Table of Contents tm1692 Service ADVISOR™ tm1692 Service ADVISOR™ (1) Safety Features Recognize Safety Information Follow Safety Instructions Operate Only If Qualified Wear Protective Equipment Avoid Unauthorized Machine Modifications Inspect Machine Stay Clear of Moving Parts Avoid High-Pressure Fluids Beware of Exhaust Fumes Prevent Fires Prevent Battery Explosions Handle Chemical Products Safely Dispose of Waste Properly Prepare for Emergencies Use Steps and Handholds Correctly Start Only From Operator's Seat Use and Maintain Seat Belt Prevent Unintended Machine Movement Avoid Work Site Hazards Keep Riders Off Machine Avoid Backover Accidents Avoid Machine Tipover Add and Operate Attachments Safely Use Special Care When Operating Operating or Traveling On Public Roads Inspect and Maintain ROPS Stay Clear of Rotating Drivelines Park and Prepare for Service Safely Service Cooling System Safely Remove Paint Before Welding or Heating Make Welding Repairs Safely Drive Metal Pins Safely Safety Sign Service Equipment and Tools Specifications Remove and Install Rear Wheel Assembly Remove and Install Front Wheel Assembly Remove and Install Tire Specifications (1) Remove and Install Drive Shaft tm1692
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Replace Drive Shaft U-Joints Service Equipment and Tools (1) Other Material Specifications (2) Remove and Install Hub Assembly Hub Assembly Remove and Install (Carraro Replacement Axle) Remove and Install Spindle and Knuckle Assembly Spindle Assembly Remove and Install (Carraro Replacement Axle) Tie Rod Remove and Install Remove and Install Non-Powered Front Axle Non-Powered Front Axle Remove and Install (Carraro Replacement Axle) Front Wheel Drive Axles—AS and MS Series Service Equipment and Tools (2) Other Material (1) Specifications (3) Remove and Install Powered Front Axle—If Equipped Essential Tools Service Equipment and Tools (3) Other Material (2) Specifications (4) Remove and Install Rear Axle Disassemble Rear Axle Disassemble and Assemble Park Brake (S.N. —881365) Disassemble and Assemble Park Brake (S.N. 881366— ) Assemble Rear Axle Check Gear Tooth Contact Pattern Specifications (5) Remove and Install Transmission Other Material (3) Specifications (6) Remove and Install Transmission Gearshift Lever Remove Shift Lever and Housing Disassemble and Assemble Shift Lever and Housing Install Shift Lever and Housing Essential Tools (1) Service Equipment and Tools (4) Other Material (4) Specifications (7) Remove Outer Components to Disassemble Manual Shift Transmission Disassemble Converter Side of Case—Manual Shift Remove Oil Suction Tube—Manual Shift Remove Reverse and Forward Clutch Packs—Manual Shift Disassemble and Assemble Reverse or Forward Clutch Pack—Manual Shift Remove Drive Shaft—Manual Shift Disassemble and Assemble Drive Shaft—Manual Shift tm1692
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Remove Rear Output Shaft with Synchronizer—Manual Shift Remove Intermediate Shaft with Synchronizer—Manual Shift Disassemble Rear Output or Intermediate Shaft with Synchronizer—Manual Shift Rear Output Shaft—Cross Section View—Manual Shift Intermediate Shaft—Cross Section View—Manual Shift Assemble Rear Output or Intermediate Shaft—Manual Shift Remove MFWD Output Shaft—Manual Shift Disassemble MFWD Shaft—Manual Shift MFWD Shaft—Cross Section View—Manual Shift Assemble MFWD Shaft—Manual Shift Remove, Disassemble, and Assemble Idler Shaft—Manual Shift Remove and Install Oil Supply Tube—Manual Shift Install Idler and MFWD Shafts to Assemble Transmission—Manual Shift Install Intermediate and Rear Output Shafts—Manual Shift Install Drive Shaft—Manual Shift Install Forward and Reverse Clutch Packs—Manual Shift Install Oil Suction Tube—Manual Shift Assemble Converter Side of Case—Manual Shift Install Outer Components to Assemble Transmission—Manual Shift Remove Outer Components to Disassemble Power Shift Transmission Disassemble Converter Side of Case—Power Shift Remove Low Range Forward, Reverse and Third Speed Clutch Packs—Power Shift Disassemble and Assemble Low Range Forward, Reverse and Third Speed Clutch Packs—Power Shift Remove First Speed, Second Speed, and High Range Forward Clutch Packs—Power Shift Disassemble and Assemble First Speed, Second Speed, and High Range Forward Clutch Packs—Power Shift Remove Drive Shaft—Power Shift Disassemble and Assemble Drive Shaft—Power Shift Remove MFWD Output Shaft—Power Shift Disassemble MFWD Shaft—Power Shift Assemble MFWD Shaft—Power Shift Remove Oil Suction Tube—Power Shift Remove and Install Oil Supply Tubes—Power Shift Install Oil Suction Tube—Power Shift Install MFWD Shaft to Assemble Transmission—Power Shift Install Drive Shaft—Power Shift Install Clutch Packs—Power Shift Assemble Converter Side of Case—Power Shift Install Outer Components to Assemble Transmission—Power Shift Other Material (5) Specifications (8) Remove and Install Control Valve—Manual Shift Disassemble and Assemble Control Valve—Manual Shift Remove and Install Transmission Charge Pump—Manual Shift tm1692
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Remove and Install Transmission Charge Pump—Power Shift Disassemble and Assemble Transmission Charge Pump—Manual Shift and Power Shift Remove and Install Manifold Plate and Solenoids—Manual Shift Remove and Install Control Valve—Power Shift Disassemble and Assemble Control Valve—Power Shift Remove and Install Shift Valve—Power Shift Disassemble and Assemble Shift Valve—Power Shift Remove and Install Manifold Plate and Solenoids—Power Shift POWERTECH 4.5L (4045) and 6.8L (6068) John Deere Engines Essential Tools (2) Specifications (9) Remove and Install Engine Specifications (10) Remove and Install Coolant Heater Remove and Install Starting Aid Nozzle Remove and Install Starting Aid Solenoid (S.N. —882699) Remove and Install Starting Aid Solenoid (S.N. 882700— ) Service Equipment and Tools (5) Specifications (11) Remove and Install Fan Remove and Install Fan Belt Remove and Install Radiator (S.N. —882699) Remove and Install Radiator (S.N. 882700— ) Disassemble and Assemble Speed Control Linkage—With Speed Control Knob (S.N. —872334) Disassemble and Assemble Speed Control Linkage—With Speed Control Knob (S.N. 872335—882699) Disassemble and Assemble Speed Control Linkage—Without Speed Control Knob (S.N. 840038—882699) Disassemble and Assemble Speed Control Linkage (S.N. 882700—) Special or Essential Tools Service Equipment and Tools (6) Specifications (12) Remove and Install Air Cleaner Air Intake System Leakage Test Remove and Install Muffler (S.N. —882699) Remove and Install Muffler (S.N. 882700— ) Other Material (6) Specifications (13) Remove and Install Fuel Tank Remove and Install Torque Converter Disassemble and Assemble Torque Converter Steering Cylinder Repair For Front Wheel Drive Axles—AS and MS Series Service Equipment and Tools (7) Other Material (7) Specifications (14) tm1692
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Remove and Install Steering Column Remove and Install Steering Valve Disassemble Steering Valve Cross Section of Steering Valve Assemble Steering Valve Remove and Install Non-Powered Axle Steering Cylinder Disassemble Non-Powered Axle Steering Cylinder Cross Section of Non-Powered Axle Steering Cylinder Assemble Non-Powered Axle Steering Cylinder Remove and Install Steering Cylinder Bushings Non-Powered Carraro Replacement Axle Steering Cylinder Remove and Install Non-Powered Carraro Replacement Axle Steering Cylinder Disassemble and Assemble Remove and Install Priority Valve (S.N. —880053) Remove and Install Priority Valve (S.N. 880054— 883904) Inspect Service Brakes Remove and Install Brake Disk and Pressure Plate Other Material (8) Specifications (15) Remove and Install Brake Valve (S.N. —880907) Remove and Install Brake Valve (S.N. 880908— ) Disassemble and Assemble Brake Valve (S.N. —880907) Disassemble and Assemble Brake Valve (S.N. 880908— ) Remove and Install Service Brake Hoses and Fittings (S.N. —880907) Remove and Install Service Brake Hoses and Fittings (S.N. 880908— ) Adjust Brake Pedals and Equalizing Valves (S.N. —880907) Bleed Service Brakes (S.N. —880907) Bleed Service Brakes (S.N. 880908— ) Remove and Install Park Brake Remove and Install Counterweights and Drawbar Remove, Disassemble, Assemble, and Install Three-Point Hitch(S.N. —880053) Remove, Disassemble, Assemble, and Install Three-Point Hitch(S.N. 880054— ) Three-Point Hitch Shim Requirements (S.N. —880053) Upper Lift Arm Mount, Left and Right Side, Shimming (S.N. —880053) Lift Cylinder Mount, Rod End, Shimming (S.N. —880053) Upper Lift Arm, Vertical Link Mount, Shimming (S.N. —880053) Upper Lift Arm, Tilt Cylinder Mount, Shimming (S.N. —880053) Draft Link, Vertical Link Mount, Shimming (S.N. —880053) Draft Link, Tilt Cylinder Mount, Shimming (S.N. —880053) Pitch Cylinder Mount, Shimming (S.N. —880053) Draft Link Mount, Left and Right Side, Shimming (S.N. —880053) Essential Tools (3) Specifications (16) Welding Repair of Major Structures Remove and Install RIVNUT® (KREMNUT) Fasteners Service Equipment and Tools (8) tm1692
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Specifications (17) FOPS Other Material (9) Specifications (18) Disassemble and Assemble Standard Seat, Belt, and Arm Rest (S.N. —843070) Disassemble and Assemble Standard Seat, Belt, and Arm Rest(S.N. 843071— ) Disassemble and Assemble Seat, Adjuster, and Swivel Pedestal Remove and Install Seat Belts for Suspension Seat Disassemble and Assemble Swivel Pedestal Remove and Install Hood (S.N. —882699) Remove and Install Hood (S.N. 882700— ) Remove and Install Engine Side Shields (S.N. —848458) Remove and Install Engine Side Shields (S.N. 848459—882699) Disassemble and Assemble Battery Box Remove and Install Grille and Cowl (S.N. —882699) Remove and Install Grille and Cowl (S.N. 882700— ) Remove and Install Fenders Remove and Install Horn Remove and Install Backup Alarm Adjust Backup Alarm Volume (S.N. —882699) Other Material (10) Specifications (19) Specifications (20) Remove and Install Hydraulic Pump (S.N. —880053) Remove and Install Hydraulic Pump with Priority Valve (S.N. 880054—883904) Remove and Install Hydraulic Pump (S.N. 883905— ) Disassemble, Inspect, and Assemble Hydraulic Pump (S.N. —880053) Disassemble and Assemble Hydraulic Pump with Priority Valve (S.N. 880054—883904) Disassemble and Assemble Hydraulic Pump (S.N. 883905— ) Remove and Install Priority Valve (S.N. —880053) (1) Disassemble and Assemble Priority Valve (S.N. —880053) Remove and Install Hydraulic Filter (S.N —883904) Remove and Install Hydraulic Filter (S.N 883905— ) Remove and Install Reservoir (S.N. —883904) Remove and Install Reservoir (S.N 883905— ) Remove and Install Hydraulic Oil Cooler (S.N. —882699) Remove and Install Hydraulic Oil Cooler (S.N. 882700— ) Hydraulic Oil Clean-Up Procedure Using Portable Filter Caddy Specifications (21) Remove Loader Install Loader Remove and Install Loader Bucket Welded Bucket Cutting Edges, Replace Cracked Cutting Edge, Repair Remove and Install Cutting Edge tm1692
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Specifications (22) Remove and Install Bucket Cylinder Linkage Boom and Multi-Purpose Bucket Cylinder Repair—120 Series Other Material (11) Specifications (23) Remove and Install Control Valve (S.N. —882699) Control Valve Remove and Install (S.N. 882700—883904) Control Valve—Disassemble and Assemble (S.N —883904) Loader Control Valve—Loader Remove and Replace Relief Valves (S.N. —883904) Boom Lower Anti-Cavitation Valve with Lift Check—Disassemble and Assemble (S.N. —883904) Bucket Curl Circuit Relief Valve with Load Check—Disassemble and Assemble (S.N. —883904) Boom Raise Plug with Load Check—Disassemble and Assemble (S.N. —883904) Bucket Dump Circuit Relief Valve with Anti-Cavitation and Load Check—Disassemble and Assemble (S.N. —883904) System Relief Valve—Disassemble and Assemble (S.N. —883904) Control Valve—Remove and Install (S.N. 883905— ) Control Valve—Remove and Replace Relief Valves (S.N. 883905— ) Anti-Cavitation Check Valve—Disassemble and Assemble (S.N. 883905— ) Relief Valve—Disassemble and Assemble (S.N. 883905— ) Relief Valve with Anti-Cavitation—Disassemble and Assemble (S.N. 883905— ) Control Valve—Disassemble and Assemble (S.N. 883905— ) Outlet Section—Disassemble and Assemble (S.N. —883904) Control Valve Inlet Section—Disassemble and Assemble (S.N. 883905— ) Disassemble and Assemble V20-Loader Control Valve Bucket Section (S.N. —883904) Disassemble and Assemble V20-Loader Control Valve Boom Section (S.N. —883904) Disassemble and Assemble Hitch Control Valve (S.N. —883904) Disassemble and Assemble V10-Hitch Control Valve Lift Section (S.N. —882699) Disassemble and Assemble V10-Hitch Control Valve Lift Section (S.N. 882700— 883904) Disassemble and Assemble V10-Hitch Control Valve Pitch Section (S.N. —882699) Disassemble and Assemble V10-Hitch Control Valve Pitch Section (S.N. 882700—883904) Disassemble and Assemble V10-Hitch Control Valve Tilt and Auxiliary Section (S.N. —882699) Disassemble and Assemble V10-Hitch Control Valve Tilt and Auxiliary Section (S.N. 882700— 883904) Disassemble and Assemble Flow Control Valve Section (S.N. —883904) Priority & Flow Control Valve—Disassemble and Assemble (S.N. 883905— ) Auxiliary Section (Loader)—Disassemble and Assemble (S.N. 883905— ) Bucket Section—Disassemble and Assemble (S.N. 883905— ) Boom Section—Disassemble and Assemble (S.N. 883905— ) Hitch Lift Section—Disassemble and Assemble (S.N. 883905— ) Hitch Tilt & Auxiliary Sections—Disassemble and Assemble (S.N. 883905— ) Pitch Section—Disassemble and Assemble (S.N. 883905— ) Disassemble and Assemble Hitch Tilt Cylinder tm1692
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Disassemble Hitch Lift Cylinder Assemble Hitch Lift Cylinder Disassemble and Assemble Hitch Pitch Cylinder Remove and Install Bucket Cylinder Remove and Install Loader Boom Cylinders Disassemble and Assemble Loader Boom Cylinders—120 Series Disassemble and Assemble Multi-Purpose Bucket Cylinder—120 Series Other Material (12) Specifications (24) Remove and Install Hydrostatic PTO Pump Valves Remove and Install Hydrostatic Charge Pump Remove and Install Hydrostatic PTO Pump Remove and Install Hydrostatic PTO Motor Cooling Bypass Valve Disassemble and Assemble Hydrostatic PTO Motor Cooling Bypass Valve Remove and Install Hydrostatic PTO Filter Manifold Remove and Install Hydrostatic PTO Oil Cooler (S.N. —882699) Remove and Install Hydrostatic PTO Oil Cooler (S.N. 882700— ) Remove and Install Hydrostatic PTO Motor Remove and Install Hydrostatic PTO Gear Case Hydrostatic PTO Start-Up Procedure—If Equipped Hydraulic and PTO Oil Clean-Up Procedure Using Portable Filter Caddy Other Material (13) Specifications (25) Disassemble and Assemble Hydrostatic PTO Gear Case Essential Tools (4) Service Equipment and Tools (9) Other Material (14) Specifications (26) Disassemble and Assemble Control Valve Disassemble Hydrostatic PTO Pump Assemble Hydrostatic PTO Pump Disassemble Hydrostatic PTO Motor Hydrostatic PTO Motor—Exploded View Assemble Hydrostatic PTO Motor DFT1101 Cab and ROPS Lift Bracket DFT1143 Transmission Support Bracket DFT1146 Axle Mounting Bracket DFT1147 Axle Rolling Torque Bar DFT1162 Power Shift Clutch Pack Snap Ring Removal and Installation Tool DFT1163 MFWD Snap Ring Removal and Installation Tool DFT1176 PTO Pump Servo Piston Snap Ring Removal and Installation Tool
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866 869 872 875 878 880 881 882 883 884 890 898 902 904 905 907 910 913 916 917 920 922 923 924 935 936 937 938 939 940 959 978 985 988 994 995 996 997 998 999 1001
Foreword This manual is wri en for an experienced technician. Essen al tools required in performing certain service work are iden fied in this manual and are recommended for use. Live with safety: Read the safety messages in the introduc on of this manual and the cau ons presented throughout the text of the manual.
This is the safety-alert symbol. When you see this symbol on the machine or in this manual, be alert to the poten al for personal injury. Technical manuals are divided in two parts: repair and opera on and tests. Repair sec ons tell how to repair the components. Opera on and tests sec ons help you iden fy the majority of rou ne failures quickly. Informa on is organized in groups for the various components requiring service instruc on. At the beginning of each group are summary lis ngs of all applicable essen al tools, service equipment and tools, other materials needed to do the job, service parts kits, specifica ons, wear tolerances, and torque values. Technical Manuals are concise guides for specific machines. They are on-the-job guides containing only the vital informa on needed for diagnosis, analysis, tes ng, and repair. Fundamental service informa on is available from other sources covering basic theory of opera on, fundamentals of troubleshoo ng, general maintenance, and basic type of failures and their causes. See DB1990 Service Publica ons Catalog to order a Technical Manual (TM). A Repair Manual includes the following sec ons:
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