve using lifting strap and hoist. 9. Remove control valve mounting cap screws. Remove control valve. 10. Install control valve and mounting cap screws.

Specification Hydraulic Reservoir—Capacity (approximate).................................................................................. 106 L 28 gal

14. Start engine and check for leaks. 15. Lower cab/ROPS. See Cab or ROPS Tilting Procedure. (Operator's Manual.)

11. Connect all control valve hoses. 12. For IGC equipped machines, install wire harness support bracket. Connect wire harness connectors. SJ25320,0000200 -19-05MAR07-1/1

TM1731 (28JAN20)

32-3260-10

850J Crawler (S.N. 130886—311988) 012820 PN=428

Hydraulic System

Hydraulic Control Valve Disassemble and Assemble

7 3 6 4

T209668 —UN—18MAR05

5 10 11 9

T209668

8 Control Valve Inlet, Outlet, and Tie Rods

1— Nut (2 used) 2— Tie Rod (2 used) 3— Tie Rod 4— Nut (4 used)

5— Inlet/Outlet Valve Housing 6— O-Ring 7— End Valve Housing

1. Remove nuts (4) and tie rods (2) as shown.

8— Fitting Plug 9— O-Ring 10— Snap-Ring 11— Spring 12— System Relief Valve

2. Separate valve sections. Continued on next page

TM1731 (28JAN20)

13— O-Ring 14— Seal Kit

32-3260-11

TX,3260,SS2342 -19-12APR07-1/3

850J Crawler (S.N. 130886—311988) 012820 PN=429

T208323 —UN—28FEB05

Hydraulic System

Hydraulic Control Valve

Continued on next page

TM1731 (28JAN20)

32-3260-12

TX,3260,SS2342 -19-12APR07-2/3

850J Crawler (S.N. 130886—311988) 012820 PN=430

Hydraulic System 1— Pressure Relief Valve 2— Plug 3— Screw 4— Valve Cover 5— Spool

6— O-Ring 7— Disk 8— O-Ring 9— O-Ring 10— Retainer 11— Retainer 12— Spring

13— Screw 14— Valve Cover 15— Screw 16— Housing 17— Poppet 18— Spring

3. Disassemble parts (1—22). IMPORTANT: Prevent damage to hydraulic control valve and machine. Check that spring (18) and poppet (17) are installed between the valve sections and that load sense disk (7) is in place for proper operation of valve.

19— Seal 20— O-Ring 21— Backup Ring 22— O-Ring

Specification Control Valve Tie Rod and Nut (7/16 in.)—Torque...................................................................65 N·m 48 lb-ft Control Valve Tie Rod and Nut (1/2 in.)—Torque...................................................................100 N·m 74 lb-ft

4. Assemble parts (1—22). 5. Assemble valve stacks together with tie rods and nuts. TX,3260,SS2342 -19-12APR07-3/3

TM1731 (28JAN20)

32-3260-13

850J Crawler (S.N. 130886—311988) 012820 PN=431

Hydraulic System

Hydraulic Control Valve Disassemble and Assemble—IGC 7

6 5

13 3 2 14 15

12 21

3 22

25 24

12 13

3 22 16

17 20

TX1013503

TX1013503 —UN—19OCT06

Exploded View of Hydraulic Control Valve—IGC Continued on next page

TM1731 (28JAN20)

32-3260-14

SJ25320,0000201 -19-07SEP10-1/3

850J Crawler (S.N. 130886—311988) 012820 PN=432

Hydraulic System 1— Spool 2— Angle Section 3— O-Ring (40 used) 4— Load Sense Relief Valve 5— Plug 6— Valve

1. Remove tie rods (19).

7— Plug 8— Inlet Section 9— Plug 10— Plug 11— Relief Valve 12— Screw (24 used) 13— Actuator (3 used)

14— Valve 15— Valve 16— Lift Section 17— End Cap Section 18— Plug 19— Tie Rod (3 used) 20— Plug

2. Separate valve sections. Continued on next page

TM1731 (28JAN20)

21— Valve 22— Cover (3 used) 23— Spool 24— Spool 25— Tilt Section

32-3260-15

SJ25320,0000201 -19-07SEP10-2/3

850J Crawler (S.N. 130886—311988) 012820 PN=433

TX1081585 —UN—02SEP10

Hydraulic System

26 TX1081585 Hydraulic Control Valve—IGC (optional auxiliary section shown) 4— Load Sense Relief Valve

26— JDG11249 Load Sense Relief Valve Socket

3. Remove load sense relief valve (4) using JDG11249 Load Sense Relief Valve Socket (26). 4. Disassemble parts (1—3). 5. Disassemble parts (5—25).

Specification Load Sense Relief Valve—Torque...............................................................................13 N·m 115 lb.-in.

9. Assemble valve stacks together with tie rods.

6. Assemble parts (1—3). 7. Assemble parts (5—25). 8. Install load sense relief valve using JDG11249 Load Sense Relief Valve Socket. Tighten to specification.

Specification Control Valve Tie Rod and Nut—Torque...........................................................................40 N·m 30 lb.-ft. SJ25320,0000201 -19-07SEP10-3/3

TM1731 (28JAN20)

32-3260-16

850J Crawler (S.N. 130886—311988) 012820 PN=434

Hydraulic System

Pilot Control Valve Remove and Install

1. Lower all equipment to ground. 2. Relieve hydraulic system pressure.

3. Disconnect pilot controller hydraulic hoses using STC special tool.

4. Disconnect all electrical connections from pilot controller.

5. Remove cap screws (4) and plate (11) with pilot controller. NOTE: Fittings (8 and 10) must be removed to separate pilot controller from plate (11). Fitting (8) is different from other fittings, mark location before removing. 6. Remove fittings (8 and 10) from pilot controller.

7. Assemble plate (11) and pilot controller. 8. Install fittings (8 and 10) to pilot controller.

9. Install pilot controller with plate (11) using cap screws (4).

10. Connect all electrical connectors to pilot controller.

11. Connect all hydraulic hoses to pilot controller.

12. Operate machine and verify all functions work correctly. 2— O-Ring 3— Flange Nut 4— Cap Screw 8— STC Adapter Fitting 9— Hydraulic Control Lever 10— STC Adapter Fitting 11— Plate 24— Plate 25— Hydraulic Enable Switch 26— Nut 27— Nut

28— Cap Screw 29— Cap Screw 30— Washer 31— Pilot Controller 32— Plate 35— Nut 36— Tie Bolt 37— Boot 38— Seal 49— Screw 52— Adapter

38 4

30 3

2 8

T212073 —UN—21JUN05

Pilot Controller—PAT Machine Shown BR81691,0000018 -19-01MAY07-1/1

TM1731 (28JAN20)

32-3260-17

850J Crawler (S.N. 130886—311988) 012820 PN=435

Hydraulic System

Pilot Control Valve Disassemble and Assemble

Perform Pressure Reducing Valve Pressure Test and Adjustment. (Group 9025-25.)

35 29

1. Perform Pilot Control Valve Remove and Install. (Group 3260.) 2. Disassemble and assemble parts as shown.

37 3— Flange Nut (4 used) 4— Screw (8 used) 8— Adapter (5 used) 9— Lever 10— Adapter (5 used) 11— Plate 17— Bolt 18— Check Valve 19— Seal Kit 20— Valve (2 used) 21— Hydraulic Pressure Valve 22— Fitting plug 23— Fitting Plug 24— Plate (2 used)

25— Rocker Switch 26— Nut (4 used) 27— Nut 28— Cap Screw (4 used) 29— Screw (2 used) 30— Washer (8 used) 31— Hydraulic Pilot Control Valve 32— Plate 35— Nut (2 used) 36— Stud 37— Boot 38— Seal 49— Screw (2 used) 52— Adapter

36 27 28 30 32 4 4

38 4

30 3

2 8

T212073 —UN—21JUN05

Pilot Control Lever—PAT Machine Shown BR81691,0000017 -19-04DEC09-1/1

TM1731 (28JAN20)

32-3260-18

850J Crawler (S.N. 130886—311988) 012820 PN=436

Hydraulic System

TX1017140 —UN—28DEC06

Integrated Grade Control (IGC) Lever Remove and Install (S.N. 130886—)

Integrated Grade Control (IGC) Lever Assembly (Joystick) (S.N. 130886-) Continued on next page

TM1731 (28JAN20)

32-3260-19

KV70328,00001E7 -19-24MAY07-1/4

850J Crawler (S.N. 130886—311988) 012820 PN=437

Hydraulic System 1— Nut (4 Used) 2— Cap Screw (4 Used) 3— Cap Screw (4 Used) 4— Washer (8 Used) 5— STC Adapter Fitting

6— IGC Lever (Joystick) (Complete) 7— Nut (4 Used) 8— Plate 9— Boot 10— Not Used 11— Handle Assembly

12— Electrical Connector 13— Cover 14— Multi-function Controller 15— Not Used 16— Not Used

17— Not Used 18— Not Used 19— Plate

1. Turn battery disconnect switch to OFF position. KV70328,00001E7 -19-24MAY07-2/4

2. Remove four cap screws (2).

TX1023038A —UN—22MAY07

3. Lift plate (19) to expose electrical connections.

Integrated Grade Control (IGC) Lever (S.N. 130886-) Continued on next page

TM1731 (28JAN20)

32-3260-20

KV70328,00001E7 -19-24MAY07-3/4

850J Crawler (S.N. 130886—311988) 012820 PN=438

Hydraulic System

4. Disconnect electrical connections (12, 20, 21) from assembly. 5. Remove complete lever assembly from machine. 6. Remove four nuts (7) from bottom of IGC lever (6) and remove IGC lever from plate. 7. Repair or replace parts as required 8. Install IGC lever (6) in plate (19) using four nuts (7) 9. Connect electrical connections (12, 20, 21) 10. Install IGC lever assembly using four cap screws (2). TX1023043A —UN—22MAY07

11. Turn battery disconnect switch to ON position. 12. Operate machine and verify all functions work correctly.

Integrated Grade Control (IGC) Lever (S.N. 130886-) (from inside right side panel) KV70328,00001E7 -19-24MAY07-4/4

TM1731 (28JAN20)

32-3260-21

850J Crawler (S.N. 130886—311988) 012820 PN=439

Hydraulic System

TX1017140 —UN—28DEC06

Integrated Grade Control (IGC) Lever Disassemble and Assemble (S.N. 130886—)

Integrated Grade Control (IGC) Lever Assembly (Joystick) (S.N. 130886-) Continued on next page

TM1731 (28JAN20)

32-3260-22

KV70328,00001E8 -19-24MAY07-1/2

850J Crawler (S.N. 130886—311988) 012820 PN=440

Hydraulic System 1— Nut (4 Used) 2— Cap Screw (4 Used) 3— Cap Screw (4 Used) 4— Washer (8 Used) 5— STC Adapter Fitting

6— IGC Lever (Joystick) (Complete) 7— Nut (4 Used) 8— Plate 9— Boot 10— Not Used 11— Handle Assembly

12— Electrical Connector 13— Cover 14— Multi-function Controller 15— Not Used 16— Not Used

17— Not Used 18— Not Used 19— Plate

Disassemble and assemble parts as shown. KV70328,00001E8 -19-24MAY07-2/2

Quick-Drop Valve Remove and Install NOTE: Quick-drop valve is only used on outside dozer (OSD) machines. 1. Lower blade to the ground. 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.

T211967A —UN—07JUN05

2. With engine off and key on, operate all hydraulic control valves to release pressure in the system. 3. Remove front hood cover. 4. Disconnect hydraulic hoses (1—4). Cap and plug all openings. 5. Disconnect quick-drop valve wiring harness (5). 6. Remove quick-drop valve.

Quick-Drop Valve

7. Install quick-drop valve. 8. Connect hydraulic hoses (1—4).

1— Hydraulic Hose 2— Hydraulic Hose 3— Hydraulic Hose

T211969A —UN—07JUN05

9. Install front hood cover. 4— Hydraulic Hose 5— Quick-Drop Valve Wiring Harness

Quick-Drop Valve Wiring Harness TX,3260,SS2491 -19-13JUL05-1/1

TM1731 (28JAN20)

32-3260-23

850J Crawler (S.N. 130886—311988) 012820 PN=441

Hydraulic System

Power Angle Tilt (PAT) Cylinder Remove and Install 1. Lower all equipment to the ground. T212727A —UN—08JUL05

2. Relieve hydraulic system pressure. CAUTION: Prevent possible crushing injury from heavy cylinders. Use an appropriate lifting device to remove and install. 3. Remove and install cylinders. Specification Lift Cylinder—PAT Machines—Approximate Weight............................................................................................. 50 kg 110 lb Tilt Cylinder-PAT Machines—Approximate Weight............................................................................................. 61 kg 135 lb

T212729A —UN—08JUL05

1— Lift Cylinder (2 used)

Lift Cylinder—PAT Machines

3— Tilt Cylinder

Tilt Cylinder-PAT Machines BR81691,000001D -19-07JUL05-1/1

Angle Cylinder (PAT) Remove and Install NOTE: Front of machine must be raised with blade down for access to angle cylinder head end pins. T212348A —UN—21JUN05

1. Relieve hydraulic system pressure. 2. Remove hose guard on angle cylinder. 3. Disconnect hydraulic hoses from angle cylinder. 4. Remove angle cylinder rod end pin. CAUTION: Prevent possible crushing injury from heavy angle cylinder. Use an appropriate lifting device.

1— Angle Cylinder Head End Pin

5. Remove angle cylinder head end pin. Specification Angle Cylinder—Approximate Weight.................................................................................... 84 kg 185 lb

6. Remove angle cylinder.

Angle Cylinder Pin

9. Install angle cylinder rod end pin. 10. Connect hydraulic hoses to angle cylinder. 11. Install hose guard on angle cylinder.

7. Install angle cylinder. 8. Install angle cylinder head end pin. CED,TX14826,12132 -19-20JUN05-1/1

TM1731 (28JAN20)

32-3260-24

850J Crawler (S.N. 130886—311988) 012820 PN=442

Hydraulic System

Hydraulic Cylinder Repair NOTE: Blade lift and tilt are 120 series hydraulic cylinders. Blade angle are 125 series hydraulic cylinders. For more information on 120 series hydraulic cylinders, see 100, 120, 125, 185, 225 Series Hydraulic Cylinders. (CTM120519.) Specification 120 Series Blade Tilt Hydraulic Cylinder Piston Retaining Nut—Torque Turn....................................................................... 475 N·m plus 45° turn 350 lb.-ft. plus 45° turn

Apply PM37421 thread lock and sealer (high strength) to threads before installing piston retaining nut. For more information on 125 series hydraulic cylinders, see 100, 120, 125, 185, 225 Series Hydraulic Cylinders. (CTM120519.) Specification 125 Series Blade Angle Hydraulic Cylinder Piston Retaining Nut—Torque..............................................................5500 N·m 4057 lb.-ft.

Apply PM37421 thread lock and sealer (high strength) to threads before installing piston retaining nut. BR81691,000001B -19-22JAN14-1/1

TM1731 (28JAN20)

32-3260-25

850J Crawler (S.N. 130886—311988) 012820 PN=443

Hydraulic System

TM1731 (28JAN20)

32-3260-26

850J Crawler (S.N. 130886—311988) 012820 PN=444

Section 42 Ground Conditioning Tool Contents Page

Group —Ripper Ripper Remove and Install—If Equipped ....................................................... 42--1 Ripper Install...................................................... 42--7

TM1731 (28JAN20)

42-1

850J Crawler (S.N. 130886—311988) 012820 PN=1

Contents

TM1731 (28JAN20)

42-2

850J Crawler (S.N. 130886—311988) 012820 PN=2

Group

Ripper Ripper Remove and Install—If Equipped

2. Operate all hydraulic controls to release pressure in hydraulic system.

Ripper Remove:

3. Apply vacuum to hydraulic reservoir.

1. Park machine on level ground and lower blade and ripper. Stop engine.

4. Turn battery disconnect switch to the OFF position.

9 10 14

13 15 12

TX1058185 —UN—13APR09

Ripper Hydraulic Plumbing 9— Branch Tee Fitting (2 used) 10— 90° Swivel Elbow (2 used)

12— Left Cylinder Hydraulic Hose 14— Right Cylinder Hydraulic (rod end) Hose (rod end) 13— Left Cylinder Hydraulic Hose 15— Right Cylinder Hydraulic (head end) Hose (head end)

5. Install identification tags and disconnect hydraulic hoses (12—15). Close all openings using caps and plugs.

CAUTION: To avoid injury from escaping fluid under pressure, relieve the pressure in the system before disconnecting or connecting hydraulic or other lines. Tighten all connections before applying pressure. NOTE: Hydraulic oil may escape from hydraulic hose ports. Collect all excess hydraulic oil in an approved container and dispose of hydraulic oil properly.

Continued on next page

TM1731 (28JAN20)

42--1

JW40272,0000506 -19-17OCT11-1/9

850J Crawler (S.N. 130886—311988) 012820 PN=447

TX1066954A —UN—28OCT09

Ripper

Ripper Frame and Rear View of Machine 2— Ripper Frame

7— Rear of Machine

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

Specification Ripper—Weight (approximate).............................................................................. 2020 kg 4450 lb.

6. Attach lifting device to ripper frame (2).

JW40272,0000506 -19-17OCT11-2/9

7. Remove ripper to frame cap screws (16 and 17). 8. Remove ripper. 17— Ripper to Frame Cap Screw (1 x 3 in.) (18 used) 18— Rear Cover

TX1058177A —UN—16APR09

11— Bulkhead Hose End 16— Ripper to Frame Cap Screw (1-1/4 x 3-1/2 in.) (6 used)

Ripper Frame Support Cap Screw Location (ripper removed) Continued on next page

TM1731 (28JAN20)

42--2

JW40272,0000506 -19-17OCT11-3/9

850J Crawler (S.N. 130886—311988) 012820 PN=448

Ripper

9. Remove rear cover (18).

TX1058829A —UN—27APR09

18— Rear Cover

Ripper Frame Support Cap Screw Location (ripper removed) JW40272,0000506 -19-17OCT11-4/9

10. Install rear cover (8). 11. Turn battery disconnect switch to the ON position. 12. Start engine and operate hydraulics. TX1058175A —UN—16APR09

13. Stop engine and check for leaks. 14. Check hydraulic oil level. See Check Hydraulic Oil Level. (Operator's Manual.) Ripper Install: 1. Park machine on level ground and lower blade. Stop engine. Machine Rear View

2. Operate all hydraulic controls to release pressure in hydraulic system. 8— Rear Cover

3. Apply vacuum to hydraulic reservoir. 4. Turn battery disconnect switch to the OFF position. 5. Remove drawbar. See Rigid Drawbar Remove and Install or see Extended Rigid Drawbar Remove and Install. (Group 1511.)

Continued on next page

TM1731 (28JAN20)

42--3

JW40272,0000506 -19-17OCT11-5/9

850J Crawler (S.N. 130886—311988) 012820 PN=449

Ripper

NOTE: Store rear access cover for later use if ripper will be removed. 6. Remove rear access cover (8). TX1058175A —UN—16APR09

NOTE: With caps and plugs removed, hydraulic oil may escape from hydraulic cylinder ports as the hydraulic cylinders move during installation. Collect all excess hydraulic oil in an approved container and dispose of hydraulic oil properly. 7. Remove caps and plugs from hydraulic cylinder ports of ripper to allow hydraulic cylinder to move freely. Machine Rear View 8— Rear Access Cover

TX1066954A —UN—28OCT09

JW40272,0000506 -19-17OCT11-6/9

Ripper Frame and Rear View of Machine 2— Ripper Frame

7— Rear of Machine

CAUTION: Prevent possible injury from crushing. Use appropriate lifting device when installing ripper.

Specification Ripper—Weight (approximate).............................................................................. 2018 kg 4450 lb.

8. Connect appropriate lifting device to ripper frame (2). Continued on next page

TM1731 (28JAN20)

42--4

JW40272,0000506 -19-17OCT11-7/9

850J Crawler (S.N. 130886—311988) 012820 PN=450

Ripper

9. Install ripper frame support to machine frame with cap screws (16 and 17) and washers. Tighten cap screws to specification.

TX1058177A —UN—16APR09

Specification Ripper to Frame Cap Screws (1-1/4 x 3-1/2 in.)—Torque...............................................................................2600 N·m 1920 lb.-ft. Ripper to Frame Cap Screws (1 x 3 in.)—Torque...............................................................................1300 N·m 960 lb.-ft.

10. Install rear cover (18) with cap screws and washers. CAUTION: To avoid injury from escaping fluid under pressure, relieve the pressure in the system before disconnecting or connecting hydraulic or other lines. Tighten all connections before applying pressure.

Ripper Frame Support Cap Screw Location (ripper removed)

NOTE: Hydraulic oil may escape from hydraulic hose ports. Collect all excess hydraulic oil in an approved container and dispose of hydraulic oil properly.

11— Bulkhead Hose End 16— Ripper to Frame Cap Screw (1-1/4 x 3-1/2 in.) (6 used)

17— Ripper to Frame Cap Screw (1 x 3 in.) (18 used) 18— Rear Cover

11. Remove caps from bulkhead hose ends (11). Continued on next page

TM1731 (28JAN20)

42--5

JW40272,0000506 -19-17OCT11-8/9

850J Crawler (S.N. 130886—311988) 012820 PN=451

Ripper

9 10 14

13 15 12

TX1058185 —UN—13APR09

Ripper Hydraulic Plumbing 9— Branch Tee Fitting (2 used) 10— 90° Swivel Elbow (2 used)

12— Left Cylinder Hydraulic Hose 14— Right Cylinder Hydraulic (rod end) Hose (rod end) 13— Left Cylinder Hydraulic Hose 15— Right Cylinder Hydraulic (head end) Hose (head end)

NOTE: To prevent oil loss when cylinders extend, connect ripper hydraulic hoses before removing lifting device. 12. Install 90° swivel elbows (10) and branch tee fittings (9) to bulkhead hose ends.

15. Turn battery disconnect switch to the ON position. 16. Start engine and operate ripper. 17. Stop engine and check for leaks. 18. Check hydraulic oil level. See Check Hydraulic Oil Level. (Operator's Manual.)

13. Connect hydraulic hoses (12—15) to branch tee fittings and hydraulic cylinder fittings as shown. 14. Tighten all fittings and check hose routing for possible contact.

JW40272,0000506 -19-17OCT11-9/9

TM1731 (28JAN20)

42--6

850J Crawler (S.N. 130886—311988) 012820 PN=452

Ripper

Ripper Install 1. Park machine on level ground and lower blade. Stop engine. TX1058175A —UN—16APR09

2. Operate all hydraulic controls to release pressure in hydraulic system. 3. Apply vacuum to hydraulic reservoir. 4. Turn battery disconnect switch to the OFF position. 5. Remove drawbar. See Rigid Drawbar Remove and Install or see Extended Rigid Drawbar Remove and Install. (Group 1511.)

Machine Rear View (850JR shown)

NOTE: Store rear access cover for later use if ripper will be removed.

8— Rear Access Cover

6. Remove rear access cover (8). NOTE: With caps and plugs removed, hydraulic oil may escape from hydraulic cylinder ports as the hydraulic cylinders move during installation. Collect all excess hydraulic oil in an approved container and dispose of hydraulic oil properly.

7. Remove caps and plugs from hydraulic cylinder ports of ripper to allow hydraulic cylinder to move freely.

Continued on next page

TM1731 (28JAN20)

42--7

JW40272,0000507 -19-27APR10-1/4

850J Crawler (S.N. 130886—311988) 012820 PN=453

TX1066954A —UN—28OCT09

Ripper

Ripper Frame and Rear View of Machine (850JR shown) 2— Ripper Frame

7— Rear of Machine

CAUTION: Prevent possible injury from crushing. Use appropriate lifting device when installing ripper.

Specification Ripper—Weight (approximate).............................................................................. 2018 kg 4450 lb.

8. Connect appropriate lifting device to ripper frame (2). Continued on next page

TM1731 (28JAN20)

42--8

JW40272,0000507 -19-27APR10-2/4

850J Crawler (S.N. 130886—311988) 012820 PN=454

Ripper

9. Install ripper frame support to machine frame with cap screws (16 and 17) and washers. Tighten cap screws to specification.

TX1058177A —UN—16APR09

Ripper Frame Support Cap Screw Location (ripper removed) (850JR shown)

NOTE: Hydraulic oil may escape from hydraulic hose ports. Collect all excess hydraulic oil in an approved container and dispose of hydraulic oil properly.

11— Bulkhead Hose End 16— Ripper to Frame Cap Screw (1-1/4 x 3-1/2 in.) (6 used)

17— Ripper to Frame Cap Screw (1 x 3 in.) (18 used) 18— Rear Cover

11. Remove caps from bulkhead hose ends (11). Continued on next page

TM1731 (28JAN20)

42--9

JW40272,0000507 -19-27APR10-3/4

850J Crawler (S.N. 130886—311988) 012820 PN=455

Ripper

9 10 14

13 15 12

TX1058185 —UN—13APR09

Ripper Hydraulic Plumbing (850JR shown) 9— Branch Tee Fitting (2 used) 10— 90° Swivel Elbow (2 used)

12— Left Cylinder Hydraulic Hose 14— Right Cylinder Hydraulic (rod end) Hose (rod end) 13— Left Cylinder Hydraulic Hose 15— Right Cylinder Hydraulic (head end) Hose (head end)

NOTE: To prevent oil loss when cylinders extend, connect ripper hydraulic hoses before removing lifting device. 12. Install 90° swivel elbows (10) and branch tee fittings (9) to bulkhead hose ends.

13. Connect hydraulic hoses (12—15) to branch tee fittings and hydraulic cylinder fittings as shown. 14. Tighten all fittings and check hose routing for possible contact.

JW40272,0000507 -19-27APR10-4/4

TM1731 (28JAN20)

42--10

850J Crawler (S.N. 130886—311988) 012820 PN=456

Contents

Section 9900 Dealer Fabricated Tools

Page

Group 0999—Dealer Fabricated Tools DF1041 Track Nut Removal Tool .......... 9900-0999-1 DF1063 Final Drive Lift Bracket............. 9900-0999-2 DF1065 Final Drive and Pump Adapter Bracket................................. 9900-0999-3 DFT1132 Hydrostatic Motor Removal and Installation Tool............ 9900-0999-4 DFT1137 Hydrostatic Motor Removal and Installation Tool............ 9900-0999-5 DFT1167 Final Drive Lifting Bracket Adapter Spacer.................................. 9900-0999-6 DFT1243 Lifting Bracket Extension........................................... 9900-0999-7 DFT1250 Lifting Bracket........................9900-0999-8 DFT1260 Final Drive Lifting Fixture.............................................. 9900-0999-10 DFT1261 Rolling Torque Measurement Tool ........................... 9900-0999-11 DFT1302 Final Drive Pressure Test Adapter ............................................ 9900-0999-11

TM1731 (28JAN20)

9900-1

850J Crawler (S.N. 130886—311988) 012820 PN=1

Contents

TM1731 (28JAN20)

9900-2

850J Crawler (S.N. 130886—311988) 012820 PN=2

Group 0999

Dealer Fabricated Tools

TX1074246 —UN—22APR10

DF1041 Track Nut Removal Tool

DF1041 Track Nut Removal Tool 1— 3/8 in. Drill and Tap 2— Weld Block; Grind Round

3— 2 Slots 9.5 mm x 19.0 mm (3/8 4— 3/8 in. Drill and Tap; Locates in. x 3.4 in.) Nut with Cap Screw in Assembly

DF1041 Track Nut Removal Tool is used to remove and install track shoe nuts. TX14826,0003243 -19-14DEC01-1/1

TM1731 (28JAN20)

9900-0999-1

850J Crawler (S.N. 130886—311988) 012820 PN=459

Dealer Fabricated Tools

DF1063 Final Drive Lift Bracket 1 2 2 2 2 2 2 2 5

4 9

7 11 12

4 13 5

14 13 8

TX1072724

TX1072724 —UN—05MAR10

DF1063 Final Drive Lift Bracket 1— 508 mm (20.0 in.) 2— 50.8 mm (2.00 in.) 3— 25.4 mm (1.00 in.) 4— 38.1 mm (1.50 in.) 5— 203.2 mm (8.00 in.)

6— 63.5 mm (2.50 in.) 7— 2286 mm (90.00 in.) 8— 152.4 mm (6.00 in.) 9— 3/4 in. Drill Through Both Sides (8 holes)

Tool used to remove and install final drives. Material required:

10— 3/8 in. Drill Through (4 holes) 14— 82.6 mm (3.25 in.) 11— 44.5 mm (1.75 in.) 15— 114.3 mm (4.50 in.) 12— 76.2 mm (3.00 in.) 13— 15.9 mm (0.625 in.)

• 1/2 in. 1020 Steel • 3/8 in. x 1.5 in. Cap Screw with Nut (4 used)

• 1.5 in. x 3.0 in. Square Tube CED,TX03399,5076 -19-24NOV98-1/1

TM1731 (28JAN20)

9900-0999-2

850J Crawler (S.N. 130886—311988) 012820 PN=460

Dealer Fabricated Tools

DF1065 Final Drive and Pump Adapter Bracket 8 9

9 2 9 9

4 7

B 5

TX1072722

TX1072722 —UN—05MAR10

DF1065 Final Drive and Pump Adapter Bracket 1— 9.50 mm (0.37 in.) Drill Through (4 holes) 2— 114.3 mm (4.50 in.) 3— 15.9 mm (0.625 in.)

4— 44.5 mm (1.75 in.) 5— 76.2 mm (3.00 in.) 6— 38.1 mm (1.50 in.) 7— 82.6 mm (3.25 in.)

8— 342.9 mm (13.50 in.) 9— 50.8 mm (2.00 in.) 10— 25.4 mm (1.00 in.) 11— 19.05 mm (0.75 in.) Drill Through (6 holes)

Adapter used with DF1063 to remove or install final drive and hydraulic pump.

12— 12.7 mm (0.50 in.)

• 1/2 in. 1020 steel plate (B) 3 x 4.5 in. • 2 x 3 in. rectangular tube 13 in. long

Material required: CED,OUO1065,1019 -19-19APR06-1/1

TM1731 (28JAN20)

9900-0999-3

850J Crawler (S.N. 130886—311988) 012820 PN=461

Dealer Fabricated Tools

T8366AC —UN—15APR13

DFT1132 Hydrostatic Motor Removal and Installation Tool

A—1 in. Nut B—Pipe 2134 mm (7 ft.) long

E—Pipe C—Pipe 457 mm (18 in.) long D—1 in. ID Heavy Wall Steel Pipe F— Weld G—Pipe

This tool is used with DFT1137 to remove and install hydrostatic motors from rear of machine.

• 1 in. piece heavy wall steel pipe 8 ft. x 6 in. long • Weld (E) to (G)

Material required: TX,9900,YY1166 -19-25NOV09-1/1

TM1731 (28JAN20)

9900-0999-4

850J Crawler (S.N. 130886—311988) 012820 PN=462

Dealer Fabricated Tools

TX1074242 —UN—22APR10

DFT1137 Hydrostatic Motor Removal and Installation Tool

DFT1137 Hydrostatic Motor Removal and Installation Tool 1— Top Piece

2— Bottom Piece

This tool is used with DFT1132 to remove and install hydrostatic motors from rear of machine.

• 750J—1/2 in. x 9 in. cap screws (2 used) • 850J—1/2 in. x 10 in. cap screws (2 used)

Material required:

Install and tighten eyebolt in bracket. Trim any excess eyebolt material so it is even with bottom surface of bracket.

• 1-1/2 in. x 3/4 in. x 12 in. long steel bars (2 used) • M12 x 1.75 eyebolt

TX,9900,YY1200 -19-25NOV09-1/1

TM1731 (28JAN20)

9900-0999-5

850J Crawler (S.N. 130886—311988) 012820 PN=463

Dealer Fabricated Tools

T118674 —UN—01DEC98

DFT1167 Final Drive Lifting Bracket Adapter Spacer

To be used with DFT1166 Final Drive Lifting Bracket Adapter when installing DFT1063 Final Drive lifting Bracket.

Material: 1/2 in. 1020 Steel Plate CED,TX03399,5085 -19-19APR06-1/1

TM1731 (28JAN20)

9900-0999-6

850J Crawler (S.N. 130886—311988) 012820 PN=464

Dealer Fabricated Tools

DFT1243 Lifting Bracket Extension

3 1

4 T212193 —UN—20JUN05

T212193 1— 38.1 mm x 63.5 mm x 6.4 mm 2— JT01748 Lifting Bracket (1 1/2 in. x 2 1/2 in. x 1/4 in. 3— 910 mm (35.8 in.) wall) rectangular steel tubing 4— 190 mm (7.5 in.)

5— 100 mm (3.94 in.) 6— 22 mm (0.866 in.) diameter 7— 31.8 mm (1.25 in.) TE14778,00000DC -19-22JUN05-1/1

TM1731 (28JAN20)

9900-0999-7

850J Crawler (S.N. 130886—311988) 012820 PN=465

Dealer Fabricated Tools

T202517 —UN—01DEC04

DFT1250 Lifting Bracket

Lifting bracket is used to remove and install final drives and other heavy components with limited access.

Material required: Continued on next page

TM1731 (28JAN20)

9900-0999-8

OUT3035,00004FB -19-27JUN06-1/2

850J Crawler (S.N. 130886—311988) 012820 PN=466

Dealer Fabricated Tools

• 50 x 50 mm (2 x 2 in.) 1020 Steel Bar Stock • 20 x 50 mm (0.75 x 2 in.) 1020 Steel Plate

• 7018 Electrodes for welding OUT3035,00004FB -19-27JUN06-2/2

TM1731 (28JAN20)

9900-0999-9

850J Crawler (S.N. 130886—311988) 012820 PN=467

Dealer Fabricated Tools

T211502 —UN—26MAY05

DFT1260 Final Drive Lifting Fixture

1— 6 mm (0.25 in.) Fillet Weld (8 places) 2— 242 mm (9.52 in.) 3— 6.35 mm (0.25 in.) Stock 4— 50 mm (1.97 in.) 5— 12.7 mm (0.5 in.) 6— 294.6 mm (11.6 in.) 8— 21.6 mm (0.85 in.) 9— 50 mm (1.97 in.)

11— 22 mm (0.866 in.) Drill Three 19— 88.9 mm (3.5 in.) Holes 20— 127 mm (5.0 in.) Stock 12— 127 mm (5.0 in.) Stock 21— 19 mm (0.75 in.) 13— 63.5 mm (2.5 in.) 22— 25.4 mm (1.0 in.) 15— 100 mm (3.94 in.) 23— 17.5 mm (0.69 in.) Drill (4 16— 394.3 mm (15.53 in.) places) 17— 342 mm (13.46 in.) 24— 19 mm (0.75 in.) 18— 196.9 mm (7.75 in.) 25— 19 mm (0.75 in.) Stock

27— 50.8 mm (2.0 in.) 28— 50.8 mm (2.0 in.) Stock 29— 609.6 mm (24 in.) Radius, Back Side Only 30— 12.7 mm (0.5 in.) 31— 45° 32— 101.6 mm (4.0 in.)

TE14778,00000DA -19-09MAR06-1/1

TM1731 (28JAN20)

9900-0999-10

850J Crawler (S.N. 130886—311988) 012820 PN=468

Dealer Fabricated Tools

DFT1261 Rolling Torque Measurement Tool 1 2 8

3 4

T211904 —UN—20JUN05

T211904 1— 627 mm (24.7 in.) (minimum) 2— 570 mm (22.4 in.) 3— 10 mm (3/8 in.) flat steel bar

4— 285 mm (11.2 in.) 5— 13 mm (0.51 in.) diameter 6— M12 (0.47 in.) cap screw, washer, and nut

7— 269 mm (10.59 in.) 8— 538 mm (21.18 in.)

TE14778,00000DB -19-22MAR10-1/1

DFT1302 Final Drive Pressure Test Adapter 1. Drill 7/16 in. hole in center of plug (4). TX1037518A —UN—17MAR08

2. Tap hole in plug (4) with 1/4-18 NPT pipe tap. 3. Assemble O-ring (1), quick coupler (3), and threaded pipe (2) into plug (4). 1— U17409 O-ring 2— 1/4 in. x 2.00 in. Threaded Pipe

3— Quick Coupler 4— T78662 Plug

DFT1302 Final Drive Pressure Test Tool MR50960,0000012 -19-22MAR10-1/1

TM1731 (28JAN20)

9900-0999-11

850J Crawler (S.N. 130886—311988) 012820 PN=469

Dealer Fabricated Tools

TM1731 (28JAN20)

9900-0999-12

850J Crawler (S.N. 130886—311988) 012820 PN=470

Index Page Page

A A/C freeze switch Remove and install ...................................... 18-1830-11 Adjust track sag ............................................... 01-0130-50 Air conditioning Cleaning procedures...................................... 18-1830-7 Clutch hub clearance ................................... 18-1830-22 Compressor clutch ....................................... 18-1830-21 Leak testing.................................................... 18-1830-3 Air conditioning compressor Remove and install ...................................... 18-1830-19 Angle cylinder Disassemble and assemble ......................... 32-3260-25 Remove and install ...................................... 32-3260-24 Attachments Adding safely ..................................................... 00-01-8 Operating safely................................................. 00-01-8 Auxiliary water separator Fuel filter ........................................................ 05-0560-3

B Backup alarm, adjust ......................................... 20-2004-1 Battery Explosions, prevent............................................ 00-01-4 Blade Remove and install ........................................ 32-3201-2 Blade edges and end bits Remove and install ........................................ 32-3201-1 Bleed procedure Hand pump bleed procedure ......................... 18-1810-2 Bottom guard, front Remove and install ........................................ 17-1746-1 Brake Disassemble and assemble ............................11-1160-1 Brake pedal Disassemble and assemble ........................... 05-0515-2 Remove and install ........................................ 05-0515-1 Bushing Bushing outside diameter for lubricated track chain inspection................................. 01-0130-31

C C-Frame Remove and install ...................................... 32-3240-14 Cab under seat heater Diassemble and assemble........................... 18-1830-16 Cab upper heater Disassemble and assemble ......................... 18-1830-14 Cab/ROPS Remove and install ........................................ 18-1800-1 Carrier roller Disassemble and assemble ........................... 01-0130-6 Leakage test ................................................ 01-0130-10 Remove and install ........................................ 01-0130-5

Wear Inspection ............................................. 01-0130-4 Chain Lubricated track, track pitch inspection ................................................... 01-0130-32 Chain, lubricated track Remove and install ...................................... 01-0130-32 Charge air cooler Remove and install ........................................ 05-0510-3 Charge pump Disassemble and assemble ........................... 03-0360-7 Chemical products Handling............................................................. 00-01-4 Cleanout cover Remove and install ........................................ 32-3260-7 Clutch hub clearance....................................... 18-1830-22 Compressor Disassemble and assemble ......................... 18-1830-23 Disassemble and assemble clutch............... 18-1830-21 Oil charge check ............................................ 18-1830-1 Oil removal..................................................... 18-1830-1 Remove and install ...................................... 18-1830-19 Condenser Remove and install ...................................... 18-1830-18 Control Lever (Integrated Grade Control) (IGC) Disassemble and assemble ......................... 32-3260-22 Remove and install ...................................... 32-3260-19 Control valve, pump Disassemble and assemble ........................... 32-3260-4 Cooling package Remove and install ........................................ 05-0510-3 Cooling system Service safely..................................................... 00-01-9 Counterweight, additional rear Remove and install ........................................ 17-1749-5 Counterweight, front Remove and install ......................17-1749-1, 17-1749-3 Cover, cleanout Hydraulic reservoir ......................................... 32-3260-7 Crossbar Disassemble and assemble ......................... 01-0130-29 Crossbar lube Remove and install ...................................... 01-0130-26 Cutting edges and end bits Remove and install ........................................ 32-3201-1 Cylinder, angle Remove and install ...................................... 32-3260-24 Cylinder, PAT Remove and install ...................................... 32-3260-24 Cylinder, track adjuster Disassemble and assemble ......................... 01-0130-62 Cylinder, track adjuster and recoil spring Remove and install ...................................... 01-0130-51

Continued on next page

TM1731 (28JAN20)

Index-1

850J Crawler (S.N. 130886—311988)

012820

PN=1

Index

Page

D Dampener drive Remove and install (SN 130866—135190) ........................................ 07-0752-1 Remove and install (SN 135190— ) .............. 07-0752-3 Dealer fabricated tool DF1041 Track nut removal tool.................. 9900-0999-1 DF1063 Final drive lift bracket ................... 9900-0999-2 DF1065 Final drive and pump adapter bracket ..................................................... 9900-0999-3 DFT1132 hydrostatic motor removal .................................................... 9900-0999-4 DFT1137 hydrostatic motor removal .................................................... 9900-0999-5 DFT1167 Final drive lifting bracket adapter spacer ...................................................... 9900-0999-6 DFT1243 lifting bracket extension ............. 9900-0999-7 DFT1250 Lifting bracket............................. 9900-0999-8 DFT1261 Rolling torque measurement tool ......................................................... 9900-0999-11 DFT1302 Final drive pressure test adapter ................................................... 9900-0999-11 Decelerator pedal Disassemble and assemble ........................... 05-0515-2 Remove and install ........................................ 05-0515-1 DF1041 Track Nut Removal Tool .................. 9900-0999-1 DFT1260 Final drive lifting fixture ............................ 9900-0999-10 Disassemble and assemble Inner final drive housing cover ..................... 02-0250-23 Dozer control valve Disassemble and assemble ......................... 32-3260-11 Disassemble and assemble - IGC ............... 32-3260-14 Drawbar, rigid Remove and install ........................................ 15-1511-2 Drawbar, rigid, extended Remove and install ........................................ 15-1511-1

E Edges, cutting Remove and install ........................................ 32-3201-1 Electrical Welding procedure......................................... 17-1740-1 Emergencies Prepare for ......................................................... 00-01-5 End bits Remove and install ........................................ 32-3201-1 Engine Remove and Install ........................................ 04-0400-1 Engine mounts Remove and install ...................................... 04-0400-22 Engine side shields Remove and install ........................................ 19-1910-3 Equipment, protective Wear .................................................................. 00-01-2

Evaporator Remove and install ........................................ 18-1830-9 Expansion valve Remove and install ...................................... 18-1830-11

F Fan blade Remove and install ........................................ 05-0510-1 Fan shroud Remove and install ........................................ 05-0510-1 Final drive Remove and install ........................................ 02-0201-1 Ring gear and hub, remove and install ............................................................ 02-0250-3 Final Drive Beanings Remove and install ........................................ 02-0250-5 Final drive housing Inner, remove and install.............................. 02-0250-21 Final drive lift bracket..................................... 9900-0999-2 Final drive lifting fixture DFT1260 .................................................. 9900-0999-10 Final Drive Metal Face Seal Remove and install ........................................ 02-0250-5 Final drive seal Leakage check............................................. 02-0250-28 Fires, prevent......................................................... 00-01-4 Fluids, high pressure Avoid .................................................................. 00-01-3 Flywheel Remove and install ...................................... 04-0400-19 FNR Disassemble and assemble ........................... 03-0315-2 Remove and install ........................................ 03-0315-1 Frame, C Remove and install ...................................... 32-3240-14 Frame, track Remove........................................................ 01-0130-64 Front bottom guard Remove and install ........................................ 17-1746-1 Front idler Disassemble and assemble ......................... 01-0130-75 Position ........................................................ 01-0130-81 Remove........................................................ 01-0130-69 Test for oil leakage ....................................... 01-0130-83 Vertical movement adjustment..................... 01-0130-81 Wear inspection ........................................... 01-0130-69 Fuel filter Auxiliary water separator ............................... 05-0560-3 Fuel tank Remove and install ........................................ 05-0560-1 Fumes, exhaust Beware............................................................... 00-01-3

Continued on next page

TM1731 (28JAN20)

Index-2

850J Crawler (S.N. 130886—311988)

012820

PN=2

Index

Page

G Grouser Track shoe, wear inspection ........................ 01-0130-23 Guard, bottom front Remove and install ........................................ 17-1746-1

H Hand pump bleed procedure ............................. 18-1810-2 Handholds Use correctly ...................................................... 00-01-6 Heater core, upper Remove and install ........................................ 18-1830-9 HIC valve Hydraulic intregrated circuit (HIC) valve disassemble and assemble........................ 03-0360-53 Hydraulic intregrated circuit (HIC) valve remove and install ...................................... 03-0360-51 Hood Remove and install ........................................ 19-1910-1 Hood support Remove and install ........................................ 19-1910-4 Hydraulic Fittings, 30° cone seat ....................................... 00-03-4 Fittings, 37° flare ................................................ 00-03-4 Hydraulic control lever Disassemble and assemble ......................... 32-3260-18 Remove and install ...................................... 32-3260-17 Hydraulic control valve Disassemble and assemble ......................... 32-3260-11 Disassemble and assemble - IGC ............... 32-3260-14 Remove and install ...................................... 32-3260-10 Hydraulic cylinder repair Disassemble and assemble ......................... 32-3260-25 Hydraulic fan motor Remove and install ...................................... 03-0360-57 Hydraulic fan pump Remove and install ...................................... 03-0360-58 Hydraulic fan reversing valve Disassemble and assemble ......................... 03-0360-60 Remove and install ...................................... 03-0360-59 Hydraulic fitting Flared connections............................................. 00-03-7 Non-restricted banjo (adjustable)..................... 00-03-18 O-ring boss with shoulder ................................ 00-03-19 Hydraulic intregrated circuit (HIC) valve Disassemble and assemble ......................... 03-0360-53 Remove and install ...................................... 03-0360-51 Hydraulic motor Hydraulic fan motor remove and install .......................................................... 03-0360-57 Hydraulic fan pump remove and install .......................................................... 03-0360-58 Hydraulic fan reversing valve disassemble and assemble............................................. 03-0360-60

Hydraulic fan reversing valve remove and install .......................................................... 03-0360-59 Hydraulic pump Disassemble and assemble ........................... 32-3260-3 Remove and install ........................................ 32-3260-1 Hydraulic pump control valve Disassemble and assemble ........................... 32-3260-4 Hydraulic reservoir cleanout cover Remove and install ........................................ 32-3260-7 Hydrostatic motor Assemble ..................................................... 03-0360-37 Disassemble ................................................ 03-0360-31 Loop flushing valve, remove/disassemble .............................................................. 03-0360-31 Motor shift solenoid valve, remove/disassemble........................................................ 03-0360-31 Operating charge relief valve, remove/disassemble .................................. 03-0360-31 Hydrostatic motors Remove and install ........................................ 03-0300-7 Hydrostatic pump Assemble ..................................................... 03-0360-14 Charge pump, disassemble and assemble...................................................... 03-0360-7 Disassemble .................................................. 03-0360-1 Multi-function valve, disassemble and assemble.................................................... 03-0360-12 PDCV, disassemble and assemble.............. 03-0360-11 Hydrostatic pumps Remove and install ........................................ 03-0300-1 Hydrostatic reservoir Remove and Install ...................................... 03-0360-55 Hydrostatic system Charge pump, disassemble and assemble...................................................... 03-0360-7 Hydraulic fan motor remove and install .......................................................... 03-0360-57 Hydraulic fan pump remove and install .......................................................... 03-0360-58 Hydraulic fan reversing valve disassemble and assemble............................................. 03-0360-60 Hydraulic fan reversing valve remove and install .......................................................... 03-0360-59 Hydraulic intregrated circuit (HIC) valve disassemble and assemble........................ 03-0360-53 Loop flushing valve, remove/disassemble .............................................................. 03-0360-31 Motor shift solenoid valve, remove/disassemble........................................................ 03-0360-31 Motor, disassemble ...................................... 03-0360-31 Multi-function valve, disassemble and assemble.................................................... 03-0360-12 Operating charge relief valve, remove/disassemble .................................. 03-0360-31 PDCV, disassemble and assemble.............. 03-0360-11 Pump, assemble .......................................... 03-0360-14 Pump, disassemble........................................ 03-0360-1

Continued on next page

TM1731 (28JAN20)

Index-3

850J Crawler (S.N. 130886—311988)

012820

PN=3

Index

Page

Hydrostatic System Remove and Install ...................................... 03-0360-51

Remove and install ...................................... 01-0130-32 Track pitch inspection .................................. 01-0130-32

Idler Front, wear inspection.................................. 01-0130-69 Idler, front Adjustment ................................................... 01-0130-81 Disassemble and assemble ......................... 01-0130-75 Remove........................................................ 01-0130-69 Test for oil leakage ....................................... 01-0130-83 Vertical movement adjustment..................... 01-0130-81 Inch bolt and cap screw Torque value ...................................................... 00-03-3 Inch series four bolt flange fitting Service recommendation, torque value for high pressure ................................................. 00-03-17 Inner final drive housing Remove and install ...................................... 02-0250-21 Inner final drive housing cover Disassemble and assemble ......................... 02-0250-23 Inspection Bushing outside diameter for lubricated track chain.................................................. 01-0130-31 Carrier roller wear .......................................... 01-0130-4 Front idler wear ............................................ 01-0130-69 Track link height........................................... 01-0130-30 Track pitch, lubricated track chain ............... 01-0130-32 Track shoe grouser wear ............................. 01-0130-23 Installation Wiper arm ...................................................... 18-1810-3

Machine modifications Avoid .................................................................. 00-01-2 Machine, inspect.................................................... 00-01-2 Metal face seals Inspect ........................................................... 01-0130-9 Metric bolt and cap screw Torque value ...................................................... 00-03-1 Motor Hydraulic fan motor remove and install .......................................................... 03-0360-57 Hydraulic fan pump remove and install .......................................................... 03-0360-58 Motor shift solenoid valve Remove/disassemble................................... 03-0360-31 Motor Shift Solenoid Valve Install............................................................ 03-0360-37 Muffler Remove and install ........................................ 05-0530-1 Multi-function valve Assemble and disassemble ......................... 03-0360-12 Remove and install ...................................... 03-0360-12

J Joystick (Integrated Grade Control) (IGC) Disassemble and assemble ......................... 32-3260-22 Remove and install ...................................... 32-3260-19

L Leakage test Carrier roller ................................................. 01-0130-10 Lift cylinder Disassemble and assemble ......................... 32-3260-25 Loop flushing valve Remove/disassemble................................... 03-0360-31 Loop Flushing Valve Install............................................................ 03-0360-37 Lubricated track chain Assemble and not relubricate ...................... 01-0130-45 Assemble to lubricate................................... 01-0130-38 Assemble to turn bushings........................... 01-0130-38 Disassemble and assemble ......................... 01-0130-45 Disassemble and not relubricate.................. 01-0130-45 Disassemble to lubricate.............................. 01-0130-36 Disassemble to turn bushing........................ 01-0130-36

O O-ring boss fitting in aluminum housingexcavators Torque value, service recommendation ................................................................... 00-03-6 O-ring boss fittings................................................. 00-03-4 O-ring face seal fitting Inch hex nut and stud end for high pressure torque values..................................... 00-03-9 Metric hex nut and stud end for high pressure torque values................................... 00-03-13 Metric hex nut and stud end for standard pressure torque values................................... 00-03-11 O-ring seal, metric 24 Service recommendation ................................. 00-03-21 Oil Cooler Remove and install ........................................ 05-0510-3 Oil pan Remove and install ...................................... 04-0400-12 Operating charge relief valve Remove/disassemble................................... 03-0360-31 Operating Charge Relief Valve Install............................................................ 03-0360-37 Operation qualification........................................... 00-01-1 Outside dozer pushbeam Remove and install ........................................ 32-3240-1

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TM1731 (28JAN20)

Index-4

850J Crawler (S.N. 130886—311988)

012820

PN=4

Index

Page

P Park brake Disassemble and assemble ............................11-1160-1 Park Brake Remove and Install .........................................11-1100-1 Park lock linkage Disassemble and assemble ............................ 11-1115-2 Remove and install ......................................... 11-1115-1 Parts, moving Stay clear ........................................................... 00-01-2 PAT cylinder Remove and install ...................................... 32-3260-24 PAT six way blade Remove and install ........................................ 32-3201-2 PDCV Disassemble and assemble ......................... 03-0360-11 Pilot control valve Disassemble and assemble ......................... 32-3260-18 Remove and install ...................................... 32-3260-17 Pivot shaft Remove and install ...................................... 01-0130-25 Planet carrier Disassemble and assemble ........................... 02-0250-2 Remove and install ........................................ 02-0250-1 Pump Charge, disassemble and assemble.............. 03-0360-7 Hand pump bleed procedure ......................... 18-1810-2 Hydrostatic, assemble.................................. 03-0360-14 Hydrostatic, disassemble ............................... 03-0360-1 Pump control valve Disassemble and assemble ........................... 32-3260-4 Pump displacement control valve (PDCV) Disassemble and assemble ......................... 03-0360-11 Pump, hydraulic Disassemble and assemble ........................... 32-3260-3 Remove and install ........................................ 32-3260-1 Push beam Outside Dozer, Remove and install................ 32-3240-1

Q Quick-drop valve Remove and install ...................................... 32-3260-23

R R134a Component oil charge.................................... 18-1830-2 R134a system Charge ........................................................... 18-1830-6 Evacuate ........................................................ 18-1830-5 Flush .............................................................. 18-1830-8 Purge ............................................................. 18-1830-7 Recover.......................................................... 18-1830-4

Radiator Remove and install ........................................ 05-0510-3 Receiver-dryer Remove and install ...................................... 18-1830-18 Recognize Safety, information ............................................. 00-01-1 Recoil spring and track adjuster cylinder Remove and install ...................................... 01-0130-51 Recoil spring, track adjuster Disassemble and assemble ......................... 01-0130-53 Recovery/charging station Installation procedure..................................... 18-1830-3 Refrigerant R134a caution................................. 18-1830-1 Remove and install Fan................................................................. 05-0510-1 Fianl drive ...................................................... 02-0201-1 Pivot shaft .................................................... 01-0130-25 Planet carrier.................................................. 02-0250-1 Track shoe ................................................... 01-0130-24 Remove and Install Park Brake ......................................................11-1100-1 Reservoir cover Remove and install ........................................ 32-3260-7 Reservoir, hydraulic Remove and install ........................................ 32-3260-5 Reverse alarm, Remove and install ........................................ 20-2004-1 Reverse warning alarm, adjust .......................... 20-2004-1 Ring gear and hub Disassemble and assemble ........................... 02-0250-4 Remove and install ........................................ 02-0250-3 Ripper Install...................................................................... 42--7 Remove.................................................................. 42--1 Rock guard Remove and install ........................................ 01-0130-1 Roller, carrier Disassemble and assemble ........................... 01-0130-6 Remove and install ........................................ 01-0130-5 Roller, track Disassemble and assemble ......................... 01-0130-13 Remove and install ...................................... 01-0130-11 Test for oil leakage ....................................... 01-0130-22 Wear inspection ........................................... 01-0130-10 ROPS or cab Remove and install ........................................ 18-1800-1 ROPS under seat heater Disassemble and assemble ......................... 18-1830-16

S Safety Add cab guarding for special uses..................... 00-01-5 Avoid backover accidents .................................. 00-01-7 Avoid machine tip over....................................... 00-01-8 Avoid work site hazards ..................................... 00-01-7 Drive metal pins safely..................................... 00-01-10 Instructions, follow ............................................. 00-01-1 Continued on next page

TM1731 (28JAN20)

Index-5

850J Crawler (S.N. 130886—311988)

012820

PN=5

Index

Page

Keep riders off machine ..................................... 00-01-7 Make welding repairs safely............................. 00-01-10 Operator's seat .................................................. 00-01-6 Park and prepare for service safely ................... 00-01-9 Prevent unintended machine movement ........................................................ 00-01-6 Safety, information Recognize .......................................................... 00-01-1 Seals, metal face Inspect ........................................................... 01-0130-9 Seat Disassemble and assemble ........................... 18-1821-1 Seat belt Use and maintain ............................................... 00-01-6 Service recommendation Inch series four bolt flange fitting for high pressure ......................................................... 00-03-17 O-ring boss fitting in aluminum housingexcavators ........................................... 00-03-6 O-ring face seal fittings with inch hex nut and stud end for high pressure ........................ 00-03-9 O-ring face seal fittings with metric hex nut and stud end for high pressure ................ 00-03-13 O-ring face seal fittings with metric hex nut and stud end for standard pressure ............... 00-03-11 O-ring seal, metric 24....................................... 00-03-21 Shroud Remove and install ........................................ 05-0510-1 Side shields Remove and install ........................................ 19-1910-3 Single lever control Disassemble and assemble ........................... 03-0315-2 Remove and install ........................................ 03-0315-1 Six way blade Remove and install ........................................ 32-3201-2 Spring, recoil and track adjuster cylinder Remove and install ...................................... 01-0130-51 Spring, track adjuster recoil Disassemble and assemble ......................... 01-0130-53 Sprocket guard Remove and install ........................................ 01-0130-1 Sprocket segment Remove and install ...................................... 01-0130-84 Starting aid assembly Remove and install ........................................ 05-0505-1 Steps Use correctly ...................................................... 00-01-6 Switch, A/C freeze Removel and install...................................... 18-1830-11

Tilt cylinder Disassemble and assemble ......................... 32-3260-25 Tool, dealer fabricated DF1041 Track nut removal tool.................. 9900-0999-1 DF1063 Final drive lift bracket ................... 9900-0999-2 DF1065 Final drive and pump adapter bracket ..................................................... 9900-0999-3 DFT1167 Final drive lifting bracket adapter spacer ...................................................... 9900-0999-6 DFT1243 lifting bracket extension ............. 9900-0999-7 DFT1250 Lifting bracket............................. 9900-0999-8 DFT1261 Rolling torque measurement tool ......................................................... 9900-0999-11 DFT1302 Final drive pressure test adapter ................................................... 9900-0999-11 Tools, dealer fabricated DFT1132 hydrostatic motor removal .................................................... 9900-0999-4 DFT1137 hydrostatic motor removal .................................................... 9900-0999-5 Torque value 30° cone seat hydraulic fittings .......................... 00-03-4 37° flare hydraulic fittings................................... 00-03-4 Flared connections............................................. 00-03-7 Flat face O-ring seal fitting ................................. 00-03-8 Inch SAE four bolt flange fitting........................ 00-03-16 Inch series four bolt flange fitting for high pressure ......................................................... 00-03-17 Metric bolt and cap screw .................................. 00-03-1 Metric cap screw ................................................ 00-03-2 Metric four bolt flange fitting............................. 00-03-15 Non-restricted banjo fittings ............................. 00-03-18 O-Ring boss fitting ............................................. 00-03-4 O-ring boss fitting in aluminum housingexcavators ........................................... 00-03-6 O-ring boss fittings with shoulder..................... 00-03-19 O-ring face seal fittings with inch hex nut and stud end for high pressure ........................ 00-03-9 O-ring face seal fittings with metric hex nut and stud end for high pressure ................ 00-03-13 O-ring face seal fittings with metric hex nut and stud end for standard pressure ............... 00-03-11 O-ring seal, metric 24....................................... 00-03-21 Unified inch bolt and cap screw ......................... 00-03-3 Track adjuster cylinder Disassemble and assemble ......................... 01-0130-62 Track adjuster cylinder and recoil spring Remove and install ...................................... 01-0130-51 Track adjuster recoil spring Disassemble and assemble ......................... 01-0130-53 Track chain Lubricated, track pitch inspection................. 01-0130-32 Track chain bushing Bushing outside diameter for lubricated track chain inspection................................. 01-0130-31 Track chain, lubricated Remove and install ...................................... 01-0130-32

T TCL Disassemble and assemble ........................... 03-0315-2 Remove and install ........................................ 03-0315-1 Test Hand pump bleed procedure ......................... 18-1810-2

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TM1731 (28JAN20)

Index-6

850J Crawler (S.N. 130886—311988)

012820

PN=6

Index

Page

Track frame Remove........................................................ 01-0130-64 Track guide Remove and install ........................................ 01-0130-1 Track guides and rock guards Remove and install ........................................ 01-0130-1 Track link bushing Bushing outside diameter for lubricated track chain inspection................................. 01-0130-31 Track link height Inspection..................................................... 01-0130-30 Track roller Disassemble and Assemble......................... 01-0130-13 Remove and install ...................................... 01-0130-11 Test for oil leakage ....................................... 01-0130-22 Wear inspection ........................................... 01-0130-10 Track sag Adjust ........................................................... 01-0130-50 Track sag adjustment ...................................... 01-0130-50 Track shoe Remove and install ...................................... 01-0130-24 Track shoe grouser wear Inspection..................................................... 01-0130-23 Transmission bottom guard ............................... 17-1746-1 Transmission control lever (TCL) Disassemble and assemble ........................... 03-0315-2 Remove and install ........................................ 03-0315-1

Hydraulic fan reversing valve remove and install .......................................................... 03-0360-59 Hydraulic intregrated circuit (HIC) valve disassemble and assemble........................ 03-0360-53 Hydraulic intregrated circuit (HIC) valve remove and install ...................................... 03-0360-51 Loop flushing, remove/disassemble............. 03-0360-31 Motor shift solenoid, remove/disassemble .............................................................. 03-0360-31 Multi-function, disassemble and assemble.................................................... 03-0360-12 Operating charge relief, remove/disassemble........................................................ 03-0360-31 Valve, control dozer disassemble and assemble.......................... 32-3260-11 disassemble and assemble - IGC ................ 32-3260-14 Valve, hydraulic control Remove and install ...................................... 32-3260-10 Valve, pilot control Disassemble and assemble ......................... 32-3260-18 Remove and install ...................................... 32-3260-17 Valve, quick-drop Remove and install ...................................... 32-3260-23

U Upper heater core Remove and install ........................................ 18-1830-9

W Waste Dispose of properly ............................................ 00-01-5 Welding or heating Paint removal ..................................................... 00-01-9 Welding procedure ............................................ 17-1740-1 Window Remove and install ........................................ 18-1810-1 Wiper arm Installation...................................................... 18-1810-3

Valve Hydraulic fan reversing valve disassemble and assemble............................................. 03-0360-60

TM1731 (28JAN20)

Index-7

850J Crawler (S.N. 130886—311988)

012820

PN=7

Index

TM1731 (28JAN20)

Index-8

850J Crawler (S.N. 130886—311988)

012820

PN=8