Documente Academic
Documente Profesional
Documente Cultură
TECHNICAL MANUAL
450G, 455G, 550G, 555G, 650G
Crawler Repair
TM1404 14JUN11 (ENGLISH)
Worldwide Construction
And Forestry Division
LITHO IN U.S.A.
Introduction
Foreword
This manual is written for an experienced technician. beginning of each group are summary listings of all
Essential tools required in performing certain service work applicable essential tools, service equipment and tools,
are identified in this manual and are recommended for other materials needed to do the job, service parts kits,
use. specifications, wear tolerances, and torque values.
Live with safety: Read the safety messages in the Technical Manuals are concise guides for specific
introduction of this manual and the cautions presented machines. They are onthejob guides containing only the
throughout the text of the manual. vital information needed for diagnosis, analysis, testing,
and repair.
This is the safetyalert symbol. When you see this Fundamental service information is available from other
symbol on the machine or in this manual, be alert to the sources covering basic theory of operation, fundamentals
potential for personal injury. of troubleshooting, general maintenance, and basic type
Technical manuals are divided in two parts: repair and of failures and their causes.
operation and tests. Repair sections tell how to repair See DB1990 Service Publications Catalog to order a
the components. Operation and tests sections help you Technical Manual (TM).
identify the majority of routine failures quickly.
Information is organized in groups for the various
components requiring service instruction. At the
TX,450GIFC 1916SEP931/1
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TX,INTR,RB241 1922JAN981/1
PN=2
Contents
Section 00General Information Group 1673Lighting System
Group 0001Safety Information Group 1674Wiring Harness and Switches
Group 0002General Specifications Group 1676Instruments and Indicators
Group 0003Torque Values Group 1677Motors and Actuators
Group 0004Fuels and Lubricants
Section 17Frames, Chassis, or Supporting
Section 01Tracks Structure
Group 0130Track System Group 1740Frame Installation
Group 0199Dealer Fabricated Tools Group 1749Chassis Weights
Group 1799Dealer Fabricated Tools
Section 02Axles and Suspension Systems
Group 0250Axle Shaft, Bearings, and Reduction Section 18Operators Station
Gears Group 1800Removal and Installation
Group 0260Hydraulic System Group 1821Seat and Seat Belt
Group 0299Dealer Fabricated Tools
Section 19Sheet Metal and Styling
Section 03Transmission Group 1910Hood and Engine Enclosure
Group 0315Control Linkage Group 1913Miscellaneous Guards
Group 0325Input Drive Shafts and UJoints Group 1921Grille and Grille Housing
Group 0350Gears, Shafts, Bearings and Clutch Group 1927Fenders
Group 0360Hydraulic System
Group 0399Dealer Fabricated Tools Section 20Safety, Convenience and
Miscellaneous
Section 04Engine Group 2004Horn and Warning Devices
Group 0400Removal and Installation
Section 21Main Hydraulic System
Section 05Engine Auxiliary Systems Group 2160Hydraulic System
Group 0505Cold Weather Starting Aid
Group 0510Cooling System Section 31Loader
Group 0515Speed Controls and Fuel ShutOff Group 3102Bucket
Linkage Group 3115Controls Linkage
Group 0520Intake System Group 3140Frames
Group 0560External Fuel Supply System Group 3160Hydraulics
PN=1
Contents
PN=2
Section 00
General Information
Contents
Page Page
PN=1
Contents
Page
PN=2
Group 0001
Safety Information
Handle Fluids SafelyAvoid Fires
When you work around fuel, do not smoke or work near
heaters or other fire hazards.
Store flammable fluids away from fire hazards. Do not
incinerate or puncture pressurized containers.
TS227 UN23AUG88
Make sure machine is clean of trash, grease, and debris.
Do not store oily rags they can ignite and burn
spontaneously.
DX,FLAME 1929SEP981/1
TS204 UN23AUG88
Do not charge a frozen battery it may explode. Warm
battery to 16C (60F).
DX,SPARKS 1903MAR931/1
TS291 UN23AUG88
DX,FIRE2 1903MAR931/1
PN=7
Safety Information
TS203 UN23AUG88
exceed 2 L (2 quarts).
3. Get medical attention immediately.
DX,POISON 1921APR931/1
TS1132 UN26NOV90
A Material Safety Data Sheet (MSDS) provides specific
details on chemical products: physical and health hazards,
safety procedures, and emergency response techniques.
Check the MSDS before you start any job using a
hazardous chemical. That way you will know exactly what
the risks are and how to do the job safely. Then follow
procedures and recommended equipment.
(See your John Deere dealer for MSDSs on chemical
products used with John Deere equipment.)
DX,MSDS,NA 1903MAR931/1
PN=8
Safety Information
X9811 UN23AUG88
connections before applying pressure.
Search for leaks with a piece of cardboard. Protect hands
and body from highpressure fluids.
If an accident occurs, see a doctor immediately. Any fluid
injected into the skin must be surgically removed within
a few hours or gangrene may result. Doctors unfamiliar
with this type of injury should reference a knowledgeable
medical source. Such information is available in Moline, Illinois, U.S.A., by calling 18008228262 or +1
English from Deere & Company Medical Department in 3097485636.
DX,FLUID 1920AUG091/1
TS230 UN24MAY89
DX,PARK 1904JUN901/1
TS229 UN23AUG88
Do not support the machine on cinder blocks, hollow tiles,
or props that may crumble under continuous load. Do not
work under a machine that is supported solely by a jack.
Follow recommended procedures in this manual.
When implements or attachments are used with a
machine, always follow safety precautions listed in the
implement or attachment operators manual.
DX,LOWER 1924FEB001/1
PN=9
Safety Information
TS206 UN23AUG88
while operating machine.
DX,WEAR2 1903MAR931/1
T6642EJ UN18OCT88
Read all instructions thoroughly do not attempt
shortcuts.
DX,CLEAN 1904JUN901/1
TS228 UN23AUG88
Remove rings and other jewelry to prevent electrical
shorts and entanglement in moving parts.
DX,LOOSE 1904JUN901/1
PN=10
Safety Information
TS220 UN23AUG88
If you do not have an exhaust pipe extension, open the
doors and get outside air into the area.
DX,AIR 1917FEB991/1
TS223 UN23AUG88
DX,LIGHT 1904JUN901/1
TS201 UN23AUG88
DX,SIGNS1 1904JUN901/1
PN=11
Safety Information
TS226 UN23AUG88
DX,LIFT 1904JUN901/1
TS220 UN23AUG88
Remove paint a minimum of 100 mm (4 in.) from area
to be affected by heating. If paint cannot be removed,
wear an approved respirator before heating or welding.
If you sand or grind paint, avoid breathing the dust.
Wear an approved respirator.
If you use solvent or paint stripper, remove stripper with
soap and water before welding. Remove solvent or
paint stripper containers and other flammable material
from area. Allow fumes to disperse at least 15 minutes Do all work in an area that is well ventilated to carry toxic
before welding or heating. fumes and dust away.
Do not use a chlorinated solvent in areas where welding Dispose of paint and solvent properly.
will take place.
DX,PAINT 1924JUL021/1
DX,TORCH 1910DEC041/1
PN=12
Safety Information
TS212 UN23AUG88
The protection offered by ROPS will be impaired if ROPS
is subjected to structural damage, is involved in an
overturn incident, or is in any way altered by welding,
bending, drilling, or cutting. A damaged ROPS should be
replaced, not reused.
DX,ROPS3 1903MAR931/1
TS211 UN23AUG88
DX,RIM 1924AUG901/1
PN=13
Safety Information
TS220 UN23AUG88
fibers are brake pads, brake band and lining assemblies,
clutch plates, and some gaskets. The asbestos used in
these components is usually found in a resin or sealed in
some way. Normal handling is not hazardous as long as
airborne dust containing asbestos is not generated.
Avoid creating dust. Never use compressed air for
cleaning. Avoid brushing or grinding material containing
asbestos. When servicing, wear an approved respirator.
A special vacuum cleaner is recommended to clean Keep bystanders away from the area.
asbestos. If not available, apply a mist of oil or water on
the material containing asbestos.
DX,DUST 1915MAR911/1
DX,SERV 1917FEB991/1
PN=14
Safety Information
TS779 UN08NOV89
For loosening and tightening hardware, use the correct
size tools. DO NOT use U.S. measurement tools on
metric fasteners. Avoid bodily injury caused by slipping
wrenches.
Use only service parts meeting John Deere specifications.
DX,REPAIR 1917FEB991/1
TS1133 UN26NOV90
Use leakproof containers when draining fluids. Do not use
food or beverage containers that may mislead someone
into drinking from them.
Do not pour waste onto the ground, down a drain, or into
any water source.
Air conditioning refrigerants escaping into the air can
damage the Earths atmosphere. Government regulations
may require a certified air conditioning service center to
recover and recycle used air conditioning refrigerants.
Inquire on the proper way to recycle or dispose of waste
from your local environmental or recycling center, or from
your John Deere dealer.
DX,DRAIN 1903MAR931/1
TS231 1907OCT88
DX,LIVE 1925SEP921/1
PN=15
Group 0002
General Specifications
450G Crawler Dozer Specifications
T7347AC UN23JUL90
NOTE: Specifications and design subject to change structure, full fuel tank, 80 kg (175 lb) operator,
without notice. Whenever applicable, specifications and standard equipment.
are in accordance with ICED and SAE standards.
Except where otherwise noted, these specifications Blade capacity shown is for a 2230 mm (7 ft
are based on a unit with rollover protective 3.8 in.) blade. All blades are interchangeable
between the 450G, 550G, and the 650G.
PN=16
General Specifications
Engine: John Deere 4045D (Direct Drive only) or 4045T (S.N. 840460) or John Deere PowerTech 4.5L engine type 4045TT061 (S.N. 840461 )
Type Naturally aspirated (4045D) altitude compensating
turbocharge (4045T)
Bore and stroke 106.5 x 127 mm (4.19 x 5.00 in.)
No. of cylinders 4
Fuel consumption, typical (S.N. 840460) 4.9 to 8.7 L/h (5 to 2.3 gal/hr)
Fuel consumption, typical (S.N. 840461 ) 6.3 to 9.5 L/h (1.7 to 2.5 gal/hr)
Compression ratio (S.N. 840460) 17.8 to 1
Compression ratio (S.N. 840461 ) 17 to 1
Electrical system 12 volt (with battery disconnect switch, if equipped)
Battery 12 volt
Alternator 65 amp
SAE net power at 2100 rpm 52 kW (70 hp)
SAE gross power at 2100 rpm 54.5 kW (73 hp)
Maximum net torque at 1300 rpm 309 Nm (228 lbft)
Drawbar 38 kW (51 hp)
Displacement (S.N. 840460) 4.524 L (276 cu in.)
Displacement (S.N. 840461 ) 4.5 L
Transmission: Powershift (4F4R) with torque converter or direct drive. Full power shift, DuraShift with torque converter or direct drive, designed
and built by John Deere. You can power shift easily from one gear to another as conditions change without stopping the machine or using a clutch.
Power control inching pedal adds versatility. Four speeds forward and reverse allow the operator to match speeds to the working conditions.
Steering:
Clutches Wet multiple disk
Brakes Wet band
Undercarriage:
Grouser, closedcenter 406 mm (16 in.)
Track shoes, each side 37
2 2
Ground contact area 15 690 cm (2432 in. )
Ground pressure (direct drive) 44.6 kPa (6.47 psi)
Ground pressure (torque converter) 45.2 kPa (6.55 psi)
PN=17
General Specifications
TX,115,FF1917 1908OCT931/1
PN=18
General Specifications
T7347AC UN23JUL90
NOTE: Specifications and design subject to change structure, full fuel tank, 80 kg (175 lb) operator,
without notice. Whenever applicable, specifications and standard equipment.
are in accordance with ICED and SAE standards.
Except where otherwise noted, these specifications Blade capacity shown is for a 2230 mm (7 ft
are based on a unit with rollover protective 3.8 in.) blade. All blades are interchangeable
between the 450G, 550G, and the 650G.
PN=19
General Specifications
Engine: John Deere 4045D (Direct Drive only) or 4045T (S.N. 840460) or John Deere PowerTech 4.5L engine type 4045TT061 (S.N. 840461 )
Type Naturally aspirated (4045D) or altitute compensating
turbocharge (4045T)
Bore and stroke 106.5 x 127 mm (4.19 x 5.00 in.)
No. of cylinders 4
Fuel consumption, typical (S.N. 840460) 4.9 to 8.7 L/h (5 to 2.3 gal/hr)
Fuel consumption, typical (S.N. 840461 ) 6.3 to 9.5 L/h (1.7 to 2.5 gal/hr)
Compression ratio (S.N. 840460) 17.8 to 1
Compression ratio (S.N. 840461 ) 17 to 1
Electrical system 12 volt (with battery disconnect switch, if equipped)
Battery 12 volt
Alternator (S.N. 840460) 65 amp
Alternator (S.N. 840461 ) 95 amp
SAE net power at 2100 rpm 52 kW (70 hp)
SAE gross power at 2100 rpm 54.5 kW (73 hp)
Maximum net torque at 1300 rpm 309 Nm (228 lbft)
Drawbar 38 kW (51 hp)
Displacement (S.N. 840460) 4.524 L (276 cu in.)
Displacement (S.N. 840461 ) 4.5 L
Transmission: Powershift (4F4R) with torque converter or direct drive. Full power shift, DuraShift with torque converter or direct drive, designed
and built by John Deere. You can power shift easily from one gear to another as conditions change without stopping the machine or using a clutch.
Power control inching pedal adds versatility. Four speeds forward and reverse allow the operator to match speeds to the working conditions.
Steering:
Clutches Wet multiple disk
Brakes Wet band
Undercarriage:
Grouser, closedcenter 406 mm (16 in.)
Track shoes, each side 40
2 2
Ground contact area 17 632 cm (2733 in. )
Ground pressure (direct drive) 41.1 kPa (5.97 psi)
Ground pressure (torque converter) 41.7 kPa (6.04 psi)
PN=20
General Specifications
TX,115,FF1917 1908OCT931/1
PN=21
General Specifications
T7347AC UN23JUL90
NOTE: Specifications and design subject to change structure, full fuel tank, 80 kg (175 lb) operator,
without notice. Whenever applicable, specifications and standard equipment.
are in accordance with ICED and SAE standards.
Except where otherwise noted, these specifications Blade capacity shown is for a 2230 mm (7 ft
are based on a unit with rollover protective 3.8 in.) blade. All blades are interchangeable
between the 450G, 550G, and the 650G.
PN=22
General Specifications
Engine: John Deere 4045D (Direct Drive only) or 4045T (S.N. 840460) or John Deere PowerTech 4.5L engine type 4045TT061 (S.N. 840461 )
Type Naturally aspirated or altitude compensating turbocharge
Bore and stroke 106.5 x 127 mm (4.19 x 5.00 in.)
No. of cylinders 4
Fuel consumption, typical (S.N. 840460) 4.9 to 8.7 L/h (5 to 2.3 gal/hr)
Fuel consumption, typical (S.N. 840461 ) 6.3 to 9.5 L/h (1.7 to 2.5 gal/hr)
Compression ratio (S.N. 840460) 17.8 to 1
Compression ratio (S.N. 840461 ) 17 to 1
Electrical system 12 volt (with battery disconnect switch, if equipped)
Battery 12 volt
Alternator 65 amp
SAE net power at 2100 rpm 52 kW (70 hp)
SAE gross power at 2100 rpm 54.5 kW (73 hp)
Maximum net torque at 1300 rpm 309 Nm (228 lbft)
Drawbar 38 kW (51 hp)
Displacement (S.N. 840460) 4.524 L (276 cu in.)
Displacement (S.N. 840461 ) 4.5 L
Transmission: Powershift (4F4R) with torque converter or direct drive. Full power shift, DuraShift with torque converter or direct drive, designed
and built by John Deere. You can power shift easily from one gear to another as conditions change without stopping the machine or using a clutch.
Power control inching pedal adds versatility. Four speeds forward and reverse allow the operator to match speeds to the working conditions.
Steering:
Clutches Wet multiple disk
Brakes Wet band
Undercarriage:
Grouser, closedcenter 610 mm (24 in.)
Track shoes, each side 40
2 2
Ground contact area 26 445 cm (4099 in. )
Ground pressure (direct drive) 29.0 kPa (4.2 psi)
Ground pressure (torque converter) 29.3 kPa (4.25 psi)
PN=23
General Specifications
TX,115,FF1917 1908OCT931/1
PN=24
General Specifications
T8196BD UN14APR94
NOTE: Specifications and design subject to change are based on a machine with rollover protective
without notice. Wherever applicable, specifications structure, full fuel tank, 80 kg (175 lb) operator,
are in accordance with ICED and SAE Standards. and standard equipment.
Except where otherwise noted, these specifications
PN=25
General Specifications
Hydraulics:
Pump Gear
Pressure 17 927 kPa (2600 psi)
Flow at 2100 rpm 118 L/min (31 gpm)
Cylinders:
Boom (bore x stroke) 100 mm (3.93 in.) x 827 mm (32.55 in.)
Bucket (bore x stroke) 90 mm (3.5 in.) x 744 mm (29.30 in.)
Cylinder rod dia. 50 mm (1.96 in.)
Steering:
Clutches Wet multiple disks
Brakes Wet band
Undercarriage:
Standard Track:
Twobar grouser, closedcenter 356 mm (14 in.)
Track shoes, each side 37
Ground clearance 330 mm (13 in.)
No. of track rollers 5
2 2
Ground contact area 13 729 cm (2128 in. )
Ground pressure, Direct Drive 60.1 kPa (8.71 psi)
Ground pressure, Torque Converter 60.7 kPa (8.8 psi)
Carrier roller 1
Wide Track:
Twobar grouser, closed center 533 mm (21 in.)
Track shoes, each side 37
Ground clearance 330 mm (13 in.)
No. of track rollers 5
2 2
Ground contact area 20 595 cm (3192 in. )
Ground pressure, Direct Drive 41.8 kPa (6.06 psi)
Ground pressure, Torque Converter 42.2 kPa (6.12 psi)
Carrier roller 1
TX,9000,RB178 1914JUN112/2
PN=26
General Specifications
Operating Weight:
Standard Track w/ROPS 8503 kg (18 745 lb)
Wide Track w/ROPS 8866 kg (19 545 lb)
Adjustment to operating weights:
Cab add 306 kg (676 lb)
Bucket teeth, bolton minus 63 kg (139 lb)
Radial ripper w/3shanks, w/o drawbar and counterweight add 32 kg (70 lb)
Counterweight add 136 kg (300 lb)
TX,115,RR3026 1914APR941/1
TX,115,RR3044 1914APR941/1
PN=27
General Specifications
T7347AC UN23JUL90
NOTE: Specifications and design subject to change structure, full fuel tank, 80 kg (175 lb) operator,
without notice. Whenever applicable, specifications and standard equipment.
are in accordance with ICED and SAE standards.
Except where otherwise noted, these specifications Blade capacity shown is for a 2230 mm (7 ft
are based on a unit with rollover protective 3.8 in.) blade. All blades are interchangeable
between the 450G, 550G, and the 650G.
PN=28
General Specifications
Engine: John Deere 4045T (S.N. 840460) or John Deere PowerTech 4.5L engine type 4045TT062 (S.N. 840461 )
Type Turbocharged
Bore and stroke 106.5 x 127 mm (4.19 x 5.00 in.)
No. of cylinders 4
Fuel consumption, typical (S.N. 840460) 7.0 to 10.5 L/h (1.8 to 2.8 gal/h)
Fuel consumption, typical (S.N. 840461 ) 4.9 to 8.7 L/h (5 to 2.3 gal/hr)
Compression ratio (S.N. 840460) 17.2 to 1
Compression ratio (S.N. 840461 ) 17 to 1
Electrical system 12 volt (with battery disconnect switch, if equipped)
Battery 12 volt
Alternator (S.N. 840460) 65 amp
Alternator (S.N. 840461 ) 95 amp
SAE net power at 2100 rpm 59.5 kW (80 hp)
SAE gross power at 2100 rpm 62 kW (83 hp)
Maximum net torque at 1300 rpm 353 Nm (260 lbft)
Drawbar 43 kW (58 hp)
Displacement (S.N. 840460) 4.524 L (276 cu in.)
Displacement (S.N. 840461 ) 4.5 L
Transmission: Powershift (4F4R) with torque converter or direct drive. Full power shift, DuraShift with torque converter or direct drive, designed
and built by John Deere. You can power shift easily from one gear to another as conditions change without stopping the machine or using a clutch.
Power control inching pedal adds versatility. Four speeds forward and reverse allow the operator to match speeds to the working conditions.
Steering:
Clutches Wet multiple disk
Brakes Wet band
Undercarriage:
Grouser, closedcenter 457 mm (18 in.)
Track shoes, each side 40
2 2
Ground contact area 17 626 cm (2732 in. )
Ground pressure (direct drive) 44.1 kPa (6.4 psi)
Ground pressure (torque converter) 44.7 kPa (6.47 psi)
PN=29
General Specifications
TX,115,FF1917 1908OCT931/1
PN=30
General Specifications
T7347AC UN23JUL90
NOTE: Specifications and design subject to change structure, full fuel tank, 80 kg (175 lb) operator,
without notice. Whenever applicable, specifications and standard equipment.
are in accordance with ICED and SAE standards.
Except where otherwise noted, these specifications Blade capacity shown is for a 2230 mm (7 ft
are based on a unit with rollover protective 3.8 in.) blade. All blades are interchangeable
between the 450G, 550G, and the 650G.
PN=31
General Specifications
Engine: John Deere 4045T (S.N. 840460) or John Deere PowerTech 4.5L engine type 4045TT062 (S.N. 840461 )
Type Turbocharged
Bore and stroke 106.5 x 127 mm (4.19 x 5.00 in.)
No. of cylinders 4
Fuel consumption, typical (S.N. 840460) 4.9 to 8.7 L/h (5 to 2.3 gal/hr)
Fuel consumption, typical (S.N. 840461 ) 7.0 to 10.5 L/h (1.8 to 2.8 gal/hr)
Compression ratio (S.N. 840460) 17.2 to 1
Compression ratio (S.N. 840461 ) 17 to 1
Electrical system 12 volt (with battery disconnect switch, if equipped)
Battery 12 volt
Alternator (S.N. 840460) 65 amp
Alternator (S.N. 840461 ) 95 amp
SAE net power at 2100 rpm 59.5 kW (80 hp)
SAE gross power at 2100 rpm 62 kW (83 hp)
Maximum net torque at 1300 rpm 353 Nm (260 lbft)
Drawbar 43 kW (58 hp)
Displacement (S.N. 840460) 4.524 L (276 cu in.)
Displacement (S.N. 840461 ) 4.5 L
Transmission: Powershift (4F4R) with torque converter or direct drive. Full power shift, DuraShift with torque converter or direct drive, designed
and built by John Deere. You can power shift easily from one gear to another as conditions change without stopping the machine or using a clutch.
Power control inching pedal adds versatility. Four speeds forward and reverse allow the operator to match speeds to the working conditions.
Steering:
Clutches Wet multiple disk
Brakes Wet band
Undercarriage:
Grouser, closedcenter 610 mm (24 in.)
Track shoes, each side 40
2 2
Ground contact arean 26 447 cm (4099 in. )
Ground pressure (direct drive) 30.8 kPa (4.47 psi)
Ground pressure (torque converter) 31.2 kPa (4.52 psi)
PN=32
General Specifications
TX,115,FF1917 1908OCT931/1
PN=33
General Specifications
T8196BD UN14APR94
NOTE: Specifications and design subject to change are based on a machine with rollover protective
without notice. Wherever applicable, specifications structure, full fuel tank, 80 kg (175 lb) operator,
are in accordance with ICED and SAE Standards. and standard equipment.
Except where otherwise noted, these specifications
PN=34
General Specifications
SAE net power at 2100 rpm SAE net 67.1 kW (90 hp)
SAE gross 74 kW (99 hp)
Bore and stroke 106.5 x 127 mm (4.19 x 5.00 in.)
No. of cylinders 4
Displacement (S.N. 840460) 4.524 L (276 cu in.)
Displacement (S.N. 846461 ) 4.5 L
Compression ratio (S.N. 840460) 16.2 to 1
Compression ratio (S.N. 846461 ) 17 to 1
Electrical system 12 volt (with battery disconnect switch if equipped)
Battery 12 volt
Alternator 65 amp
Maximum net torque rise at 1300 rpm 339 Nm (250 lbft)
Transmission: Full power shift, DuraShift direct drive transmission is designed and built by John Deere. Four speeds forward and reverse
allow the operator to match speeds to the working conditions. Shift easily from one gear to another as conditions change without stopping the
machine or using a clutch. Power control inching pedal adds versatility.
Hydraulics:
Pump Gear
Pressure 17927 kPa (2600 psi)
Flow 148 L/min (39 gpm)
Cylinders:
Boom (bore x stroke) 115 mm (4.53 in.) x 811 mm (31.93 in.)
Bucket (bore x stroke) 100 mm (3.94 in.) x 744 mm (29.30 in.)
Bucket cylinder rod dia. 50 mm (1.96 in.)
Boom cylinder rod dia. 63 mm (2.48 in.)
Steering:
Clutches Wet multiple disk
Brakes Wet band
Undercarriage:
Standard Track:
Twobar grouser, closedcenter 410 mm (16 in.)
Track shoes, each side 36
Ground clearance 362 mm (14.25 in.)
No. of track rollers 6
2 2
Ground contact area 16 270 cm (2522 in. )
Ground pressure, Direct Drive 57 kPa (8.27 psi)
Ground pressure, Torque Converter 57.6 kPa (8.35 psi)
Carrier roller 1
Track gauge 1550 mm (61 in.)
Wide Track:
Continued on next page TX,9000,RB179 1914JUN112/3
PN=35
General Specifications
TX,9000,RB180 1906JAN981/1
PN=36
General Specifications
T7347AC UN23JUL90
NOTE: Specifications and design subject to change structure, full fuel tank, 80 kg (175 lb) operator,
without notice. Whenever applicable, specifications and standard equipment.
are in accordance with ICED and SAE standards.
Except where otherwise noted, these specifications Blade capacity shown is for a 2230 mm (7 ft
are based on a unit with rollover protective 3.8 in.) blade. All blades are interchangeable
between the 450G, 550G, and the 650G.
PN=37
General Specifications
Engine: John Deere 4045T (S.N. 840460) or John Deere PowerTech 4.5L engine type 4045TT063 (S.N. 840461 )
Type Turbocharged
Bore and stroke 106.5 x 127 mm (4.19 x 5.00 in.)
No. of cylinders 4
Fuel consumption, typical (S.N. 840460) 4.9 to 8.7 L/h (5 to 2.3 gal/hr)
Fuel consumption, typical (S.N. 840461 ) 8.0 to 11.9 L/h (2.1 to 3.1 gal/hr)
Compression ratio (S.N. 840460) 17.8 to 1
Compression ratio (S.N. 840461 ) 17 to 1
Electrical system 12 volt (with battery disconnect switch, if equipped)
Battery 12 volt
Alternator (S.N. 840460) 65 amp
Alternator (S.N. 840461 ) 95 amp
SAE net power at 2100 rpm 67.5 kW (90 hp)
SAE gross power at 2100 rpm (direct drive) 71 kW (95 hp)
SAE gross power at 2100 rpm (torque converter) 74 kW (99 hp)
Maximum net torque at 1300 rpm 397 Nm (293 lbft)
Drawbar 49 kW (66 hp)
Displacement (S.N. 840460) 4.524 L (276 cu in.)
Displacement (S.N. 840461 ) 4.5 L
Transmission: Powershift (4F4R) with torque converter or direct drive. Full power shift, DuraShift with torque converter or direct drive, designed
and built by John Deere. You can power shift easily from one gear to another as conditions change without stopping the machine or using a clutch.
Power control inching pedal adds versatility. Four speeds forward and reverse allow the operator to match speeds to the working conditions.
Steering:
Clutches Wet multiple disk
Brakes Wet band
Undercarriage:
Grouser, closedcenter 457 mm (18 in.)
Track shoes, each side 37
2 2
Ground contact area 19 884 cm (3082 in. )
Ground pressure (direct drive) 41.0 kPa (5.94 psi)
Ground pressure (torque converter) 41.4 kPa (6.01 psi)
PN=38
General Specifications
TX,115,FF1917 1908OCT931/1
PN=39
General Specifications
T7347AC UN23JUL90
NOTE: Specifications and design subject to change structure, full fuel tank, 80 kg (175 lb) operator,
without notice. Whenever applicable, specifications and standard equipment.
are in accordance with ICED and SAE standards.
Except where otherwise noted, these specifications Blade capacity shown is for a 2230 mm (7 ft
are based on a unit with rollover protective 3.8 in.) blade. All blades are interchangeable
between the 450G, 550G, and the 650G.
PN=40
General Specifications
Engine: John Deere 4045T (S.N. 840460) or John Deere PowerTech 4.5L engine type 4045TT063 (S.N. 840461 )
Type Turbocharged
Bore and stroke 106.5 x 127 mm (4.19 x 5.00 in.)
No. of cylinders 4
Fuel consumption, typical (S.N. 840460) 4.9 to 8.7 L/h (5 to 2.3 gal/hr)
Fuel consumption, typical (S.N. 840461 ) 8.0 to 11.9 L/h (2.1 to 3.1 gal/hr)
Compression ratio (S.N. 840460) 17.8 to 1
Compression ratio (S.N. 840461 ) 17 to 1
Electrical system 12 volt (with battery disconnect switch, if equipped)
Battery 12 volt
Alternator (S.N. 840460) 65 amp
Alternator (S.N. 840461 ) 95 amp
SAE net power at 2100 rpm 67.5 kW (90 hp)
SAE gross power at 2100 rpm (direct drive) 71 kW (95 hp)
SAE gross power at 2100 rpm (torque converter) 74 kW (99 hp)
Maximum net torque at 1300 rpm 397 Nm (293 lbft)
Drawbar 49 kW (66 hp)
Displacement (S.N. 840460) 4.524 L (276 cu in.)
Displacement (S.N. 840461 ) 4.5 L
Transmission: Powershift (4F4R) with torque converter or direct drive. Full power shift, DuraShift with torque converter or direct drive, designed
and built by John Deere. You can power shift easily from one gear to another as conditions change without stopping the machine or using a clutch.
Power control inching pedal adds versatility. Four speeds forward and reverse allow the operator to match speeds to the working conditions.
Steering:
Clutches Wet multiple disk
Brakes Wet band
Undercarriage:
Grouser, closedcenter (standard shoe) 610 mm (24 in.)
Grouser, closedcenter (wide shoe) 660 mm (26 in.)
Track shoes, each side 38
2 2
Ground contact area (standard shoe) 26 510 cm (4109 in. )
2
Ground contact area (wide shoe) 28 717 cm (4451 in. 2)
Ground pressure (direct drive, standard shoe) 32.1 kPa (4.65 psi)
Ground pressure (torque converter, standard shoe) 32.4 kPa (4.70 psi)
Ground pressure (direct drive, wide shoe) 30.4 kPa (4.41 psi)
Ground pressure (torque converter, wide shoe 30.7 kPa (4.45 psi)
PN=41
General Specifications
TX,115,FF1917 1908OCT931/1
T7394BK UN20DEC90
TX,115,FF2056 1914APR941/1
PN=42
General Specifications
T7395DA 1912OCT90
A1700 kg (3750 lb) F 910 kg (2010 lb) K795 kg (1755 lb) P785 kg (1730 lb)
B1525 kg (3365 lb) G900 kg (1990 lb) L 770 kg (1700 lb) QDipper Lift, Boom at 65
C1530 kg (3370 lb) H880 kg (1940 lb) M750 kg (1660 lb) RSwing Pivot
D1640 kg (3620 lb) I 850 kg (1880 lb) N740 kg (1630 lb) SBoom Lift
E880 kg (1950 lb) J 820 kg (1814 lb) O740 kg (1630 lb)
PN=43
General Specifications
T7395DA1 UN12DEC92
A1700 kg (3750 lb) F 960 kg (2120 lb) K845 kg (1865 lb) P835 kg (1845 lb)
B1525 kg (3365 lb) G955 kg (2105 lb) L 820 kg (1810 lb) QDipper Lift, Boom at 65
C1530 kg (3370 lb) H930 kg (2050 lb) M800 kg (1765 lb) RSwing Pivot
D1670 kg (3685 lb) I 900 kg (1990 lb) N790 kg (1740 lb) SBoom Lift
E930 kg (2050 lb) J 870 kg (1925 lb) O790 kg (1740 lb)
PN=44
Group 0003
Torque Values
Specifications
Item Measurement Specification
TS176 UN23AUG88
The protection offered by ROPS will be
impaired if ROPS is subjected to structural
damage, is involved in an overturn incident,
or is in any way altered. A damaged ROPS
should be replaced, not reused.
PN=45
Torque Values
T82862 UN08NOV88
If machine is operated with loose track shoes, the cap
screw holes in the shoes and links will wear and it may be
difficult to keep the track shoes tight. Loose shoes can
also cause hardware failure and loss of track shoes.
Install all track shoe nuts with rounded edges (A) against
the link and chamfered edges (B) away from the link. Be
sure nut is properly positioned in the link so there is full
contact area between the nut and the link.
450G, 455G, 550GSpecification
Track Shoe Cap
Screw(1/2
T6794AM UN23FEB89
in.)Torque........................................................61 Nm (45 lbft) second
passadditional 1/3 (120) turn
Track Shoe Cap
Screw(9/16
in.)Torque........................................................88 Nm (65 lbft) second
passadditional 1/3 (120) turn
555G, 650GSpecification
Track Shoe Cap
Screw(5/8 ARounded Edge BChamfered Edge
in.)Torque.................................................... 149 Nm (110 lbft) second
passadditional 1/3 (120) turn
450G, 455G, 550GSpecification 555G, 650GSpecification
Track Shoe/Split Link Track Shoe/Split Link
Cap Screw(1/2 Cap Screw(5/8
in.)Torque........................................................61 Nm (45 lbft) second in.)Torque.................................................... 149 Nm (110 lbft) second
passadditional 1/2 (180) turn passadditional 1/2 (180) turn
Track Shoe/Split Link
Cap Screw(9/16 NOTE: Replacement hardware should be lubricated
in.)Torque........................................................88 Nm (65 lbft) second and tightened to above specification.
passadditional 1/2 (180) turn
TX,90,RR2494 1903AUG921/1
PN=46
Torque Values
Bolt or Screw SAE Grade 1 SAE Grade 2a SAE Grade 5, 5.1 or 5.2 SAE Grade 8 or 8.2
b c
Size Lubricated Dry Lubricatedb Dryc Lubricatedb Dryc Lubricatedb Dryc
Nm lb.in. Nm lb.in. Nm lb.in. Nm lb.in. Nm lb.in. Nm lb.in. Nm lb.in. Nm lb.in.
1/4 3.7 33 4.7 42 6 53 7.5 66 9.5 84 12 106 13.5 120 17 150
Nm lb.ft. Nm lb.ft.
5/16 7.7 68 9.8 86 12 106 15.5 137 19.5 172 25 221 28 20.5 35 26
Nm lb.ft. Nm lb.ft.
3/8 13.5 120 17.5 155 22 194 27 240 35 26 44 32.5 49 36 63 46
Nm lb.ft. Nm lb.ft. Nm lb.ft.
7/16 22 194 28 20.5 35 26 44 32.5 56 41 70 52 80 59 100 74
Nm lb.ft.
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
1 285 210 360 265 285 210 360 265 730 540 920 680 1030 760 1300 960
11/8 400 300 510 375 400 300 510 375 910 670 1150 850 1450 1075 1850 1350
11/4 570 420 725 535 570 420 725 535 1280 945 1630 1200 2050 1500 2600 1920
13/8 750 550 950 700 750 550 950 700 1700 1250 2140 1580 2700 2000 3400 2500
11/2 990 730 1250 930 990 730 1250 930 2250 1650 2850 2100 3600 2650 4550 3350
Torque values listed are for general use only, based on the strength of the bolt Replace fasteners with the same or higher grade. If higher
or screw. DO NOT use these values if a different torque value or tightening grade fasteners are used, tighten these to the strength of the
procedure is given for a specific application. For plastic insert or crimped steel original. Make sure fastener threads are clean and that you
type lock nuts, for stainless steel fasteners, or for nuts on Ubolts, see the properly start thread engagement. When possible, lubricate
tightening instructions for the specific application. Shear bolts are designed to fail plain or zinc plated fasteners other than lock nuts, wheel bolts
under predetermined loads. Always replace shear bolts with identical grade. or wheel nuts, unless different instructions are given for the
specific application.
a
Grade 2 applies for hex cap screws (not hex bolts) up to 6 in. (152 mm) long. Grade 1 applies for hex cap screws over 6
in. (152 mm) long, and for all other types of bolts and screws of any length.
b
Lubricated means coated with a lubricant such as engine oil, fasteners with phosphate and oil coatings, or 7/8 in.
and larger fasteners with JDM F13C, F13F or F13J zinc flake coating.
c
Dry means plain or zinc plated without any lubrication, or 1/4 to 3/4 in. fasteners with JDM F13B, F13E or F13H zinc flake coating.
DX,TORQ1 1912JAN111/1
PN=47
Torque Values
Bolt or Screw Class 4.8 Class 8.8 or 9.8 Class 10.9 Class 12.9
Size Lubricateda Dryb Lubricateda Dryb Lubricateda Dryb Lubricateda Dryb
Nm lb.in. Nm lb.in. Nm lb.in. Nm lb.in. Nm lb.in. Nm lb.in. Nm lb.in. Nm lb.in.
M6 4.7 42 6 53 8.9 79 11.3 100 13 115 16.5 146 15.5 137 19.5 172
Nm lb.ft. Nm lb.ft. Nm lb.ft. Nm lb.ft.
M8 11.5 102 14.5 128 22 194 27.5 243 32 23.5 40 29.5 37 27.5 47 35
Nm lb.ft. Nm lb.ft. Nm lb.ft.
M10 23 204 29 21 43 32 55 40 63 46 80 59 75 55 95 70
Nm lb.ft.
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
Torque values listed are for general use only, based on the strength of Shear bolts are designed to fail under predetermined loads. Always
the bolt or screw. DO NOT use these values if a different torque value or replace shear bolts with identical property class. Replace fasteners with
tightening procedure is given for a specific application. For stainless steel the same or higher property class. If higher property class fasteners are
fasteners or for nuts on Ubolts, see the tightening instructions for the used, tighten these to the strength of the original. Make sure fastener
specific application. Tighten plastic insert or crimped steel type lock nuts threads are clean and that you properly start thread engagement. When
by turning the nut to the dry torque shown in the chart, unless different possible, lubricate plain or zinc plated fasteners other than lock nuts,
instructions are given for the specific application. wheel bolts or wheel nuts, unless different instructions are given for the
specific application.
a
Lubricated means coated with a lubricant such as engine oil, fasteners with phosphate and oil coatings, or M20
and larger fasteners with JDM F13C, F13F or F13J zinc flake coating.
b
Dry means plain or zinc plated without any lubrication, or M6 to M18 fasteners with JDM F13B, F13E or F13H zinc flake coating.
DX,TORQ2 1912JAN111/1
PN=48
Torque Values
T6873AA UN18OCT88
CAUTION: Use only metric tools on metric
hardware. Other tools may not fit properly.
They may slip and cause injury.
T6873AB UN18OCT88
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 you properly
start thread engagement. This will prevent them from
failing when tightening.
T6873AC UN18OCT88
Tighten cap screws having lock nuts to approximately 50
percent of amount shown in chart.
METRIC CAP SCREW TORQUE VALUESa
TBolt HBolt MBolt
Nomi
nal Dia Nm lbft Nm lbft Nm lbft
8 29 21 20 15 10 7
10 63 46 45 33 20 15
12 108 80 88 65 34 25
14 176 130 137 101 54 40
16 265 195 206 152 78 58
18 392 289 294 217 118 87
20 539 398 392 289 167 125
22 735 542 539 398 216 159
24 931 687 686 506 274 202
27 1372 1012 1029 759 392 289
30 1911 1410 1421 1049 539 398
33 2548 1890 1911 1410 735 542
36 3136 2314 2401 1772 931 687
a
Torque tolerance is 10%.
04T,90,M170 1929SEP991/1
PN=49
Torque Values
X9811 UN23AUG88
all connections before applying pressure. Search
for leaks with a piece of cardboard. Protect hands
and body from high pressure fluids.
If an accident occurs, see a doctor immediately.
Any fluid injected into the skin must be surgically
removed within a few hours or gangrene
may result. Doctors unfamiliar with this
type of injury may call the Deere & Company
Medical Department in Moline, Illinois, or other Tubing with dents may cause the oil to overheat. If you
knowledgeable medical source. find tubing with dents, install new tubing immediately.
IMPORTANT: Tighten fittings as specified
Check all oil lines, hoses, and fittings regularly for leaks or in torque chart.
damage. Make sure all clamps are in position and tight.
Make sure hoses are not twisted or touching moving When you tighten connections, use two wrenches to
machine parts. If abrasion or wear occurs, replace prevent bending or breaking tubing and fittings.
immediately.
T82,FLMA,AI 1914MAR901/1
T6234AC UN18OCT88
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.
5. Index angle fittings and tighten by hand.
STRAIGHT FITTING OR SPECIAL NUT TORQUE CHART
6. Tighten fitting or nut to torque value shown on torque Thread Size Nm lbft
chart. Do not allow hoses to twist when tightening
3/8 24 UNF 8 6
fittings.
7/16 20 UNF 12 9
1/2 20 UNF 16 12
9/16 18 UNF 24 18
3/4 16 UNF 46 34
7/8 14 UNF 62 46
11/16 12 UN 102 75
13/16 12 UN 122 90
15/16 12 UN 142 105
15/8 12 190 140
17/8 12 UN 217 160
T82,BHMA,EL 1929SEP991/1
PN=50
Torque Values
T6243AE UN18OCT88
2. Lubricate Oring with petroleum jelly. Place electrical
tape over threads to protect Oring. Slide Oring over
tape and into Oring groove of fitting. Remove tape.
3. Tighten fitting to torque value shown on chart.
04T,90,K66 1929SEP991/2
Angle Fitting
1. Backoff lock nut (A) and backup washer (B)
completely to headend (C) of fitting.
2. Turn fitting into threaded boss until backup washer
contacts face of boss.
T6520AB UN18OCT88
3. Turn fitting headend counterclockwise to proper index
(maximum of one turn).
NOTE: Do not allow hoses to twist when tightening fittings.
04T,90,K66 1929SEP992/2
PN=51
Torque Values
Service Recommendations For Flat Face 4. Tighten fitting or nut to torque value shown on the
ORing Seal Fittings chart. Do not allow hoses to twist when tightening
1. Inspect the fitting sealing surfaces and Oring. They fittings, use backup wrench on straight hose couplings.
must be free of dirt or defects. IMPORTANT: Tighten fittings to 150% of listed torque
2. Lubricate Orings and install into grove using value if indexing is necessary or if fitting is
petroleum jelly to hold in place. attached to an actuating device.
3. Index angle fittings and tighten by hand pressing joint Tighten fittings to 50% of listed torque value
together to insure Oring remains in place. if used in aluminum housing.
OUO6092,00010A4 1931MAY111/1
PN=52
Torque Values
T6890BB UN01MAR90
ASealing Surface BSplit Flange CPinched ORing DSingle Piece Flange
PN=53
Torque Values
T6890BB UN01MAR90
ASealing Surface BSplit Flange CPinched ORing DSingle Piece Flange
PN=54
Group 0004
Fuels and Lubricants
Fuel Specifications
Use ONLY clean, highquality fuel. Use fuel with less than 1.0 per cent
Use Grade No. 2D fuel above 40F (4C). sulfur. If possible, use fuel with less
than 0.5 per cent sulfur.
Specification
Grade No. 2D For maximum filter life, sediment and water should not
FuelTemperature....................................................... Above 40F (4C) be more than 0.10 per cent.
Use Grade No. 1D fuel below 40F (4C). The cetane number should be 40 minimum. If you operate
Specification your machine where air temperatures are normally low or
Grade No. 1D where altitudes are high, you may need fuel with a higher
FuelTemperature....................................................... Below 40F (4C) cetane number.
Use Grade No. 1D fuel for all air temperatures at altitudes Cloud PointFor cold weather operation, cloud point
above 5000 ft (1 500 m). should be 10F (6C) below lowest normal air temperature.
Specification Specification
Grade No. 1D Cloud PointTempera
FuelHeight.................................................................5000 ft (1 500 m) ture.......................................................................................... 10F (6C)
below lowest normal air temperature
IMPORTANT: If fuel sulfur content exceeds 0.5 per
cent, the engine oil drain interval must be
reduced by 50 per cent (to 125 hours).
TX,45,DH1223 1915MAY921/1
PN=55
Fuels and Lubricants
T8358AJ 1927MAR95
Use oil viscosity based on the expected air temperature
range during the period between oil changes. Other oils may be used if they meet one or more of the
following:
The following oil is preferred.
John DeereUNIGARD
John Deere PLUS50 API Service Classification CG4
If John Deere PLUS50 engine oil and a John Deere oil
API Service Classification CF4
filter are used, the service interval for oil and filter changes Viscosity grade SAE 15W40 is preferred.
may be extended by 50 hours.
If diesel fuel with sulfur content greater than 0.5% is used,
The following oil is also recommended: reduce the service interval by 50%.
John DeereTORQGARD SUPREME
PLUS50 is a registered trademark of Deere & Company
TORQGARD SUPREME is a registered trademark of Deere & Company
UNIGARD is a trademark of Deere & Company
TX,45,JC276 1914JUN111/1
PN=56
Fuels and Lubricants
T100663 1910MAY96
Use oil viscosity based on the expected air temperature
range during the period between oil changes. John Deere BIOHYGARD
* 1BIOHYGARD meets or exceeds the minimum
The following oils are preferred:
biodegradability of 80% within 21 days according to
JOHN DEEREHYGARD CECL33T82 test method.
John Deere Low ViscosityHYGARD *BIOHYGARD should not be mixed with mineral oils
Other oils may be used if they meet one of the following: because this reduces the biodegradability and makes
proper oil recycling impossible.
John Deere Standard JDM J20C
John Deere Standard JDM J20D
Use the following oil when a biodegradable fluid is
required:
HYGARD is a registered trademark of Deere & Company
BIOHYGARD is a trademark of Deere & Company
02T,45,RR2760 1914JUN111/1
PN=57
Fuels and Lubricants
T100663 1910MAY96
Use oil viscosity based on the expected air temperature
range during the period between oil changes. John DeereBIOHYGARD 1
* 1BIOHYGARD meets or exceeds the minimum
The following oils are preferred:
biodegradability of 80% within 21 days according to
JOHN DEEREHYGARD CECL33T82 test method.
John Deere Low ViscosityHYGARD *BIOHYGARD should not be mixed with mineral oils
Other oils may be used if they meet one of the following: because this reduces the biodegradability and makes
proper oil recycling impossible.
John Deere Standard JDM J20C
John Deere Standard JDM J20D
Use the following oil when a biodegradable fluid is
required:
HYGARD is a registered trademark of Deere & Company
BIOHYGARD is a trademark of Deere & Company
TX,45,RR2761 1914JUN111/1
PN=58
Fuels and Lubricants
Grease
T6722AA 1927JAN89
Depending on the expected air temperature range, use SAE Multipurpose Grease with Extreme Pressure
grease shown on chart above. (EP) performance and containing 3 to 5 per cent
molybdenum disulfide
Greases recommended are:
SAE multipurpose EP Grease
John Deere Moly High Temperature/EP Grease Grease meeting MILG10924C specifications may be
(Preferred) used as arctic grease.
02T,45,C49 1901AUG941/1
PN=59
Fuels and Lubricants
John Deere COOLGARD II Premix The additive package must be part of one of the following
John Deere COOLGARD II PG Premix coolant mixtures:
Use John Deere COOLGARD II PG Premix when a ethylene glycol or propylene glycol base prediluted
nontoxic coolant formulation is required. (4060%) heavy duty coolant
ethylene glycol or propylene glycol base heavy
Additional Recommended Coolants duty coolant concentrate in a 4060% mixture of
concentrate with quality water
The following engine coolant is also recommended:
Water Quality
John Deere COOLGARD II Concentrate in a 4060%
mixture of concentrate with quality water. Water quality is important to the performance of the
cooling system. Distilled, deionized, or demineralized
John Deere COOLGARD II Premix, COOLGARD II PG
water is recommended for mixing with ethylene glycol and
Premix, and COOLGARD II Concentrate coolants do not
propylene glycol base engine coolant concentrate.
require use of supplemental coolant additives.
IMPORTANT: Do not use cooling system sealing
Other Coolants additives or antifreeze that contains
John Deere COOLGARD II and COOLGARD II PG sealing additives.
coolants might not be available in the geographical area Do not mix ethylene glycol and propylene
where service is performed. glycol base coolants.
If these coolants are unavailable, use a coolant Do not use coolants that contain nitrites.
concentrate or prediluted coolant intended for use with
heavy duty diesel engines and with a minimum of the
following chemical and physical properties:
PN=60
Fuels and Lubricants
Lubricant Storage
Your equipment can operate at top efficiency only when
clean lubricants are used. Make certain that all containers are properly marked to
identify their contents.
Use clean containers to handle all lubricants.
Properly dispose of all old containers and any residual
Store lubricants and containers in an area protected from lubricant they may contain.
dust, moisture, and other contamination. Store containers
on their side to avoid water and dirt accumulation.
DX,LUBST 1911APR111/1
PN=61
Fuels and Lubricants
PN=62
Section 01
Tracks
Contents
Page Page
PN=1
Contents
PN=2
Group 0130
Track System
T6926BA UN06DEC88
Special or Essential Tools
NOTE: Order tools according to information given in
the U.S. SERVICEGARDCatalog or in the
European Microfiche Tool Catalog (MTC).
PN=65
Track System
T6926BB UN06DEC88
Install stopper in lubricated track pins.
Seal Centering Fixture Tool .................................. JDG798
Used to install seal ring on front idler assembly for
555G and 650G machines (S.N. 771024 ).
To install seal ring on front idler assembly for 555G and
T6926BB UN06DEC88
650G machines (S.N. 771024 ).
Seal Centering Fixture Tool ..................................JT30018
Used to install seal ring on front idler assembly for
450G, 455G and 550G machines, and 555G and
650G machines (S.N. 771023).
T6926BB UN06DEC88
To install seal ring on front idler assembly for 450G, 455G
and 550G machines, and 555G and 650G machines (S.N.
771023).
Seal Centering Fixture Tool ..................................JT30019
Used to install seal ring in track roller assembly.
T6926BC UN06DEC88
To install seal ring in track roller assembly.
Hydraulic Track Adjuster Service Set ...................... JD284
Used to install track adjuster seals.
To install track adjuster seals.
Special Bolt (18 UNC2A x 151/2 JDM A17D) .... T16678 T6926BD UN06DEC88
stopper.
1
Order from: Centurin Industries Inc., 45 Capitol Dr., Oconomowoc, WI
DX,TOOLS 1914JUN113/3
Service Equipment and Tools Tool Catalog (MTC). Some tools may be
available from a local supplier.
NOTE: Order tools from the U.S. SERVICEGARD
Catalog or from the European Microfiche
PN=66
Track System
Bearing, Bushing and Seal Driver Set Used to remove and install bushings.
TX,01,DY71 1914JUN114/20
Track Press Tooling Set Used with track press to disassemble and
assemble track chain.
TX,01,DY71 1914JUN116/20
Saddle ......................................................................40989
Used with track press to disassemble and
assemble track chain.
TX,01,DY71 1914JUN118/20
Saddle ......................................................................42101
Used with track press to disassemble and
assemble track chain.
TX,01,DY71 1914JUN1110/20
Saddle ......................................................................40989
Used with track press to disassemble and
assemble track chain.
Continued on next page TX,01,DY71 1914JUN1112/20
PN=67
Track System
Saddle (Used for Stepped Bushing Design) .. 052657001 Used with track press to disassemble and
assemble track chain.
TX,01,DY71 1914JUN1113/20
Saddle ......................................................................42101
Used with track press to disassemble and
assemble track chain.
TX,01,DY71 1914JUN1115/20
Saddle (Used for Stepped Bushing Design) .. 052657001 Used with track press to disassemble and
assemble track chain.
TX,01,DY71 1914JUN1116/20
1/8 in. NPT Grease Fitting Used to add oil to idler, carrier roller and track roller.
TX,01,DY71 1914JUN1117/20
Adapter .................................................... AN142253 (7/16 Used with grease fitting to add oil to idler and rollers.
Male ORing Boss C 1/8 Female Pipe
TX,01,DY71 1914JUN1118/20
TX,01,DY71 1914JUN1120/20
PN=68
Track System
Other Material
Number Name Use
PT569 (U.S.) John Deere NEVERSEEZ Lubricant Apply to threads of master bolt
and mating surfaces of split link
on track chain.
PN=69
Track System
Specifications
Item Measurement Specification
Carrier Roller:
450G, 455G, 550G Outside Diameter 152.4 mm (6.0 in.)
100% Worn 139.7 mm (5.5 in.)
555G, 650G Outside Diameter 160.0 mm (6.3 in.)
100% worn 147.0 mm (5.8 in.)
BrackettoFrame Cap Screw Torque 675 Nm (500 lbft)
Upper Plate Socket Head Cap Torque 54 Nm (40 lbft)
Screws
Upper Cover Cap Screws Torque 47 Nm (35 lbft)
Upper Oil Level Check Cap Screw Torque 41 Nm (30 lbft)
Oil Level Plug Torque 41 4 Nm (30 3 lbft)
Track Roller:
450G, 455G, 550G Outside Diameter 182.6 mm (7.2 in.)
100% Worn 168.2 mm (6.6 in.)
555G, 650G Outside Diameter 182.6 mm (7.2 in.)
100% Worn 164.0 mm (6.5 in.)
RollertoBracket Cap Screw Torque 225 Nm (160 lbft)
Roller Bushing Inside Diameter 60.416.44 mm (2.37852.3795 in.)
Oil Level Plug Torque 41 4 Nm (30 3 lbft)
Seal Ring Socket Head Cap Torque 68 Nm (50 lbft)
Screws
Track Shoe:
Single Bar Grouser 450G, 455G, Height 48.0 mm (1.89 in.)
550G New Shoe
Single Bar Grouser 450G, 455G, Height 20.0 mm (0.8 in.)
550G 100% Worn
Single Bar Grouser 555G, 650G Height 50.0 mm (1.97 in.)
New Shoe
Single Bar Grouser 555G, 650G Height 23.0 mm (0.9 in.)
100% Worn
Two Bar Grouser 450G, 455G, Height 25.0 mm (0.98 in.)
550G New Shoe
Two Bar Grouser 450G, 455G, Height 16.0 mm (0.63 in.)
550G 100% Worn
Two Bar Grouser 555G, 650G New Height 30.0 mm (1.18 in.)
Shoe
Two Bar Grouser 555G, 650G Height 12.0 mm (0.47 in.)
100% Worn
Three Bar Grouser 450G, 455G, Height 21.1 mm (0.83 in.)
550G New Shoe
Three Bar Grouser 450G, 455G, Height 12.0 mm (0.47 in.)
550G 100% Worn
Continued on next page TX,0130,BD805 1926AUG021/4
PN=70
Track System
PN=71
Track System
PN=72
Track System
T5819AC UN01NOV88
3. Flat spots on roller thread indicates roller is not free
to turn.
Specification
450G, 455G,
550GOutside
Diameter...................................................................... 152.4 mm (6.0 in.)
100% Worn................................................................. 139.7 mm (5.5 in.)
555G, 650GOutside Tread Wear, Carrier Roller Flange Wear, and
Diameter...................................................................... 160.0 mm (6.3 in.) Carrier Roller Flange Top Wear in Undercarriage
100% worn.................................................................. 147.0 mm (5.8 in.) Appraisal Manual SP326.
NOTE: For additional information on measuring carrier
roller wear, refer to Carrier Roller, Carrier Roller
0130,BB5 1908OCT931/1
T6674AC UN01NOV88
0130,BB6 1924AUG931/1
PN=73
Track System
T93565 UN01NOV88
0130,BB7 1924AUG931/9
T93566 UN01NOV88
0130,BB7 1924AUG932/9
T93567 UN01NOV88
PN=74
Track System
T93568 UN01NOV88
Minimum Length ................................................................. 51 mm (2 in.)
0130,BB7 1924AUG934/9
T93569 UN01NOV88
0130,BB7 1924AUG935/9
T93570 UN01NOV88
PN=75
Track System
T93567 UN01NOV88
7. A new seal kit should be installed. Install oil seal into
support with the retainer ring side going into support.
0130,BB7 1924AUG937/9
T93571 UN01NOV88
0130,BB7 1924AUG938/9
T94007 UN01NOV88
Cap ScrewTorque....................................................... 41 Nm (30 lbft)
Upper Cover Cap
ScrewTorque............................................................... 47 Nm (35 lbft)
PN=76
Track System
T6499EF1 UN09FEB89
oil. A small amount of low volume air forced into
the roller will overcome the vacuum and allow a
small amount of oil to flow from roller.
1. Put the oil level plug (B) at the three oclock or nine
oclock position.
2. Remove the oil fill plug (A).
If oil flows out, oil level is correct and install plug
quickly.
If oil does not flow, remove the oil level plug (B). Insert
the nozzle of a plastic bottle (C) into the hole and
squeeze air pressure into roller. A slight amount of
T7883AN UN09NOV92
pressure inside the roller will relieve any vacuum and
allow oil to flow from hole (A).
Oil level must be level with fill hole (A) or not more
than 3 mm (0.12 in.) below the bottom of hole.
Specification
OilMaximum Distance...........3 mm (0.12 in.) below the bottom of hole
PN=77
Track System
T93617 UN23FEB89
2. Clean track roller to be measured.
3. Measure track roller using roller calipers and a scale.
Measure inside and outside tread diameters of the
roller at the area of most wear using the calipers. Then
measure caliper tip spread with the scale to nearest
0.020 in.
Specification 555G, 650GOutside
450G, 455G, Diameter...................................................................... 182.6 mm (7.2 in.)
550GOutside 100% Worn................................................................. 164.0 mm (6.5 in.)
Diameter...................................................................... 182.6 mm (7.2 in.)
100% Worn................................................................. 168.2 mm (6.6 in.)
0130,BB16 1908OCT931/1
T113330 UN12FEB98
rock guard and loosen inner rock guard cap screws.
If machine is equipped with chain guides, remove rear
chain guide.
3. Raise crawler to provide a clearance for roller removal.
Block securely.
4. Remove four roller bracket cap screws (B) to remove
roller assembly.
NOTE: On machines (S.N. XXXXXX), put roller on
track frame with special cap screw (A) toward
the outside of the machine.
5. Install roller assembly and tighten cap screws (B). T6556AB UN01NOV88
PN=78
Track System
T93589 UN01NOV88
1. Remove cap screws and Orings to remove roller
brackets (A).
TX,01,RB542 1917FEB981/7
2. Remove seal ring (A) and oil seal (B) on each side.
NOTE: Keep metal face of seals lubricated and together
at all times while disassembled.
T93590 UN01NOV88
4. Inspect parts for wear or damage. Replace as
required.
T93591 UN01NOV88
Continued on next page TX,01,RB542 1917FEB982/7
PN=79
Track System
T93592 UN01NOV88
Roller BushingID.....................60.4160.44 mm (2.37852.3795 in.)
If necessary to replace bushings, use 60 mm and 63
mm disks. Install new bushings 0.79 mm (0.031 in.)
below face of roller with open ends of oil grooves to
the inside.
Specification
BushingDistance.....................0.79 mm (0.031 in.) below face of roller
TX,01,RB542 1917FEB983/7
T93593 UN01NOV88
T93591 UN01NOV88
PN=80
Track System
T6044AH UN01NOV88
Centering Fixture (B).
TX,01,RB542 1917FEB985/7
11. Install the other three cap screws and tighten all six
cap screws.
12. Remove seal centering fixture.
13. Install a new oil seal kit (A) with plastic retainer ring in
place. Side with retainer ring goes into seal ring. Seal
T6044AA UN01NOV88
must be straight in bore.
14. Tighten cap screws. Repeat steps 814 on the other
side.
Specification
Seal Ring Socket Head
Cap ScrewTorque....................................................... 68 Nm (50 lbft)
T6044AC UN01NOV88
Continued on next page TX,01,RB542 1917FEB986/7
PN=81
Track System
T93595 UN01NOV88
without the pin. Install Oring, washer and cap screw.
Tighten finger tight.
17. Install roller bracket with plugs on pin end of shaft.
Install Oring and special cap screw. Tighten finger
tight.
18. Tighten inner roller and outer roller bracket cap screws.
Specification
RollertoBracket Cap 19. Fill roller with oil. (See Adding Oil to the Roller in this
ScrewTorque........................................................... 407 Nm (300 lbft) group.)
TX,01,RB542 1917FEB987/7
PN=82
Track System
T113331 UN10FEB98
ASpring Pin (2 used) CORing (2 used) ERoller GShaft
BBracket (2 used) DSeal Kit (2 used) F Plug HBushing (2 used)
NOTE: Spring pins (A) are tapered on top (flat of 6. Remove grease from sealing surfaces in roller and
bracket). Drive pin out from the bottom. roller brackets.
1. Remove parts (AD) from both ends of roller. 7. Install new oil seal kits (D) in roller.
NOTE: Keep metal faces of seals (D) lubricated and 8. Install Orings (C) in both brackets.
together at all times while disassembled.
9. Install brackets (B).
2. Remove shaft (G) and bushings (H). 10. Install new spring pins in through top (flat of bracket).
3. Inspect parts for wear or damage. Replace as Tapered end of pin should be flush with top of bracket.
required. 11. Fill roller with oil. (See Adding Oil to the Roller in this
4. Install bushings (H) in roller. group.)
PN=83
Track System
T6499EB1 UN09FEB89
A small amount of low volume air forced into the roller will
overcome the vacuum inside the roller and force a small
amount of oil to flow out fill hole.
1. Remove the oil level fill plug (B). If oil runs out, oil
level is correct.
If oil does not run out, remove the oil level check plug
(A). Insert the nozzle of the plastic bottle (C) into the (S.N. XXXXXX)
oil check hole and squeeze air pressure inside the
roller assembly. A slight amount of air pressure inside
the roller will relieve any vacuum inside the roller and
allow oil to flow out of the fill hole.
2. Install the plugs.
T7896AX UN07JAN93
(S.N. XXXXXX)
TX,01,BA2225 1916FEB981/1
T113532 UN17FEB98
IMPORTANT: Oil fill plug has bakedon sealant.
Discard old fill plug and install a new one.
(S.N. XXXXXX )
TX,01,RB595 1902MAR981/1
PN=84
Track System
T6499EB1 UN09FEB89
NPT grease fitting).
3. Install a grease zerk (E) into adapter fitting.
4. Fill a grease gun (F) with oil. (See Fuels and
Lubricants Group 0004.)
5. Add oil to grease fitting until it comes out of oil level
Inside of Crawler
check hole (C).
6. Install and tighten oil level plug.
Specification
Oil Level PlugTorque....................................... 41 4 Nm (30 3 lbft)
T8055AO UN03AUG93
ACheck Plug DAN142253 Adapter Fitting
BFill Plug EGrease Zerk
CCheck Hole F Grease Gun
TX,01,RB501 1917FEB981/1
T113532 UN17FEB98
3. Fill roller with oil until the oil starts to drip out. (See
Fuels and Lubricants Group 00004.)
IMPORTANT: Oil fill plug has bakedon sealant.
Discard old fill plug and install a new one.
PN=85
Track System
T93612 UN23FEB89
Specification
Single Bar Grouser
450G, 455G, 550G New
ShoeHeight.............................................................. 48.0 mm (1.89 in.)
Single Bar Grouser
450G, 455G, 550G 100%
Worn Height............................................................... 20.0 mm (0.8 in.)
Single Bar Grouser
Three Bar Grouser
555G, 650G New
450G, 455G, 550G 100%
ShoeHeight.............................................................. 50.0 mm (1.97 in.)
WornHeight.............................................................. 12.0 mm (0.47 in.)
Single Bar Grouser
555G, 650G 100% NOTE: See Undercarriage Appraisal Manual SP326
WornHeight................................................................ 23.0 mm (0.9 in.) for additional information.
Two Bar Grouser 450G,
455G, 550G New See Grouser Wear
ShoeHeight.............................................................. 25.0 mm (0.98 in.) See Grouser Bar Height
Two Bar Grouser 450G,
455G, 550G 100% See 450G, 455G, 550G Single Bar Grouser Height
WornHeight.............................................................. 16.0 mm (0.63 in.)
Two Bar Grouser
See 450G, 455G, 550G Two Bar Grouser Height
555G, 650G New See 450G, 455G, 550G Three Bar Grouser Height
ShoeHeight.............................................................. 30.0 mm (1.18 in.)
Two Bar Grouser 555G, See 555G, 650G Single Bar Grouser Height
650G 100% Worn
See 555G, 650G Two Bar Grouser Height
Height.......................................................................... 12.0 mm (0.47 in.)
Three Bar Grouser
450G, 455G, 550G New
ShoeHeight.............................................................. 21.1 mm (0.83 in.)
TX,0130,BD776 1914JUN111/1
PN=86
Track System
T96291 UN23FEB89
1. Remove nuts using DF1041 Track Nut Removal
Tool. (See Group 0199 for instructions to make tool.)
Remove cap screws and shoes.
2. Before installing shoes, clean paint, dirt and debris
from mounting surfaces of shoes and links.
3. For all cap screws except split master links cap
screws, apply SAE 30W oil to threads and bearing
surface under head.
For split master link and shoe cap screws, apply John
Deere NEVERSEEZ Lubricant (or equivalent) to
T96292 UN23FEB89
threads and bearing surface under head.
IMPORTANT: Never use an impact wrench to
start cap screws in a split master link to
avoid crossthreading.
T6352AH UN23FEB89
not, repeat Steps 25.
Specification
Cap Screws (450G,
455G, 550G) (1/2
in.)Torque....................................................... 61 Nm (45 lbft) Second
PassAdditional 1/3 (120) turn
Cap Screws (450G,
455G, 550G) (9/16
in.)Torque....................................................... 88 Nm (65 lbft) Second Split Link Cap Screw
PassAdditional 1/3 (120) turn (450G, 455G, 550G)
Cap Screw (555G, 650G) (9/16 in.)Torque.............................................. 88 Nm (65 lbft) Second
(5/8 in.)Torque............................................ 149 Nm (110 lbft) Second PassAdditional 1/2 (180) turn
PassAdditional 1/3 (120) turn Split Link Cap Screw
Split Link Cap Screw (555G, 650G) (5/8
(450G, 455G, 550G) (1/2 in.)Torque................................................... 149 Nm (110 lbft) Second
in.)Torque..................................................... 61 Nm (45 lbft) Seconds PassAdditional 1/2 (180) turn
PassAdditional 1/2 (180) turn
TX,01,RB503 1914JUN112/2
PN=87
Track System
T5802AD UN02NOV88
0.5 mm (0.020 in.).
Specification
Chain Link 450G, 455G,
550G NewHeight.......................................................... 90 mm (3.5 in.)
Chain Link 450G, 455G,
550G 100% Worn
Height.......................................................................... 82.8 mm (3.26 in.)
Chain Link 555G, 650G
NewHeight.................................................................... 96 mm (3.8 in.)
Chain Link 555G, 650G
100% WornHeight...................................................... 86.7 mm (3.4 in.)
0130,BB33 1908OCT931/1
PN=88
Track System
T6033CD UN01JUN89
455G, 550G 100% Worn
(Normal Impact)OD.................................................. 46.2 mm (1.82 in.)
Sealed Bushing 450G,
455G, 550G 100% Worn
(High Impact)OD...................................................... 48.0 mm (1.89 in.)
Sealed Bushing 555G,
650G NewOD.......................................................... 53.8 mm (2.12 in.)
Sealed Bushing 555G,
650G 100% Worn
Lubricated Step Bushings
(Normal Impact)OD.................................................. 49.0 mm (1.93 in.)
450G, 455G, 550G
Sealed Bushing 555G,
NewOD.......................................................................... 51 mm (20 in.)
650G 100% Worn (High
Lubricated Step Bushings
Impact)OD............................................................... 50.8 mm (2.00 in.)
450G, 455G, 550G
Lubricated Bushing
100% Worn (Normal
450G, 455G, 550G
Impact)OD............................................................... 44.5 mm (1.75 in.)
NewOD.................................................................... 51.8 mm (2.01 in.)
Lubricated Step Bushings
Lubricated Bushing
450G, 455G, 550G
450G, 455G, 550G
100% Worn (High
100% Worn (Normal
Impact)OD............................................................... 46.3 mm (1.82 in.)
Impact)OD............................................................... 44.5 mm (1.75 in.)
Lubricated Step Bushings
Lubricated Bushing
555G, 650G NewOD................................................ 56.8 mm (2.24 in.)
450G, 455G, 550G
Lubricated Step Bushings
100% Worn (High
555G, 650G 100% Worn
Impact)OD............................................................... 46.3 mm (1.82 in.)
(Normal Impact)OD.................................................. 48.2 mm (1.90 in.)
Lubricated Bushing
Lubricated Step Bushings
555G, 650G NewOD................................................ 53.8 mm (2.12 in.)
555G, 650G 100% Worn
Lubricated Bushing
(High Impact)OD...................................................... 50.8 mm (2.00 in.)
555G, 650G 100% Worn
(Normal Impact)OD.................................................. 46.2 mm (1.82 in.)
Lubricated Bushing
555G, 650G 100% Worn
(High Impact) OD..................................................... 48.8 mm (1.92 in.)
TX,0130,BD785 1908OCT931/1
PN=89
Track System
T93611 UN23FEB89
and idler. Measure from the left edge of one track pin
to the left edge of fifth track pin. This measurement
covers wear in four pin and bushing joints.
3. Record measurement to the nearest 0.5 mm (0.020
in.) and repeat for several sections.
Do not measure across the master pin joint.
Specification
Chain Pitch 555G, 650G
Chain Pitch 450G, 455G,
Sealed Distance
550G SealedDistance
Across Four Pins of
Across Four Pins of New
New Chain................................................................. 685.2 mm (27.0 in.)
Chain......................................................................... 640.1 mm (25.2 in.)
100% Worn....................................................................697.5 mm (27.5)
100% Worn............................................................... 652.8 mm (25.7 in.)
Chain Pitch 555G, 650G
Chain Pitch 450G,
LubricatedDistance
455G, 550G
Across Single Joint......................................................... 171 mm (6.7 in.)
LubricatedDistance
100% Worn.................................................................... 185 mm (8.7 in.)
Across Four Pins of New
Chain.............................................................................. 160 mm (6.3 in.)
100% Worn.................................................................... 171 mm (6.7 in.)
TX,0130,BD806 1908OCT931/1
T6044CJ UN23FEB89
NOTE: Check sag after a short period of operation when
changing from one ground condition to another or
when operating in extreme soil packing conditions.
PN=90
Track System
T7756AC UN03NOV92
and 555G and 650G machines (S.N. 791415 ),
remove cap screw to open cover (D) over adjuster
fittings.
IMPORTANT: Track adjuster cylinder has a
special high pressure fitting. Replace with
correct type fitting only.
(S.N. 781708)
4. To decrease track sag (tighten chain), apply grease to
special high pressure fitting (C) using a 55,200 kPa
(550 bar) (8000 psi) capacity grease gun.
Specification
Grease GunPressure......................... 55,200 kPa (550 bar) (8000 psi)
T7756AA UN03NOV92
(A). DO NOT loosen special fitting (C). Tighten valve.
After releasing grease, operate machine to allow track
adjuster cylinder to fully adjust. Check sag again.
T8055BE UN29JUL93
Latest Units
TX,0130,BD740 1908OCT932/2
PN=91
Track System
T93554 UN01NOV88
CAUTION: Make sure track is off floor
before rotating.
TX,01,RB504 1917FEB981/5
T8043AG UN29JUL93
drive machine forward and reverse until grease
escapes then close relief or check valve.
T8055BF UN29JUL93
(S.N. 781709 )
PN=92
Track System
T93556 UN01NOV88
aligning bushings (C) over forcing pin (D) and install
adapter (E) in Cframe.
TX,01,RB504 1917FEB983/5
T93557 UN01NOV88
remove master pin.
8. Remove forcing pin to separate track.
T93644 UN01NOV88
Continued on next page TX,01,RB504 1917FEB984/5
PN=93
Track System
T93558 UN01NOV88
11. Place a jack under both crossbars and raise crawler to
provide clearance. Block crawler up securely.
T59376 UN17MAY89
1 Track Chain 4 Bushing 7 Master Bushing
2 Right Track Link 5 Left Track Link 8 Spacer (Master Bushing)
3 Belleville Seals 6 Pin, Standard Pin, Master 9 Pin and Bushing Repair Kit
(Drill Point On End)
TX,01,RB504 1917FEB985/5
PN=94
Track System
T6044AY UN01NOV88
1. Sealed track must be removed and disassembled to
turn bushings and pins. (See procedures in this
group.)
2. Mark lines (5 and 4) on worn sides of pins (1) and
bushings (2) in respect to links. Mark lines (3 and 6)
on link 180 from lines (4 and 5).
3. Turn pins and bushings 180 in saddle until location 1 Pin 4 Bushing Worn Side
2 Bushing Reference Mark
marks (4 and 5) on pins and bushings align with marks 3 New Position Reference 5 Pin Worn Side Reference
(3 and 6) on link. Mark Mark
6 New Position Reference
4. Assemble track chain and install on machine. (See Mark
procedures in this group.)
TX,01,RB418 1910FEB981/1
PN=95
Track System
T113175 UN29JAN98
1. Position track chain under crawler with wide part of
links (A) toward rear of crawler.
2. Put end of chain on sprocket then slowly turn sprocket
in forward direction to pull chain across top of frame
to front idler.
3. Put two seals (5) into counterbore of end link with seal Drive Sprocket End Shown
inside diameters touching.
4. Install master bushing spacers (3) with flat side against
seal and push end links together.
5. Install forcing pin to align links (1 and 6), bushing (4),
seals (5), and spacers (3).
T6043AR UN01NOV88
PN=96
Track System
T6552AD UN01NOV88
oversize master pin is recommended.
T6043AQ UN01NOV88
TX,01,RB505 1917FEB982/2
PN=97
Track System
T8043AG UN29JUL93
If grease does not escape immediately from vent
hole (D) when relief or check valve is open, slowly
drive machine forward and reverse until grease
escapes then close relief or check valve.
T8055BF UN29JUL93
2. Rotate track until split link pin is at 11 oclock position
for the right side and 1 oclock position for the left side
with respect to idler.
3. Block track at front idler.
4. Put a block on top of recoil spring cover to keep chain
at proper height. (S.N. 781709 )
PN=98
Track System
T6549BR UN10FEB89
T6913AN UN10FEB89
TX,0130,BD744 1914JUN112/6
PN=99
Track System
T6549BT UN10FEB89
stand at end of track.
TX,0130,BD744 1914JUN114/6
T113175 UN29JAN98
oclock for the right side, 1 oclock for the left side (12
oclock for new track) in relation to the front idler.
12. Bring other end of chain over carrier roller.
13. Apply John Deere NEVERSEEZ Lubricant to mating
surfaces of master link.
14. Use a comealong device to bring master link halves Drive Sprocket Rear End Shown
together. Bushing end must go over pin end.
T6549BU UN10FEB89
PN=100
Track System
T6352AH UN23FEB89
17. Install shoe. Start cap screws by hand to avoid
crossthreading.
Specification
Split Link Cap Screw
(450G, 455G, 550G) (1/2
in.)Torque..................................................... 61 Nm (45 lbft) Seconds
PassAdditional 1/2 (180) turn
Split Link Cap Screw
(450G, 455G, 550G)
IMPORTANT: Tighten cap screws to the initial torque
(9/16 in.)Torque.............................................. 88 Nm (65 lbft) Second
using a crisscross pattern. Repeat pattern for
PassAdditional 1/2 (180) turn
a second time. Finally turn each cap screw the
Split Link Cap Screw
additional turn using the same pattern.
(555G, 650G) (5/8
in.)Torque................................................... 149 Nm (110 lbft) Second
PassAdditional 1/2 (180) turn
NEVERSEEZ is a registered trademark of Emhart Chemical Group.
TX,0130,BD744 1914JUN116/6
T8055BG UN29JUL93
3. Put a block on top of recoil spring cover, near front
idler to keep chain supported.
PN=101
Track System
T8043AG UN29JUL93
drive machine forward and reverse until grease
escapes then close relief or check valve.
T8055BF UN29JUL93
master link. DO NOT stand at end of track.
T8055AE UN27JUL93
Continued on next page TX,01,RB506 1914JUN112/4
PN=102
Track System
6. To join master link, locate master link pin end at the top
T113175 UN29JAN98
of the front idler. Put a block at the front of the idler.
7. Apply John Deere NEVERSEEZ Lubricant to mating
surfaces of master link.
8. Use a comealong device to bring master link halves
together.
9. Install shoe and new caps screws. Apply John Deere Drive Sprocket End Shown
NEVERSEEZ Lubricant to cap screw threads. Start
cap screws by hand to avoid crossthreading.
NEVERSEEZ is a registered trademark of Emhart Chemical Group.
TX,01,RB506 1914JUN113/4
T6352AH UN23FEB89
Item Measurement Specification
PN=103
Track System
T96266 UN27OCT88
and Not Relubricate, in this group.
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.
9. Retract left ram. The left link, with seal and thrust ring,
will remain on the ram tools.
T96267 UN27OCT88
PN=104
Track System
T6682AJ UN01NOV88
12. If pin and bushing contains oil when disassembled,
new pins, seal rings, bushings, thrust ring and load
rings are not necessary. Do not remove usable seals
from link counterbore. Do not remove any dirt from
around seals.
13. Repeat steps 412 to disassemble rest of chain.
14. Remove rubber stopper (F) from pins using a drill.
ABushing DThrust Ring
BSeal Ring EPin
CLoad Ring F Stopper
TX,01,RB507 1917FEB983/4
T96269 UN27OCT88
PinChamfer......................................................... 4 mm (0.16 in.) x 30
TX,01,RB507 1917FEB984/4
PN=105
Track System
T96273 UN27OCT88
3. Assemble master split link halves using master shoe
bolts and washers (as required). Tighten bolts just
enough to hold links together.
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.
TX,01,RB508 1914JUN112/14
T96274 UN27OCT88
PN=106
Track System
T96275 UN27OCT88
tion450G, 455,
550GDistance.................................... 1.88 0.25 mm (.074 .010 in.)
Bushing Protec
tion555G, 650GDis
tance...................................................... 1.70 0.25 mm (0.67 .010 in.)
T96276 UN27OCT88
TX,01,RB508 1914JUN115/14
T96277 UN27OCT88
link wear surface. Install all pins so hole (A) in end is
toward same side of chain, either left or right.
PN=107
Track System
T96278 UN27OCT88
TX,01,RB508 1914JUN117/14
T96279 UN27OCT88
LOCTITE is a registered trademark of Loctite Corp.
Continued on next page TX,01,RB508 1914JUN118/14
PN=108
Track System
15. Install bushing (D) in front saddle seat. Install left link
(A) and right link on ram plungers.
Assemble load ring (C) and seal ring (B). Install
assembly into link (A) counterbore so pointed lip of
seal ring is toward bushing (D).
T7158AU UN12APR90
TX,01,RB508 1914JUN119/14
T96282 UN27OCT88
DPlunger I Left Link
ERight Ram
T96283 UN27OCT88
PN=109
Track System
17. Retract left ram. Install special spacer (A) between the
joint in rear seat of saddle and ram.
T96284 UN27OCT88
IMPORTANT: Too much pressure will crush
the thrust rings.
T96285 UN27OCT88
PN=110
Track System
T96286 UN27OCT88
tion450G, 455,
550GDistance.................................... 1.88 0.25 mm (.074 .010 in.)
Bushing Protec
tion555G, 650GDis
tance...................................................... 1.70 0.25 mm (0.67 .010 in.)
TX,01,RB508 1914JUN1113/14
23. Add oil (SAE 80W 90) using a D0890 Seal Tester and
Lubricator and A2679 Nozzle (C). Push nozzle through
stopper all the way into pin. Depress control lever on
the handle enough to draw a vacuum of 68102 kPa
(2030 in. Hg) as indicated on the gauge.
Specification
T96287 UN01NOV88
GaugeVacuum........................................68102 kPa (2030 in. Hg)
T6465AY UN01NOV88
26. Slowly pull nozzle out to allow any compressed air to
escape through nozzle from first hole (A) to second
hole (B).
27. Repeat Steps 1025 for all joints.
28. Install assembled split links on ram plungers, and
advance rams to press split links together.
29. Install lubricated track chain. (See procedure in this
group.) 30. Install track shoes. (See procedure in this group.)
TX,01,RB508 1914JUN1114/14
PN=111
Track System
Disassemble and Assemble Lubricated Track Chain to Turn Pins and Not Relubricate
NOTE: The following procedure is for disassembly of
track chain only to turn pins and bushings. (Chain
is not relubricated after assembly.)
If this procedure does not apply to repair job,
see Disassemble Lubricated Track Chain to Turn
Bushings and Relubricate Chain.
T96266 UN27OCT88
1. Remove track shoes. (See procedure in this group.)
2. Use the following track press tool sets:
450G, 455G, 550G
Tooling Set A2656213
Saddle 40989
ALeft Ram EBushing
555G, 650G BSaddle F Left Link
CRight Ram GPin
Tooling Set A2656217 DRight Link
Saddle 421011
IMPORTANT: Track press disassembly tools must
be in proper alignment with links to prevent
broaching of pin and bushing. Damaged CAUTION: Always wear safety glasses when
links cannot be reused. operating the press. Parts may break or chip,
which could create a risk of personal injury.
3. Check for proper alignment of tools with pin and
bushing. 5. Extend right ram (C) to push pin (G) and bushing (E)
from the right link (D). The right link is forced against
4. Make an index mark on bushings and pins to aid in the side of saddle (B) as the pin and bushing are
assembly, when turning bushings 1/2 turn (180) to pushed out.
expose a new wear surface.
6. Retract right ram. The right link, with seals and thrust
ring, will stay on the ram tools.
1
For stepped bushing design, use 052657001 saddle.
TX,01,RB509 1914JUN111/10
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.
8. Retract left ram. The left link, with seal and thrust ring,
will remain on the ram tools.
T96267 UN27OCT88
PN=112
Track System
T5798AJ UN26OCT88
TX,01,RB509 1914JUN113/10
T96289 UN27OCT88
TX,01,RB509 1914JUN114/10
T96273 UN27OCT88
555G, 650G
Tooling Set A2656217
Saddle 421011
NOTE: 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. Split links are a matched set 16. Install assembled split links on ram plungers.
and must be assembled as a set. 17. Install bushing (A) in front seat of saddle (B) so the
mark is 180 opposite original location to expose a
15. Assemble master split link halves using master shoe new wear surface.
bolts and washers (as required). Tighten bolts just
enough to hold link together.
1
For stepped bushing design, use 052657001 saddle.
Continued on next page TX,01,RB509 1914JUN115/10
PN=113
Track System
T96274 UN27OCT88
TX,01,RB509 1914JUN116/10
T96277 UN27OCT88
of pin is toward the same side of chain, either left or
right side.
PN=114
Track System
T96278 UN27OCT88
TX,01,RB509 1914JUN118/10
22. Install bushing (G) on front saddle seat. Install left and
right links on ram plungers.
23. Advance left ram until left link contacts the saddle.
Advance right ram until link is pressed together and
bolts can be installed.
T96283 UN27OCT88
ALeft Ram F Right Link
BSaddle GBushing
CPin HPlunger Shims
DPlunger I Left Link
ERight Ram
TX,01,RB509 1914JUN119/10
T96286 UN27OCT88
tion450G, 455,
550GDistance.................................... 1.88 0.25 mm (.074 .010 in.)
Bushing Protec
tion555G, 650GDis
tance...................................................... 1.70 0.25 mm (0.67 .010 in.)
PN=115
Track System
T7225BA UN21FEB90
and D05231ST 300 mm Ruler from JT05518 or JT05523
Undercarriage Inspection Service Tool Kit.
Specification
450G, 455G, 550G
Flange NewHeight................................................... 19.5 mm (0.77 in.)
450G, 455G, 550G
Flange 100%
WornHeight.............................................................. 24.4 mm (0.96 in.)
555G, 650G Flange
See Front Idler Visual Checks
NewHeight............................................................... 17.5 mm (0.69 in.)
555G, 650G Flange See Front Idler Vertical Adjustment Check
100% WornHeight.................................................... 23.0 mm (0.91 in.)
See 450G, 455G, 550G Front Idler Flange Height
NOTE: See Undercarriage Appraisal Manual SP326
for additional information. See 555G and 650G Front Idler Flange Height
T113329 UN12FEB98
frame.
4. Install idler on track frame. Install and tighten four cap
screws and washers (A).
Specification
Adjusting Cylinder
YoketoIdler Bracket
Cap ScrewsTorque................................................. 163 Nm (120 lbft)
5. Connect track chain. (See procedure in this group.) 6. Adjust idler. (See procedure in this group.)
TX,01,RB510 1917FEB981/1
(C).
450G Shown
PN=116
Track System
T93574 UN01NOV88
TX,01,RB511 1917FEB982/4
T8056AX UN09AUG93
Continued on next page TX,01,RB511 1917FEB983/4
PN=117
Track System
T113189 UN19FEB98
AORing (555G and 650G, S.N. DPlate (2 used) GShaft (S.N. 771024 ) J Bushing (2 used)
771024 ) (2 used) ECap Screw (12 used) HDowel Pin (S.N. 771023) KIdler
BSeal Assembly (2 used) F Gasket (2 used) I Shaft (S.N. 771023)
CRing (2 used)
IMPORTANT: Keep metal face of seals (B) lubricated 4. Remove shaft (G or I) and inspect bushings (J) for
and together at all times while disassembled. wear or damage. Replace if necessary.
3. Remove parts (AF) on both sides of idler.
TX,01,RB511 1917FEB984/4
T93578 UN01NOV88
BushingDistance.....................0.79 mm (0.031 in.) below face of roller
TX,01,RB512 1914JUN111/8
PN=118
Track System
T93576 UN01NOV88
TX,01,RB512 1914JUN113/8
T6044AK UN01NOV88
and 555G, 650G machines (S.N. 771023).
For 555G and 650G machines (S.N. 771024 ), use
JDG798 Seal Centering Fixture.
PN=119
Track System
T6044AI UN01NOV88
9. Install a new oil seal kit (A) with plastic retainer ring in
place. Side with retainer ring goes into seal ring. Seal
must be straight in bore.
10. Tighten cap screws. Repeat Steps 410 on other
side.
Specification
Seal Ring Socket Head
Cap ScrewsTorque..................................................... 68 Nm (50 lbft)
T6044AJ UN01NOV88
TX,01,RB512 1914JUN115/8
T93580 UN01NOV88
IMPORTANT: DO NOT hit or strike brackets to
compress seals components can be damaged.
PN=120
Track System
T8056AX UN09AUG93
e. Install and tighten cap screws (B) and washers (C).
Specification
Idler Shaft Retainer Cap
ScrewTorque............................................................... 54 Nm (40 lbft)
13. Install shims (A), guide (B), and four cap screws and
lock washers on each side. Tighten cap screws.
Specification
Bracket Guide Cap
ScrewTorque..............................................................115 Nm (85 lbft)
T93581 UN01NOV88
same shims (D) as removed.
450G Shown
TX,01,RB512 1914JUN118/8
PN=121
Track System
T6555DI UN10FEB89
Front Roller Clearance
Wear Strip and Clearance 0.8 mm 0.25 mm (0.030 0.010
in.)
Cap Screw Distance 05 mm (00.2 in.) below wear
strip surface
T6555DK UN25MAY89
a. Move machine so tip (dozer) or track pin (loader) is
directly under center line of idler.
b. Dozer machines onlyIf grouser tip touches floor
before it gets to center line or if too high (over 2 mm
[0.08 in.] off the ground), adjust idler height (Steps
720).
Specification
Grouser TipMaximum
Height........................................................ 2 mm [0.08 in.] off the ground
Continued on next page TX,01,RB513 1917FEB982/9
PN=122
Track System
T6744BA UN23AUG93
RollerClearance......................................................... 3.5 mm (0.13 in.)
If roller cannot be turned freely or clearance is too
great, adjust idler height (Steps 720).
TX,01,RB513 1917FEB983/9
T6555DJ UN25MAY89
PN=123
Track System
T6549BV UN10FEB89
10. Remove cap screws (B).
11. Remove bottom wear strip and shims from both sides.
TX,01,RB513 1917FEB985/9
T6549BW UN10FEB89
side of idler to keep front idler in a vertical position.
14. Install inner and outer shims and guide plates.
15. Lower blade or bucket to raise track frame. Install
block under first roller for safety to prevent machine
from moving if oil moves from cylinders.
TX,01,RB513 1917FEB986/9
16. Install bottom wear strips (A). Add or remove shims (B)
under wear strip to obtain 0.8 mm 0.25 mm (0.030
0.010 in.) clearance (C).
Specification
Wear StripClearance................ 0.8 mm 0.25 mm (0.030 0.010 in.)
T6926BG UN06DEC88
PN=124
Track System
T6555DM UN25MAY89
Cap ScrewDistance................................................................05 mm
(00.2 in.) below wear strip surface
Washers can be added under head of cap screw if
needed.
TX,01,RB513 1917FEB988/9
T6555DN UN25MAY89
20. Install shoe, if removed. (See procedure in this group.)
21. Repeat this procedure for other idler.
TX,01,RB513 1917FEB989/9
PN=125
Track System
T7883AP UN10NOV92
forced air into the idler will overcome the vacuum and
allow a small amount of oil to flow from idler.
NOTE: For the 555G and 650G machines, the oil fill hole
should be on outside of idler on the left side of
machine. The oil fill hole should be on the inside
of idler on the right hand side of the machine. On
555G and 650G machines (S.N. 771024 ), there
are no special cap screws on end of idler shafts.
Oil fill plug (B) is in the end of shaft.
T7883AS UN10NOV92
quickly.
If oil does not flow, remove the oil level plug (A). Insert
the nozzle of a plastic bottle (C) into the hole and
squeeze air pressure into idler. A slight amount of
pressure inside the idler will relieve any vacuum and
allow oil to flow from hole (B).
2. Add proper oil as necessary:
a. Install oil level plug (A).
f. Install and tighten oil level plug.
b. Remove the fill plug (B) and IMMEDIATELY install
Specification
AN142253 adapter and (1/8 in. NPT) grease fitting
Oil Level PlugTorque....................................... 41 4 Nm (30 3 lbft)
into the adapter.
g. Quickly remove grease fitting and adapter and
c. Remove the oil level plug (A).
install fill plug.
d. Fill grease gun with recommended oil. (See Section
00, Group 0004.)
e. Add oil to grease fitting until oil flows from oil level
hole.
TX,01,RB424 1912FEB981/1
PN=126
Track System
T6676AA UN04OCT93
APiston DGrease Fitting GYoke
BPiston Seal EGrease Fitting HWasher (4 used)
CScraper Seal F Relief Valve I Cap Screw (4 used)
CAUTION: Grease for track adjuster cylinder 1. Remove front idler. (See procedure in this group.)
is under high pressure. Never remove special
2. Remove adjuster assembly from track frame.
grease fitting to release the grease. If grease
does not escape immediately from vent hole IMPORTANT: Do not pull piston from track adjusting
with relief valve open, slowly drive machine yoke unless seal and piston seal are to be
in forward and reverse until grease escapes. replaced or seals will be damaged.
DO NOT disassemble parts unless you know
the correct procedure and have correct tools. 3. To aid disassembly, remove grease fitting (E) to
(See your authorized dealer.) prevent suction.
If an accident occurs, see a doctor immediately. 4. Pull track adjusting piston (A) from yoke (G).
Any fluid injected into the skin must be surgically
removed within a few hours or gangrene 5. Remove and discard piston seal (B).
may result. Doctors unfamiliar with this 6. Remove and discard yoke scraper seal (C).
type of injury may call the Deere & Company
Medical Department in Moline, Illinois, or other 7. Inspect and clean all parts.
knowledgeable medical source.
TX,01,RB514 1917FEB981/1
PN=127
Track System
T93583 UN01NOV88
grease in bottom cylinder, (b) move piston to bottom
of bore without seating oil seal. A small amount
of grease should be forced out the bleed hole.
If necessary, add grease and repeat procedure
until grease is observed at bleed hole.
T93584 UN01NOV88
Hydraulic Adjuster Service Kit on piston seal. Tighten
cap screws. Force piston in by hand until seal clears
the flange. Remove piston guide.
6. Install scraper seal (B) into recess of cylinder using
driver (C).
7. Install track adjuster in track frame.
8. Install front idler. (See procedure in this group.)
TX,01,RB515 1917FEB982/2
PN=128
Track System
PN=129
Track System
T7247BM UN04OCT93
APiston DYoke GCap Screw (4 used)
BScraper Seal EGrease Fitting HWasher (4 used)
CSeal F Relief Valve I Vent Hole
CAUTION: Grease for track adjuster cylinder 1. Remove front idler. (See procedure in this group.)
is under high pressure. Never remove special
2. Remove adjuster assembly from track frame.
grease fitting to release the grease. If grease
does not escape immediately from vent hole IMPORTANT: Do not pull piston from track adjusting
with relief valve open, slowly drive machine yoke unless seal and piston seal are to be
in forward and reverse until grease escapes. replaced or seals will be damaged.
DO NOT disassemble parts unless you know
the correct procedure and have correct tools. 3. To aid disassembly, remove grease fitting (E) to
(See your authorized dealer.) prevent suction.
If an accident occurs, see a doctor immediately. 4. Pull track adjusting piston (A) from yoke (D).
Any fluid injected into the skin must be surgically
removed within a few hours or gangrene 5. Remove and discard scraper seal (B).
may result. Doctors unfamiliar with this 6. Remove and discard yoke seal (C).
type of injury may call the Deere & Company
Medical Department in Moline, Illinois, or other 7. Inspect and clean all parts.
knowledgeable medical source.
TX,01,RB425 1912FEB981/1
PN=130
Track System
T113174 UN29JAN98
APiston DYoke GCap Screw (4 used) J Cover (Later Units)
BScraper Seal EGrease Fitting HWasher (4 used) KCap Screw (Later Units)
CSeal F Check Valve I Vent Hole L Spring Pin (Later Units)
CAUTION: Grease for track adjuster cylinder IMPORTANT: Do not pull piston from track adjusting
is under high pressure. Never remove special yoke unless seal and piston seal are to be
grease fitting to release the grease. If grease replaced or seals will be damaged.
does not escape immediately from vent hole
with relief valve open, slowly drive machine NOTE: Grease fitting cover parts (J, K and L) will be
in forward and reverse until grease escapes. found on the following machines:
DO NOT disassemble parts unless you know
the correct procedure and have correct tools. 450G, 455G, 550G (S.N. 791496 )
(See your authorized dealer.) 555G, 650G (S.N. 791415 )
If an accident occurs, see a doctor immediately. 3. To aid disassembly, remove grease fitting (E) to
Any fluid injected into the skin must be surgically prevent suction.
removed within a few hours or gangrene
4. Pull track adjusting piston (A) from yoke (D).
may result. Doctors unfamiliar with this
type of injury may call the Deere & Company 5. Remove and discard scraper seal (B) and yoke seal
Medical Department in Moline, Illinois, or other (C).
knowledgeable medical source.
6. Inspect and clean all parts.
1. Remove front idler. (See procedure in this group.)
2. Remove adjuster assembly from track frame.
TX,01,RB426 1912FEB981/1
PN=131
Track System
T7247BP UN09APR90
3. Install piston.
4. Install grease fitting.
T7247BQ UN09APR90
T7247BR UN09APR90
TX,01,RB516 1917FEB981/2
TX,01,RB516 1917FEB982/2
PN=132
Track System
T6555DH UN01JUN89
assembly forward.
2. Remove cover.
3. Thoroughly clean threads of rear cap.
PN=133
Track System
T6557DY UN25OCT88
Specification
Recoil SpringApproxi
mate Free Length......................................................... 447 mm (18.0 in.)
Test Length at 37 900
3790 N @ 8514 851 lb
force.......................................................... 378 3 mm (14.88 0.12 in.)
PN=134
Track System
T7126AA UN15SEP89
Guard Tool
T7247BN UN09APR90
Continued on next page TX,01,RB429 1914JUN112/4
PN=135
Track System
T7247BO UN09APR90
ARear End Cap BSpring CStop Tube DFront End Cap
PN=136
Track System
T7126AA UN15SEP89
T7247BN UN09APR90
NEVERSEEZ is a registered trademark of Emhart Chemical Group.
TX,01,RB429 1914JUN114/4
PN=137
Track System
T93560 UN01NOV88
Floor JackForce........................................................ 89 000 N (10 ton)
T6674AE UN01NOV88
2. Attach hoist to frame using two chains to balance
track frame.
Specification
Track FrameWeight.................................................... 464 kg (1000 lb)
TX,01,RB431 1912FEB981/1
PN=138
Track System
PN=139
Track System
T8058AH UN13SEP93
1. Remove front idler. (See procedure in this group.) 3. Grind track frame (A) wear strip surfaces smooth.
2. Remove wear strips (B). Area must be free of any weld spatter.
PN=140
Track System
IMPORTANT: Good welds are important. Have 5. Clamp wear strip in position, using dimensions (C and
only a qualified welder do the procedure. D).
Use E7018 electrodes.
6. Weld each wear strip in eight places as indicated using
Before welding, clean all dirt and paint from E7018 electrodes.
the weld areas and turn battery disconnect
switch to OFF. Connect the welder ground clamp 7. Install and adjust front idler. (See procedures in this
close to each weld area so electrical current group.)
does not pass through any bearings.
PN=141
Track System
PN=142
Group 0199
Dealer Fabricated Tools
DF1041 Track Nut Removal Tool
TX1074246 UN22APR10
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
PN=143
Dealer Fabricated Tools
T7306AA 1930MAY90
2. Put DF1067 Tool on pin end of master link, making
sure there is no interference preventing separation.
3. Put track shoe over Tool and tighten cap screws at pin
end of master link.
4. Alternately tighten bushing end cap screws of master
link until there is approximately 10 mm (3/8 in.) of
separation.
IMPORTANT: Cap screw threads may strip
if overtightened.
PN=144
Dealer Fabricated Tools
T7306AC 1930MAY90
PN=145
Dealer Fabricated Tools
T7162AF UN17OCT89
A3/16 in. 1020 CR Steel Plate C1/2 in. Nut (2 used) E1/2 x 3 in. Steel Round Stock
B9/16 in. Hole (2 places) D1/2 x 2 in. Cap Screw (2 used) (2 used)
PN=146
Dealer Fabricated Tools
T6585UY UN24MAR98
and Cap Screws (H).
"F" Grade (SAE Grade 8) for Studs (B).
Print Numbers:
AST4050 Nut
BST4045 Bolt
CST4035 Holder (Plate)
ST4036 Holder (Plate)
ST4037 Holder (Plate)
ANut (12 used) F Base Plate
DST4047 Eyebolt BStud (4 used) GBase (4 used)
EST4040 Supporting Base CHolder HCap Screw (8 used)
FST4042 Base Plate DEyebolt (2 used) I Lock Washer (8 used)
GST4041 Base ESupporting Plate
HST4046 Cap Screw
IST4049 Lock Washer
Continued on next page TX,01,RB519 1917FEB981/4
PN=147
Dealer Fabricated Tools
T7029CI UN06JUL89
PN=148
Dealer Fabricated Tools
T7029CH UN06JUL89
PN=149
Dealer Fabricated Tools
T7029CG UN06JUL89
PN=150
Section 02
Axles and Suspension Systems
Contents
Page Page
Group 0250Axle Shaft, Bearings, and Remove and Install Steering Clutch
Reduction Gears Valve ...................................................... 0202601
Service Equipment and Tools .................... 0202501 Disassemble and Assemble
Other Material............................................ 0202502 Steering Clutch Valve (S.N.
Specifications ............................................ 0202503 770807).............................................. 0202602
Remove and Install Final Drive.................. 0202505 Disassemble and Assemble
Disassemble and Assemble Final Steering Clutch Valve (S.N.
Drive .................................................... 02025010 770808 )............................................. 0202603
Adjust Pinion Shaft Preload..................... 02025017 Adjust Steering Clutch Valve ..................... 0202604
Adjust Idler Shaft Preload for Remove and Install Steering Brake
Double Reduction Drives..................... 02025018 Cylinder ................................................. 0202606
Adjust Axle Shaft Preload........................ 02025020
Remove and Install Steering Group 0299Dealer Fabricated Tools
Clutch .................................................. 02025022 DF1030 Brake Assembly Tool ................... 0202991
Disassemble and Assemble DF1063 Final Drive Lift Bracket................. 0202992
Steering Clutch (S.N. DF1063A Single Reduction
770807)............................................ 02025028 Adapter Plate......................................... 0202993
Disassemble and Assemble DF1063B Double Reduction
Steering Clutch (S.N. 770808 Adapter Plate......................................... 0202993
) ........................................................... 02025030
Disassemble and Assemble
Steering Brake Anchor (S.N.
770807)............................................ 02025032
Disassemble and Assemble
Steering Brake Anchor (S.N.
770808 )........................................... 02025034
Disassemble and Assemble
Steering Brake Linkage (S.N.
770807)............................................ 02025035
Disassemble and Assemble
Steering Brake Linkage (S.N.
770808 )........................................... 02025039
Adjust Steering Brake Linkage ................ 02025043
Adjust Steering Brake SelfAdjuster
Linkage (S.N. 770807) ..................... 02025045
Manual Steering Brake Adjustment
(S.N. 770807)................................... 02025046
Manual Steering Brake Adjustment
(S.N. 770808 ).................................. 02025048
Adjust Steering Brakes
LinkagePedal Steer.......................... 02025050
Adjust Steering Brakes
LinkageLever Steer (S.N.
770807)............................................ 02025052
Adjust Steering Brakes
LinkageLever Steer (S.N.
770808)............................................ 02025054
Engage Tow Disconnect Pins
Manually .............................................. 02025056
PN=1
Contents
PN=2
Group 0250
Axle Shaft, Bearings, and Reduction Gears
Service Equipment and Tools
NOTE: Order tools from the U.S. SERVICEGARD or
from the European Microfiche Tool Catalog (MTC).
Some tools may be available from a local supplier.
Adapter .................................................................JT01773
Used to remove pinion and steering clutch shafts.
TX,02,RB520 1914JUN114/9
Service Stand
Used to hold final drives for service.
TX,02,RB520 1914JUN115/9
TX,02,RB520 1914JUN116/9
TX,02,RB520 1914JUN117/9
Single Reduction Adapter Plate1 ........................ DF1063A Remove and install final drive.
1
Dealer fabricated tool. (See Group 0299 for instructions to make tool.)
TX,02,RB520 1914JUN118/9
TX,02,RB520 1914JUN119/9
PN=153
Axle Shaft, Bearings, and Reduction Gears
Other Material
Number Name Use
T43512 (U.S.) Thread Lock and Sealer (Medium To be applied to cap screw threads.
TY9473 (Canadian) Strength)
242 (LOCTITE)
PN=154
Axle Shaft, Bearings, and Reduction Gears
Specifications
Item Measurement Specification
PN=155
Axle Shaft, Bearings, and Reduction Gears
PN=156
Axle Shaft, Bearings, and Reduction Gears
T113221 UN03FEB98
1. Disconnect track chain and remove drive
sprocket. (See procedures in Group 0130.)
Single Reduction450GLT
T113222 UN03FEB98
Single Reduction450GLGP
T113223 UN03FEB98
Double Reduction (S.N. 785187)
T113224 UN03FEB98
PN=157
Axle Shaft, Bearings, and Reduction Gears
T6656DQ UN19OCT88
550G, 650GCapacity.................................................... 9.8 L (2.50 gal)
T6656DR UN19OCT88
ADrain Plug CJack Screw
BPlug DSteering Clutch
T7247AR UN09APR90
Transmission Removed for Clarity
TX,02,RB521 1917FEB982/9
PN=158
Axle Shaft, Bearings, and Reduction Gears
T6926BM UN17JUL93
spacer cannot be removed as an assembly.
Remove final drive and then hidden cap
screw (A) to remove spacer.
T113173 UN19FEB98
Final Drive Cap
ScrewSingle Reduction
with SpacerQuantity
Per Side................................................................................................ 23
Final Drive Cap
ScrewSingle Reduction
for Long TrackQuantity
Per Side................................................................................................ 16 Single Reduction450G Standard and Wide Track
Final Drive Cap
ScrewDouble
Specification
Reduction (550G and
HousingtoFinal
650G Only)Quantity
Drive Housing Cap
Per Side................................................................................................ 17
ScrewsTorque......................................................... 320 Nm (236 lbft)
8. Install new seals between transverse case and spacer
(if used) and final drive.
9. Apply thread lock and sealer (medium strength) to
threads of cap screws. Install spacer (if used), final
drive and cap screws. Tighten cap screws.
Continued on next page TX,02,RB521 1917FEB984/9
PN=159
Axle Shaft, Bearings, and Reduction Gears
T8046AA UN17JUL93
COuter Cap Screws (3 used per side)
TX,02,RB521 1917FEB985/9
T113172 UN29JAN98
ACap Screw (13 used per side)
BCap Screw (2 used per side)
Final Drive HousingtoFinal Drive Spacer
CCap Screw (2 used per side)
DCap Screw (4 used per side)
ECap Screw (1 used per side)
Single Reduction450G, 455G Wide Track
Final Drive SpacertoTransverse Case
FCap Screw (1 used per side)
TX,02,RB521 1917FEB986/9
PN=160
Axle Shaft, Bearings, and Reduction Gears
T8046AD UN17JUL93
Double Reduction 550G, 650G:
Final Drive HousingtoTransverse Case
ACap Screw (14 used per side)
BCap Screw (2 used per side)
CCap Screw (1 used per side)
TX,02,RB521 1917FEB988/9
T8081AB UN28SEP93
c. Apply thread lock and sealer (medium strength) to
threads of cap screws (A). Install and tighten cap
screws.
Specification
Bearing Quill Cap
Screws (S.N.
785187)Torque....................................... 149 Nm (110 lbft) Second
PassTighten to 196 Nm (145 lbft), but do
not exceed more than 60 (1/6 turn) 11. Turn jack screw counterclockwise until screw is free of
Bearing Quill Cap Screws steering clutch. Install plug.
450G, 455G, 555G (S.N. 12. Install drain plug and fill final drive housing with
785188 )Torque...................................... 149 Nm (110 lbft) Second recommended oil. (Refer to Section 00, Group 0004.)
PassTighten to 196 Nm (145 lbft), but do
not exceed more than 60 (1/6 turn) 13. Install drive sprocket and connect chain. (See
Bearing Quill Cap Screws procedure in Group 0130.)
550G, 650G (S.N.
785188 )Torque................................................... 278 Nm (205 lbft)
TX,02,RB521 1917FEB989/9
PN=161
Axle Shaft, Bearings, and Reduction Gears
T112980 UN30JAN98
PN=162
Axle Shaft, Bearings, and Reduction Gears
CAUTION: Approximate component weights: 4. Install final drive pinion shaft assembly parts (39
and 1114):
Flanged Axle Shaft..........25 kg (56 lb)
a. Use disk driver to install bearing cups tight to bottom
Final Drive Gear............35 kg (78 lb) of bores.
NOTE: Steps 17 are for repair of 450G, 455G and b. Adjust final drive pinion shaft preload. (See
555G crawler final drives only. procedure in this group.)
NOTE: The design of the final drive housing NOTE: Pinion shaft assembly will be removed and
varies between production models. Repair installed again after other adjustments are made.
procedures remain the same.
5. Remove final drive pinion shaft assembly, keeping
1. SINGLE REDUCTION FINAL DRIVES required shim pack with quill.
Remove parts as shown. Use a press to remove 6. Apply a thin layer of Gasket Maker to ID of housing
flanged axle shaft (15). bore before installing pinion shaft seal. Install seal (2)
with seal lip and spring side towards mounting surface
Specification of final drive (as shown). Push seal into housing until
Flanged Axle even with shoulder of bore.
ShaftWeight...................................................................... 25 kg (56 lb)
Final Drive 7. Install axle shaft assembly parts (1526):
GearWeight....................................................................... 35 kg (78 lb)
a. Use disk driver to install bearing cups tight to bottom
2. Inspect parts, replace as necessary. of bores.
3. Install bushing (6) into pinion shaft using a disk driver. b. Adjust axle shaft preload. (See procedure in this
Push bushing into bore until bushing is 1.0 0.5 mm group.)
(0.04 0.02 in.) below end of shaft.
Specification
BushingDepth Below
End Of Shaft.............................................. 1.0 0.5 mm (0.04 0.02 in.)
Continued on next page TX,0250,BD794 1908OCT932/7
PN=163
Axle Shaft, Bearings, and Reduction Gears
T112981 UN30JAN98
PN=164
Axle Shaft, Bearings, and Reduction Gears
CAUTION: Approximate component weights: 12. Remove final drive pinion shaft assembly, keeping
required shim pack with quill.
Flanged Axle Shaft..........25 kg (56 lb)
13. Apply a thin layer of Gasket Maker to ID of housing
Final Drive Gear............35 kg (78 lb) bore before installing pinion shaft seal (10). Install seal
with seal lip and spring side towards mounting surface
NOTE: Steps 815 are for repair of 550G and of final drive (as shown). Push seal into housing until
650G crawler final drives only. even with shoulder of bore.
NOTE: The design of the final drive housing 14. Install idler shaft assembly parts (17, 18, 2025 and
varies between production models. Repair 3133):
procedures remain the same.
a. Use disk driver to install bearing cups tight to bottom
of bores.
8. DOUBLE REDUCTION FINAL DRIVES
b. Adjust idler shaft preload. (See procedure in this
Remove parts as shown. Use a press to remove
group.)
flanged axle shaft (30).
IMPORTANT: On 550G and 650G machines (S.N.
9. Inspect parts, replace as necessary.
785188 ), BOTH halves of the seal must
10. Install bushing (13) into pinion shaft using a disk driver. be installed on the axle shaft before outer
Push bushing into bore until bushing is 1.0 0.5 mm bearing cone is installed.
(0.04 0.02 in.) below end of shaft.
15. Install axle shaft assembly parts (27, 2630 and
11. Install final drive pinion shaft assembly parts (1116 38):
and 1821):
a. Use disk driver to install bearing cups tight to bottom
a. Use disk driver to install bearing cups tight to bottom of bores.
of bores.
b. Adjust axle shaft preload. (See procedure in this
b. Adjust final drive pinion shaft preload. (See group.)
procedure in this group.)
NOTE: Pinion shaft assembly will be removed and
installed again after other adjustments are made.
Continued on next page TX,0250,BD794 1908OCT934/7
PN=165
Axle Shaft, Bearings, and Reduction Gears
T112982 UN30JAN98
PN=166
Axle Shaft, Bearings, and Reduction Gears
1 Cap Screw (3 used) 13 Bearing Cone 25 Axle Shaft 37 Axle Shaft Gear
2 Retainer 14 Pinion Shaft 26 Snap Ring 38 Plug
3 Shim (as required) 15 Bushing 27 Bearing Cone (2 used) 39 ORing
4 Bearing Cone 16 Bearing Cone 28 Bearing Cup (2 used) 40 Seal
5 Bearing Cup 17 Bearing Cup 29 Idler Gear 41 Socket Screw
6 Spacer 18 Oil Seal 30 Spacer 42 Cap Screw (3 used)
7 Cap Screw (3 used) 19 Final Drive Housing 31 Gasket 43 ORing
8 Washer (3 used) 20 Seal 32 Plug (2 used) 44 Idler Gear Shaft
9 Pinion Shaft Quill 21 Outer Spacer 33 Final Drive Pan 45 ORing
10 Shim (as required) 22 Bearing Cone 34 Cap Screw (12 used)
11 ORing 23 Bearing Cup 35 Washer (12 used)
12 Bearing Cup 24 Oil Seal 36 Plug
Final Drive Gear............35 kg (78 lb) 22. Install idler shaft gear parts (2630) into final drive
housing:
NOTE: Steps 1624 are for repair of 450GLT and a. Use disk driver to install bearing cups in idler gear.
450GLGP crawler final drives only.
b. Use wire or string to keep bearings and gear in
NOTE: The design of the final drive housing housing and away from axle shaft assembly. Idler
varies between production models. Repair shaft will be installed later.
procedures remain the same.
23. Install axle shaft assembly parts (16, 2125 and
16. SINGLE REDUCTION, 450GLT AND 450GLGP 37):
FINAL DRIVES a. Use disk driver to install bearing cups tight to bottom
Remove parts as shown. Use a press to remove of bores.
flanged axle shaft (25). b. Adjust axle shaft preload. (See procedure in this
17. Inspect parts, replace as necessary. group.)
18. Install bushing (15) into pinion shaft using a disk driver. 24. Install idler shaft parts (4245):
Push bushing into bore until bushing is 1.0 0.5 mm a. Install shaft through housing, bearing cones and
(0.04 0.02 in.) below end of shaft. gear. Align tapped holes in shaft with holes in
19. Install final drive pinion shaft assembly parts (710 housing.
and 1217): b. Use three M12 X 1.75 X 170 mm full threaded cap
a. Use disk driver to install bearing cups tight to bottom screws to align and pull shaft into position. Tighten
of bores. cap screws until shaft bottoms against housing and
bearings.
b. Adjust final drive pinion shaft preload. (See
procedure in this group.) c. Remove alignment cap screws. Apply thread lock
and sealer (medium strength) to cap screws (42).
NOTE: Pinion shaft assembly will be removed and Install and tighten cap screws.
installed again after other adjustments are made.
Specification
ShafttoHousing Cap
20. Remove final drive pinion shaft assembly, keeping
Screw, 450GLT and
required shim pack with quill.
450GLGPTorque...................................................... 130 Nm (96 lbft)
21. Apply a thin layer of Gasket Maker to ID of housing
bore before installing pinion shaft seal (18). Install seal
Continued on next page TX,0250,BD794 1908OCT936/7
PN=167
Axle Shaft, Bearings, and Reduction Gears
T7931BL UN28JAN93
450G, 450GLT and
450GLGP (S.N.
795142), 455G,
555GInitial Torque
........................................................................ 61 12 Nm (45 9 lbft)
Final Torque (after 20
min.).................................. 81 Nm (60 lbft) but do not exceed a 90 turn 450G, 455G, 555G
450GLT and 450GLGP
(S.N. 795143 ), 550G,
650GInitial Torque.................................... 130 26 Nm (96 20 lbft)
Final Torque (after 20
min.)................................................................................... 170 Nm (125
lbft) but do not exceed a 90 turn
T7931BK UN28JAN93
26. Install final drive assembly on transverse case. (See
procedure in this group.)
550G, 650G
TX,0250,BD794 1908OCT937/7
PN=168
Axle Shaft, Bearings, and Reduction Gears
T6567AC UN09APR90
Bearing Quill Cap Screws (S.N. 149 Nm (110 lbft) Second
785187) Torque PassTighten to 196 Nm (145
lbft), but do not exceed more than
60 (1/6 turn)
Bearing Quill Cap Screws 450G, 149 Nm (110 lbft) Second
455G, 555G (S.N. 785188 ) PassTighten to 196 Nm (145
Torque lbft), but do not exceed more than
60 (1/6 turn)
Bearing Quill Cap Screws 550G, 278 Nm (205 lbft)
650G (S.N. 785188 ) Torque
This will provide a maximum pinion shaft preload of
OTHER MATERIAL 0.00.08 mm (0.00.003 in.).
T43512 U.S. Thread Lock and Sealer (Medium Strength) Specification
TY9473 Canadian Thread Lock and Sealer (Medium Strength) BearingPreload.....................................0.00.08 mm (0.00.003 in.)
242 LOCTITE Thread Lock and Sealer (Medium Strength)
6. For 550G and 650G, remove bearing quill. Remove
1. 450G, 455G, 555GInstall outer bearing cone on enough shims to provide a maximum of 0.08 mm
shorter end of pinion shaft tight against shoulder. endplay to a preload of 0.025 mm (0.001 in.).
Specification
Install inner bearing cone in mating bearing cup (in
BearingPreload to
final drive housing).
Endplay................................................................... 0.025 mm (0.001 in.)
550G, 650GInstall inner and outer bearing cones on
7. Apply thread lock and sealer (medium strength) to
pinion shaft tight against shoulders.
retainer cap screws. Tighten cap screws. Retighten
2. Install pinion shaft in housing. Install quill with enough cap screws per following specifications.
shims to provide a measurable amount of end play. Specification
On 550G and 650G machines, make sure arrow on Bearing Quill Cap
quill points toward idler shaft bore. Tighten three cap Screws (S.N.
screws: All machines (S.N. 785187) and 450G, 785187)Torque....................................... 149 Nm (110 lbft) Second
455G, 555G (S.N. 785188 ) to 149 Nm (110 lbft) PassTighten to 196 Nm (145 lbft), but do
550G and 650G (S.N. 785188 ) to 278 Nm (205 not exceed more than 60 (1/6 turn)
lbft). Bearing Quill Cap Screws
3. Rotate pinion shaft a minimum of three turns to seat 450G, 455G, 555G (S.N.
bearings. 785188 )Torque...................................... 149 Nm (110 lbft) Second
PassTighten to 196 Nm (145 lbft), but do
4. With the pinion shaft in the vertical position, measure not exceed more than 60 (1/6 turn)
and record pinion shaft endplay. Bearing Quill Cap Screws
550G, 650G (S.N.
5. For 450G, 455G and 555G machines, remove bearing 785188 )Torque................................................... 278 Nm (205 lbft)
quill. Remove shims to just eliminate endplay. Then
remove up to an additional 0.08 mm (0.003 in.)
maximum thickness of shims.
Specification
ShimMaximum
Thickness.................................................................. 0.08 mm (0.003 in.)
PN=169
Axle Shaft, Bearings, and Reduction Gears
T8059FE UN16AUG93
AInner Bearing Cup DIdler Pinion Shaft GORing J Washer (3 used)
BInner Bearing Cone EOuter Bearing Cone HShims (as required) KCap Screw (3 used)
CIdler Shaft Gear F Outer Bearing Cup I Idler Pinion Quill L Final Drive Housing
Install inner bearing cone (B) in mating bearing cup. This will provide a maximum idler shaft preload of 0.1
mm (0.004 in.).
2. Install idler shaft gear (C) and shaft in housing (L).
Specification
Install quill (I) without Oring (G) or shims (H). Make
Idler ShaftMaximum
sure arrow on quill points toward pinion shaft bore.
Preload........................................................................ 0.1 mm (0.004 in.)
3. Tighten three cap screws (K) to 37 Nm (27 lbft).
7. Remove quill. Put calculated shim pack on quill.
Specification
Cap ScrewsTorque..................................................... 37 Nm (27 lbft)
Continued on next page TX,02,RB438 1912FEB981/2
PN=170
Axle Shaft, Bearings, and Reduction Gears
9. Apply thread lock and sealer (medium strength) to 10. Apply thread lock and sealer (medium strength) to
threads of cap screws. Install and tighten cap screws. edges of shims.
LOCTITE is a registered trademark of Loctite Corp.
TX,02,RB438 1912FEB982/2
PN=171
Axle Shaft, Bearings, and Reduction Gears
T6565AC UN20APR89
Bearing(All Other Models) 0.23 0.05 mm (0.009 0.002 in.)
Preload
Bearing Quill Cap Screws (S.N. 149 Nm (110 lbft) Second
785187) Torque PassTighten to 196 Nm (145
lbft), but do not exceed more than
60 (1/6 turn)
Bearing Quill Cap Screws 450G, 149 Nm (110 lbft) Second
455G, 555G (S.N. 785188 ) PassTighten to 196 Nm (145
Torque lbft), but do not exceed more than
60 (1/6 turn)
Bearing Quill Cap Screws 550G, 278 Nm (205 lbft)
650G (S.N. 785188 ) Torque
OTHER MATERIAL
T7942AE UN08FEB93
T43512 U.S. Thread Lock and Sealer (Medium Strength)
TY9473 Canadian Thread Lock and Sealer (Medium Strength)
242 LOCTITE Thread Lock and Sealer (Medium Strength)
PN=172
Axle Shaft, Bearings, and Reduction Gears
T7942AE UN08FEB93
cap screws do not turn when tightened to specification
after tapping plate.
8. Attach final drive housing to a hoist.
9. Put a dial indicator at the center of retainer.
NOTE: On some machines, the weight of the housing
may not be enough to fully compress the oil seal
to prevent false end play reading. Additional
downward force may be required.
T7247AS UN09APR90
11. Lift the housing and rotate axle to insure the bearings
are seated. Measure end play of axle shaft.
12. Remove enough shims (D) to just eliminate measured
end play. Then remove an additional 0.13 0.03
mm (0.0050.001 in.) thickness of shims on the
450GLGP and 0.23 0.05 mm (0.009 0.002 in.)
thickness of shims on all other machines to provide
the necessary preload. Specification
Specification Bearing Quill Cap
Bearing450G Screws (S.N.
LGPPreload................................... 0.13 0.03 mm (0.0050.001 in.) 785187)Torque....................................... 149 Nm (110 lbft) Second
Bearing(All Other PassTighten to 196 Nm (145 lbft), but do
Models)Preload.............................. 0.23 0.05 mm (0.009 0.002 in.) not exceed more than 60 (1/6 turn)
Bearing Quill Cap Screws
13. Install shim pack and retainer. 450G, 455G, 555G (S.N.
785188 )Torque...................................... 149 Nm (110 lbft) Second
14. Apply thread lock and sealer (medium strength) to PassTighten to 196 Nm (145 lbft), but do
retainer cap screws. Tighten cap screws. Retighten not exceed more than 60 (1/6 turn)
cap screws per following specifications. Bearing Quill Cap Screws
550G, 650G (S.N.
785188 )Torque................................................... 278 Nm (205 lbft)
TX,02,RB522 1917FEB982/2
PN=173
Axle Shaft, Bearings, and Reduction Gears
T6926BU UN06DEC88
carrier roller on 550G and 650G. (See Remove
and Install Carrier Roller, Group 0130.)
T6645AC UN27OCT88
Specification
Rear CoverWeight............................................................ 36 kg (80 lb)
Install two M162 x 150 mm metric hex screws (B) as
guide pins. Remove all other rear cover cap screws.
5. Install two JT01748 Lifting Brackets (A) using 16 mm
(0.625 in.) cap screws and nuts. Remove rear cover.
PN=174
Axle Shaft, Bearings, and Reduction Gears
T6589BC UN19OCT88
and Assemble Internal Brake Control Linkage in Group
0250).
7. On machines (S.N. 770807), disconnect line (A) to
remove fitting (B) from steering clutch housing.
On machines (S.N. 770808 ), disconnect lines (D
and E) to remove fittings (F and G).
T7247AN UN09APR90
TX,02,RB523 1914JUN113/10
T6656DR UN19OCT88
Continued on next page TX,02,RB523 1914JUN114/10
PN=175
Axle Shaft, Bearings, and Reduction Gears
T6645AD UN27OCT88
clutch shaft (B). Pinion puller hole is tapped 12 mm x
1.75. Keep shim pack with quill for reinstallation and
preload adjustment.
T6645AE UN27OCT88
TX,02,RB523 1914JUN115/10
PN=176
Axle Shaft, Bearings, and Reduction Gears
T6582AB UN01NOV88
Continued on next page TX,02,RB523 1914JUN117/10
PN=177
Axle Shaft, Bearings, and Reduction Gears
17. Lift steering clutch housing onto 2 in. x 4 in. block (B)
in transverse housing.
NOTE: Clutch housing must slide onto the front pin
easily, if interference, remove and inspect
brake band to clutch housing fit.
T6582AA UN01NOV88
TX,02,RB523 1914JUN118/10
T6585BI UN19OCT88
PN=178
Axle Shaft, Bearings, and Reduction Gears
T6589BC UN19OCT88
NOTE: If pinion shaft bearings were replaced, adjust
pinion shaft preload. (See procedure in this group.)
T7247AN UN09APR90
not exceed more than 60 (1/6 turn)
Pinion Shaft Bearing Quill
Cap Screws 450G, 455G,
555G (S.N. 785188
)Torque....................................................... 149 Nm (110 lbft) Second
PassTighten to 196 Nm (145 lbft), but do
not exceed more than 60 (1/6 turn)
Pinion Shaft Bearing
Quill Cap Screws 550G,
650G (S.N. 785188 APressure Line ELube Line
)Torque.................................................................... 278 Nm (205 lbft) BElbow Fitting F Elbow Fitting
CCap Screw GElbow Fitting
22. Turn hexagon cap screw (C) counterclockwise until DPressure Line
even with casting. Install plug in bottom of transfer
case.
27. Install transmission if removed. (See Group 0350.)
23. On machines (S.N. 770807), apply pipe sealant with
TEFLON to fitting (B) and install. Install pressure 28. Clean mounting surface of transverse case and rear
line (A). cover.
On machines (S.N. 770808 ), apply pipe sealant 29. Install gasket with rubber bead facing rear cover.
with TEFLON to fittings (F and G) and install. Install Install rear cover.
pressure line (D) and lube line (E).
30. Install small rear cover cap screws from center of
IMPORTANT: Anchor assembly tool must be housing toward corners. Tighten cap screws.
removed to prevent damage to anchor or
Specification
steering clutch housing.
Transverse Case Cover
Cap Screws (Small
24. Remove brake anchor assembly tool. Install washer
Rear)Torque.............................................. 130 26 Nm (96 19 lbft)
and tighten cap screw.
Specification 31. Install large rear cover cap screws from center of
Piston Housingto housing toward corners. Tighten cap screws.
Brake Drum Cap Specification
ScrewsTorque............................................................. 61 Nm (45 lbft) Transverse Case Cover
Cap Screws (Large
25. Connect brake anchor linkage.
Rear)Torque.......................................... 620 124 Nm (458 91 lbft)
26. Adjust brakes. (See procedure in this group.)
TEFLON is a registered trademark of Du Pont Co.
TX,02,RB523 1914JUN1110/10
PN=179
Axle Shaft, Bearings, and Reduction Gears
T7247AA UN09APR90
PN=180
Axle Shaft, Bearings, and Reduction Gears
1 Brake Steering Drum 6 Steering Clutch Lining (6 11 Hardened Washer (10 used) 16 Thrust Ring
2 Snap Ring used) 12 Cap Screw (6 used) 17 Pressure Port
3 Snap Ring 7 Piston 13 Sealing Ring (2 used)
4 Steering Clutch Hub 8 Inner Sealing Ring 14 Clutch Pressure Manifold
5 Steering Clutch Disk (6 used) 9 Outer Sealing Ring 15 Cap Screw (4 used)
10 Piston Housing
2. Remove cap screws (12), hardened washers (11), and Alternately install steering clutch disc (5) and steering
piston housing (10). clutch lining (6). A total of six linings and disc are used.
Specification
3. Remove piston (7) from piston housing (10).
Piston HousingtoBrake
4. Remove the inner (8) and outer (9) sealing ring. Drum (12) Cap
ScrewsTorque............................................................. 61 Nm (45 lbft)
5. Remove steering clutch lining (6), steering clutch disc Thrust RingtoPiston
(5), steering clutch hub (4), snap ring (3) and snap Housing (15) Cap
ring (2). ScrewsTorque............................................................. 68 Nm (50 lbft)
NOTE: Steering clutch linings (6) are reusable until the
groove pattern is no longer visible. Steering clutch
disc (5) must be flat and free of any defects.
TX,02,RB524 1917FEB982/2
PN=181
Axle Shaft, Bearings, and Reduction Gears
T7247AB UN01AUG90
PN=182
Axle Shaft, Bearings, and Reduction Gears
1 Brake Steering Drum 6 Steering Clutch Lining (6 11 Hardened Washer (10 used) 16 Thrust Ring
2 Snap Ring used) 12 Cap Screw (6 used) 17 Pressure Port
3 Snap Ring 7 Piston 13 Sealing Ring (2 used) 18 Lube Port
4 Steering Clutch Hub 8 Inner Sealing Ring 14 Clutch Pressure Manifold
5 Steering Clutch Disk (7 used) 9 Outer Sealing Ring 15 Cap Screw (4 used)
10 Piston Housing
2. Remove cap screws (12), hardened washers (11), and Alternately install steering clutch lining (6) and steering
piston housing (10). clutch disc (5). A total of six linings and seven discs
are used.
3. Remove piston (7) from piston housing (10).
Specification
4. Remove the inner (8) and outer (9) sealing ring. Piston HousingtoBrake
Drum (12) Cap
5. Remove steering clutch lining (6), steering clutch disc ScrewsTorque............................................................. 61 Nm (45 lbft)
(5), steering clutch hub (4), snap ring (3) and snap Thrust RingtoPiston
ring (2). Housing (15) Cap
ScrewsTorque............................................................. 68 Nm (50 lbft)
NOTE: Steering clutch linings (6) are reusable until the
groove pattern is no longer visible. Steering clutch
disc (5) must be flat and free of any defects.
TX,02,RB442 1912FEB982/2
PN=183
Axle Shaft, Bearings, and Reduction Gears
T6677AF UN19OCT88
1 Bearing (2 used) 5 Spring 9 Yoke 13 Lock Nut
2 Lever 6 Pin 10 Yoke 14 Snap Ring (4 used)
3 Trigger 7 Anchor 11 Snap Ring (4 used) 15 Washer
4 Nut 8 Lever (2 used) 12 Link
PN=184
Axle Shaft, Bearings, and Reduction Gears
PN=185
Axle Shaft, Bearings, and Reduction Gears
T7247AC UN01AUG90
ABearing (2 used) EPin I Yoke MSnap Ring (4 used)
BLever F Anchor J Snap Ring (4 used) NShim (as required)
CNut GLever (2 used) KLink OSnap Ring
DRetainer HYoke L Lock Nut
PN=186
Axle Shaft, Bearings, and Reduction Gears
T113200 UN17FEB98
PN=187
Axle Shaft, Bearings, and Reduction Gears
NOTE: Steering brake control linkage can be 1. Remove transmission. (See Group 0350.)
disassembled and assembled with transmission in
place, but it is faster and easier to remove
transmission first.
Do not stop track with grouser in front of plugs.
Pin removal may be difficult or impossible.
TX,02,RB445 1912FEB982/6
T6585BI UN19OCT88
TX,02,RB445 1912FEB983/6
T7247AF UN09APR90
assembly (C). Remove anchor assembly.
PN=188
Axle Shaft, Bearings, and Reduction Gears
ALever CNut
BPin DSpecial Nut
T6926BS UN05JAN89
Continued on next page TX,02,RB445 1912FEB985/6
PN=189
Axle Shaft, Bearings, and Reduction Gears
T7247BE UN09APR90
1 Brake Lever 8 OverCenter Brake Lever 15 Trigger 22 Spring
2 Seal 9 Rod 16 Bearing (2 used) 23 Seal
3 Bearing Cover 10 Anchor 17 Lever 24 Lock Nut
4 Bearing 11 Lever (2 used) 18 Nut 25 Spacer (4 used)
5 Needle Bearing (2 used) 12 Yoke 19 Spring 26 Cap Screw (2 used)
6 Shaft 13 Yoke 20 Pin 27 Shims (as required)
7 Spring Lever 14 Link 21 Lockout Pin
IMPORTANT: Anchor levers must engage brake band If length of rod (9) has NOT been
ears or brakes will not function properly. changed, do Steering Brakes Linkage
Adjustment in this group.
13. Position anchor assembly on brake band so anchor
levers (11) engage break band ears. 18. Apply thread lock and sealer (medium strength) to cap
14. Move anchor (10) and brake assembly to top of clutch screw (26). Align rod (9) hole with levers (8 and 17).
housing until anchor assembly is stopped by front pin. Install spacers (25) and cap screws.
15. Install rear pin to hold anchor in position. 19. Install transmission but DO NOT install transverse
case rear cover. (See procedure in Group 0350.)
16. Connect link (14) to lever (17). Install retainer.
20. Adjust steering brakes and linkage as necessary. (See
17. Use shims (27) to align lever (17) with center of link procedure in this group.)
(14). Use minimum of one shim on end of lever
towards center of crawler. 21. Install transverse case cover.
PN=190
Axle Shaft, Bearings, and Reduction Gears
T8067AB UN09SEP93
PN=191
Axle Shaft, Bearings, and Reduction Gears
NOTE: Steering brake control linkage can be 1. Remove transmission. (See Group 0350.)
disassembled and assembled with transmission in
place, but it is faster and easier to remove
transmission first.
Do not stop track with grouser in front of plugs.
Pin removal may be difficult or impossible.
TX,02,RB526 1917FEB982/6
T6585BI UN19OCT88
TX,02,RB526 1917FEB983/6
T7247AF UN09APR90
assembly (C). Remove anchor assembly.
PN=192
Axle Shaft, Bearings, and Reduction Gears
ALever CNut
BPin DSpecial Nut
T6926BS UN05JAN89
Continued on next page TX,02,RB526 1917FEB985/6
PN=193
Axle Shaft, Bearings, and Reduction Gears
T7247AG UN09APR90
ABrake Lever HOverCenter Brake Lever OBearing (2 used) VSeal
BSeal I Rod PLever WLock Nut
CBearing Cover J Anchor QNut XSpacer (4 used)
DBearing KLever (2 used) RRetainer YCap Screw (2 used)
ENeedle Bearing (2 used) L Yoke SPin Z Shims (as required)
F Shaft MYoke T Lockout Pin
GSpring Lever NLink USpring
IMPORTANT: Anchor levers must engage brake band If length of rod (I) has NOT been changed, do
ears or brakes will not function properly. Steering Brakes Linkage Adjustment in
this group.
13. Position anchor assembly on brake band so anchor
levers (K) engage break band ears. 18. Apply thread lock and sealer (medium strength) to cap
14. Move anchor (J) and brake assembly to top of clutch screw (Y). Align rod (I) hole with levers (H and P).
housing until anchor assembly is stopped by front pin. Install spacers (X) and cap screws.
15. Install rear pin to hold anchor in position. 19. Install transmission. (See procedure in Group 0350.)
16. Connect link (N) to lever (P). Install retaining clip. 20. Adjust steering brakes and linkage as necessary. (See
procedure in this group.)
17. Use shims (Z) to align lever (P) with center of link (N).
Use minimum of one shim on end of lever toward
center of crawler.
IMPORTANT: If length of rod (I) has been changed,
do Internal Steering Brake Control Linkage
Adjustment in this group.
TX,02,RB526 1917FEB986/6
PN=194
Axle Shaft, Bearings, and Reduction Gears
OTHER MATERIAL
T6589BF UN09APR90
T43512 U.S. Thread Lock and Sealer (Medium Strength)
TY9473 Canadian Thread Lock and Sealer (Medium Strength)
242 LOCTITE Thread Lock and Sealer (Medium Strength)
T6926BX UN06DEC88
5. Install a center punch (C) in brake lever. Punch must
fit tightly in hole.
NOTE: Later transverse housings have chisel mark at
195 mm (7.67 in.) from machined surface. Punch
tip must align with chisel mark (E).
PN=195
Axle Shaft, Bearings, and Reduction Gears
T6589BD UN09APR90
(C) and punch is distance (E) from machined surface
(D) or aligns with chisel mark in top of case.
9. Push lever forward to check that all free travel has bee
eliminated. If not, turn rod (A) to remove free travel.
10. Turn brake lever rearward enough to remove cap
screw (C).
11. Apply thread lock and sealer (medium strength) to
cap screw (C).
NOTE: Tow disconnect pin must be up.
12. Install cap screw (C) with lock nut in hole (F) until
T6589BE UN09APR90
punch distance (E) is 195 2 mm (7.67 0.08 in.)
from machined surface (D) or punch tip aligns with
chisel mark while holding lever forward.
Specification
Chisel MarkDistance
From Machined Surface.............................. 195 2 mm (7.67 0.08 in.)
TX,02,RB447 1912FEB982/2
PN=196
Axle Shaft, Bearings, and Reduction Gears
T6685AK UN19OCT88
Machines Distance Traveled
Lever Travel Distance 127 mm (5 in.)
Pedal Travel Distance From 279 mm (11 in.)
Firewall
3. Operate machine in 1st gear at low idle. a. Adjust one side at a time. Slowly push on brake
pedal until track stops.
NOTE: It is normal for brake pedals to vary up to
13 mm (1/2 in.) in travel when checked to b. Measure pedal travel from firewall to bottom
forward and reverse stop track position. Lever center of pedal. Track should stop when pedal is
steer machines can vary up to 25 mm (1 in.) approximately 279 mm (11 in.) from firewall.
difference at stop track positions. Specification
Pedal TravelDistance
4. Adjust brakes to specifications. From Firewall................................................................... 279 mm (11 in.)
PN=197
Axle Shaft, Bearings, and Reduction Gears
T6677AH 1921DEC92
forward/reverse cycle, pulling steering lever or pushing
steering pedal to stop ten times. Check number
of notches adjuster (A) has moved. In ten brake
applications, adjuster should move only one notch.
8. To slow down the rate of selfadjustment, loosen lock
nut and turn stop screw 1/4turn IN.
9. To increase the rate of selfadjustment, loosen lock
nut and turn stop screw 1/4turn OUT.
IMPORTANT: If stop screw has been adjusted more
than 1/2turn, see Steering Brakes Linkage
Adjustment in this group, to adjust lower
pedal/lever stops ONLY. Lower stops must be
T8065AA 1903SEP93
adjusted to prevent damage to brake linkage.
TX,02,RB527 1917FEB982/2
T6766BZ UN19OCT88
Adjuster Resistance 55 N (12 lb)
Adjuster Distance 127 mm (5 in.)
Brake Pedal Distance Traveled 13 mm (1/2 in.)
Brake PedalLever Steer 25 mm (1 in.)
Machines Distance Traveled
PN=198
Axle Shaft, Bearings, and Reduction Gears
T6499CK UN09FEB89
could occur. When loosening brakes, the
selfadjuster tab (B) may have to be held away
from notches to reduce resistance.
T6677AH 1921DEC92
b. Push pedal to lower stop several times to seat
linkage, then check step a again.
LEVER STEER:
a. Turn adjuster (A) until approximately 55 N (12 lb) of
resistance is felt when lever travels 127 mm (5 in.)
as measured at top of handles from forward stop.
Specification
AdjusterResistance............................................................ 55 N (12 lb)
Distance............................................................................ 127 mm (5 in.)
T8065AA 1903SEP93
IMPORTANT: If brakes selfadjust too tight or too
loose, see Adjust Steering Brake SelfAdjuster
Linkage in this group.
PN=199
Axle Shaft, Bearings, and Reduction Gears
T6766BZ UN19OCT88
Adjuster Resistance 55 N (12 lb)
Adjuster Distance 127 mm (5 in.)
Brake Pedal Distance Traveled 13 mm (1/2 in.)
Brake PedalLever Steer 25 mm (1 in.)
Machines Distance Traveled
PN=200
Axle Shaft, Bearings, and Reduction Gears
T6499CK UN09FEB89
must be springloaded against teeth on
adjuster. Do not pry on retainer.
T7247AH UN09APR90
b. Push pedal to lower stop several times to seat
linkage, then check step a again.
LEVER STEER:
a. Turn adjuster (A) until approximately 55 N (12 lb) of
resistance is felt when lever travels 127 mm (5 in.)
as measured at top of handles from forward stop.
Specification
AdjusterResistance............................................................ 55 N (12 lb)
Distance............................................................................ 127 mm (5 in.)
T8065AB 1903SEP93
4. Check adjustment by operating machine in first gear
at low idle.
PEDAL STEER: Slowly push on brake pedal until
track stops. Measure pedal travel from firewall to
bottom center of pedal. Track should stop when pedal
is approximately 279 mm (11 in.) from firewall.
LEVER STEER: Slowly pull back on lever until track
stops. Measure lever travel at top lever handles. NOTE: It is normal for brake pedals to vary up to
Track should stop at approximately 127 mm (5 in.) of 13 mm (1/2 in.) in travel when checked to
lever travel. forward and reverse stop track position. Lever
Specification steer machines can vary up to 25 mm (1 in.)
Brake PedalDistance difference at stop track positions.
Traveled............................................................................ 13 mm (1/2 in.)
Brake PedalLever
Steer MachinesDis
tance Traveled..................................................................... 25 mm (1 in.)
TX,02,RB529 1917FEB982/2
PN=201
Axle Shaft, Bearings, and Reduction Gears
T7247AJ UN09APR90
AUpper Pedal Stop DUpper Rod GTow Disconnect Pins J Stop Screw
BLower Pedal Stop ELower Bellcrank HRear Bellcrank KInspection Plug
CPedals F Brake Rod I Brake Adjuster L Return Spring (2 used)
SPECIFICATIONS
3. Adjust upper pedal stop (A) until distance from firewall
Firewall To Bottom Edge Of Pedal 362 3 mm (14.25 0.125 in.)
Distance
to bottom edge of pedal (C), at the center, is 362
3 mm (14.25 0.125 in.).
Pedals Distance From Firewall 197 3 mm (7.75 0.125 in.)
Center Of Bottom Hole In 91 2 mm (3.58 0.08 in.) Specification
Bellcranks Distance From Firewall Firewall To Bottom Edge
Bottom Center of Pedal Distance 338 3 mm (13.25 0.125 in.) Of PedalDistance................................. 362 3 mm (14.25 0.125 in.)
From Firewall Adjust other pedal upper stop until pedals are even
at center.
IMPORTANT: The internal linkage of the transverse
case must be adjusted properly before Adjust lower pedal stops (B) until bottom edge of
starting this adjustment. Linkage is set at the pedals are 197 3 mm (7.75 0.125 in.) from firewall.
factory and needs service only if damaged Specification
or length of rod was changed. PedalsDistance From
This adjustment must be performed in the Firewall...................................................... 197 3 mm (7.75 0.125 in.)
following order to adjust the linkage properly. 4. Adjust length of rods (D) until center of bottom hole in
bellcranks (E) are 91 2 mm (3.58 0.08 in.) from
NOTE: Pedal steer brake linkage adjustment is firewall.
the same for all machines.
Specification
1. Remove floor panels. Remove fenders under reservoir Center Of Bottom Hole
and fuel tank. In BellcranksDistance
From Firewall................................................. 91 2 mm (3.58 0.08 in.)
2. Remove pins from lower bellcranks (E).
Continued on next page TX,02,RB530 1917FEB981/2
PN=202
Axle Shaft, Bearings, and Reduction Gears
T6766BZ UN19OCT88
upper stop hold down tow disconnect pin (G) then
release pedal. Tow disconnect pin must stay down.
Repeat step for other side.
6. Hold one pedal upward until freeplay is gone, turn
brake rod (F) until bottom center of pedal is 338 3
mm (13.25 0.125 in.) from firewall.
Specification linkage until quadlever is against stop screw (J) when
Bottom Center of engine is off.
PedalDistance From
Firewall.................................................... 338 3 mm (13.25 0.125 in.) IMPORTANT: Quadlever must be visible and even
with bottom of inspection plug (K) hole.
Release pedal, adjust other brake rod (F) until pedals If not, see Adjust Internal Steering Brake
are even at the center. Control Linkage in this group.
7. Remove large plug in side of transverse housing.
NOTE: Step 10 will insure that stop screw (J) is
8. Pull pedals to upper stop to release tow disconnect contacted before lower stop (B).
pins. Push pedals to lower stop (B).
10. With quadlever against stop screw (J), turn pedal
CAUTION: Install cap screw (P) through shift lower stop screw (B) in until freeplay is evident. Then
control console locking shift lever in neutral turn screw in one turn.
position to prevent accidental shifting into
11. Check and adjust steering valve. (See Adjust Steering
gear during this adjustment.
Valve in Group 0260.)
9. Remove inspection plug (K). Check that stop screw 12. Check brake adjustment. (See Manual Steering Brake
(J) is contacting quadlever. If not, start engine and Adjustment in this group.)
shift to neutral. Turn brake adjuster (I) to loosen brake
TX,02,RB530 1917FEB982/2
PN=203
Axle Shaft, Bearings, and Reduction Gears
T7247AP UN09APR90
ASteering Valve Pull Rod EUpper Pedal Stop I Lockout (Tow) Pin MAdjuster
BBrake Lever Pull Rod F Pull Rod J Ball Joint NInspection Plug
CLower Lever (Rear) Stop GLower Bellcrank KRear Brake Lever OStop Screw
DLower Pedal Stop HBrake Pedal Pull Rod L Clutch Valve Bellcrank
SPECIFICATIONS
Specification
Bottom Edge of Pedal Distance 362 3 mm (14.25 0.125 in.)
Bottom Edge of
From Firewall
PedalDistance From
Bottom Edge of Pedal Distance 197 3 mm (7.75 0.125 in.)
Firewall.................................................... 362 3 mm (14.25 0.125 in.)
From Firewall
Center Of Bottom Hole In Bellcrank 91 2 mm (3.58 0.08 in.) 3. Adjust brake pedal lower stop (D) until bottom edge of
Distance From Firewall pedal is 197 3 mm (7.75 0.125 in.) from firewall.
Lever Travel Distance 241 mm (9.5 in.)
Specification
Bottom Edge of
IMPORTANT: The internal linkage of the transverse
PedalDistance From
case must be adjusted properly before
Firewall...................................................... 197 3 mm (7.75 0.125 in.)
starting this adjustment. Linkage is set at the
factory and needs service only if damaged 4. Adjust length of rod (F) until center of bottom hole
or length of rod was changed. in bellcrank (G) is 91 2 mm (3.58 0.08 in.) from
firewall when pedal is against upper stop.
This adjustment must be performed in the
following order to adjust the linkage properly. Specification
Center Of Bottom Hole
1. Remove floor panels and slide seat back. Remove In BellcrankDistance
fenders under fuel tank and reservoir. From Firewall................................................. 91 2 mm (3.58 0.08 in.)
2. Adjust brake pedal upper stop (E) until bottom edge of 5. Adjust lower lever (rear) stops (C) to stop lever at
pedal is 362 3 mm (14.25 0.125 in.) from firewall. 241 mm (9.5 in.) of lever travel, measured at top of
handles from forward stop.
Specification
Lever TravelDistance.................................................. 241 mm (9.5 in.)
Continued on next page TX,02,RB531 1917FEB981/3
PN=204
Axle Shaft, Bearings, and Reduction Gears
T6766BZ UN19OCT88
(O) is contacting quadlever. If not, remove large plugs
in side of transverse case. Start engine and shift to
neutral. Turn adjuster (M) to loosen brake linkage until
quadlever is against stop screw (O) when the engine
is off.
IMPORTANT: Quadlever must be visible and even
with bottom of inspection plug (N) hole. If
not, see Internal Steering Brake Control
Linkage Adjustment in this group. 10. Shorten rod (H) one turn and tighten lock nuts. This
ensures that quadlever stop screw (O) is contacted
7. Adjust length of rod (B) so rear lever stop and before the brake pedal stop.
quadlever contact at the same time. 11. Check and adjust steering valve. (See procedure in
8. Shorten rod (B) one turn and tighten lock nut. This Group 0260.)
ensures that quadlever stop screw (O) is contacted 12. Check brake adjustment. (See Manual Steering Brake
before the steering lever stop. Adjustment in this group.)
9. Adjust length of rod (H) so lower brake pedal stop and
quadlever stop contact at the same time.
Continued on next page TX,02,RB531 1917FEB982/3
PN=205
Axle Shaft, Bearings, and Reduction Gears
T7247AK UN09APR90
ASteering Valve Pull Rod EUpper Pedal Stop I Lockout (Tow) Pin MAdjuster
BBrake Lever Pull Rod F Pull Rod J Ball Joint NInspection Plug
CLower Lever (Rear) Stop GLower Bellcrank KRear Brake Lever OStop Screw
DLower Pedal Stop HBrake Pedal Pull Rod L Clutch Valve Bellcrank
SPECIFICATIONS
Specification
Bottom Edge of Pedal Distance 362 3 mm (14.25 0.125 in.)
Bottom Edge of
From Firewall
PedalDistance From
Bottom Edge of Pedal Distance 200 3 mm (7.87 0.125 in.)
Firewall.................................................... 362 3 mm (14.25 0.125 in.)
From Firewall
Center Of Bottom Hole In Bellcrank 91 2 mm (3.58 0.08 in.) 3. Adjust brake pedal lower stop (D) until bottom edge of
Distance From Firewall pedal is 200 3 mm (7.87 0.125 in.) from firewall.
Lever Travel Distance 273 mm (10.75 in.)
Specification
Bottom Edge of
IMPORTANT: The internal linkage of the transverse
PedalDistance From
case must be adjusted properly before
Firewall...................................................... 200 3 mm (7.87 0.125 in.)
starting this adjustment. Linkage is set at the
factory and needs service only if damaged 4. Adjust length of rod (F) until center of bottom hole
or length of rod was changed. in bellcrank (G) is 91 2 mm (3.58 0.08 in.) from
firewall when pedal is against upper stop.
This adjustment must be performed in the
following order to adjust the linkage properly. Specification
Center Of Bottom Hole
1. Remove floor panels and slide seat back. Remove In BellcrankDistance
fenders under fuel tank and reservoir. From Firewall................................................. 91 2 mm (3.58 0.08 in.)
2. Adjust brake pedal upper stop (E) until bottom edge of 5. Adjust lower lever (rear) stops (C) to stop lever at 273
pedal is 362 3 mm (14.25 0.125 in.) from firewall. mm (10.75 in.) of lever travel, measured at top of
handles from forward stop.
Specification
Lever TravelDistance.............................................. 273 mm (10.75 in.)
Continued on next page TX,02,RB532 1917FEB981/3
PN=206
Axle Shaft, Bearings, and Reduction Gears
T6766BZ UN19OCT88
(O) is contacting quadlever. If not, remove large plugs
in side of transverse case. Start engine and shift to
neutral. Turn adjuster (M) to loosen brake linkage until
quadlever is against stop screw (O) when the engine
is off.
IMPORTANT: Quadlever must be visible and even
with bottom of inspection plug (N) hole. If
not, see Internal Steering Brake Control
Linkage Adjustment in this group. 10. Shorten rod (H) one turn and tighten lock nuts. This
ensures that quadlever stop screw (O) is contacted
7. Adjust length of rod (B) so rear lever stop and before the brake pedal stop.
quadlever contact at the same time. 11. Check and adjust steering valve. (See procedure in
8. Shorten rod (B) one turn and tighten lock nut. This Group 0260.)
ensures that quadlever stop screw (O) is contacted 12. Check brake adjustment. (See Manual Steering Brake
before the steering lever stop. Adjustment in this group.)
9. Adjust length of rod (H) so lower brake pedal stop and
quadlever stop contact at the same time.
Continued on next page TX,02,RB532 1917FEB982/3
PN=207
Axle Shaft, Bearings, and Reduction Gears
T6624AM UN19OCT88
CAUTION: Engaging tow disconnect pins
will release brakes and machine could
move if on a grade.
Pedal Steer
1. Remove center floor plate.
2. Pull brake pedal up to upper stop, hold down tow AScrewdriver DLockout (Tow) Pin
disconnect pin (D), then release pedal. Tow disconnect BBall Joint ECombination Wrench
CClutch Spool Rod F Ratchet Wrench
pin must stay down.
Repeat for other side.
Lever Steer Loader Machines OnlyUse ratchet wrench (F) and
15 mm combination wrench (E).
1. Remove left and right floor panels. Remove fender
under reservoir and fuel tank. a. Insert ratchet into box end of wrench at about 90
angle to the wrench.
2. On left side, insert screwdriver (A) in front of ball joint
(B) and behind control valve spool rod (C). b. Insert open end of wrench under link (C) and head
of ball joint.
3. Pull back on screwdriver until brake linkage hits stop
and depress and hold tow disconnect pin (D). Release c. Push ratchet rearward until brake linkage hits stop.
screwdriver. Push tow disconnect pin down and hold. Slowly
release wrench.
Tow disconnect pin must stay down.
d. Tow disconnect pin must stay down.
4. Dozer Machines OnlyRepeat procedure on right
side.
TX,02,RB533 1917FEB981/1
PN=208
Group 0260
Hydraulic System
Other Material
Number Name Use
T43512 (U.S.) Thread Lock and Sealer (Medium To be applied to threads of steering
TY9473 (Canadian) Strength) clutch valve and cylinder cap screws.
242 (LOCTITE)
Specifications
Item Measurement Specification
T6563AA UN25OCT88
2. Disconnect hose (A) and linkage (B). Remove valve.
PN=209
Hydraulic System
T6561AA UN01JUN89
ASeal (2 used) CSpool (Lever Steer) (2 used) EHousing
BSpool (Pedal Steer) (2 used) DSpring (2 used)
CAUTION: Do not remove or turn spool eye 3. Install spool seals (A), spring lip to inside of housing,
bolts. Steering control of machine can be to bottom of bores.
lost. If spool eye bolts have been removed,
4. Install elbow in valve housing (E) and tighten.
reinstall them 10 turns in spool, then do
Steering Clutch Valve Adjustment in this Specification
group before operating machine. ElbowtoSteering Clutch
Valve BodyTorque......................................................11 Nm (97 lbin.)
1. Disassemble valve as shown.
2. Inspect spools (B and C) for wear or damage. If spools
are damaged, replace housing and valves.
TX,02,RB534 1917FEB981/1
PN=210
Hydraulic System
T7247AL UN09APR90
ASeal (2 used) CSpool (Lever Steer) (2 used) EHousing
BSpool (Pedal Steer) (2 used) DSpring (2 used)
CAUTION: Do not remove or turn spool eye 3. Install spool seals (A), spring lip to inside of housing,
bolts. Steering control of machine can be to bottom of bores.
lost. If spool eye bolts have been removed,
4. Install elbow in valve housing (E) and tighten.
reinstall them 10 turns in spool, then do
Steering Clutch Valve Adjustment in this Specification
group before operating machine. ElbowtoSteering Clutch
Valve BodyTorque......................................................11 Nm (97 lbin.)
1. Disassemble valve as shown.
2. Inspect spools (B and C) for wear or damage. If spools
are damaged, replace housing and valves.
TX,02,RB535 1917FEB981/1
PN=211
Hydraulic System
T6688AN UN23AUG93
Adjust Steering Clutch Valve
SPECIFICATIONS
Spool Preset Length in Nertral
Lever Steer Units Length 35 mm (1.38 in.)
Pedal Steer Units Length 33 mm (1.30 in.)
Engine Approximate Speed 1500 rpm
OilDirect Drive Units 40 6 10F)
Temperature
OilTorque Converter Units 65 6C (150 10F)
Temperature
Steering Clutch Valve
Direct Drive Units Pressure 1241 103 kPa (12.4 1.0 bar)
(180 15 psi)
Torque Converter Units Pressure 1724 103 kPa (17.2 1.0 bar)
T6688AO UN25OCT88
(250 15 psi)
Lever Units(S.N. 770807) 38 2 mm (1.50 0.08 in.)
Pressure Drops to Zero After
Travel
Lever Units(S.N. 770808 ) 55 2 mm (2.20 0.08 in.)
Pressure Drops to Zero After
Travel
Pedal Units(S.N. 770807) 22 2 mm (0.87 0.08 in.)
Pressure Drops to Zero After
Travel
Pedal Units(S.N. 770808 40 2 mm (1.60 0.08 in.)
) Pressure Drops to Zero After
Travel
T6766BZ UN19OCT88
ESSENTIAL TOOLS
JT03111 (B) Adapter (7/16 M 37 x 9/16 M ORB)
Parker No. 050364 (B) Adapter (7/16 M 37 x 9/16 M ORB)
JT05483 90 Elbow (7/16 M 37 x 7/16 F 37)
(Parker No. 390344) 90 Elbow (7/16 M 37 x 7/16 F 37)
PN=212
Hydraulic System
IMPORTANT: Steering spools MUST be adjusted (S.N. 770808 ) 55 2 mm (2.20 0.08 in.)
EVEN to synchronize steering before final Specification
adjustments are made. Lever Units(S.N.
770808 )Pressure
5. Steering clutch valve pressure must be to specification. Drops to Zero After
Travel............................................................. 55 2 mm (2.20 0.08 in.)
Steering Clutch ValveSpecification
Direct Drive PEDAL STEER UNITSSlowly depress pedal, one at
UnitsPressure.............................................................. 1241 103 kPa a time and watch pressure gauge. Pedal must travel
(12.4 1.0 bar) (180 15 psi) specified distance (measured at bottom center of
Torque Converter pedal) before pressure drops to zero.
UnitsPressure.............................................................. 1724 103 kPa
(17.2 1.0 bar) (250 15 psi) (S.N. 770807) 22 2 mm (0.87 0.08 in.)
If not, turn steering spool OUT (counterclockwise) to Specification
increase pressure. Pedal Units(S.N.
770807)Pressure
If pressure will not adjust up to specification, check for Drops to Zero After
restricted line to clutch valve or low system pressure. Travel............................................................. 22 2 mm (0.87 0.08 in.)
Do Steering Clutch Pressure Test in TM1403 Group
902025. (S.N. 770808 ) 40 2 mm (1.60 0.08 in.)
Specification
NOTE: Move lever or pedal to specified distance and hold
Pedal Units(S.N.
in position using a block or threaded rod.
770808 )Pressure
Drops to Zero After
6. Move lever or pedal specified distance for pressure
Travel............................................................. 40 2 mm (1.60 0.08 in.)
drop:
7. If lever or pedal travel is not to specification, block or
LEVER STEER UNITSSlowly pull back on lever,
hold lever or pedal to specified travel position. Adjust
one at a time and watch pressure gauge. Lever must
point of pressure drop by turning steering spool into or
travel specified distance (measured at top of handle)
out of housing.
before pressure drops to zero.
NOTE: Loosen nut on spool eye bolt and turn spool
(S.N. 770807) 38 2 mm (1.50 0.08 in.) OUT (counterclockwise) to increase pedal or lever
Specification travel IN (clockwise) to decrease travel.
Lever Units(S.N.
770807)Pressure 8. Adjust brakes. (See Manual Steering Brake
Drops to Zero After Adjustment in Group 0250.)
Travel............................................................. 38 2 mm (1.50 0.08 in.)
TX,02,RB536 1917FEB982/2
PN=213
Hydraulic System
T8066AD UN09SEP93
ASteering Clutch Valve DGasket GBrake Cylinder J Cap Screw and Washer (2
BCap Screw and Washer (11 EGasket HBrake Piston (2 used) used)
used) F Spring Pin I Pipe PlugPedal Steer Units KBrake Locking Spring
CPlate Only (2 used) L Second Brake Locking Spring
(S.N. 786471 ) Only
NOTE: Brake cylinder is pressurized to release Engage lock out pins again.
steering brakes whenever speed control valve
is not in P (PARK) position. 6. Push spring pin (F) into brake cylinder (G) until just
below machined surface.
1. Engage lock out pins.
7. For pedal steer machines only, apply thread lock and
2. Remove steering clutch valve (A). (See procedure in sealer (medium strength) to threads of pipe plugs (I).
this group.) Install plugs into plate (C) until even with or just below
surface of plate.
3. Remove cap screw (B) to remove parts (CJ).
8. Apply thread lock and sealer (medium strength) to
4. Inspect parts replace as necessary. threads of cap screws (J). Install gasket, cylinder,
5. Slowly release lockout pins to relieve spring (K and L) washers and cap screws tighten to specification.
tension. Replace springs if necessary.
Continued on next page TX,02,RB537 1917FEB981/2
PN=214
Hydraulic System
Steering Valve
9. Install gasket and plate assembly. Apply thread
PlateToTransverse
lock and sealer (medium strength) to threads of cap
Housing Cap Screws
screws (B). Install washers and cap screws tighten
(B)Torque.................................................................... 73 Nm (54 lbft)
to specification.
Steering ValveToPlate
Specification Cap ScrewsTorque......................................... 27 5 Nm (20 4 lbft)
Brake CylinderToPlate
Cap Screws (J)Torque................................................. 73 Nm (54 lbft) 10. Install steering clutch valve. (See procedure in this
group.)
TX,02,RB537 1917FEB982/2
PN=215
Hydraulic System
PN=216
Group 0299
Dealer Fabricated Tools
DF1030 Brake Assembly Tool
Tool can be made in dealers shop. Used to hold brake
anchor assembly to steering clutch during removal and
installation of steering clutch.
Material: 1020 Flat stock 1/4 x 3/4 in.
T6579AM UN19MAY89
A10 mm (0.39 in.) E8 mm (0.39 in.)
B45 F 20 mm (0.79 in.)
C20 mm (0.79 in.) G50 mm (1.97 in.)
D20 mm (0.79 in.)
9900,U95 1903AUG901/1
PN=217
Dealer Fabricated Tools
2
2
2
5
3
5 4
9
6
7
11
12 10
6
5
4
TX1072724 UN05MAR10
13
5 14
13
8 15
TX1072724
Final Drive Lift Bracket
1 508 mm (20.0 in.) 5 203.2 mm (8.00 in.) 9 3/4 in. Drill Through Both 13 15.9 mm (0.625 in.)
2 50.8 mm (2.00 in.) 6 63.5 mm (2.50 in.) Sides (8 holes) 14 82.6 mm (3.25 in.)
3 25.4 mm (1.00 in.) 7 2286 mm (90.00 in.) 10 3/8 in. Drill Through (4 15 114.3 mm (4.50 in.)
4 38.1 mm (1.50 in.) 8 152.4 mm (6.00 in.) holes)
11 44.5 mm (1.75 in.)
12 76.2 mm (3.00 in.)
PN=218
Dealer Fabricated Tools
T113230 1903FEB98
Adapter is used with DF1063 Lift Bracket to remove and
install single reduction final drives. 1/2 in. 1020 Steel Plate
11/2 in. x 3 in. x 3/16 in. Square Tube
Material required: 5/8 in. x 5 in. Cap Screw
TX,02,RB539 1917FEB981/1
T113229 1903FEB98
PN=219
Dealer Fabricated Tools
PN=220
Section 03
Transmission
Contents
Page Page
PN=1
Contents
PN=2
Group 0315
Control Linkage
Other Material
Number Name Use
T43512 (U.S.) Thread Lock and Sealer (Medium Apply to threads of bellcrank mount
TY9473 (Canadian) Strength) and cap screws.
242 (LOCTITE)
TY15147 (U.S.) John Deere Instant Super Bonder Apply to threads of levers.
Specifications
Item Measurement Specification
PN=223
Control Linkage
T7247AU UN09APR90
PN=224
Control Linkage
NOTE: Power control pedal and linkage is used on Cap Screw (17)
direct drive machines only. Cap Screw (24)
Cap Screw (25)
1. Disassemble and assemble parts (130). Bellcrank Mount (27)
Specification Shift Quadrant (3) Cap Screws (use Loctite 271,
450G, 550G, highstrength thread lock and sealer).
650G: Speed
Selector Horizontal 3. Tighten bellcrank mount.
RoadLength........................................................... 332.5 mm (13.1 in.) Specification
450G, 550G, Bellcrank
650G: Direction MountTorque........................................... 175 87 Nm (130 65 lbft)
Selector Horizontal
RoadLength................................................................ 230 mm (9.1 in.) 4. Tighten cap screws (24 and 25).
455G, 555G: Speed Specification
Selector Horizontal Lower Bellcrank Bracket
RoadLength............................................................. 89.23 mm (3.5 in.) Cap ScrewsTorque................................... 37 7.4 Nm (27 5.5 lbft)
455G, 555G: Direction
Selector Horizontal 5. Apply instant bonder to thread of levers (2 and 4).
RoadLength................................................................ 193 mm (7.6 in.) Install knobs (1 and 5).
2. Apply thread lock and sealer (medium strength) to the 6. On early machines, adjust spring nut on rod (31) to
following threads: preload spring 0.5 mm (0.02 in.). (Not used on later
machines.)
Cap Screw (8)
Cap Screw (9)
TX,0315,QQ429 1919OCT932/2
PN=225
Control Linkage
T8074AC UN13SEP93
PN=226
Control Linkage
NOTE: Power control pedal and linkage is used on Cap Screw (9)
direct drive machines only. Cap Screw (13)
Cap Screw (20)
1. Disassemble and assemble parts (145). Cap Screw (21)
Specification
Bellcrank Mount (23)
450G, 550G,
Cap Screw (45)
650G: Speed Shift Quadrant (3) Cap Screws (use Loctite 271, high
Selector Horizontal strength, thread lock and sealer).
RoadLength........................................................... 332.5 mm (13.1 in.)
450G, 550G, 3. Tighten bellcrank mount (23).
650G: Direction Specification
Selector Horizontal Bellcrank
RoadLength................................................................ 230 mm (9.1 in.) MountTorque........................................... 175 87 Nm (130 65 lbft)
455G, 555G: Speed
Selector Horizontal 4. Tighten cap screws (20 and 21).
RoadLength............................................................. 89.23 mm (3.5 in.) Specification
455G, 555G: Direction Lower Bellcrank Bracket
Selector Horizontal Cap ScrewsTorque................................... 37 7.4 Nm (27 5.5 lbft)
RoadLength................................................................ 193 mm (7.6 in.)
5. Apply instant bonder to thread of levers (2 and 4).
2. Apply thread lock and sealer (medium strength) to the Install knobs (1 and 5).
following threads:
Cap Screw (8)
TX,0315,BD885A 1919OCT932/2
PN=227
Control Linkage
T6820AA UN19OCT88
APark Lock Fork Roller CShift Lever Pivot Ball Joint ESpeed Selector Horizontal
BVertical Speed Selector Rod DDirection Selector Vertical Rod
Rod F Direction Selector Horizontal
Rod
PN=228
Control Linkage
T8103AA UN11OCT93
12. After all linkage adjustments have been made, the
shift lever when in park position, must not move
more than 2 mm (0.08 in.) towards neutral position.
Measurement is taken at quadrant cover front edge
to shift lever front edge.
902020,QQ26 1919OCT933/3
PN=229
Control Linkage
PN=230
Group 0325
Input Drive Shafts and UJoints
Remove and Install Drive Shaft
NOTE: Torque converter machine shown procedures
for direct drive machines are the same.
T112893 UN20JAN98
2. Remove four cap screws (B).
3. Slide drive shaft (A) toward transmission to remove.
4. Install drive shaft (A). Tighten bearing straptoyoke
cap screws (B).
5. Install floor plates.
(S.N. 803601 ) Shown
Specification
Drive Shaft Bearing
StraptoYoke Cap
ScrewsTorque.............................................. 47.5 9 Nm (35 7 lbft)
TX,03,RB243 1922JAN981/1
PN=231
Input Drive Shafts and UJoints
PN=232
Group 0350
Gears, Shafts, Bearings and Clutch
Special or Essential Tools
NOTE: Order tools according to information given in
the U.S. SERVICEGARDCatalog or in the
European Microfiche Tool Catalog (MTC).
T8078AB UN28SEP93
Puller Legs............................................................ JDG831
To remove and install gears and bearings.
DX,TOOLS 1914JUN112/3
Service Equipment and Tools Tool Catalog (MTC). Some tools may be
available from a local supplier.
NOTE: Order tools from the U.S. SERVICEGARD
Catalog or from the European Microfiche
TX,03,DY59 1914JUN113/4
400 mm (16 in.) Nylon Tie Band KD Tools No. 1114 Piston Ring Compressor Pliers and
No. 1126 Piston Ring Compressor Band
To compress clutch pack sealing ring.
To compress clutch pack sealing ring.
TX,03,DY59 1914JUN114/4
PN=233
Gears, Shafts, Bearings and Clutch
Other Material
Number Name Use
T43512 (U.S.) Thread Lock and Sealer (Medium Apply to cap screw threads as
TY9473 (Canadian) Strength) specified.
242 (LOCTITE)
T43515 (U.S.) LOCTITE Retaining Compound Apply to ring gear and ring gear hub.
TY9479 (Canadian)
635 (LOCTITE)
PN=234
Gears, Shafts, Bearings and Clutch
Specifications
Item Measurement Specification
PN=235
Gears, Shafts, Bearings and Clutch
T6645AB UN27OCT88
1 Rear Cover 8 Transverse Case 15 Steering Clutch Shaft 22 Washer (18 used)
2 Cap Screw (2 used) 9 Cap Screw (3 used) 16 Socket Head Cap Screw (2 23 Cap Screw (18 used)
3 Washer (2 used) 10 Washer (3 used) used) 24 Washer (13 used)
4 Lifting Bracket (2 used) 11 Pinion Quill 17 Pipe Plug (3 used) 25 Cap Screw (13 used)
5 Transmission Assembly 12 ORing 18 Drain Plug 26 Cap Screw (2 used)
6 Washer (2 used) 13 Shim Pack (as required) 19 Tube Clamp Support
7 Cap Screw (2 used) 14 Final Drive Pinion 20 Washer
21 Cap Screw
Continued on next page 0350,BB82 1919OCT931/7
PN=236
Gears, Shafts, Bearings and Clutch
T6499DQ UN09FEB89
Specification
Transverse
CaseApproximate
Oil Weight............................................................................. 83 L (22 gal)
T6891AR UN10FEB89
Weight.............................................................................. 138 kg (304 lb)
Later Machines
0350,BB82 1919OCT932/7
T6645AC UN27OCT88
cover is 36 kg (80 lb).
PN=237
Gears, Shafts, Bearings and Clutch
T6656DR UN19OCT88
final drive pinion removal.
T6656DS UN19OCT88
jack screw up into the transverse case until contact is
made with the steering clutch (D).
0350,BB82 1919OCT934/7
T6645AD UN27OCT88
and shaft have been removed.
PN=238
Gears, Shafts, Bearings and Clutch
T6926BZ UN06DEC88
to install JT01748 Lifting Brackets (D).
Specification
Transmission
AssemblyApproximate
Weight.............................................................................. 265 kg (584 lb)
T6645AG UN27OCT88
align with control valve manifold.
PN=239
Gears, Shafts, Bearings and Clutch
T6562AB UN01NOV88
and rear cover.
20. Install gasket with continuous rubber bead facing in.
Install rear cover.
21. Install small cap screws from center of housing toward
corners. Tighten cap screws.
Specification
Rear Cover Cap Screws
(M12)Torque............................................................149 Nm (110 lbft) ACap Screw (3 used) DShims (as needed)
BQuill EPinion
22. Install large cap screws from center of housing toward CORing F Slide Hammer and Adapter
corners. Tighten cap screws.
Specification
Rear Cover Cap Screws 24. Apply thread lock and sealer (medium strength) to
(M20)Torque........................................................... 620 Nm (458 lbft) threads of cap screws (A). Install quill and cap screws
and tighten.
23. Install drain plug. Fill transmission with approximately
83 L (22 gal) of oil. Specification
Final Drive Pinion Quill
Specification Cap ScrewsTorque..................................................149 Nm (110 lbft)
TransmissionApproxi
mate Oil Capacity................................................................. 83 L (22 gal)
0350,BB82 1919OCT937/7
PN=240
Gears, Shafts, Bearings and Clutch
PN=241
Gears, Shafts, Bearings and Clutch
Disassemble Transmission
T8075AA UN13SEP93
PN=242
Gears, Shafts, Bearings and Clutch
1 Bearing Cone (2 used) 12 Shims (as required) 23 Thrust Race (2 used) 34 Shims (as required)
2 Spiral Bevel Ring Gear 13 Cap Screw (12 used) 24 Roller Bearing (2 used) 35 Nut
3 Rivet (10 used) 14 Quill (2 used) 25 Idler Cluster Gear 36 Plate
4 Ring Gear Hub 15 Bearing Cup (2 used) 26 Thrust Spacer 37 Washer (4 used)
5 Cap Screw (S.N. 762832) 16 Shims (as required) 27 Washer (4 used) 38 Cap Screw (4 used)
6 Washer 17 Transmission Housing 28 Cap Screw (4 used) 39 1st/2nd Speed Clutch Pack
7 Snap Ring 18 Dowel Pin (2 used) 29 Ball Bearing (3 used) 40 Forward/Reverse Clutch
8 Splined Coupler 19 Sealing Ring (12 used) 30 Retaining Ring (3 used) Pack
9 Spiral Bevel Pinion Shaft 20 3rd/4th Speed Clutch Pack 31 Snap Ring (3 used) 41 Transmission Cover
10 Bearing Cone 21 High Range Gear 32 Bearing Cup 42 Snap Ring (S.N. 762833 )
11 Bearing Cup 22 Thrust Bearing (2 used) 33 Bearing Cone
TX,0350,BD892 1919OCT932/4
T6645AJ UN27OCT88
Continued on next page TX,0350,BD892 1919OCT933/4
PN=243
Gears, Shafts, Bearings and Clutch
T6645AK UN27OCT88
remaining cluster gears, gears and clutch packs.
9. Clean and inspect all components.
APlate F Nut
BSnap Ring (3 used) GPinion Shaft
CForward/Reverse Clutch HWood Block (2 in. x 4 in. x
Pack 12 in.)
DCover I High Range Gear
ESplined Coupler
T7247BD UN09APR90
TX,0350,BD892 1919OCT934/4
PN=244
Gears, Shafts, Bearings and Clutch
T8088AB UN30SEP93
4. Using two pry bars, lift backing plate against snap ring
(B). Record measurement.
Repeat step 24 at two other tabs.
5. Set clutch pack assembly so opposite end is up to
check other clutch pack. Repeat steps 24.
Specification
Clutch Pack Disks/Plates
WearBacking Plate
Minimum Movement.................................................. 2.03 mm (0.080 in.)
Backing Plate Maximum
Movement................................................................. 3.05 mm (0.120 in.)
T8088AC UN30SEP93
6. Repeat procedure for other clutch pack assemblies.
TX,0350,BD949 1919OCT931/1
PN=245
Gears, Shafts, Bearings and Clutch
T8076AZ UN23SEP93
PN=246
Gears, Shafts, Bearings and Clutch
1 Cap Screw 8 Cap Screw (2 used) 15 1st/2nd Clutch Lubrication 22 3rd/4th Clutch Lubrication
2 Washer 9 Bearing Cone (2 used) Line Line
3 Transmission Cover 10 Bearing Cup (2 used) 16 1st Speed Clutch Pressure 23 3rd Speed Clutch Pressure
4 Cap Screw 11 Snap Ring Line Line
5 Washer 12 Reverse Idler Gear 17 Output Shaft Pressure Line 24 Cap Screw (4 used)
6 Clamp 13 Idler Shaft 18 Forward Clutch Pressure 25 Plate
7 Washer (2 used) 14 2nd Speed Clutch Pressure Line 26 ORing (7 used)
Line 19 Forward/Reverse 27 ORing (3 used)
Lubrication Line 28 Bearing Cup
20 Reverse Clutch Pressure
Line
21 4th Speed Clutch Pressure
Line
T6656DN UN27OCT88
TX,0350,BD898 1919OCT933/3
PN=247
Gears, Shafts, Bearings and Clutch
T6942AA UN06DEC88
PN=248
Gears, Shafts, Bearings and Clutch
T8078AD UN28SEP93
Speed Clutch Packs (S.N. 794172 )
1 Sealing Ring (4 used) 8 Snap Ring (2 used) 15 Pin 22 Snap Ring (2 used)
2 Shaft 9 Seat (2 used) 16 1st Speed Piston or 3rd 23 2nd Speed Piston or 4th
3 Shaft Key (2 used) 10 Bleed Ball (2 used) Speed Piston Speed Piston
4 Ball Bearing (4 used) 11 Spring (2 used) 17 Spring Washer (12 used) 24 2nd Speed Gear with
5 Snap Ring (2 used) 12 Outer Sealing Ring (2 used) 18 Snap Ring (2 used) Bushing or 4th Speed Gear
6 1st Speed Gear with Bushing 13 Inner Sealing Ring (2 used) 19 Steel Plate (7 used) with Bushing
or 3rd Speed Gear with 14 Drum 20 Clutch Disk with Facing (7 25 1st/2nd Low Range Output
Bushing used) Gear
7 Snap Ring (4 used) 21 Backing Plate (2 used) 26 3rd/4th High Range Output
Gear
27 Ball Bearing
28 Notched Wavy Steel Plate (2
used)
Continued on next page TX,03,RB409 1902JUN112/14
PN=249
Gears, Shafts, Bearings and Clutch
T6942AB UN21SEP93
(S.N. 794171) 3rd/4th Clutch Pack
T8078AC UN28SEP93
(S.N. 794172 ) 3rd/4th Clutch Pack
PN=250
Gears, Shafts, Bearings and Clutch
T6645AR UN27OCT88
4. Remove snap ring and spring washers.
5. Remove piston (B) and sealing rings.
TX,03,RB409 1902JUN114/14
T6645AS UN27OCT88
Continued on next page TX,03,RB409 1902JUN115/14
PN=251
Gears, Shafts, Bearings and Clutch
10. If bleed ball and seat (I) were removed, install new
seat and bleed ball. Apply plastic gasket to the outside
diameter of seat (I). Install parts (GI).
11. Install sealing rings (B) on pistons (A and F).
IMPORTANT: Lip of sealing ring must be to inside
of drum for proper sealing function.
13. Align pin cavity in piston (F) with pin (E). Install pistons
into drum.
T6645AU UN27OCT88
DDrum I Seat
EPin J Snap Ring
TX,03,RB409 1902JUN116/14
T6645AV UN27OCT88
uses only two steel plates and a notched wavy plate.
Thinner piston (1st or 3rd speed) uses three steel
plates and a notched wavy plate.
PN=252
Gears, Shafts, Bearings and Clutch
19. Use 1st or 3rd gear (A) to align disks in clutch drum.
Carefully remove gear.
20. Turn drum so the end with two steel plates and a wavy
plate are down.
T6645AX UN27OCT88
TX,03,RB409 1902JUN118/14
T6645AT UN27OCT88
Shaft Assembly for Machines S.N. 79471
PN=253
Gears, Shafts, Bearings and Clutch
T8083AD UN30SEP93
ring. (See Group 0399 for instructions to make
tools.)
e. Install snap ring on shaft next to inner ball bearing.
f. Carefully install sealing rings (I) so not to damage
or break rings.
Snap Ring, Gear, Ball Bearing Installation
ASnap Ring F DFT1128 Bearing Installer
B1st or 3rd Gear GInner Ball Bearing
COuter Ball Bearing HDFT1127 Support Tube
DDFT1126 Bearing Installer I Sealing Ring (4 used)
EClutch Shaft
T8083AE UN30SEP93
PN=254
Gears, Shafts, Bearings and Clutch
T8083AF UN28SEP93
down. Align drum keyway with shaft keys and push
shaft through drum.
As gear enters clutch drum, move gear back and forth
to make sure clutch teeth engage with gear. Push
shaft tight against drum hub.
24. For machines (S.N. 794172 ):
Middle, End and Upper Keyways Location
a. Put the two keys into middle and end keyways (A
and B).
b. Put the end of the clutch drum assembly (D) with
only three steel plates, down. Align drum keyway
with shaft keys.
c. Push shaft into drum until end key (B) is just clear
of clutch drum hub. Remove key and put key in
upper keyway (C).
IMPORTANT: Use care not to damage clutch disks or
gear while pressing. Move gear to make sure
teeth engage and do not interfere.
T8083AG UN15OCT93
PN=255
Gears, Shafts, Bearings and Clutch
T8083AJ UN23SEP93
low (E) range output gear.
PN=256
Gears, Shafts, Bearings and Clutch
PN=257
Gears, Shafts, Bearings and Clutch
T81191 UN23FEB89
IMPORTANT: Do not install new end bearing (A) with
supplied snap ring. Remove and discard snap
ring before installing bearing. Install bearing
with snap ring groove toward clutch pack.
27. Heat end bearing (A) and install with snap ring groove
toward clutch pack as shown. End bearing must be
Do Not Overheat Oil
installed tight against shoulder of shaft.
AEnd Bearing
T8084AA UN28SEP93
End Bearing Installation
TX,03,RB409 1902JUN1114/14
PN=258
Gears, Shafts, Bearings and Clutch
T6942AE UN06DEC88
(S.N. 794171)
1 Sealing Ring (4 used) 7 Reverse Gear with Bushing 13 Steel Plate (8 used) 19 Inner Sealing Ring (2 used)
2 Shaft Key (2 used) 8 Sealing Ring (2 used) 14 Snap Ring (2 used) 20 Drum with Piston Mounting
3 Shaft 9 Snap Ring (2 used) 15 Spring Washer (12 used) Ring
4 Spacer (2 used) 10 Snap Ring (2 used) 16 Lube ShutOff Washer (2 21 Forward Gear with Bushing
5 Dowel Pin (2 used) 11 Backing Plate (2 used) used) 22 Ball Bearing
6 Thrust Washer (4 used) 12 Clutch Disk with Facing (8 17 Outer Sealing Ring (2 used) 23 Notched Wavy Steel Plate (2
used) 18 Piston (2 used) used)
Continued on next page TX,0350,BD927 1902JUN111/15
PN=259
Gears, Shafts, Bearings and Clutch
T8083AK UN23SEP93
(S.N. 794172 )
1 Sealing Ring (4 used) 7 Snap Ring (3 used) 13 Notched Wavy Steel Plate (2 19 Inner Sealing Ring (2 used)
2 Shaft Key (2 used) 8 Snap Ring (2 used) used) 20 Drum with Piston Mounting
3 Shaft 9 Snap Ring (2 used) 14 Snap Ring (2 used) Ring
4 Ball Bearing (4 used) 10 Backing Plate (2 used) 15 Spring Washer (12 used) 21 Forward Gear
5 Reverse Gear 11 Clutch Disk with Facing (8 16 Lube ShutOff Washer (2 22 Ball Bearing
6 Sealing Ring (2 used) used) used)
12 Steel Plate (8 used) 17 Outer Sealing Ring (2 used)
18 Piston (2 used)
Continued on next page TX,0350,BD927 1902JUN112/15
PN=260
Gears, Shafts, Bearings and Clutch
T6942AD UN06DEC88
T8083AL UN23SEP93
(S.N. 794171) (S.N. 794172 )
1. Remove bearing (A) using a knife edge puller.
NOTE: Bearings (O and Q) must be replaced
when removed from shaft.
T8078AE UN20OCT93
For (S.N. 794172 ) machines, use an Hbeam,
forcing screw and JDG831 Puller Legs to remove gear
with ball bearing (Q) and then second ball bearing.
PN=261
Gears, Shafts, Bearings and Clutch
T6645AZ UN27OCT88
TX,0350,BD927 1902JUN114/15
T6656DC UN27OCT88
7. Repeat Steps 25 for other end of drum assembly.
8. Remove keys, reverse gear and sealing rings from
shaft.
PN=262
Gears, Shafts, Bearings and Clutch
T6942AC UN06DEC88
Clutch Drum Assembly Installation
ASnap Ring (2 used) DOuter Sealing Ring (2 used) GDrum with Piston Mounting J Backing Plate
BSpring Washer (12 used) EPiston (2 used) Rings KSnap Ring
CLube ShutOff Washer (2 F Inner Sealing Ring (2 used) HSteel Plate (3 used) L Notched Wavy Steel Plate
used) I Disk with Facing (4 used)
9. Install inner sealing ring (F) to O.D. of piston mounting Repeat Steps 911 for other end of clutch drum.
ring. Install outer sealing ring (D) to O.D. of piston (E).
13. Assemble one side of clutch drum. Install notched
10. Apply oil to I.D. of drum (G) and O.D. of inner sealing wavy steel plate (L). Alternately install plates (H) and
ring (F) and install piston in drum. disks with facing (I) starting with a disk. Install outer
11. Install washer (C) into drum, over piston seal ring and backing plate (J) and snap ring (K).
install six spring washers (B). Be sure concave sides 14. Check backing plate movement. (See procedure in
are toward each other. this group.)
12. Compress spring washers (B) to install snap ring (A) If not within 23 mm (0.0800.120 in.), check for
using DF1031 Clutch Assembly Tool. (See Group proper assembly or replace disks and plates.
0399 for instructions to make tool.)
Continued on next page TX,0350,BD927 1902JUN116/15
PN=263
Gears, Shafts, Bearings and Clutch
T6656DE UN27OCT88
TX,0350,BD927 1902JUN117/15
T6656DF UN27OCT88
AShaft F Sealing Ring
BDowel Pin GThrust Washer
CSpacer HSnap Ring
DThrust Washer I Shaft Key (2 used)
EReverse Gear J Sealing Ring (4 used)
PN=264
Gears, Shafts, Bearings and Clutch
T8083AM UN30SEP93
e. Carefully install sealing rings (I and J) so not to
damage or break rings
T8083AN UN30SEP93
PN=265
Gears, Shafts, Bearings and Clutch
T6656DG UN27OCT88
Continued on next page TX,0350,BD927 1902JUN1110/15
PN=266
Gears, Shafts, Bearings and Clutch
T8083AO UN28SEP93
ring during installation.
IMPORTANT: Use care not to damage clutch disks or
gear while pressing. Move gear to make sure
teeth engage and do not interfere.
PN=267
Gears, Shafts, Bearings and Clutch
20. Install snap ring (F) (with points up) against drum hub.
21. Assemble other side of clutch drum. Install notched
wavy steel plate (A). Alternately install plates (B) and
disks with facing (C) starting with a disk. Install outer
backing plate (D) and snap ring (E).
T8083AQ UN23SEP93
22. Check backing plate movement. (See procedure in
this group.)
If not within 23 mm (0.0800.120 in.), check for
proper assembly or replace disks and plates.
23. For machines (S.N. 794171) only, install thrust
washer (G).
Steel Plate Assembly Installation
TX,0350,BD927 1902JUN1112/15
24. For machines (S.N. 794171), put a nylon tie band (A)
on sealing ring (B) to compress ring during installation.
T6580AA UN27OCT88
As forward gear (C) enters clutch drum, move gear
back and forth to make sure clutch teeth engage with
gear.
Install parts (DG).
T8083AR UN23SEP93
PN=268
Gears, Shafts, Bearings and Clutch
PN=269
Gears, Shafts, Bearings and Clutch
T81191 UN23FEB89
IMPORTANT: Do not install new end bearing (A) with
supplied snap ring. Remove and discard snap
ring before installing bearing. Install bearing
with snap ring groove toward clutch pack.
26. Heat end bearing (A) and install with snap ring grove
toward clutch pack as shown. End bearing must be
Do Not Overheat Oil
installed tight against shoulder of shaft.
T8083AU UN28SEP93
End Bearing Installation
TX,0350,BD927 1902JUN1115/15
T112877 UN21JAN98
from 0.000.02 mm (0.000.001 in.) interference.
Heat the ring gear in an oven to 110C (230F) ARing Gear DRivet (10 used)
maximum. BRing Gear Hub EDFT1121 Rivet Forming
Apply retaining compound to mating surfaces of CRiveted Mating Surfaces Tool
ring gear and ring gear hub (B). Install ring gear on
ring gear hub and turn ring gear slightly to distribute
compound evenly. Use a press and DFT1121 tool (E) (see Group 0399
Use cap screws to hold ring gear in position while for instructions to make tool) to form rivets. Do not
installing rivets. exceed 267 kN (30 tons force) to form rivet. Use a
disk support under head of rivets. Make sure rivets
IMPORTANT: Use dealer fabricated tool to form rivets. are tight. Install rivets in a crisscross pattern.
A flat tool causes the entire rivet to expand
and possibly break the ring gear hub.
TX,03,RB244 1922JAN981/1
PN=270
Gears, Shafts, Bearings and Clutch
T6645AL UN27OCT88
1. Press the bearing cone (B) on the pinion shaft (A) and
install the bearing cup (C).
2. With the bearing cup (C) tight against the cone,
measure the width from the mounting shoulder on the
cone (B) to the mounting shoulder on the cup (C).
Add 0.06 mm (0.0025 in.) to measurement to get
dimension.
Specification
Cone Point Shim
PackWidth.................................. Width from the mounting shoulder on
the cone to the mounting shoulder on the cup
at 0.06 mm (0.0025 in.)
T6645AM UN27OCT88
Make a record of this dimension.
3. Add the dimension in Step 2 to the dimension etched
on the face of the pinion shaft (A). Make a record of
this dimension.
4. Make a record of dimension (F) stamped on the side
of the transmission case.
5. Determine shim pack (D) required by subtracting the
sum of Step 3 from dimension in Step 4. Measure
each shim separately to obtain shim pack required.
Example for finding cone point shim pack
Width of bearing cup and cone in 36.78 mm (1.448 in.)
T7247BJ UN09APR90
Step 2
Standard press tolerance 00.06 mm (0.0025 in.)
Dimension stamped on pinion +160.91 mm (6.335 in.)
shaft in Step 3
Sum of Step 2 and 3 197.75 mm (7.785 in.)
Dimension stamped on housing 198.35 mm (7.809 in.)
(E) (Step 4)
Sum of Step 2 and 3 197.75 mm (7.785 in.)
Shim pack required 0.60 mm (0.024 in.) APinion Shaft DShim Pack (as required)
BBearing Cone ETransmission Housing
CBearing Cup F Dimension
6. Install the required shim pack (D) and press bearing
cup (C) into the transmission housing. DO NOT install
pinion shaft.
TX,0350,QQ451 1919OCT931/1
PN=271
Gears, Shafts, Bearings and Clutch
T6645AN UN27OCT88
installed properly in transmission housing.
Machine will move in the opposite direction
if installed the wrong way.
Install ring gear on left side of pinion for use
with double reduction final drive and single
reduction final drive long track.
Install ring gear on right side for single
reduction standard track. ATransmission Housing F Cap Screw (12 used)
BBearing Cone (2 used) GQuill (2 used)
2. Install ring gear assembly into transmission housing CSpiral Bevel Ring Gear HBearing Cup (2 used)
(A) with just enough shims to obtain end play. Tighten DRivet (10 used) I Shims (as required)
cap screws (F). ERing Gear Hub
Specification
Ring Gear Bearing Quill
Cap ScrewsTorque..................................................... 73 Nm (54 lbft) Specification
Ring Gear Hub
3. Turn ring gear several revolutions to seat bearings. BearingPreload...............................0.050.13 mm (0.0020.005 in.)
Install dial indicator and measure end play.
5. Remove ring gear assembly. Keep shims with
4. Remove enough shims (I) to just eliminate measured respective bearing quills.
end play. Then remove additional 0.050.13 mm
(0.0020.005 in.) thickness of shims to provide the
necessary preload.
TX,0350,BD896 1919OCT931/1
PN=272
Gears, Shafts, Bearings and Clutch
T6645AI UN27OCT88
and 180 apart on pinion shaft (D) below nut. Install
and tighten nut until rolling drag torque on shaft is
1.11.7 Nm (1015 lbin.).
Specification
Spiral Bevel
PinionRolling Torque................................ 1.11.7 Nm (1015 lbin.)
PN=273
Gears, Shafts, Bearings and Clutch
Assemble Transmission
NOTE: Assembly of bushingtype and bearingtype
transmissions is the same. Bushingtype
is shown here.
T6656DI UN27OCT88
Continued on next page TX,0350,BD908 1919OCT931/4
PN=274
Gears, Shafts, Bearings and Clutch
T6656DJ UN27OCT88
Continued on next page TX,0350,BD908 1919OCT932/4
PN=275
Gears, Shafts, Bearings and Clutch
T6656DK UN27OCT88
pins (G).
11. Apply thread lock and sealer (medium strength) and
install washers and cap screws (F). Tighten cap
screws.
Specification
Transmission Cover Cap
ScrewsTorque........................................................... 130 Nm (96 lbft)
T6657AC UN27OCT88
16. Retain gear (O) with soft metal wedge (brass). On
later machines, nut (H) has a groove on one side.
Apply thread lock and sealer (medium strength) and
install with groove out. Tighten nut and remove wedge.
Specification
Pinion Shaft Gear
Retainer NutTorque................................................. 407 Nm (300 lbft)
17. Apply plastic gasket to plate cover (J). Apply thread ASnap Ring (3 used) I Bearing Cone
lock and sealer (medium strength) to cap screws (K) BSnap Ring (3 used) J Plate Cover
and install plate cover, washer and cap screws. CBall Bearing (3 used) KCap Screw (4 used)
DShim (As Required) L 2 in. x 4 in. x 12 in. Wood
ETransmission Cover Block
F Cap Screw (4 used) M2 in. x 6 in. Wood Block
GDowel Pin (2 used) NPinion Shaft
HNut OHigh Range Gear
PIdler Cluster Gear
PN=276
Gears, Shafts, Bearings and Clutch
T113186 UN30JAN98
Cap ScrewTorque....................................................... 73 Nm (54 lbft)
T6656DM UN27OCT88
22. For machines (S.N. 762832), apply thread lock and
sealer (medium strength) on threads of cap screw (C).
Install washer and cap screw). Tighten cap screw.
For machines (S.N. 762833 ), install snap ring on
forward/reverse shaft to retain coupler to shaft.
TX,0350,BD908 1919OCT934/4
PN=277
Gears, Shafts, Bearings and Clutch
T6656DN UN27OCT88
1. Use JDG185 Air Test Plug to apply 350550 kPa
(3.55.5 bar) (5080 psi) of air to clutch ports (D and
F) and note air leakage.
Specification
Reverse and Forward
ClutchAir Pressure..............350550 kPa (3.55.5 bar) (5080 psi)
Look at each clutch to see if piston moves and is
returned by spring washers. Clutch plate tangs must
be loose when no air is applied.
2. Apply air to each lube tube while lightly holding finger
over each clutch tube, note air flow.
T6656DO UN27OCT88
Clutch packs 1st (I), 2nd (J), 3rd (B) and 4th (A) should
make a clunking sound when air is applied. This sound
is the piston moving against the spring return washers.
Clutch packs for forward (F) and reverse (D) will leak
more air and will not make as loud a noise when air is
applied. Observe clutch plate tangs exposed through
clutch drum packs to see if piston moves and retracts.
Tangs of separator plates must more freely when
piston is not pressurized. A4th Clutch F Forward Clutch
B3rd Clutch G1st and 2nd Gear Lube
Air leakage from lube tube while pressurizing adjacent C3rd and 4th Gear Lube HOutput Shaft Lube
DReverse Clutch I 1st Clutch
clutches should be slight and even for all packs. EForward/Reverse Lube J 2nd Clutch
Excessive leakage from lube to clutch tubes is caused
by defective sealing ring on clutch shaft.
Air leakage to lube tubes, when clutch tubes are IMPORTANT: Check tubetomanifold connection,
pressurized, should be slight and even for all clutches. reseat tubes after air test.
Excessive air leakage to sump could indicate a clutch
shaft sealing rings or piston seal failure.
0350,WW20 1919OCT931/1
PN=278
Gears, Shafts, Bearings and Clutch
PN=279
Gears, Shafts, Bearings and Clutch
T6942AS UN13JAN89
1 Suction Line 5 Plug 9 Snap Ring 13 Support Shaft (2 used)
2 Dipstick 6 Suction Screen 10 Shaft 14 Plug (2 used)
3 Tube 7 Yoke 11 Bearing 15 Jack Screw (2 used)
4 Strainer Housing 8 Seal 12 Snap Ring (2 used) 16 Plug
1. Remove yoke (7) from shaft (10). 7. Install seal (8) using a disk driver. Push seal into bore
2. Remove seal (8). until seal is approximately 3 mm (0.12 in.) below
machined counterbore.
3. Remove snap ring (9). Pull shaft assembly out of front
of housing. 8. Install suction line (1). Apply thread lock and sealer
(medium strength) to cap screw threads and install.
4. Remove snap rings (12) to remove bearing (11). Tighten cap screws to specification.
Remove remaining parts if necessary.
9. Install dipstick tube (3). Apply plastic gasket to
5. Install bearing (11) and snap rings (12) onto shaft (10). underside of mounting flange and install. Apply
thread lock and sealer (medium strength) to cap
6. Install shaft through front of housing. Install snap ring
screw threads and install. Tighten cap screws to
(9).
specification.
PN=280
Gears, Shafts, Bearings and Clutch
Transmission Support
10. Use a press to install support shafts until shafts are
Rod ScrewsTorque..................................................... 73 Nm (54 lbft)
even with front surface of gussets. Tighten cap screws
Rear Cover Cap Screws
to specification.
(M12)Torque............................................................149 Nm (110 lbft)
Specification Rear Cover Cap Screws
Suction Tube Cap (M20)Torque........................................................... 620 Nm (457 lbft)
ScrewsTorque............................................................. 73 Nm (54 lbft)
Dipstick Tube Cap 11. Apply pipe sealant to threads of plugs (5, 14 and 16)
ScrewsTorque............................................................. 73 Nm (54 lbft) and install.
TX,0350,BD910 1919OCT932/2
PN=281
Gears, Shafts, Bearings and Clutch
PN=282
Group 0360
Hydraulic System
Service Equipment and Tools Tool Catalog (MTC). Some tools may be
available from a local supplier.
NOTE: Order tools from the U.S. SERVICEGARD
Catalog or from the European Microfiche
Other Material
Number Name Use
T43512 (U.S.) Thread Lock and Sealer (Medium Applied to threads of cap screws.
TY9473 (Canadian) Strength)
242 (LOCTITE)
PN=283
Hydraulic System
Specifications
Item Measurement Specification
PN=284
Hydraulic System
T6560AK UN25OCT88
2. Remove rear platform plate.
3. Disconnect hose (A) and all wiring harness leads.
4. Loosen nuts to release compression of power control
pedal return spring (C) (if equipped).
5. Disconnect linkages (B).
Continued on next page TX,0360,BA946 1919OCT931/3
PN=285
Hydraulic System
T8081AA UN28SEP93
8. Place 25.4 mm (1 in.) wooden block under plug
bosses on each side of valve.
T6560AL UN25OCT88
10. Use 7/1614 UNC cap screw to install lifting eye in
tapped hole (B).
11. Remove valve.
12. Repair valve. (See procedure in this group.)
13. Apply thread lock and sealer (medium strength) to
threads of all cap screws.
14. Install cap screws into front half of control valve and Specification
hold them up with rubber bands. Control Valve
15. Place two 25.4 mm (1 in.) wooden blocks on toTransmission
transverse case. Socket Head Cap
ScrewsTorque............................................................. 36 Nm (27 lbft)
16. Slide valve into place.
17. Remove blocks. Install remaining cap screws. Tighten
cap screws beginning with the center screws and
working outward in a spiral.
TX,0360,BA946 1919OCT932/3
Power Control
Pedal Return
SpringCompression.................................................... 142 mm (5.6 in.)
PN=286
Hydraulic System
T112894 UN21JAN98
1 Guide 10 Neutral Start Switch 19 Speed Selector Spool 28 Oil Cooler Relief Valve
2 Seal 11 Modulating Valve Spring 20 Plug Spring
3 Pin 12 Accumulator Piston 21 Detent Spool 29 Oil Cooler Relief Valve
4 Power Control Valve Spool 13 Modulating Spool 22 Plug 30 Transmission Pressure
Spring 14 Modulating Valve Spring 23 Detent Cone Compression Regulating Valve
5 Direction Selector Spool 15 Orifice Spring 31 Transmission Pressure
6 Groove Pin 16 Special Screw 24 Detent Cones Regulating Valve Spring
7 Power Control Spool 17 ORing Port Spring 25 Lubrication Relief Valve 32 Transmission Pressure
8 Transmission Low Pressure 18 Sump Spool 26 Lubrication Relief Valve Regulating Valve Spring
Switch Spring 33 Shims (as required)
9 Reverse Warning Switch 27 Plug (3 used) 34 Seal
35 Plunger
36 Seal
Power Control Valve Spool Spring Approximate Free Length 93 mm (3.66 in.)
Test Length at 177 N (39.8 lb force) 74.7 mm (2.94 in.)
Modulating Valve Spring OD 22.1 mm (0.87 in.)
Free Length 98.6 mm (3.88 in.)
Test Length at 135 N (30.6 lb force) 77 mm (3.03 in.)
Modulating Valve Spring OD 15.6 mm (0.61 in.)
Free Length 80.3 mm (3.16 in.)
Test Length at 177.6 N (40.6 lb force) 68.1 mm (2.68 in.)
ORing Port Spring Approximate Free Length 83.7 mm (3.3 in.)
Test Length at 19.6 N (4.4 lb force) 55 mm (2.17 in.)
PN=287
Hydraulic System
Detent Cone Compression Spring Approximate Free Length 50.8 mm (2.0 in.)
Test Length at 28.5 N (6.4 lb force) 23.8 mm (0.94 in.)
Lubricating Relief Valve Spring Approximate Free Length 103.9 mm (4.1 in.)
Test Length at 104.5 N (23.5 lb force) 72 mm (2.83 in.)
Oil Cooler Relief Valve Spring Free Length 73 mm (2.87 in.)
Test Length at 391.4 N (88 lb force) 44.5 mm (1.75 in.)
Transmission Pressure Regulating OD 15.8 mm (0.62 in.)
Springwith Direct Drive
Free Length 113 mm (4.45 in.)
Test Length at 267 N (60 lb force) 81.5 mm (3.21 in.)
Transmission Pressure Regulating OD 22.3 mm (0.90 in.)
Springwith Direct Drive
Free Length 109.7 mm (4.32 in.)
Test Length at 280 N (63 lb force) 65 mm (2.56 in.)
Transmission Pressure Regulating OD 11.9 mm (0.47 in.)
Springwith Torque Converter
Free Length 100 mm (3.94 in.)
Test Length at 293 N (66 lb force) 87.4 mm (3.44 in.)
Transmission Pressure Regulating OD 22.5 mm (0.89 in.)
Springwith Torque Converter
Free Length 87.4 mm (3.44 in.)
Test Length at 645 N 145 lb force) 65.5 mm (2.57 in.)
TX,0360,BA949 1919OCT932/9
T6560AB UN19MAY89
Housing
PN=288
Hydraulic System
T6560AC UN19MAY89
TX,0360,BA949 1919OCT934/9
T6560AD UN25OCT88
TX,0360,BA949 1919OCT935/9
T6560AE UN25OCT88
PN=289
Hydraulic System
T6942AR UN09JAN89
out of hole when drift is removed.
9. Put petroleum jelly on spring to hold it in detent cone.
Install spring (A) and detent cone (B).
Compress spring solid using a rod. Retain detent cone
by inserting a drift into hole below detent. Hold drift
until spools are installed.
IMPORTANT: Arrow (G) stamped in end of detent
spool must point up to prevent spool drag.
10. Install spools. Look into upper detent bore. If notch (E)
is visible, rotate spools 180 by turning clevis on front
T6560AH UN19MAY89
end. If notch is not visible (F), spool location is good.
Release detent cone. Tighten plug to specification.
Specification
Speed Selector Spool
PlugTorque................................................................ 102 Nm (75 lbft)
11. Install upper detent cone (C), spring (D), and plug.
ASpring ENotch
BDetent Cone F Spools
CUpper Detent Cone GArrow
DSpring
T6666AC UN25OCT88
TX,0360,BA949 1919OCT937/9
12. Install special screw (B) into orifice (A) until it bottoms,
then unscrew seven turns (machines with direct drive)
or ten turns (machines with torque converter).
T6560AI UN19MAY89
PN=290
Hydraulic System
13. Install and center groove pin (A) into power control
spool.
14. Apply oil to guide (B) and install.
15. Assemble regulating valve housing, separator plate,
and control valve housing.
T6560AJ UN19MAY89
16. Apply thread lock and sealer (medium strength) to
threads of cap screws. Tighten socket head screws.
Specification
Regulating Valveto
Transmission Control
Valve Socket Head Cap
ScrewsTorque............................................................. 36 Nm (27 lbft)
TX,0360,BA949 1919OCT939/9
PN=291
Hydraulic System
T7247AZ UN09APR90
(S.N. 768272)
T7247BA UN09APR90
(S.N. 768273 )
TX,0360,QQ437 1919OCT931/1
TX,0360,BA973 1919OCT931/1
PN=292
Hydraulic System
PN=293
Hydraulic System
T8081AD UN30SEP93
PN=294
Hydraulic System
1. Remove rear fender and covers. 6. Disassemble and assemble solenoid valve (F) (if
2. Remove parts (FN) and (R). necessary).
3. Disconnect wire leads (O) at switch (P) and crawler 7. Install parts (R) and (FO) and connect wire leads.
wiring harness (Q). 8. Check and adjust engine high and low idle positions
4. Remove decelerator wiring harness (O). (if necessary).
5. Inspect for worn or damaged parts. Replace as 9. Install rear fender and covers.
necessary.
TX,0360,BA954 1919OCT932/2
PN=295
Hydraulic System
T8081AE UN28SEP93
7. Attach lifting device to pump.
8. Remove two cap screws (A) to remove pump (E).
9. Repair pump as necessary. (See Disassemble and
Assemble Transmission Oil PumpWith Torque
Converter, this group.)
(S.N. 803600)
APumptoTorque Converter DSuction ScreentoPump
Housing Cap Screw (2 Inlet Hose
used) ETransmission Oil Pump
BPump Outletto
Transmission Filter Hose
CClamp (2 used)
T112930 UN22JAN98
(S.N. 803601 )
Continued on next page TX,0360,BA974 1919OCT931/2
PN=296
Hydraulic System
T8081AE UN28SEP93
14. Remove fill plug from top of suction screen housing
and fill hose (D) and housing with oil. (See Section 00,
Group 0004 for oil recommendations.)
15. Install fill plug.
NOTE: Steps 16 and 17 apply to all machines except
loaders with a torque converter. (S.N. 803600)
16. Squirt oil into inlet side of pump. Install hose (D) on
pump only.
17. Fill hose with oil and install on strainer. (See Section
00, Group 0004 for oil recommendations.)
18. Connect clamps (C).
T112930 UN22JAN98
19. Install bottom access cover and floor plates.
TX,0360,BA974 1919OCT932/2
Remove and Install Transmission Oil be removed to service transmission oil pump. Refer
PumpDirect Drive Machines to Group 2160 for removal procedure.
PN=297
Hydraulic System
T8072AB UN13SEP93
AVent F Washer (4 used) KGear Housing PSeal
BReducer Bushing GCap Screw (4 used) L Front Housing QSeal Retainer
CSquare Seal (2 used) HRear Housing MSeal RSeal Lip
DThrust Plate (2 used) I Gear/Shaft Set NORing
EChannel Seal (2 used) J Dowel Pin (2 used) ORetaining Ring
NOTE: For repair of shaft seals (M and P) only, NOTE: Pump parts (CE and HL) are not
do steps 13. serviceable. If any of these parts are worn
or damaged, replace pump.
1. Remove retaining ring (O) to remove seal retainer (Q).
2. Remove seals (M and P). 6. Apply petroleum jelly to seal lip (R) of seals.
3. Install seals: 7. Put a light coat of clean hydraulic oil on all internal
parts.
Seal (M) must be installed flush with face of recess
in housing (L) and with lip (R) toward gear as shown. 8. Assemble parts as shown. Tighten cap screws (G).
Seal (P) must be installed flush with counterbore in Specification
retainer (Q) and with seal lip (R) away from gear. Transmission Pump
Assembly Cap
4. Put a mark on housings (H, K and L) to aid in assembly.
Screws with Torque
5. Remove parts and inspect for wear. Mark gear set ConverterTorque..................................................... 319 Nm (235 lbft)
to aid in assembly.
TX,0360,BD945 1919OCT931/1
PN=298
Hydraulic System
T6550AA UN01JUN89
ASeal Retainer F Driven Gear KSeal PGasket (2 used)
BRear Carrier GCover L Nut (2 used) QDriven Gear
CBushing (4 used) HDriven Shaft Assembly MStud (5/8 x 111/2 in.)
DThrust Plate (2 used) I ORing NStud (5/8 x 131/2 in.)
EHousing J Seal Retainer OWasher (4 used)
TX,0360,BA976 1919OCT931/4
T6550AB UN25OCT88
AMain Hydraulic Pump ECap Screw (5/8 x 41/2 in.)
BStud (5/8 x 131/2 in.) F Nut (2 used)
CTransmission Oil Pump GWasher (2 or 4 used)
DCap Screw (5/8 x 61/2 in.) HStud (5/8 x 111/2 in.)
PN=299
Hydraulic System
T6534AN UN25OCT88
AHousing EDriven Shaft Assembly I Set Screw (2 used) MGasket
BDowel Pin (2 used) F ORing J Gear (2 used)
CBushing (2 used) GSeal Retainer KThrust Plate (2 used)
DCover HSeal L Seal (2 used)
3. Put a mark on gears and thrust plates to aid in NOTE: Install seal (H) with flat side toward seal
assembly. retainer. Cover groove on shaft with shim
4. Remove parts. stock when installing seal.
NOTE: Set screws (I) must be removed before 7. Install new Oring (F) and seals (H and L). Apply
removing seal retainer (G). petroleum jelly to seal lips.
5. Remove set screws (I). Remove seal retainer (G), 8. Put a light coat of clean hydraulic oil on all parts.
using a punch, through holes provided. Assemble parts as shown.
PN=300
Hydraulic System
T6550AB UN25OCT88
and Nutswith Direct
DriveTorque............................................................ 271 Nm (200 lbft)
TX,0360,BA976 1919OCT934/4
PN=301
Hydraulic System
X9811 UN23AUG88
all connections before applying pressure. Search
for leaks with a piece of cardboard. Protect hands
and body from high pressure fluids.
If an accident occurs, see a doctor immediately.
Any fluid injected into the skin must be surgically
removed within a few hours or gangrene
may result. Doctors unfamiliar with this type
of injury should reference a knowledgeable
medical source. Such information is available
from Deere & Company Medical Department
in Moline, Illinois, U.S.A.
Continued on next page 0360,SS1 1919OCT931/2
PN=302
Hydraulic System
T6670AQ UN02APR90
DOil Filter Outletto Transmission Oil Cooler
Transmission Control Line (S.N. 803600)
Valve Line GFilter Element
HOil Filter Port from Pump
Outlet Line
(S.N. 803600)
T112931 UN28JAN98
(S.N. 803601 )
0360,SS1 1919OCT932/2
PN=303
Hydraulic System
T8081AG UN05OCT93
3. Remove drain plug from bottom of suction screen
housing to drain oil. Install drain plug after oil has
drained.
4. Loosen clamp (A) to disconnect hose at housing
(loaders with torque converter only) or loosen two
clamps (A) to remove hose. Loader Torque Converter Machines (S.N. 794020 )
T6520AK UN10FEB89
IMPORTANT: Damage to pump may occur if pump
is not primed with oil. The transmission oil
reservoir is lower than pump inlet and pump
cannot draw oil fast enough after initial start up.
PN=304
Hydraulic System
T6687AD UN20OCT88
Oil Cooler in Group 2160.)
7. Install oil cooler. Tighten cap screws.
8. Install hydraulic oil cooler (if equipped).
9. Connect transmission oil cooler lines.
10. Install fan shroud and guard assembly.
11. Tilt grille housing rearward or install grille housing.
(See Remove and Install Radiator in Group 0510 for
procedure.)
TX,0360,BA981 1919OCT931/1
PN=305
Hydraulic System
PN=306
Group 0399
Dealer Fabricated Tools
DF1126 Bearing Installer
T8080AC UN30SEP93
Bearing Installer is used to install ball bearings in
transmission clutch packs. Steel tubing machined to dimensions shown.
Material Required:
TX,0399,BD918 1920SEP931/1
PN=307
Dealer Fabricated Tools
T8080AD UN30SEP93
TX,0399,BD919 1920SEP931/1
PN=308
Dealer Fabricated Tools
T8080AE UN30SEP93
TX,0399,BD920 1920SEP931/1
T6579AL UN19MAY89
3 1/2 in. black steel pipe (4.00 in. O.D. x 0.226 in. wall)
A241 mm (9.50 in.) C38 mm (1.50 in.)
B51 mm (2.0 in.)
9900,U96 1921OCT871/1
PN=309
Dealer Fabricated Tools
T7947AY 1914MAR94
Tool is used to install rivets in differential ring gear.
22 mm (7/8 in.) round bar stock
Material Required:
TX,03,RB245 1922JAN981/1
PN=310
Dealer Fabricated Tools
RW5335L 1912MAY89
Differential Lifting Tool is used to remove and install One piece of (13 x 305 mm) 1/2 x 12 in. round bar stock.
differential ring gear. One piece of 1/213 UNC x 9.5 in. ready rod.
Make tool as shown from specified material mild steel
One piece of (7 x 51 x 25 mm) 1/4 x 2 x 1 in. flat steel.
(1020).
One piece of (13 x 51 x 292 mm) 1/2 x 2 x 111/2 in.
flat steel.
Material Required:
Two 1/213 UNC nuts.
9900,415 1921OCT871/1
PN=311
Dealer Fabricated Tools
PN=312
Section 04
Engine
Contents
Page
PN=1
Contents
PN=2
Group 0400
Removal and Installation
4276 John Deere Engine RepairUse CTM4
(S.N. 299999)
For complete repair information the component technical
manual (CTM) is also required.
Use the component manual in conjunction with this
M44215 UN07SEP88
machine manual.
TX,04,RB248 1922JAN981/1
M44215 UN07SEP88
machine manual.
TX,04,RB247 1922JAN981/1
M44215 UN07SEP88
TX,04,RB247 1922JAN981/1
PN=315
Removal and Installation
M44215 UN07SEP88
machine manual.
TX,04,RB247 1922JAN981/1
T8015AG UN01JUN93
Special or Essential Tools
NOTE: Order tools according to information given in
the U.S. SERVICEGARD Catalog or in the
European Microfiche Tool Catalog (MTC).
T6585NN UN03NOV88
To remove and install engine.
Lifting Bracket.......................................................JT01748
Used to remove and install hood.
To remove and install hood.
DX,TOOLS 1920JUL953/3
PN=316
Removal and Installation
Specifications
Item Measurement Specification
T7931AI UN02FEB93
Crawler Loader
Continued on next page TX,04,RB253 1923JAN981/6
PN=317
Removal and Installation
T6670AA UN25OCT88
machine.
7. If machine is equipped with front counterweight,
remove cap screw (A) on each side and remove grille
housing.
8. If machine is NOT equipped with front counterweight,
loosen, but do not remove, cap screw (A) on each side
of machine and tilt grille housing forward.
9. Remove hydraulic oil cooler (if equipped) from front
of radiator without disconnecting hoses. (See Group
2160.)
TX,04,RB253 1923JAN982/6
T112622 UN03FEB98
PN=318
Removal and Installation
T8043AB UN15JUL93
17. Remove four cap screws (D) to disconnect drive shaft
from torque converter.
18. Disconnect transmission pump (B) from torque
converter housing without disconnecting hoses.
19. Disconnect hydraulic pump (E) from torque converter
housing without disconnecting hoses. (S.N. 840460)
T112623 UN03FEB98
(S.N. 840461 )
TX,04,RB253 1923JAN984/6
PN=319
Removal and Installation
T112624 UN21JAN98
31. Install JT01748 Lifting Brackets on cylinder head at
left front and right rear corners. Connect D01043AA
LoadPositioning Sling to Lifting Brackets and a hoist.
32. Remove engine just enough to disconnect coolant
temperature switch wire lead and remove harness
clamp from rear of engine.
(S.N. 840461 ) Shown
Specification
Engine with Torque
ConverterWeight............................... 820 kg (1800 lb) (Approximately) AMuffler EStarter
BStart Aid Tube Fitting F Wiring Harness
33. Remove engine. CFront SupporttoFrame GClamp
Cap Screw (2 used) HAir Cleaner
34. Put engine in engine repair stand. DAlternator
PN=320
Removal and Installation
T112624 UN21JAN98
Engine SupporttoMain
Frame Cap
ScrewsTorque......................................................... 840 Nm (620 lbft)
PN=321
Removal and Installation
T8043AB UN15JUL93
Specification
Hydraulic Pumpto
Torque Converter
Housing Cap
ScrewsTorque..........................................................149 Nm (110 lbft)
Transmission
PumptoTorque (S.N. 840460)
Converter Housing Cap
ScrewsTorque......................................................... 319 Nm (235 lbft)
T112623 UN03FEB98
ScrewsTorque............................................................. 48 Nm (35 lbft)
PN=322
Removal and Installation
T112622 UN03FEB98
(S.N. 840461 ) Shown
TX,04,RB252 1923JAN984/6
T6670AA UN25OCT88
22. Use a sling and hoist to lift grille housing into position.
Install cap screws (A and B) on each side of machine.
PN=323
Removal and Installation
T7931AI UN02FEB93
Crawler Loader
TX,04,RB252 1923JAN986/6
PN=324
Removal and Installation
T7931AI UN02FEB93
TX,04,RB251 1923JAN981/6
T6670AA UN25OCT88
8. If machine is NOT equipped with front counterweight,
loosen, but do not remove, cap screw (A) on each side
of machine and tilt grille housing forward.
9. Remove hydraulic oil cooler (if equipped) from front
of radiator without disconnecting hoses. (See Group
2160.)
Continued on next page TX,04,RB251 1923JAN982/6
PN=325
Removal and Installation
T8043AE UN15JUL93
TX,04,RB251 1923JAN983/6
T112622 UN03FEB98
PN=326
Removal and Installation
T6578AE UN18OCT88
TX,04,RB251 1923JAN985/6
T112624 UN21JAN98
26. Install JT01748 Lifting Brackets on cylinder head at
left front and right rear corners. Connect D01043AA
LoadPositioning Sling to Lifting Brackets and a hoist.
27. Remove engine just enough to disconnect coolant
temperature switch wire lead and remove harness
clamp from rear of engine.
(S.N. 840461 ) Shown
28. Remove engine.
Specification AMuffler EStarter
Engine with Direct BStart Aid Tube Fitting F Wiring Harness
DriveWeight...................................... 658 kg (1450 lb) (Approximately) CFront SupporttoFrame GClamp
Cap Screw (2 used) HAir Cleaner
29. Put engine in a engine repair stand. DAlternator
TX,04,RB251 1923JAN986/6
PN=327
Removal and Installation
T112624 UN21JAN98
Engine SupporttoMain
Frame Cap
ScrewsTorque......................................................... 840 Nm (620 lbft)
PN=328
Removal and Installation
T112622 UN03FEB98
(S.N. 840461 ) Shown
TX,04,RB250 1923JAN983/6
T8043AE UN15JUL93
PN=329
Removal and Installation
T6670AA UN25OCT88
18. Use a sling and hoist to lift grille housing into position.
Install cap screws (A and B) on each side of machine.
TX,04,RB250 1923JAN985/6
T7931AI UN02FEB93
TX,04,RB250 1923JAN986/6
PN=330
Removal and Installation
T6077AN UN20OCT88
NOTE: If there is no fuel flow, push primer lever
toward engine, turn crankshaft using starting
motor to reposition camshaft.
(S.N. 840460)
T112375 UN16DEC97
(S.N. 840461 )
TX,04,RB255 1923JAN981/3
T112626 UN21JAN98
Injection Line
ConnectionsTorque..................................................... 27 Nm (20 lbft)
PN=331
Removal and Installation
X9811 UN23AUG88
and body from high pressure fluids.
If an accident occurs, see a doctor immediately.
Any fluid injected into the skin must be surgically
removed within a few hours or gangrene
may result. Doctors unfamiliar with this
type of injury may call the Deere & Company
Medical Department in Moline, Illinois, or other
knowledgeable medical source.
T92924 UN01NOV88
4. Loosen injection line connections using two wrenches.
5. Move speed control lever to approximately half speed.
Crank engine until a small amount of fuel leaks from
injection lines.
6. Tighten injection line connections using two wrenches.
Specification
Injection Line
Start engine.
ConnectionsTorque..................................................... 27 Nm (20 lbft)
TX,04,RB255 1923JAN983/3
PN=332
Section 05
Engine Auxiliary Systems
Contents
Page
PN=1
Contents
PN=2
Group 0505
Cold Weather Starting Aid
Specifications
Item Measurement Specification
Other Material
Number Name Use
TY9375 (U.S.) Pipe Sealant Applied to nozzle holder male threads.
TY9480 (Canadian)
592 (LOCTITE)
T96052 UN24JAN90
Engine Cooling
SystemCapacity........................................17 L (18 qt) (Approximately)
AAdapter CCord
BLock Nut
T112796 UN13JAN98
(S.N. 840461 )
PN=335
Cold Weather Starting Aid
ACord EGasket
BCap F ORing
T105617 UN06DEC96
CNut GHeater Element
DAdapter
TX,05,RB256 1923JAN982/4
T91790 UN13FEB90
TX,05,RB256 1923JAN983/4
T96053 UN24JAN90
Element NutTorque..................................................... 34 Nm (25 lbft)
TX,05,RB256 1923JAN984/4
PN=336
Cold Weather Starting Aid
T112628 UN21JAN98
(S.N. 840461 ) Shown
TX,05,RB257 1923JAN981/5
T112630 UN21JAN98
TX,05,RB257 1923JAN982/5
T88491 UN21OCT88
PN=337
Cold Weather Starting Aid
T112631 UN21JAN98
Connect starting aid tube (C).
Install engine right side shield. On loaders, remove
boom lock bar and lower loader to ground.
T112629 UN21JAN98
TX,05,RB257 1923JAN984/5
T8056AL UN29JUL93
NOTE: Arrow on nozzle holder indicates
direction of nozzle.
TX,05,RB257 1923JAN985/5
PN=338
Cold Weather Starting Aid
T112632 UN21JAN98
(S.N. 803601 ) Shown
TX,05,RB258 1923JAN981/3
T8056AN UN09AUG93
PN=339
Cold Weather Starting Aid
T112632 UN21JAN98
(S.N. 803601 ) Shown
TX,05,RB258 1923JAN983/3
PN=340
Group 0510
Cooling System
Service Equipment and Tools Tool Catalog (MTC). Some tools may be
available from a local supplier.
NOTE: Order tools from the U.S. SERVICEGARD
Catalog or from the European Microfiche
Specifications
Item Measurement Specification
TX,05,RB259 1923JAN981/1
PN=341
Cooling System
T112840 UN21JAN98
within specification, replace tensioner.
Checking Belt Wear
The belt tensioner is designed to operate within the limit
of arm movement provided by the cast stops when correct
belt length and geometry is used.
1. Visually inspect cast stops on belt tensioner assembly.
2. If the tensioner stop on swing arm is hitting the
fixed stop, check mounting brackets (alternator, belt
tensioner, etc.) and the belt length. Replace belt as
needed.
T112841 UN21JAN98
Checking Tensioner Spring Tension
A belt tension gauge will not give an accurate measure of
the belt tension when automatic spring tensioner is used.
Measure tensioner spring tension using a torque wrench
and procedure outlined below:
1. Release tension on belt using a breaker bar on tension
arm. Remove belt from pulleys.
5. Rotate the swing arm using a torque wrench until
2. Release tension on tension arm and remove breaker marks (A and B) are aligned (C).
bar.
6. Record torque wrench measurement and compare
3. Put a mark (A) on swing arm of tensioner as shown. with specification below. Replace tensioner assembly
as required.
4. Measure 21 mm (0.83 in.) from (A) and put a mark (B)
on tensioner mounting base. Specification
Tensioner
Specification
SpringTension.............................................. 1822 Nm (1316 lbft)
Tensioner Swing Arm
toTensioner Mounting
BaseDistance.............................................................. 21 mm (0.83 in.)
TX,05,RB260 1923JAN981/1
PN=342
Cooling System
T8056AO UN29JUL93
10. Place offset side of screen in upper left gusset of
radiator with slotted opening of screen over cap screw.
11. Push screen against left channel of radiator and
tighten cap screw.
12. Place the next two screens under the first and repeat
step 10 for each screen. (S.N. 840460) Shown
PN=343
Cooling System
T8056AP UN29JUL93
5. Install fan guard using six cap screws.
6. Install hood and engine side shields. Remove boom
lock bar and lower loader to ground (if equipped).
PN=344
Cooling System
T95938 UN25MAY89
TX,0510,BA870 1908OCT931/1
T6670AA UN25OCT88
3. Loosen, but do not remove, rearmost cap screw (A)
on each side of machine.
4. If machine is equipped with front counterweights,
either remove the counterweights and continue or
remove the grille housing as detailed in Group 1921
and go to step 7.
CAUTION: Grille housing is heavy. Use a lifting 6. Remove two cap screws (B) from each side and tilt
device for heavy components. grille housing forward using a hoist.
PN=345
Cooling System
TS281 UN23AUG88
before removing completely.
7. Drain radiator.
Specification
Cooling SystemCapac
ity...........................................................................................17 L (18 qt.)
PN=346
Cooling System
T8056AR UN29JUL93
CAUTION: Radiator with oil cooler weighs
approximately 34 kg (75 lb).
20. Assemble transmission oil cooler to radiator. 24. Connect transmissiontooil cooler hoses.
21. Install air baffles. Tighten cap screws. 25. Install hydraulic oil cooler (if equipped). (See Remove
Specification and Install Hydraulic Oil Cooler, Group 2160.)
Air Baffle Mounting Cap
ScrewsTorque........................................................... 16 Nm (144 lbft)
PN=347
Cooling System
T112633 UN21JAN98
(S.N. 840461 ) Shown
TX,05,RB261 1923JAN984/5
T6670AA UN25OCT88
33. Install hood and engine side shields. (See Group
1910.)
34. Install precleaner and exhaust pipe.
35. Start machine and allow engine to come up to
operating temperature.
NOTE: On machines equipped with coolant recovery
system, check and add fluid (if necessary) at 37. Remove boom lock bar and lower loader to ground
the coolant recovery bottle. (if equipped).
36. Shut off engine and allow system to cool. Check for
leaks. Check coolant level. Add coolant if necessary.
TX,05,RB261 1923JAN985/5
PN=348
Group 0515
Speed Controls and Fuel ShutOff Linkage
Remove and Install Speed Control Cable
T112801 UN21JAN98
(S.N. 840461 ) Shown
ANut CCable Bracket Cap Screw ECable Yoke Pin
BSpring DCable Bracket Cap Screw
2. Remove four cap screws and lower cover from front of 9. Adjust cable length. (See TM1403, Group 901020.)
transmission control console. 10. Install lower cover to front of transmission control
3. Remove floor plate. console using four cap screws.
4. Remove nut (A) to disconnect speed control cable 11. Install floor plate.
from injection pump. 12. Install engine left side shield.
5. Remove cable bracket cap screws (C and D). 13. Remove boom lock bar and lower loader to ground.
6. Remove yoke pin (E).
7. Install injection pump end of cable through grommet
in firewall.
TX,05,RB262 1923JAN981/1
PN=349
Speed Controls and Fuel ShutOff Linkage
T112802 UN21JAN98
(S.N. 840461 ) Shown
1 Snap Ring (2 used) 10 Snap Ring 19 Cotter Pin 28 Washer
2 Bearing (2 used) 11 Shaft 20 Angle 29 Cotter Pin
3 Washer 12 Speed Control Cable 21 Angle 30 Cotter Pin
4 Snap Ring 13 Washer 22 Spring 31 Washer
5 Decelerator Pedal 14 Cotter Pin 23 Arm 32 Pin
6 Low Idle Stop Screw 15 Rod 24 Arm 33 Cap Screw
7 Spring Pin (2 used) 16 Nut (2 used) 25 Yoke 34 Washer (2 used)
8 Bushing (2 used) 17 Yoke 26 Nut 35 Nut
9 Washer 18 Pin 27 Rod 36 Lock Nut
1. On loaders, raise loader and install boom lock bar. 6. Assemble parts.
2. Remove engine left side shield. 7. Adjust speed control linkage. (See TM1403, Group
3. Remove floor plates. 901020.)
4. Disassemble parts. 8. Install floor plates and engine left side shield.
5. Inspect for worn or damaged parts. Replace parts as 9. Remove boom lock bar and lower loader to ground
necessary. (if equipped).
TX,05,RB263 1923JAN981/1
PN=350
Speed Controls and Fuel ShutOff Linkage
PN=351
Speed Controls and Fuel ShutOff Linkage
T112803 UN21JAN98
PN=352
Speed Controls and Fuel ShutOff Linkage
1. On loaders, raise loader and install boom lock bar. 9. Install switch (H). Connect ground wire to terminal
2. Remove engine left side shield. marked COMMON. Connect wire from harness to
terminal marked N.C. or NORMALLY CLOSED.
3. Remove floor plates.
10. Assemble parts (KQ).
4. Remove parts (AH) and (KP).
11. Adjust speed control linkage and declutch switch
5. Inspect for worn or damaged parts. Replace as setting. (See TM1403, Group 901020.)
necessary.
12. Install floor plates and engine left side shield.
6. Install parts (AD) and (F) on decelerator shaft (G).
13. Remove boom lock bar and lower loader to ground
7. Place shaft assembly in a vice. Rotate bellcrank (D) (if equipped).
putting tension on spring (B). Index arm (F) to align
with hole in shaft (G) and install spring pin (E).
8. Install decelerator shaft assembly using support
brackets (J). Install and tighten cap screws.
TX,05,RB264 1923JAN982/2
PN=353
Speed Controls and Fuel ShutOff Linkage
PN=354
Group 0520
Intake System
Disassemble and Assemble Air Cleaner
T8056AT UN09AUG93
1 Base 5 Seal 9 Wing Nut 13 Air Cleaner Assembly
2 Bowl 6 Clamp 10 Secondary Element
3 Cover 7 Hose 11 Cover
4 Precleaner Assembly 8 Clamp 12 Primary Element
1. Raise loader (if equipped) and install boom lock bar. 8. Assemble parts (912)
2. Remove engine side shields, precleaner (4), seal (5), 9. Install air cleaner assembly using three cap screws.
exhaust pipe and hood. Tighten hose clamp.
3. Loosen hose clamp (6). 10. Install hood, exhaust pipe, seal, precleaner and
4. Remove three cap screws to remove air cleaner engine shields.
assembly (13). 11. Remove boom lock bar and lower loader to ground
5. Disassemble parts (912). (if equipped).
PN=355
Intake System
PN=356
Group 0560
External Fuel Supply System
Specifications
Item Measurement Specification
T8056AU UN29JUL93
Continued on next page TX,0560,BA885 1918AUG931/5
PN=357
External Fuel Supply System
T8056AV UN29JUL93
Continued on next page TX,0560,BA885 1918AUG932/5
PN=358
External Fuel Supply System
T6683AA UN20OCT88
and plug to close openings.
11. Remove three fuel tank front brackettotransmission
housing cap screws (D).
12. Remove two cross member supporttofuel tank front
bracket cap screws (E).
13. Remove two fuel tank rear brackettofuel tank nuts
(F).
T8056AW UN29JUL93
14. Remove fuel tank.
Specification
Fuel Tank
(Empty)Weight................................................................ 80 kg (175 lb)
17. Connect fuel supply hose (B). 19. Connect fuel return hose (C) (early machines).
18. Close petcock (A) (later machines) or turn valve lever
(A) (early machines) to close fuel tank drain opening.
Continued on next page TX,0560,BA885 1918AUG933/5
PN=359
External Fuel Supply System
T8056AV UN29JUL93
TX,0560,BA885 1918AUG934/5
T8056AU UN29JUL93
TX,0560,BA885 1918AUG935/5
PN=360
Section 06
Torque Converter
Contents
Page
PN=1
Contents
PN=2
Group 0600
Removal and Installation
T7522AA UN25APR91
Special or Essential Tools
NOTE: Order tools according to information given in
the U.S. SERVICEGARDCatalog or in the
European Microfiche Tool Catalog (MTC).
Other Material
Number Name Use
PT569 (U.S.) John Deere NEVERSEEZ Applied to torque converter
pilot sleeve.
Specifications
Item Measurement Specification
PN=363
Removal and Installation
T8059FD UN09AUG93
NOTE: There are 12 cap screws that secure torque
converter to flywheel housing. One cap screw
was removed during engine removal.
10. Install and tighten 11 torque converter 12. Install bottom plate on flywheel housing.
housingtoflywheel housing cap screws.
13. Connect engine manifoldtotorque converter hose.
Specification
Torque Converter 14. Install engine. (See procedure in Group 0400.)
HousingtoFlywheel
Housing Cap
ScrewsTorque............................................................. 61 Nm (45 lbft)
NEVERSEEZ is a registered trademark of Emhart Chemical Group.
TX,06,RB415 1914JUN111/1
PN=364
Group 0651
Turbine, Gears and Shaft
T8084AC UN23SEP93
Special or Essential Tools
NOTE: Order tools according to information given in
the U.S. SERVICEGARDCatalog or in the
European Microfiche Tool Catalog (MTC).
Test Plug with Port................................................ JDG835 Used to close opening and provide an inlet
port for pressure testing
DX,TOOLS 1914JUN112/2
Other Material
Number Name Use
PT569 (U.S.) John Deere NEVERSEEZ Applied to splines of gears.
T43513 (U.S.) Thread Lock and Sealer (High Applied to torque converter
TY9474 (Canadian) Strength) cap screws.
271 (LOCTITE)
Specifications
Item Measurement Specification
Torque Converter
HubtoImpeller Cap Screw Torque 25 Nm (18 lbft)
Flex PlatetoCover Cap Screws Torque 50 Nm (37 lbft)
Idler Shaft/HousingtoManifold Torque 87 Nm (64 lbft)
Cap Screw
Support TubetoManifold Cap Torque 25 Nm (18 lbft)
Screw
Pump AdaptertoHousing Cap Torque 87 Nm (64 lbft)
Screw
CovertoImpeller Screws
450G, 455G, 550G, 555G Torque 57 Nm (42 lbft)
650G Torque 50 Nm (37 lbft)
Drive Shaft
Bearing StraptoYoke Cap Screws Torque 47.5 9 Nm (35 7 lbft)
Turbine Shaft Cap Screw Torque 215 Nm (159 lbft)
TX,0651,BD873 1916SEP931/1
PN=365
Turbine, Gears and Shaft
T7926AA UN29JAN93
PN=366
Turbine, Gears and Shaft
NOTE: Orings and seals are shown in black. The cross section shown is for 650G. The 450G, 455G,
550G and 555G are similar with the following exceptions:
Differences 650G All Other Units
Torque Converter Size 330.2 mm (13 in.) 298.5 mm (11.75 in.)
Torque Converter CovertoImpeller Hardware Cap screw (20)24 used. Cap screw, two washers and nut20 sets used
Impeller Hub Flange outside and 12 cap screws and washers Flange inside and 8 cap screws and washers
(32) installed from inside torque converter installed from outside torque converter impeller.
impeller (17).
Turbine Shaft Front Bearing Ball bearing (26). Needle bearing and thrust bearing with races.
Flex PlatetoCover Spacer Ring Not used. Installed between cover and flex plate.
TX,0651,BD802 1920AUG932/2
PN=367
Turbine, Gears and Shaft
T7935AD UN29JAN93
of photograph.
To replace the rear oil seal (D), ball bearing (E), turbine
shaft (G) and seal ring with torque converter in the
machine:
1. Disconnect drive shaft.
2. Remove cap screw (A) to remove yoke (C), washer
(B), and Oring.
3. Remove oil seal.
4. Remove snap ring (F).
T7935AB UN29JAN93
5. Remove turbine shaft and ball bearing.
6. Replace parts as necessary.
7. Use a piece of pipe to install rear seal. Install seal
with seal lip (spring side) towards ball bearing until
even with housing.
8. Tighten cap screw (A).
Drive ShaftSpecification ACap Screw EBall Bearing
Turbine Shaft Cap BWasher F Snap Ring
CYoke GTurbine Shaft
ScrewTorque........................................................... 215 Nm (159 lbft) DOil Seal
9. Tighten drive shaft bearing straptoyoke cap screws.
Drive ShaftSpecification
Bearing StraptoYoke
Cap ScrewsTorque...................................... 47.5 9 Nm (35 7 lbft)
TX,0651,BD801 1916SEP931/1
PN=368
Turbine, Gears and Shaft
PN=369
Turbine, Gears and Shaft
T112858 1910FEB98
PN=370
Turbine, Gears and Shaft
1 Cap Screw (12 used) 8 ORing 15 Thrust Bearing (2 used) 22 Impeller Hub
2 Ring 9 Needle Bearing 16 Snap Ring (2 used) 23 ORing
3 Flex Plate 10 Bearing Race (2 used) 17 Retainer (2 used) 24 Impeller
4 Spacer Ring 11 Thrust Bearing 18 Stator 25 Seal Ring
5 Nut (20 used) 12 Turbine Hub 19 Outer Clutch Race 26 Washer (8 used)
6 Washer (40 used) 13 Turbine 20 Freewheel (Sprag) Clutch Washer650G (12 used)
7 Cover 14 Bearing Race (4 used) 21 Inner Clutch Race 27 Cap Screw (8 used), Cap
Screw650G (12 used)
28 Socket Head Screw (20
used) Cap Screw650G (24
used)
NOTE: Procedures shown 450G, 455G, 550G, and 555G 3. Remove cap screws (650G) or socket head screws,
torque converter. 650G torque converter is similar. washers and nuts (450G, 455G, 550G) to remove
torque converter cover and Oring.
1. Slide torque converter from housing.
4. Remove remaining parts as necessary.
2. Remove cap screws to remove ring, flex plate and
spacer ring (if equipped).
TX,06,RB265 1923JAN982/6
T7935AC UN29JAN93
flange side (F) of clutch cage is on the same side as
the thicker end of the stator blades.
7. Install retainers and snap rings, making sure ring is
fully in groove.
T7943AB UN10FEB93
T7934BL UN13SEP93
PN=371
Turbine, Gears and Shaft
T7935AE UN29JAN93
Continued on next page TX,06,RB265 1923JAN984/6
PN=372
Turbine, Gears and Shaft
T112858 1910FEB98
PN=373
Turbine, Gears and Shaft
1 Cap Screw (12 used) 8 ORing 15 Thrust Bearing (2 used) 22 Impeller Hub
2 Ring 9 Needle Bearing 16 Snap Ring (2 used) 23 ORing
3 Flex Plate 10 Bearing Race (2 used) 17 Retainer (2 used) 24 Impeller
4 Spacer Ring 11 Thrust Bearing 18 Stator 25 Seal Ring
5 Nut (20 used) 12 Turbine Hub 19 Outer Clutch Race 26 Washer (8 used)
6 Washer (40 used) 13 Turbine 20 Freewheel (Sprag) Clutch Washer650G (12 used)
7 Cover 14 Bearing Race (4 used) 21 Inner Clutch Race 27 Cap Screw (8 used) Cap
Screw650G (12 used)
28 Socket Head Screw (20
used), Cap Screw650G (24
used)
PN=374
Turbine, Gears and Shaft
T8084AB UN28SEP93
are seen, repair or replace torque converter.
TX,0651,BD827 1916SEP931/1
PN=375
Turbine, Gears and Shaft
T8054AP UN13SEP93
NOTE: Rear oil seal and turbine shaft can be replaced
without removing torque converter from the
machine. See procedure in this group.
T8055BB UN29JUL93
converter in housing or put housing at a slight
angle so converter does not slide out.
PN=376
Turbine, Gears and Shaft
T8055AP UN13SEP93
1 Cap Screws (7 used) 9 Ball Bearing (2 used) 17 Pump Drive Gear 25 Manifold
2 Idler Shaft (2 used) 10 Pump Driven Gear (2 used) 18 Thrust Bearing 26 Ball Plug
3 ORing (2 used) 11 Ball Bearing (2 used) 19 Bearing Race 27 Cooler/Switch Tee Fitting
4 Ball Bearing (4 used) 12 Retainer (2 used) 20 Stator Support Tube with ORings
5 Idler Gear (2 used) 13 Snap Ring (2 used) 21 Cap Screw (7 used) 28 Drain Elbow with ORings
6 ORing (2 used) 14 ORing (2 used) 22 ORing 29 Hydraulic Pump Adapter
7 Cotter Pin (2 used) 15 Oil Seal 23 Check Valve with ORings 30 Cap Screw (4 used)
8 Torque Converter Housing 16 Torque Converter Ball 24 Inlet Elbow with ORings 31 Hydraulic Pump Stub Shaft
Bearing 32 ORing
5. Remove seven cap screws (1) to remove manifold and 6. Remove seven cap screws (21) to remove support
support tube assembly (2027), thrust bearing (18), tube (20) from manifold (25).
race (19) and pump drive gear (17).
PN=377
Turbine, Gears and Shaft
7. Install cap screw or slide hammer in tapped hole of 16. Apply petroleum jelly to Orings. Install ball bearings,
idler shafts (2). Remove shaft and Orings (3 and 6) to idler gear, idler shaft and Orings. Make sure shaft
remove idler gear (5) and ball bearings (4). throughhole aligns with tapped hole in housing.
8. Remove four cap screws (30) to remove pump adapter 17. Install support tube on manifold using seven cap
(29) and Orings (14 and 32). screws. Tighten cap screws (21) to specification.
9. Remove snap ring (13) to remove retainer (12), ball Torque Converter Specification
bearings (9 and 11) and pump driven gear (10). Support TubetoManifold
Cap ScrewTorque....................................................... 25 Nm (18 lbft)
10. Remove torque converter ball bearing (16) and oil
seal (15). 18. Install pump drive gear, thrust bearing and race
manifold and support tube assembly and seven cap
11. Repair or replace parts as necessary. screws. Tighten cap screws (1) to specification.
12. Install torque converter ball bearing to bottom of bore. Torque Converter Specification
Idler Shaft/Housing
13. Install seal with seal lip (spring side) toward bearing. toManifold Cap
Push seal into bore until even with housing. ScrewTorque............................................................... 87 Nm (64 lbft)
14. Install ball bearings, pump driven gears, retainers and
snap rings. Apply NEVERSEEZ to splines of driven
gears. 19. Install ball bearing (G) and ring seal (I) on turbine
shaft (H). Make sure bearing is tight against shoulder
15. Install Oring, pump adapter and four cap screws. of shaft.
Tighten cap screws (30) to specification.
Torque Converter Specification
Pump Adapter
toHousing Cap
ScrewTorque............................................................... 87 Nm (64 lbft)
NEVERSEEZ is a registered trademark of Emhart Chemical Group.
Continued on next page TX,0651,BD790 1914JUN113/4
PN=378
Turbine, Gears and Shaft
T8054AP UN13SEP93
20. Install turbine shaft and snap ring (F).
21. Use a piece of pipe to install oil seal (E). Install seal
with seal lip (spring side) towards ball bearing. Push
seal into bore until even with top of bore.
22. Install yoke (D), Oring (C), washer (B), and cap screw
T8055BC UN29JUL93
(A). Tighten cap screw.
Drive ShaftSpecification
Turbine Shaft Cap
ScrewTorque........................................................... 215 Nm (159 lbft)
T8055BB UN29JUL93
TX,0651,BD790 1914JUN114/4
PN=379
Turbine, Gears and Shaft
PN=380
Section 07
Dampener Drive
Contents
Page
PN=1
Contents
PN=2
Group 0700
Removal and Installation
Other Material
Number Name Use
PT569 (U.S.) John Deere NEVERSEEZ Lubricant Applied to splines to pump shaft.
T43512 (U.S.) Thread Lock and Sealer (Medium Applied to threads of dampener
TY9473 (Canadian) Strength) toflywheel cap screws and drive
242 (LOCTITE) shaft cap screws.
Specifications
Item Measurement Specification
PN=383
Removal and Installation
T6681AA UN07NOV88
cable and strap connections.
Specification
Drive Shaft Cap
(Refer to Group 2160.)
ScrewsTorque............................................................. 47 Nm (35 lbft)
NEVERSEEZ is a registered trademark of Emhart Chemical Group.
TX,0700,BD761 1914JUN111/1
PN=384
Section 09
Steering Systems
Contents
Page
PN=1
Contents
PN=2
Group 0920
Power Steering Linkage
Specifications
Item Measurement Specification
Pedal Steer Linkage
Pedal Stop Jam Nut Torque 12.2 Nm (108 lbin.)
Upper Brake Rod Jam Nuts Torque 30.5 Nm (22.5 lbft)
Lower Brake Rod Jam Nuts Torque 13.6 Nm (120 lbin.)
Lower Brake RodtoRear Bellcrank Torque 30 Nm (22 lbft)
Cap Screw
Lever Steer Linkage
Brake Pedal Stop Jam Nut Torque 12.2 Nm (108 lbin.)
Upper Brake Rod Jam Nuts Torque 30.5 Nm (22.5 lbft)
Front Lower Brake Rod Yoke Jam Torque 30.5 Nm (22.5 lbft)
Nuts
Rear Lower Brake Rod Yoke Jam Torque 13.6 Nm (120 lbin.)
Nuts
Rear Brake RodtoBellcrank Cap Torque 30 Nm (22 lbft)
Screw
Steering Lever Stop Jam Nuts Torque 24.4 Nm (18 lbft)
Steering RodtoSteering Hub Cap Torque 6.8 Nm (60 lbin.)
Screw and Nut
Front and Rear Brake Torque 13.6 Nm (120 lbin.)
RodstoFloating Lever Cap
Screw and Nut
TX,0920,BD774 1920AUG931/1
PN=387
Power Steering Linkage
T8043AQ UN15JUL93
1 Support 9 Vertical Tie Rod Assembly (2 17 Tie Rod End (2 used) 25 Spring (2 used)
2 Seal (8 used) used) 18 Rear Bellcrank (2 used, right 26 Lower Support (2 used)
3 Needle Bearing (8 used) 10 Cotter Pin (6 used) shown) 27 Lower Bellcrank (2 used)
4 Right Steering Pedal 11 Jam Nut (4 used) 19 Key (2 used) 28 Yoke (2 used)
5 Snap Ring (4 used) 12 Stop Cap Screw (2 used) 20 Lock Washer 29 Washer (4 used)
6 Washer (as required) 13 Left Steering Pedal 21 Cap Screw (2 used) 30 Cap Screw (10 used)
7 Pin (4 used) 14 Cap Screw (2 used) 22 Horizontal Tie Rod (2 used) 31 Washer (10 used)
8 Washer (8 used) 15 Washer (2 used) 23 RightHand Thread Nut (2 32 Stop Cap Screw (2 used)
16 LeftHand Thread Nut (2 used)
used) 24 Pin (2 used)
1. Remove floor plates and fenders under reservoir and if any adjustments are necessary, they can
fuel tank. be made equally on each side.
2. Repair or replace parts as necessary. NOTE: Horizontal tie rod (22) has righthand and
3. Install needle bearings (3) until even with bottom of lefthand threads. The lefthand thread engages
counterbore in pedals (4 and 13) and lower bellcranks the rear tie rod end (17).
(27). Apply multipurpose grease to bearings.
5. When rods (9 and 22) are assembled, install tie rod
4. Install washers (6) as necessary to provide a minimum ends and yokes onto rods six turns. This will keep the
clearance between pedals. There must be no pedal right and left rods at equal lengths.
interference when pedals are moved individually.
6. Connect spring (25) to bellcrank and rear most hole
Also use washers to align bellcranks with pedals. in floor support.
IMPORTANT: Right and left paired rods MUST be
assembled to the same length initially so
Continued on next page TX,0920,BD762 1920AUG931/2
PN=388
Power Steering Linkage
PN=389
Power Steering Linkage
T7247AJ UN09APR90
AUpper Pedal Stop DUpper Rod GLockout (Tow) Pins J Stop Screw
BLower Pedal Stop ELower Bellcrank HRear Bellcrank KInspection Plug
CSteering Pedals F Horizontal Brake Rod I Brake Adjusting Nut L Return Spring
PN=390
Power Steering Linkage
T7247AJ UN09APR90
AUpper Pedal Stop DUpper Rod GTow Disconnect Pins J Stop Screw
BLower Pedal Stop ELower Bellcrank HRear Bellcrank KInspection Plug
CSteering Pedals F Horizontal Brake Rod I Brake Adjusting Nut L Return Spring
NOTE: For complete steering adjustment, see procedures 3. If stop contacts are not sequenced properly, adjust
in TM1403, Section 9020, Group 20. horizontal brake rod (F):
1. Remove plugs (K). Adjust rod (F) so stops are contacted at the same
time.
2. Depress one pedal and observe lower pedal stop (B)
and inside end of stop screw (J). Contact must be
Shorten rod one turn and tighten jam nuts.
made at stop screw (J) before pedal contacts stop (B). 4. Repeat Steps 2 and 3 for opposite side linkage.
TX,0920,BD764 1931MAR941/1
PN=391
Power Steering Linkage
T8043AR UN15JUL93
Brake Linkage
1 Pin (2 used) 15 Pedal Shaft 29 RightHand Thread Nut (2 43 Jam Nut (2 used)
2 Washer (12 used) 16 Key (5 used) used) 44 Spring (2 used)
3 Left Pedal Bellcrank 17 Brake Pedal 30 Tie Rod End (2 used) 45 Bracket (2 used)
4 Seal (4 used) 18 Pedal Rod (2 used) 31 Lock Washer (2 used) 46 Yoke (2 used)
5 Needle Bearing (6 used) 19 Cotter Pin (6 used) 32 Cap Screw (2 used) 47 Washer (4 used)
6 Bracket 20 Cap Screw (10 used) 33 Cotter Pin (2 used) 48 Pin (2 used)
7 Jam Nut 21 Washer (10 used) 34 Pin (2 used) 49 Pedal Return Spring
8 Cap Screw 22 Three Platform Plates 35 Yoke (2 used) 50 Lower Bellcrank (2 used)
9 Seal (4 used) 23 Left Steering Valve Bellcrank 36 Jam Nut (2 used) 51 Snap Ring (2 used)
10 Right Pedal Bellcrank 24 Left Brake Bellcrank 37 Steering Lever Tie Rod (2 52 Washer (as required)
11 Washer (3 used) 25 Right Brake Bellcrank used) 53 Support (2 used)
12 Cap Screw (3 used) 26 Tie Rod End (4 used) 38 Snap Ring (2 used)
13 Jam Nut 27 LeftHand Thread Nut (4 39 Washer (4 used)
14 Cap Screw used) 40 Ball Bearing (2 used)
28 Rear Brake Tie Rod (2 used) 41 Right Steering Valve
Bellcrank
42 Front Brake Tie Rod (2 used)
1. Remove floor plates and fenders under reservoir and 4. Install washers (52) as necessary to provide a
fuel tank. minimum side play between supports (53), lower
2. Repair or replace parts as necessary. bellcranks (50) and snap rings (51). Lower bellcranks
must pivot freely.
3. Install needle bearings (5) until even with bottom of
counterbore in bracket (6) and lower bellcranks (50). Also use washers to align bellcranks with pedal rods
Apply multipurpose grease to bearings. (18).
Continued on next page TX,0920,BD765 1920AUG931/6
PN=392
Power Steering Linkage
IMPORTANT: Right and left paired rods MUST be unit is operated. For complete steering/brake
assembled to the same length initially so adjustment, see TM1403, Section 9020.
if any adjustments are necessary, they can
be made equally on each side. 7. Adjust stops and linkage. (See procedures in this
group.)
NOTE: Rods (28 and 42) have righthand and 8. Tighten hardware to specification after adjustment:
lefthand threads. The lefthand thread engages
the rear tie rod end (26). Specification
Tie Rod (18) Jam
5. When rods (18, 28, 37 and 42) are assembled, install NutsTorque........................................................... 30.5 Nm (22.5 lbft)
tie rod ends and yokes onto rods six turns. This will Stop Jam Nuts (7 and
keep the right and left rods at equal lengths. 13)Torque............................................................. 12.2 Nm (108 lbin.)
Tie Rod Jam Nuts (27
6. Connect springs (44) to bracket (45) and forward most and 29)Torque...................................................... 13.6 Nm (120 lbin.)
hole in floor support. Cap Screw
(32)Torque.................................................................. 30 Nm (22 lbft)
CAUTION: Machine can lose steering and Tie Rod Jam Nuts
brake control if linkage is not adjusted before (43)Torque............................................................ 30.5 Nm (22.5 lbft)
Continued on next page TX,0920,BD765 1920AUG932/6
PN=393
Power Steering Linkage
T8043AS UN15JUL93
PN=394
Power Steering Linkage
1 Left Steer Lever 8 Left Floating Lever 15 Cap Screw (2 used) 22 Lock Washer (4 used)
2 Right Steer Lever 9 Support (2 used) 16 Nut (2 used) 23 Right Floating Lever
3 Snap Ring (2 used) 10 Sleeve (3 used) 17 Right Hub 24 Front Brake Tie Rod (2 used)
4 Lever Shaft 11 Cap Screw (4 used) 18 Nut (2 used) 25 Cap Screw (2 used)
5 Washer (as required) 12 Washer (10 used) 19 Cap Screw (2 used) 26 Rear Brake Tie Rod (2 used)
6 Seal (8 used) 13 Left Hub 20 Steering Lever Tie Rod (2 27 Cap Screw (6 used)
7 Needle Bearing (8 used) 14 Center Support used, right shown)
21 Nut (2 used)
9. For lever linkage of machines (S.N. 770807): Adjust stops and linkage. (See procedures in this
group.)
Repair or replace parts as necessary. Tighten hardware to specification after adjustment:
Install needle bearings (7) until even with bottom of
counterbore in hubs (13 and 17) and floating levers Specification
(8 and 23). Apply multipurpose grease to bearings. Stop Jam Nuts
Install washers (5) as necessary to provide a (16)Torque............................................................... 24.4 Nm (18 lbft)
minimum side play between supports (9 and 14), Tie Rod Cap Screw and
hubs, floating levers and snap rings (3). Hubs and Nut (18)Torque......................................................... 6.8 Nm (60 lbin.)
floating levers must pivot freely. Tie Rod Cap Screw and
Nut (21)Torque..................................................... 13.6 Nm (120 lbin.)
PN=395
Power Steering Linkage
T8043AT UN15JUL93
PN=396
Power Steering Linkage
1 Left Steer Lever 8 Left Floating Lever 15 Left Hub 22 Right Floating Lever
2 Right Steer Lever 9 Support (2 used) 16 Right Hub 23 Front Brake Tie Rod (2 used)
3 Snap Ring (2 used) 10 Cap Screw (2 used) 17 Nut (2 used) 24 Cap Screw (2 used)
4 Lever Shaft 11 Jam Nut (2 used) 18 Cap Screw (2 used) 25 Rear Brake Tie Rod (2 used)
5 Washer (as required) 12 Sleeve (3 used) 19 Steering Lever Tie Rod (2 26 Cap Screw (4 used)
6 Seal (8 used) 13 Cap Screw (4 used) used, right shown)
7 Needle Bearing (8 used) 14 Washer (10 used) 20 Nut (2 used)
21 Lock Washer (4 used)
10. For lever linkage of machines (S.N. 770808 ): Adjust stops and linkage. (See procedures in this
group.)
Repair or replace parts as necessary. Tighten hardware to specification after adjustment:
Install needle bearings (7) until even with bottom of
counterbore in hubs (15 and 16) and floating levers Specification
(8 and 22). Apply multipurpose grease to bearings. Stop Jam Nuts
Install washers (5) as necessary to provide a (11)Torque................................................................ 24.4 Nm (18 lbft)
minimum side play between supports (9), hubs, Tie Rod Cap Screw and
floating levers and snap rings (3). Hubs and floating Nut (17)Torque......................................................... 6.8 Nm (60 lbin.)
levers must pivot freely. Tie Rod Cap Screw and
Nut (20)Torque..................................................... 13.6 Nm (120 lbin.)
CAUTION: Machine can lose steering and brake 11. Install fenders and floor plates.
control if linkage is not adjusted before machine
is operated. For complete steering/brake
adjustment, see TM1403, Section 9020.
TX,0920,BD765 1920AUG936/6
PN=397
Power Steering Linkage
T7247AP UN09APR90
ASteering Valve Tie Rod ELower Brake Pedal Stop I Tow Disconnect Pin MAdjuster
BBrake Tie RodRear F Vertical Brake Tie Rod J Tie Rod End NInspection Plug
CLever Stop Screw GLower Bellcrank KRear Brake Lever OStop Screw
DUpper Brake Pedal Stop HBrake Tie RodFront L Steering Valve Bellcrank
PN=398
Power Steering Linkage
T7247AK UN09APR90
ASteering Valve Tie Rod ELower Brake Pedal Stop I Tow Disconnect Pin MAdjuster
BBrake Tie RodRear F Vertical Brake Tie Rod J Tie Rod End NInspection Plug
CLever Stop Screw GLower Bellcrank KRear Brake Lever OStop Screw
DUpper Brake Pedal Stop HBrake Tie RodFront L Steering Valve Bellcrank
4. If removed, install center floor plate with rubber 7. Install pin in lower bellcrank (G).
stopblock.
TX,0920,BD772 1931MAR941/1
PN=399
Power Steering Linkage
T7247AK UN09APR90
ASteering Valve Tie Rod ELower Brake Pedal Stop I Lockout (Tow) Pin MAdjuster
BBrake Tie RodRear F Vertical Brake Tie Rod J Tie Rod End NInspection Plug
CLever Stop Screw GRear Lower Bellcrank KRear Brake Lever OStop Screw
DUpper Brake Pedal Stop HBrake Tie RodFront L Steering Valve Bellcrank
1. Remove inspection plugs (N). made at stop screw (O) before lever contacts pedal
stop (E).
2. Pull one lever and observe lower lever stop screw (C)
and inside end of stop screw (O). Contact must be 6. If stop contacts are not sequenced properly, adjust
made at stop screw (O) before lever contacts stop front brake tie rod (H):
screw (C).
Adjust tie rod (H) so stops are contacted at the same
3. If stop contacts are not sequenced properly, adjust time.
rear brake tie rod (B): Shorten rod one turn and tighten jam nuts.
Adjust rod (B) so stops are contacted at the same 7. Repeat Steps 5 and 6 for opposite side linkage.
time.
8. Install inspection plugs.
Shorten rod one turn and tighten jam nuts.
4. Repeat Steps 2 and 3 for opposite side linkage.
5. Depress pedal and observe lower brake pedal stop
(E) and inside end of stop screw (O). Contact must be
TX,0920,BD773 1931MAR941/1
PN=400
Group 0960
Hydraulic System
Hydraulic System
See Group 0260.
TX,0920,BD773 1931MAR941/1
PN=401
Hydraulic System
PN=402
Section 16
Electrical System
Contents
Page Page
Group 1671Batteries, Support and Cables Remove and Install Logic Module or
Specifications ............................................ 1616711 Circuit Breaker (S.N. 768318 )
Battery Safety ............................................ 1616711 (Module Package) ................................. 1616762
Check Battery Electrolyte Level Remove and Install Display
and Terminals ........................................ 1616712 Monitor................................................... 1616763
Procedure for Testing Batteries ................. 1616714 Remove and Install Display Monitor
Using Booster Batteries12Volt Lights ..................................................... 1616764
System................................................... 1616715 Remove and Install Switch, Gauge,
Remove and Install Batteries..................... 1616716 Hour Meter or Indicator Light................. 1616764
PN=1
Contents
PN=2
Group 1671
Batteries, Support and Cables
Specifications
Item Measurement Specification
Volts Voltage 12
Cold Cranking Amps at 18 (0F) 625 Amps
Reserve Capacity at 25 Amps and 27C (80F) 160 minutes
SAE Group 9H9A
Fully Charged Electrolyte Specific Gravity 1.2651.280
TX,1671,AA8 1904APR901/1
Battery Safety
Prevent Battery Explosions:
Keep sparks, lighted matches, and open flame away from
the top of battery. Battery gas can explode.
Never check battery charge by placing a metal object
TS204 UN23AUG88
across the posts. Use a voltmeter or hydrometer.
Do not charge a frozen battery it may explode. Warm
battery to 16C (60F).
Specification
BatteryTemperature........................................................... 16C (60F)
vegetable oil.
3. Get medical attention immediately.
TX,16,DY49 1915OCT961/1
PN=405
Batteries, Support and Cables
TS203 UN23AUG88
electrolyte is added.
4. Avoiding spilling or dripping electrolyte.
5. Use proper jump start procedure.
If you spill acid on yourself:
1. Flush your skin with water.
2. Apply baking soda or lime to help
neutralize the acid.
3. Get medical attention immediately.
3. Flush your eyes with water for 1530 minutes.
Get medical attention immediately.
IMPORTANT: If water is added to batteries during
If acid is swallowed: freezing weather, batteries must be charged
after water is added to prevent batteries from
1. Do not induce vomiting. freezing. Charge battery using a battery
2. Drink large amounts of water or milk, but charger or by running the engine.
do not exceed 1.9 L (2 quarts).
Specification 1. Remove battery box cover.
Milk or WaterMaximum
Volume.............................................................................1.9 L (2 quarts)
Continued on next page TX,75,DH1574 1928APR931/3
PN=406
Batteries, Support and Cables
T6996DB UN10FEB89
3. Disconnect battery clamps, grounded clamp first.
T6996DA UN10FEB89
TX,75,DH1574 1928APR932/3
T6758AA UN21OCT88
TX,75,DH1574 1928APR933/3
PN=407
Batteries, Support and Cables
Procedure for Testing Batteries Record specific gravity reading for each cell.
Visual Check If high and low readings vary LESS than 0.050 and
1. Check for damage such as cracked or broken case average specific gravity is between 1.225 and 1.280,
and electrolyte leakage. battery is fully charged, go to LOAD TEST.
If damage is seen, replace battery. If high and low readings vary LESS than 0.050 and
average specific gravity is LESS than 1.225, charge
2. Check electrolyte level. (See procedure in this group) battery and repeat test. If average specific gravity is still
LESS than 1.225, replace both batteries.
If low, add distilled water to specified level and charge
battery. If high and low readings vary MORE than 0.050, charge
battery and repeat test. If high and low readings still vary
3. Check terminals for corrosion. MORE than 0.050, replace both batteries.
If corroded, clean using a wire brush or battery post Load Test
cleaner such as JT05838 Battery Post/Clamp Cleaner.
Check battery capacity with a load tester such as JT05832
4. Check posts for looseness.
Battery Load Tester. Follow tester manufacturers
If posts are loose, replace battery. instructions for proper load test procedures.
Hydrometer Test If one battery fails load test, replace both batteries.
PN=408
Batteries, Support and Cables
T6508AE1 UN24OCT91
SingleBattery Application
T6713AI1 UN24OCT91
TwoBattery Application
TX,1671,BA909 1910AUG931/1
PN=409
Batteries, Support and Cables
T6766BG UN18OCT88
TX,1671,AA9 1904APR901/1
PN=410
Group 1672
Alternator, Regulator, and Charging System Wiring
John Deere Engine AccessoriesUse CTM11
For additional engine information, the component
technical manual (CTM) is also required.
Use the CTM in conjunction with this machine manual.
M44215 UN07SEP88
TX,901505,QQ994 1910AUG951/1
Service Equipment and Tools Tool Catalog (MTC). Some tools may be
available from a local supplier.
NOTE: Order tools from the U.S. SERVICEGARD
Catalog or from the European Microfiche
Specifications
Item Measurement Specification
PN=411
Alternator, Regulator, and Charging System Wiring
T8059BK UN16AUG93
pump.
Remove fan belt from alternator.
Remove washer and cap screw to remove alternator
and guard (C).
8. On machines (S.N. 840461 ):
Remove nut (B), cap screw and washer to remove (S.N. 840460)
alternator.
9. On machines (S.N. 840460):
Loosely install alternator and guard (C) using nut (B)
with washer and cap screw. Head of cap screw must
be on side of bracket toward fan belt.
Install fan belts.
Adjust belt tension. Use belt tension gauge applied
halfway between alternator and crankshaft pulleys.
Belt deflection should be 13 mm at 45 N force (1/2
in. at 10 lb force).
Specification
Alternator
VBeltTension........................ 13 mm (0.50 in.) deflection with 45N (10
lb) force applied halfway between alternator
T113143 UN30JAN98
PN=412
Alternator, Regulator, and Charging System Wiring
T8059BL UN16AUG93
65Amp Alternator (S.N. 768317)
T8059BM UN16AUG93
PN=413
Alternator, Regulator, and Charging System Wiring
TX,1672,BA890 1910AUG933/3
PN=414
Group 1673
Lighting System
Replace Halogen Bulbs
IMPORTANT: To get the correct lighting pattern,
lens must be installed so the word TOP is
on top when the lamp is installed in machine.
Bezel must be installed so wider section is
T5894AG1 UN17APR89
on top when lamp is installed.
1673,AA1 1902AUG901/2
T5894AI1 UN20OCT88
bulb failure. If bulb glass is touched, clean
using a soft, oilfree cloth and alcohol.
T6249AU UN19OCT88
wiring leads are not crimped.
9. Install bezel (G) so wider section is on top. Sealing
flange must be inside housing on all four sides before
tightening screws.
10. Tighten screws (H) alternately. Do not overtighten as
screws may strip out plastic.
ANut EGasket
BWasher F Lens
CHousing GBezel
DBulb HScrew (4 used)
1673,AA1 1902AUG902/2
PN=415
Lighting System
T6287AP UN20OCT88
premature failure of halogen bulbs.
1673,AA3 1904APR901/1
PN=416
Group 1674
Wiring Harness and Switches
RW18164 UN20APR90
Special or Essential Tools
NOTE: Order tools according to information given in
the U.S. SERVICEGARDCatalog or in the
European Microfiche Tool Catalog (MTC).
T6514ET UN23AUG88
Remove contacts from electrical connectors.
Crimping Pliers .................................................... JDG144
Used to crimp open barrel connectors to wire.
Crimp open barrel connectors to wire.
Electrical Repair Tool Kit DEUTSCH ................ JDG359 T6606AB UN23AUG88
Specifications
Item Measurement Specification
PN=417
Wiring Harness and Switches
TS0124 UN23AUG88
JDG363 Extractor Tool for 20 gauge wire.
2. Start correct size extractor tool over wire at handle (A).
3. Slide extractor tool rearward along wire until tool tip
snaps onto wire.
IMPORTANT: Do NOT twist tool when inserting
in connector.
TS120 UN23AUG88
DEUTSCH is a trademark of the Deutsch Co.
DX,ECONN,J 1903NOV941/2
TS122 UN23AUG88
place.
8. Transfer remaining wires to correct terminal in new
connector.
DX,ECONN,J 1903NOV942/2
PN=418
Wiring Harness and Switches
TS117 UN23AUG88
until it stops.
TS0134 UN23AUG88
DX,ECONN,W 1904JUN902/4
TS118 UN23AUG88
PN=419
Wiring Harness and Switches
TS0135 UN23AUG88
8. Inspect contact to be certain all wires are in crimped
barrel.
DX,ECONN,W 1904JUN904/4
TS0128 UN23AUG88
2. Insert JDG364 Extraction Tool over terminal contact in
connector body.
3. Hold extractor tool fully seated and pull wire from
connector body.
NOTE: If terminal cannot be removed, insert wire
or nail through extractor tool handle and push
terminal contact from connector.
WEATHER PACK is a trademark of Packard Electric.
DX,ECONN,O 1903NOV941/2
4. Push contact into new connector body until fully TS0130 UN23AUG88
seated.
5. Pull on wire slightly to be certain contact is locked in
place.
6. Transfer remaining wires to correct terminal in new
connector.
7. Close connector body.
DX,ECONN,O 1903NOV942/2
PN=420
Wiring Harness and Switches
TS0136 UN23AUG88
1. Slip correct size cable seal on wire.
2. Strip insulation from wire to expose 6 mm (1/4 in.) and
align cable seal with edge of insulation.
NOTE: Contacts have numbered identification for two
sizes of wire: a) #15 for 14 to 16 gauge wire
b) #19 for 18 to 20 gauge wire
TS1623 UN02NOV94
WEATHER PACK is a trademark of Packard Electric.
DX,ECONN,AA 1904JUN901/2
TS0139 UN02DEC88
DX,ECONN,AA 1904JUN902/2
DX,ECONN,V1 1902NOV941/1
PN=421
Wiring Harness and Switches
T6563AE UN19OCT88
AScrew EMounting Nut
BSwitch Lever F Switch
CMounting Nut GBattery Cable Terminal
DLock Washer HStarter Cable Terminal
1674,AA22 1904APR901/1
T6809AA UN07OCT93
2. Remove panel at rear of unit.
3. Remove transmission low pressure switch (A), reverse
warning alarm switch (B) and neutral start switch (C).
4. Inspect parts for wear and damage.
5. Install switches (AC). Tighten switches.
Specification
Low Pressure, Reverse
Warning Alarm
and Neutral Start
SwitchesTorque.......................................................... 40 Nm (30 lbft)
TX,1674,QQ479 1911OCT931/1
PN=422
Wiring Harness and Switches
T6552AA UN19OCT88
Specification
Start Circuit
Relay Terminal
ScrewsTorque............................................................. 2 Nm (18 lbin.)
START CIRCUIT RELAY CONNECTIONS
Terminal Wire No. Color
30 B02B Red
85 G01B Black
86 E02 White
87 E04 White
T6567AA UN07OCT93
TX,1674,BA892 1910AUG931/1
T113146 UN30JAN98
3. Remove engine right side shield.
4. Remove two cap screws (A) to remove relay (B) from
firewall.
5. Disconnect wires (CF).
6. Connect wires. (S.N. 794618 ) Shown
PN=423
Wiring Harness and Switches
T6576AF UN20APR89
(C) with indicator light toward the front of machine.
Specification
Switch from
MagnetDistance............................................... 9 3 mm (3/8 1/8 in.)
TX,1674,BB29 1911OCT931/1
PN=424
Wiring Harness and Switches
T8080AA UN13SEP93
rod end.
Specification
Cylinder Center Line
From Cylinder Barrel Rod
EndDistance............................................................... 83 mm (3.25 in.)
Tighten strap bolts.
Specification
ReturntoDig Switch
Strap BoltsTorque.................................................... 17 Nm (12.5 lbft)
T6475AZ1 UN25MAY89
4. Hand tighten magnet (C) to magnet support bracket
(H). Put cylinder in full rollback position. Attach
magnet support bracket (H) to cylinder rod 6 mm (0.25
in.) (J) from front of cylinder barrel.
5. Pivot magnet support until there is 9 mm (3/8 in.) gap
(D) between returntodig switch (B) and magnet (C).
Tighten cap screws (A).
Specification
ReturntoDig
Switch Assembly
Bracket Mounting
ScrewsTorque............................................................. 73 Nm (54 lbft)
T6575AA1 UN10FEB89
6. Adjust returntodig (see procedure in this group).
TX,1674,BB30 1931MAR941/1
PN=425
Wiring Harness and Switches
ReturntoDig Adjustment
SPECIFICATIONS
Support to Cylinder Distance 83 mm (3.25 in.)
Boom Height 600 mm (2 ft) off ground
Magnet Support To Cylinder (With 6 mm (0.250 in.)
T8080AA UN13SEP93
Bucket Rolled back) Distance
Magnet Air Gap 9 3 mm (3/8 1/8 in.)
Rear Wear Stips Height 15 mm (9/16 in.) above ground
Indicator to Magnet Air Gap 8 4 mm (0.31 0.16 in.)
T6475AZ1 UN25MAY89
T6575AA1 UN10FEB89
ACap Screw (2 used) F Cylinder Center Line
BSwitch G83 mm (3.25 in.)
CMagnet HMagnet Support Bracket
D9 mm (3/8 in.) I Visual Indicator
ESwitch Support Bracket J 6 mm (0.25 in.)
PN=426
Wiring Harness and Switches
PN=427
Wiring Harness and Switches
PN=428
Group 1676
Instruments and Indicators
Remove and Install Logic Module or Circuit
Breaker (S.N. 768317) (Module Package)
1. Remove instrument panel with logic module (A).
2. Disconnect 6wire (B) and 4wire (C) harness
connectors from logic module.
3. Remove two cap screws (D) and logic module.
4. Install screws and logic module, connect harness
connectors to logic module connectors.
5. Remove nuts (E) and nuts holding harness leads to
circuit breaker.
6. Install nuts (E) and nuts to harness leads.
7. Connect harness leads as follows:
Circuit Breaker Terminal Key Wire
Number/Color
T8059BP UN16AUG93
LMain F P00 and P03
RED
(25amp) G B01 RED
MAuxiliary H P01 RED
(15amp) I P02 RED, P10
RED
NLights J L01 BRN
(15amp) K L02 BRN, E05
WHT
ALogic Module F KCircuit Breaker
B6Wire Connector Terminals
C4Wire Connector L Main Circuit Breaker
DCap Screw (2 used) MAuxiliary Circuit Breaker
EHex Nut (3 used) NLight Circuit Breaker
OHour Meter Relay
TX,1676,BA894 1911OCT931/1
PN=429
Instruments and Indicators
T8059BQ UN16AUG93
9. Install circuit breaker using cap screw.
10. Connect wire leads as follows:
Key Terminal Wire Nos. (Color)
D BAT L01 (BRN)
AUX (15amp) P10 (RED), L02 (BRN)
F BAT P01 (RED)
AUX (15amp) P02 (RED), E05 (WHT)
G BAT B01 (RED) ALogic Module EHour Meter Relay
BAlternator Relay F Auxiliary Circuit Breaker
AUX (25amp) P00, P03, P03A (ALL RED) C4Wire Connector (15Amp)
DLights Circuit Breaker GMain Circuit Breaker
11. Turn battery disconnect switch to ON or connect (15Amp) (25Amp)
battery ground () cable. H6Wire Connector
TX,1676,BA895 1911OCT931/1
PN=430
Instruments and Indicators
T8059BR UN16AUG93
3. Tag harness connectors to aid assembly and
disconnect harness from display monitor at connectors
(F and G).
4. Disconnect STOP and CAUTION bulb holders from
monitor.
5. Install bulb holders and connect harness in proper
(S.N. 768318794617) Shown
locations.
Key Wire Number Wire No. (Color) (S.N. 768318 )
(S.N.
768317)
C Z04B, Z05A Z04 (RED), Z05 (RED)
D Z04D, Z05B Z04 (GRY), Z05 (GRY)
T6567AI1 UN19OCT88
E Z04C, Z01 Z01 (YEL), Z04 (YEL)
F Z04A, X01, Z04 (GRY), X01 (YEL), N02 (YEL), R01
N02A, R01, (BLK), Z03 (GRY), Z02 (GRY)
Z03, Z02
G N01, N03, X00, N01 (YEL), N03 (YEL), X00 (YEL), M00B
M00B (PUR)
H N04 N04 YEL
(S.N. 768317) Shown
6. Install instrument panel to machine.
NOTE: On machines (S.N. 794618 ), a fuel gauge is
added to the instrument panel and the location
of the hour meter will vary. Repair of the display
monitor remains the same.
T6196AH1 UN19OCT88
ADisplay Monitor ECAUTION Light Bulb Holder
BMonitortoPanel Screw (4 F Left Connector (6Wire)
used) GCenter Connector (6Wire)
CSTOP Light Bulb Holder HRight Connector (4Wire)
DBuzzer
TX,1676,BA896 1911OCT931/1
PN=431
Instruments and Indicators
T6196AJ UN20OCT88
3. Pull bulbs (C) from holders and replace as required.
4. Install gasket (B) and bulb holder to display monitor.
5. Install display monitor to instrument panel, connect
harness connectors and warning bulbs.
6. Install instrument panel in machine.
TX,1676,AA4 1911OCT931/1
T8059DC UN16AUG93
2. Remove instrument panel.
3. Disconnect wiring and remove component(s) as
required.
4. Install component(s) as required.
5. Connect wiring leads on module package as follows:
MODULE PACKAGE Module Package
Key Termi Wire Number Wire No. (Color)
nal (S.N. 794617) (S.N. 794618 )
AKey Switch CStart Aid Switch
A ACC L01, J00, J01 L01, J00, J01 BHour Meter DLight Switch
BAT P00 P00
IGN P01, E00 P01, P01A, E00
ST E01 (WHITE) E01 (WHITE) NOTE: On machines (S.N. 794618823918), the
G R01, R01A R01, R01A hour meter was moved to the R.H. side
Housing G01, G01A G01, G01A filter access compartment.
B N00, P02, P02A N00, P02
C E05, E03 E05, E03
D L02, L04, L02, L04
Continued on next page TX,1676,BA897 1911OCT931/2
PN=432
Instruments and Indicators
T113147 UN30JAN98
IGN E00, P01, P01A
ST E01
G Not used
Housing G01, G01A
G N00A, P02A
H G01H, P02, P02E, Y00 Gauge Package
I G01G, G01H, P01D, P01G, X00
J E03, E05 AEngine Water Temperature GHour Meter
K G01F, G01G, N02, P01C, P01F Gauge HFuel Gauge
BTransmission Low Oil I Transmission Oil
L L02, L04
Pressure Indicator Temperature Gauge
CTransmission Oil Filter J Start Aid Switch
NOTE: On machines (S.N. 794618823918), the Restriction Indicator KEngine Oil Pressure Gauge
hour meter was moved to the R.H. side DHydraulic Oil Filter L Light Switch
filter access compartment. Restriction Indicator
EEngine Alternator Low
Voltage Indicator
7. Install instrument panel. F Key Switch
PN=433
Instruments and Indicators
PN=434
Group 1677
Motors and Actuators
John Deere Engine AccessoriesUse CTM11
For additional engine information, the component
technical manual (CTM) is also required.
Use the CTM in conjunction with this machine manual.
M44215 UN07SEP88
TX,901505,QQ994 1910AUG951/1
T7883AK UN09NOV92
to pump.
TX,1677,BA898 1910AUG931/2
T6569AA UN19OCT88
motor.
Specification
Starting MotorWeight........................................................ 23 kg (50 lb)
PN=435
Motors and Actuators
T8059BS UN16AUG93
terminal on solenoid.
3. Remove screw (B) to remove cover over solenoid
small terminals.
4. Disconnect remaining wire leads to solenoid.
T113148 UN09FEB98
8. Install cover and screw.
9. Connect large wire leads to solenoid.
10. Turn battery disconnect switch to ON or connect
battery ground () cable.
(S.N. 840461 )
TX,1677,BA900 1910AUG931/1
PN=436
Section 17
Frames, Chassis, or Supporting Structure
Contents
Page
PN=1
Contents
PN=2
Group 1740
Frame Installation
Other Material
Number Name Use
T43514 (U.S.) Plastic Gasket To be applied to threads of main frame
TY9475 (Canadian) to transverse housing cap screws.
277 (LOCTITE)
Specifications
Item Measurement Specification
Connect welder ground clamp close to Preheat ground engaging tools (cutting edges, skid shoes,
each weld area so electrical current does and teeth shanks) to 177C (350F).
not arc inside any bearings. Specification
Ground Engaging
Use one of the following weld processes: ToolsTemperature.......................................................... 177C (350F)
AWSE7018 covered electrode with shielded metal arc To repair base metal failure remove enough material to
welding (SMAW) process allow weld to penetrate to the bottom of crack. Preheat
AWSER70S3 wire electrode with gas metal arc structural assemblies to a minimum of 38C (100F).
welding (GMAW) process Preheat ground engaging tools (cutting edges, skid shoes,
AWSE70T1 or E71T1 wire electrode with flux core and teeth shanks) to 177C (350F).
arc welding (FCAW) process.
Preheat area to be repaired to allow better weld
penetration.
T52,1740,C1 1905FEB941/1
PN=439
Frame Installation
T6942AP UN07OCT93
1. Remove ROPS or cab. (See Group 1800.)
6. Remove cap screws (A and B) from both sides of
2. Remove hydraulic reservoir. (See Group 2160.) transverse housing through opening on both sides of
main frame.
3. Remove fuel tank. (See Group 0560.)
7. Install transverse housing using a lifting device.
4. Remove ROPS/cab support. (See Group 1800.)
8. Apply plastic gasket to threads of upper cap screws
CAUTION: The approximate weight of transverse (A). Install and tighten cap screws (A and B).
housing is 454 kg (1000 lb). Specification
Main Frameto
5. Attach lifting device to transverse housing. Transverse Housing
Cap ScrewsTorque................................................. 600 Nm (442 lbft)
Specification
Transverse
HousingWeight........................................................... 454 kg (1000 lb)
TX,1740,DB729 1911OCT931/1
PN=440
Group 1749
Chassis Weights
Service Equipment and Tools Tool Catalog (MTC). Some tools may be
available from a local supplier.
NOTE: Order tools from the U.S. SERVICEGARD
Catalog or from the European Microfiche
Sprocket Weight Lifting Tool1 ...............................JT38022 Used to remove and install sprocket counterweight.
1
Fabricated tool, dealer made. (See Group 1799 for in
structions to make tool.)
TX,1749,BD731 1914JUN112/2
Specifications
Item Measurement Specification
T35235 UN03NOV88
TX,1749,BD784 1914JUN111/1
PN=441
Chassis Weights
T6942AJ UN07OCT93
Specification
Rear Counterweightto
Transverse Case Cap
ScrewTorque........................................................... 620 Nm (458 lbft)
1749,VV74 1911OCT931/1
PN=442
Chassis Weights
T6686AD UN07OCT93
1749,VV75 1919AUG931/1
PN=443
Chassis Weights
PN=444
Group 1799
Dealer Fabricated Tools
JT38022 Sprocket Weight Lifting Tool
Sprocket Weight Lifting Tool can be made in dealer shop
to remove and install sprocket weights.
T35238 UN26MAY89
9900,VV75 1921OCT871/1
PN=445
Dealer Fabricated Tools
PN=446
Section 18
Operators Station
Contents
Page
PN=1
Contents
PN=2
Group 1800
Removal and Installation
Other Material
Number Name Use
AT63519 (U.S.) Nitritebase rubber adhesive To be applied to headliner.
T43512 (U.S.) Thread Lock and Sealer (Medium To be applied to threads of ROPS
TY9473 (Canadian) Strength) support cap screws.
242 (LOCTITE)
Specifications
Item Measurement Specification
PN=449
Removal and Installation
PN=450
Removal and Installation
T8070AB UN13SEP93
Continued on next page TX,1800,BD877 1911OCT931/3
PN=451
Removal and Installation
T6657AD UN07OCT93
ALifting Hook DAlarm Harness (Early Models GShim (as required) J Cap Screw (2 used)
BGround Wire only) HIsolator (8 used)
CLight Harness EWasher (8 used) I Nut (4 used)
F Cap Screw (2 used)
2. Disconnect ground wire (B), backup alarm harness 7. Apply a soap and water solution to isolator (H).
(D), and light harness (C).
8. Install rear of ROPS/Cab using parts (EI).
CAUTION: The approximate weight of ROPS is 9. Tighten cap screw (F).
250 kg (550 lb). Cab weight is 545 kg (1200 lb). Specification
ROPStoROPS
3. Attach lifting strap to hooks (A). Support Cap Screw
4. Remove parts (EJ). (Rear)Torque........................................................... 407 Nm (300 lbft)
5. Carefully remove ROPS/Cab using overhead hoist. NOTE: Install shims equally to both sides.
Specification 10. Install parts (E, G, H, I and J) to front of ROPS.
ROPSWeight................................................................ 250 kg (550 lb)
CabWeight.................................................................. 545 kg (1200 lb) 11. Tighten cap screw (J).
6. Inspect ROPS/Cab for structural damage and replace Specification
if necessary. ROPStoROPS
Support Cap Screw
IMPORTANT: Do not use grease or petroleum (Front)Torque.......................................................... 407 Nm (300 lbft)
based lubricants on isolator. It will cause
deterioration of isolator. 12. Connect wire leads (B, C and D).
Continued on next page TX,1800,BD877 1911OCT932/3
PN=452
Removal and Installation
T8070AB UN13SEP93
TX,1800,BD877 1911OCT933/3
PN=453
Removal and Installation
T8070AE UN13SEP93
TX,1800,BD881 1908SEP931/1
PN=454
Group 1821
Seat and Seat Belt
Disassemble and Assemble NonSuspension
Seat
ASeat HWasher
BBracket I Nut
CRod J Adjuster
DAdjuster KCap Screw
EWasher L Washer
F Washer MAngle
GScrew
T8070AC UN13SEP93
TX,1821,BD882 1908SEP931/1
PN=455
Seat and Seat Belt
T113198 UN03FEB98
1 Cushion Seat 9 Spacer Bar 17 Spacer (2 used) 25 Flat Washer (4 used)
2 Cushion Back 10 Nut (2 used) 18 Strap (2 used) 26 Cap Screw (2 used)
3 Nut (2 used) 11 Nut (2 used) 19 Bracket (2 used) (Welded 27 Cap Screw (4 used)
4 Tilt Plate (2 used) 12 Spacer (2 used) to Seat Frames on Late 28 Left Seat Frame
5 Washer (2 used) 13 Flat Washer (2 used) Models) 29 Nut (4 used)
6 Cap Screw (2 used) 14 Cap Screw (2 used) 20 Flat Washer 30 Cap
7 Spring (2 used) 15 Nut (2 used) 21 Seat Belt 31 Tilt Latch Weldment
8 Right Seat Frame 16 Flat Washer (4 used) 22 Cap Screw (2 used) 32 Spring (2 used)
23 Cap Screw (2 used)
24 Cap Screw (2 used)
1821,QQ1 1902AUG901/1
PN=456
Seat and Seat Belt
T6694AC UN19OCT88
1821,QQ2 1902AUG901/1
PN=457
Seat and Seat Belt
T113190 UN11FEB98
PN=458
Seat and Seat Belt
CAUTION: Release tension on spring. Spring NOTE: Backhoe has a onepiece seat.
under pressure can cause injury when released.
PN=459
Seat and Seat Belt
PN=460
Section 19
Sheet Metal and Styling
Contents
Page
Group 1927Fenders
Disassemble and Assemble Side
Fenders ................................................. 1919271
Disassemble and Assemble Back
Fender (S.N. 763492) ........................ 1919272
Disassemble and Assemble Back
Fender (S.N. 763493 ) ....................... 1919274
PN=1
Contents
PN=2
Group 1910
Hood and Engine Enclosure
Other Material
Number Name Use
T43513 (U.S.) Thread Lock and Sealer (High Used to install hasp onto cowl.
TY9474 (Canadian) Strength)
271 (LOCTITE)
T8033AO UN17JUL93
AEngine Left Side Shield EClamp I Cap Screw MHood
BNut F Spring (2 used) J Rubber Bumper (3 used)
CWasher (2 used) GWeldon Strap (4 used) KCap Screw (13 used)
DExhaust Pipe HEngine Right Side Shield L Washer (13 used)
PN=463
Hood and Engine Enclosure
T8033AP UN17JUL93
3. Assemble parts.
AHasp F Panel
BCowl GScrew (4 used)
CBracket HCap Screw (4 used)
DSeal I Strap (2 used455G and
ELabel 555G only)
J Grab Bar
TX,1910,BA841 1914JUN111/1
PN=464
Group 1913
Miscellaneous Guards
Remove and Install Bottom Guards and
Access Covers
ABottom Guard F Cap Screw (2 used)
BAccess Cover (Loaders S.N. GCover (Oil Pan Access)
768272 and all Dozers) HWasher (6 used)
T8033AQ UN17JUL93
CAccess Cover (Loaders I Cap Screw (6 used)
S.N. 768273 )
DWasher (2 used)
ECap Screw (2 used)
TX,1913,BA843 1908JUL931/1
PN=465
Miscellaneous Guards
PN=466
Group 1921
Grille and Grille Housing
Disassemble and Assemble Grille Housing
T8033AR UN17JUL93
TX,1921,BA844 1908JUL931/1
PN=467
Grille and Grille Housing
PN=468
Group 1927
Fenders
Disassemble and Assemble Side Fenders
T8033AS UN17JUL93
ACap Screw (2 used) ESpring (S.N. 763492) I Right Front Fender (left front MWasher (8 used)
BWasher (2 used) F Strap (S.N. 763492) fender similar) NRight Rear Fender
CCover GWasher (S.N. 763492) J Cap Screw (4 used)
DLeft Rear Fender HCap Screw (S.N. 763492) KWasher (4 used)
L Cap Screw (8 used)
PN=469
Fenders
T8033AU UN17JUL93
PN=470
Fenders
PN=471
Fenders
T8033AT UN17JUL93
(S.N. 763493816937)
ALatch GCap Screw (2 used) MBack Fender (Dozer only) SCap Screw (2 used)
BLid HHardened Washer (2 used) NAngle T Washer (2 used)
CRubber Bumper (2 used) I Back Fender (Loader only) ONut (4 used) UCap Screw (2 used)
DAngle (2 used) J Cap Screw (2 used) PHardened Washer (4 used) VWasher (2 used)
ECap Screw (2 used) KWasher (2 used) QHardened Washer (2 used)
F Angle (Loader only) L Angle (Dozer only) RPlate
Continued on next page TX,19,RB407 1905FEB981/2
PN=472
Fenders
T113199 UN03FEB98
(S.N. 816938 )
TX,19,RB407 1905FEB982/2
PN=473
Fenders
PN=474
Section 20
Safety, Convenience and Miscellaneous
Contents
Page
PN=1
Contents
PN=2
Group 2004
Horn and Warning Devices
Remove and Install Horn
1. Remove right engine side shield.
2. Disconnect wire lead (A).
3. Remove nut to remove horn.
T113149 UN30JAN98
4. Install horn and tighten nut.
5. Connect wire lead (A). Install engine side shield.
TX,20,RB408 1905FEB981/1
T113150 UN30JAN98
3. Remove two cap screws to remove reverse warning
alarm (A).
4. Remove ground wire (B).
5. Install reverse warning alarm ground wire and two
cap screws.
(S.N. 840461 ) Shown
TX,DS1843 1911OCT931/1
PN=477
Horn and Warning Devices
T6782AG UN18OCT88
NOTE: Alarm removed from machine for clarity
of photograph.
ANut CNut
BShorting Bar DTerminal
T6782AH UN18OCT88
TX,DS1844 1902AUG901/1
PN=478
Section 21
Main Hydraulic System
Contents
Page
PN=1
Contents
PN=2
Group 2160
Hydraulic System
Other Material
Number Name Use
PT569 (U.S.) John Deere NEVERSEEZ Lubricant Apply to splines on pump shaft.
T43512 (U.S.) Thread Lock and Sealer (Medium Apply to threads on front
TY9473 (Canadian) Strength) yoketooutput shaft cap screw.
242 (LOCTITE)
Specifications
Item Measurement Specification
PN=481
Hydraulic System
X9811 UN23AUG88
NOTE: For repair of drive shaft only, go to Step 4.
T7247AQ UN09APR90
Avoid the hazard by relieving pressure before
disconnecting hydraulic or other lines. Tighten
all connections before applying pressure. Search
for leaks with a piece of cardboard. Protect hands
and body from high pressure fluids.
If an accident occurs, see a doctor immediately.
Any fluid injected into the skin must be surgically
removed within a few hours or gangrene
may result. Doctors unfamiliar with this type ASuction ScreentoPump DPump OutlettoControl
of injury should reference a knowledgeable Inlet Hose Valve Line
medical source. Such information is available BReservoirtoPump Inlet ETransmission Pump
from Deere & Company Medical Department Hose F Pump Outletto
CHydraulic Pump Transmission Filter and
in Moline, Illinois, U.S.A. Accumulator Line
PN=482
Hydraulic System
T6675AK UN25OCT88
ACap Screw (4 used per yoke) CCap Screw (4 used) EFront Yoke GRear Yoke
BCap Screw DSnap Ring F Drive Shaft
PN=483
Hydraulic System
14. Squirt oil into inlet side (A) of transmission pump (E).
T7247AQ UN09APR90
15. Connect hoses and lines (A, B, D and F) and install
drive shaft. Tighten drive shaft bearing straptoyoke
cap screws.
Specification
Bearing StraptoYoke
Cap ScrewsTorque...................................... 47.5 9 Nm (35 7 lbft)
Suction Hose
ElbowtoPump Inlet
Cap ScrewsTorque...................................... 6090 Nm (4467 lbft) ASuction ScreentoPump DPump OutlettoControl
Inlet Hose Valve Line
Pressure Lineto BReservoirtoPump Inlet ETransmission Pump
Pump Outlet Cap Hose F Pump Outletto
ScrewsTorque.............................................. 3448 Nm (2535 lbft) CHydraulic Pump Transmission Filter and
Accumulator Line
TX,21,RB405 1914JUN113/3
T6534AO UN18NOV89
PN=484
Hydraulic System
T6550AB UN25OCT88
CTransmission Pump GWasher (4 used)
DCap Screw HStud (5/8 in. x 11 1/2 in.)
PN=485
Hydraulic System
T7247BH UN01AUG90
Transmission Pump
AHousing EDriven Shaft I Groove MSeal (2 used)
BDowel Pin (2 used) F ORing J Set Screw (2 used) NGasket
CBushing (2 used) GSeal Retainer KGear (2 used)
DCover HSeal L Thrust Plate (2 used)
NOTE: Set screws must be removed before NOTE: Install seal (H) with flat side toward seal retainer.
removing seal retainer.
Cover groove (I) with tape when installing seal
3. Remove parts as shown. retainer (G) to prevent damage to seal (H).
4. To remove seal retainer (G), turn counterclockwise 7. Install new Oring (F) and seals (H and M). Apply
using a punch through holes provided. petroleum jelly to seal lips.
5. Inspect parts for wear or damage. Driven shaft 8. Put a light coat of clean hydraulic oil on all parts.
assembly (E) has no service parts. Assemble parts as shown.
6. Replace assembly if required.
Continued on next page TX,2160,BA920 1911OCT933/5
PN=486
Hydraulic System
T6550AB UN25OCT88
AMain Hydraulic pump ECap Screw
BStud (5/8 in. x 13 1/2 in.) F Nut (2 used)
CTransmission Pump GWasher (4 used)
DCap Screw HStud (5/8 in. x 11 1/2 in.)
TX,2160,BA920 1911OCT934/5
T6534AL UN25OCT88
Hydraulic Pump
ASnap Ring F Dowel Pin (4 used) KSeal Retainer PSeal (2 used)
BBearing GHousing L Cap Screw (2 used) QSeal (3 used)
CCover HFront Carrier MORing (2 used)
DBushing (4 used) I Air Vent NDriven Gear Shaft
EDrive Gear Shaft J Rear Carrier OThrust Plate (2 used)
10. Remove parts as shown. 14. Assemble parts. Tighten cap screws.
11. Inspect parts for wear or damage. Specification
Pump Assembly Cap
12. Install new Orings (M) and seals (Q and P).
ScrewsTorque......................................................... 271 Nm (200 lbft)
13. Apply clean hydraulic oil to all parts and petroleum
jelly on lip of seals.
TX,2160,BA920 1911OCT935/5
PN=487
Hydraulic System
T8071AV UN08SEP93
2. Drain hydraulic reservoir.
Specification
ReservoirApproximate
Capacity............................................................................ 41.5 L (11 gal)
T112878 UN20JAN98
(S.N. 803601 )
TX,2160,BA921 1911OCT931/3
X9811 UN23AUG88
and body from high pressure fluids.
If an accident occurs, see a doctor immediately.
Any fluid injected into the skin must be surgically
removed within a few hours or gangrene
may result. Doctors unfamiliar with this type
of injury should reference a knowledgeable
medical source. Such information is available
from Deere & Company Medical Department 5. Repair pump. (See procedure in this group.)
in Moline, Illinois, U.S.A.
6. Apply antiseize lubricant to splines on pump input
3. Disconnect lines (E and F). Use caps and plugs to shaft.
close all openings.
4. Remove cap screws (A) to remove pump (B).
Continued on next page TX,2160,BA921 1911OCT932/3
PN=488
Hydraulic System
T8071AV UN08SEP93
9. Fill reservoir with recommended hydraulic fluid. (See
Section 00, Group 0004.)
10. Install floor plates.
T112878 UN20JAN98
(S.N. 803601 )
TX,2160,BA921 1911OCT933/3
PN=489
Hydraulic System
T8071AW UN13SEP93
AVent F Washer (4 used) KGear Housing PSeal
BReducer Bushing GCap Screw (4 used) L Front Housing QSeal Retainer
CSquare Seal (2 used) HRear Housing MSeal RSeal Lip
DThrust Plate (2 used) I Gear/Shaft Set NORing
EChannel Seal (2 used) J Dowel Pin (4 used) ORetaining Ring
NOTE: For repair of shaft seals (M and P) only, 6. Inspect parts for wear or damage.
do steps 13.
NOTE: Pump parts (CE and HL) are not
1. Remove retaining ring (O) to remove seal retainer (Q). serviceable. If any of these parts are worn
or damaged, replace pump.
2. Remove seals (M and P).
3. Install seals: 7. Apply petroleum jelly to lip of seal lip (R).
a. Install seal (M) flush with face of recess in housing 8. Put a light coat of clean hydraulic oil on all internal
(L) and with lip (R) toward gear. parts.
b. Install seal (P) flush with counterbore in retainer 9. Assemble parts as shown. Tighten cap screws (G).
(Q) and with lip (R) away from gear. Specification
Pump Assembly Cap
4. Put a mark on housings (H, K and L) to aid in assembly.
ScrewsTorque......................................................... 271 Nm (200 lbft)
5. Remove parts. Mark gear/shaft set (I) and thrust
plates (D) to aid in assembly.
TX,2160,BA922 1911OCT931/1
PN=490
Hydraulic System
T6672AA UN07OCT93
6. Install filter.
7. Connect lines and wiring lead.
8. Install start aid solenoid (if necessary).
9. Start engine and check for leaks.
Specification
Filter Base
FittingsTorque............................................115 23 Nm (85 17 lbft) AOrifice (if equipped with DFiltertoHydraulic Oil
hydraulic oil cooler) Cooler Line
BFilter Restriction Switch ENut
Wiring Lead
CControl ValvetoFilter Line
TX,2160,BA923 1911OCT931/1
PN=491
Hydraulic System
T6675AN UN20OCT88
TX,2160,BA924 1911OCT931/1
PN=492
Hydraulic System
T6675AM UN20OCT88
2160,SS5 1911OCT931/1
X9811 UN23AUG88
all connections before applying pressure. Search
for leaks with a piece of cardboard. Protect hands
and body from high pressure fluids.
If an accident occurs, see a doctor immediately.
Any fluid injected into the skin must be surgically
removed within a few hours or gangrene
may result. Doctors unfamiliar with this type
of injury should reference a knowledgeable
medical source. Such information is available
from Deere & Company Medical Department
in Moline, Illinois, U.S.A.
Continued on next page TX,2160,BA926 1911OCT931/7
PN=493
Hydraulic System
T112880 UN20JAN98
Port of Hydraulic Reservoir SectiontoCylinder Head
(if equipped) End
MControl ValvetoOutlet T Control Valve Angle
Port of Pump SectiontoRight Cylinder
NControl Valve Blade Head End and Left Cylinder
SectiontoCylinder Rod Rod End
End UReservoirtoTop Port of
OControl Valve Tilt Hydraulic Oil Cooler (if
SectiontoCylinder Rod equipped) (S.N. 834561 ) Dozer Shown
End VTransmission Oil
PReservoirtoInlet Port of FiltertoPressure
Pump Regulating Valve
QControl Valve Blade WTransmission Oil
SectiontoCylinder Head FiltertoTransmission
End Pump
RControl Valve Angle XTransmission Oil
SectiontoRightCylinder FiltertoTransmission
Rod End and Left Cylinder Lube Circuit (TFitting on
Head End Control Valve) (Tfitting
located on transmission
filter on early machines.)
PN=494
Hydraulic System
T112879 UN20JAN98
to Cylinder Rod End FiltertoPressure
DControl Vale Boom Regulating Valve
SectiontoCylinder Head J Transmission Oil
End FiltertoTransmission
EControl Valve Bucket Pump
SectiontoCylinder Head KTransmission Oil
End FiltertoTransmission
F Control Valve Boom Lube Circuit (TFitting on
SectiontoCylinder Rod Control Valve) (Tfitting (S.N. 803601 ) Loader Shown
End located on transmission
filter on early machines.)
PN=495
Hydraulic System
T6942AK UN07OCT93
ACap Screw (3 used) BCap Screw (2 used) CNut (2 used) DNut (2 used)
PN=496
Hydraulic System
T6942AK UN07OCT93
8. Remove nuts (F), cover (E) and strainer (H). Replace
or repair as necessary.
9. Tighten nuts (F).
Specification
Reservoir CleanOut
Cover NutsTorque........................................ 2734 Nm (2025 lbft)
PN=497
Hydraulic System
T112880 UN20JAN98
SectiontoCylinder Rod Rod End
End UReservoirtoTop Port of
OControl Valve Tilt Hydraulic Oil Cooler (if
SectiontoCylinder Rod equipped)
End VTransmission Oil
PReservoirtoInlet Port of FiltertoPressure
Pump Regulating Valve
QControl Valve Blade WTransmission Oil
SectiontoCylinder Head FiltertoTransmission (S.N. 834561 ) Dozer Shown
End Pump
RControl Valve Angle XTransmission Oil
SectiontoRightCylinder FiltertoTransmission
Rod End and Left Cylinder Lube Circuit (TFitting on
Head End Control Valve) (Tfitting
located on transmission
filter on early machines.)
TX,2160,BA926 1911OCT936/7
TX,2160,BA926 1911OCT937/7
PN=498
Section 31
Loader
Contents
Page
Group 3102Bucket
Specifications ............................................ 3131021
Remove and Install Bucket Tooth
Shanks................................................... 3131021
Remove and Install Bucket Tooth
Tips ........................................................ 3131021
Remove and Install Loader
Bucket.................................................... 3131022
Repair Cracked Cutting Edge.................... 3131023
Replace Cutting Edge................................ 3131023
Group 3140Frames
Specifications ............................................ 3131401
Remove Loader Boom............................... 3131401
Install Loader Boom................................... 3131403
Group 3160Hydraulics
Other Material............................................ 3131601
Specifications ............................................ 3131602
Loader Hydraulic Component
Location ................................................. 3131603
Remove and Install Loader Control
Valve ...................................................... 3131604
Disassemble and Assemble Loader
Control Valve ......................................... 3131605
Disassemble and Assemble Bucket
Section................................................... 3131606
Disassemble and Assemble Boom
Section................................................... 3131609
Disassemble and Assemble
Auxiliary Section .................................. 31316012
Cross Section of System Relief
Valve .................................................... 31316013
Inspect System Relief Valve .................... 31316014
Inspect AntiCavitation Bucket
Circuit Relief Valve .............................. 31316014
Inspect Bucket and Boom Adjusting
Circuit Relief Valves............................. 31316015
Disassemble and Inspect Boom
and Bucket Cylinders........................... 31316015
Cross Section of Bucket and Boom
Cylinder ............................................... 31316018
Assemble Boom and Bucket
Cylinders.............................................. 31316018
Disassemble and Assemble Ripper
Cylinder ............................................... 31316024
PN=1
Contents
PN=2
Group 3102
Bucket
Specifications
Item Measurement Specification
T91397 UN27OCT88
2. Install tooth shanks.
Install cap screws to tooth shanks with cap screw
heads on bottom. Tighten cap screws.
Install cap screws to corner tooth shanks with cap
screw heads to outside. Tighten cap screws.
Specification
Corner Tooth Shank Cap
ScrewsTorque....................................................... 1070 Nm (790 lbft)
Tooth Shank Cap
ScrewsTorque......................................................... 620 Nm (458 lbft)
TX,31,RB411 1905FEB981/1
T91479 UN25MAY89
2. Drive new tooth tip on shank until pin can be installed
or until center of hole (A) in shank is centered to the
rear of slot in tooth tip.
3. Install pin from washer side of shank.
4. Pin should not contact front edge of tooth tip slot (B).
If it does, pin will fail under load. Try another tooth
tip or lengthen slot.
T6972BF UN30JAN89
PN=501
Bucket
T91480 UN25MAY89
hardware tight before welding.
TX,3102,BD855 1908SEP932/2
T6672AB UN27OCT88
3. Remove bucket.
4. Inspect bushings in boom and link arm replace if
necessary.
TX,3102,BD856 1908SEP931/2
T91399 UN27OCT88
5. Install bucket, shims and pins.
6. Install cap screws.
7. Lubricate all pivot points.
TX,3102,BD856 1908SEP932/2
PN=502
Bucket
Repair Cracked Cutting Edge 5. Fill the Vgrooves with weld. Use E7018 electrodes.
1. Clean the area to find end of crack. Extend the weld approximately 13 mm (0.5 in.) beyond
end of crack.
2. Drill a small hole at end of crack to prevent spreading.
Specification
3. Grind Vgrooves along crack on top and bottom of WeldApproximate
cutting edge. Distance......................................... 13 mm (0.5 in.) beyond end of crack
T6439AC UN18OCT88
1. Level bucket and lower onto stand. Remove teeth.
2. Tack weld or clamp a straightedge along weld.
IMPORTANT: Use a straightedge to avoid cutting into
bucket. This will minimize gaps during welding.
T6439AM UN18NOV89
PN=503
Bucket
T6439AD UN18OCT88
8. Use E7018 electrodes. Weld full length of cutting edge
with an 8 mm (0.315 in.) fillet weld.
Specification
Cutting EdgeLength.............................8 mm (0.315 in.) with fillet weld
3102,05 1908SEP933/4
T6439AE UN18OCT88
3102,05 1908SEP934/4
PN=504
Group 3115
Controls Linkage
Other Material
Number Name Use
PT569 (U.S.) John Deere NEVERSEEZ Lubricant Apply to bushing cap screw joint.
T43512 (U.S.) Thread Lock and Sealer (Medium Apply to all linkage hardware that
TY9473 (Canadian) Strength) do not have locking nuts.
242 (LOCTITE)
T8067AC 1903SEP93
ABall Joint CHex Nut EShim (as required)
BBushing DCap Screw (2 used)
1. Remove linkage assembly. 5. Apply thread lock and sealer (medium strength) to ball
2. Disassemble parts. joint (A), hex nut (C) and cap screws (D).
PN=505
Controls Linkage
PN=506
Group 3140
Frames
Specifications
Item Measurement Specification
T6676AD UN07OCT93
ABucket Cylinder (2 used) BPin (2 used) CLifting Strap DBoom Cylinder (2 used)
1. Lower all equipment to ground and stop engine. 6. Disconnect wire leads from returntodig switch.
2. Operate control valves to release pressure in hydraulic 7. Attach lifting strap (C) to boom cylinder (D).
system.
8. Remove pin (B) and lower cylinder using a hoist.
3. Remove bucket. (See procedure in Group 3102). Check seals for wear. Repeat procedure on other side.
4. Raise boom approximately 24inches above ground 9. Install a 3inch wooden block under cylinder (A) at
and support with blocks. head end of both cylinders.
5. With engine OFF, operate hydraulics to retract bucket
cylinder (A).
Continued on next page 3140,QQ1 1911OCT931/3
PN=507
Frames
CAUTION:
Escaping fluid under pressure can penetrate the
skin causing serious injury. Avoid the hazard
by relieving pressure before disconnecting
hydraulic or other lines. Tighten all connections
X9811 UN23AUG88
before applying pressure. Search for leaks
with a piece of cardboard. Protect hands and
body from high pressure fluids.
If an accident occurs, see a doctor immediately.
Any fluid injected into the skin must be surgically
removed within a few hours or gangrene
may result. Doctors unfamiliar with this type
of injury should reference a knowledgeable 10. Loosen hose clamps.
medical source. Such information is available
from Deere & Company Medical Department
in Moline, Illinois, U.S.A.
3140,QQ1 1911OCT932/3
T113213 UN03FEB98
AChain CLink (2 used) EHydraulic Line (Bucket GPin (2 used)
BChain DHydraulic Line (Bucket Cylinder Head End)
Cylinder Rod End) F Pin (2 used)
15. Remove pins (G) from loader boom. Check seals for 17. Inspect all bushings and pivot points for excess wear
wear. or damage. Replace as necessary.
3140,QQ1 1911OCT933/3
PN=508
Frames
T113213 UN03FEB98
AStrap CLink (2 used) EHydraulic Line (Bucket GPin (2 used)
BChain DHydraulic Line (Bucket Cylinder Head End)
Cylinder Rod End) F Pin (2 used)
1. Install seals with lip of seal facing out. 4. Connect hydraulic lines (D and E) to bucket cylinders.
2. Lubricate all pivot points. Tighten hose clamp cap screws.
Specification
3. Install loader boom, links (C), pins (F and G), and cap
Hose Clamp Cap
screws.
ScrewTorque............................................................. 130 Nm (96 lbft)
NOTE: Use shims (as required) between main frame
boss and boom to remove end play.
Continued on next page TX,31,RB412 1905FEB981/2
PN=509
Frames
T6942AL UN07OCT93
ABucket Cylinder (2 used) BPin (2 used) CLifting Strap DBoom Cylinder (2 used)
5. Connect rod end of boom cylinder (D) and install pin 6. Connect wiring lead to returntodig switch. Adjust
(B). returntodig switch (See procedure in Group 1674).
NOTE: The returntodig switch must be adjusted 7. Install bucket. (See procedure in Group 3102).
whenever switch is disconnected.
TX,31,RB412 1905FEB982/2
PN=510
Group 3160
Hydraulics
Other Material
Number Name Use
T43512 (U.S.) Thread Lock and Sealer (Medium To be applied to cylinder rod
TY9473 (Canadian) Strength) guide threads.
242 (LOCTITE)
T43513 (U.S.) Thread Lock and Sealer (High To be applied to threads of magnetic
TY9474 (Canadian) Strength) shell cap screw, spool end cap screw,
271 (LOCTITE) and shoulder cap screws.
PN=511
Hydraulics
Specifications
Item Measurement Specification
PN=512
Hydraulics
T112517 1905JAN98
AReservoir F Boom Section KOil Cooler PStabilizer Valve
BBreather GHydraulic Pump (Torque L Return Filter QBackhoe Control Valve
CAuxiliary Section Converter) MFrom Power Beyond Port RBackhoe System (if equipped)
DBucket Section HHydraulic Pump (Direct Drive) NDiverter Valve SLoader Hydraulic System
EPower Beyond Port I Bucket Cylinders OReturn To Loader Valve End T Transmission Filter (S.N.
J Boom Cylinders Cap 803601 )
TX,3160,BD869 1911OCT931/1
PN=513
Hydraulics
X9811 UN23AUG88
all connections before applying pressure. Search
for leaks with a piece of cardboard. Protect hands
and body from high pressure fluids.
If an accident occurs, see a doctor immediately.
Any fluid injected into the skin must be surgically
removed within a few hours or gangrene
may result. Doctors unfamiliar with this type
of injury should reference a knowledgeable
medical source. Such information is available
from Deere & Company Medical Department
in Moline, Illinois, U.S.A.
3160,SS1 1911OCT931/2
T6680AA UN18OCT88
3160,SS1 1911OCT932/2
PN=514
Hydraulics
1. Disassemble valve.
2. Inspect parts for wear or damage.
3. Replace Orings.
4. Assemble parts. Tighten nuts (H and I).
Specification
Loader Control
Valve Tie Rod Nuts
(7/16)Torque............................................................... 65 Nm (48 lbft)
Loader Control Valve Tie
Rod Nuts (1/2)Torque............................................... 100 Nm (74 lbft)
T6680AB UN18OCT88
with anticavitation (L), place wrench on nut (N).
6. If removing circuit reliefs (E and G) place wrench on
nut (O).
T6680BA UN18OCT88
T6680BB UN18OCT88
3160,SS2 1911OCT931/1
PN=515
Hydraulics
T6680BC UN18OCT88
IMPORTANT: Keep valve section components
together as a matched set.
T6680BD UN18OCT88
cap screw (30). Tighten cap screw.
Specification
Spool CaptoMagnetic
Shell Cap Screw
(Bucket)Torque........................................................... 7 Nm (60 lbin.)
PN=516
Hydraulics
T6680BE UN18OCT88
9. Install spring seat (D) and spool end screw (G).
Tighten spool end screw finger tight.
10. Compress cam detent and spring using a punch to
seat balls. Slide spring seat down to hold balls in
place.
11. Remove spool end screw (G).
T6680BF UN18OCT88
3160,BB2 1911OCT932/4
T6680BG UN18OCT88
End Screw
(Bucket)Torque............................................ 2027 Nm (1520 lbft)
PN=517
Hydraulics
T6680BH UN18OCT88
toSpool End Screw
(Bucket)Torque.............................................911 Nm (8496 lbin.)
Spool CaptoValve
Section Cap Screw
(Bucket)Torque......................................... 16 2 Nm (144 18 lbin.)
Seal PlatetoValve
Section Cap Screw
(Bucket)Torque......................................... 16 2 Nm (144 18 lbin.)
16. Install spool cap (N). ACap Screw (2 used) HCap Screw (2 used)
BSpacer (2 used) I Seal Plate
CShoulder Cap Screw J Spacer (2 used)
DClapper KWiper Seal
ELift Check L Spool Spacer Cap
F Spring MSpool Assembly
GORing NSpool Cap
3160,BB2 1911OCT934/4
PN=518
Hydraulics
T6680BI UN18OCT88
1 Cam Detent 8 ORing 15 Cap Screw (2 used) 22 Spring Seat
2 Spring 9 Backup Ring 16 Seal Plate 23 Spool End Screw
3 Ball (4 used) 10 Poppet 17 Wiper Seal 24 Spool Cap
4 Spool 11 Spring 18 Oring (2 used) 25 ORing
5 AntiCavitation Plug 12 Lift Check 19 Valve Section 26 Detent Sleeve
6 ORing 13 ORing 20 Detent Spring Seal 27 Cap Screw (2 used)
7 Spring 14 Adjusting Circuit Relief 21 Spring
PN=519
Hydraulics
T6680BJ UN18OCT88
7. Install balls (C) using petroleum jelly (one ball per
hole) in spool.
8. Install detent spring seat (F).
9. Compress cam detent and spring using a punch to
seat balls. Side detent spring seat down to hold balls
in place.
T6680BV UN18OCT88
3160,BB3 1911OCT932/4
T6680BW UN18OCT88
ScrewTorque.................................................911 Nm (8496 lbin.)
PN=520
Hydraulics
T6680BX UN18OCT88
ScrewTorque................................................ 7 0.7 Nm (60 6 lbin.)
AntiCavitation
PlugTorque................................................. 81108 Nm (6080 lbft)
Seal PlatetoValve
Section Cap Screws
(Bucket)Torque......................................... 16 2 Nm (144 18 lbin.)
3160,BB3 1911OCT934/4
PN=521
Hydraulics
T8067AD UN09SEP93
ACircuit Relief (2 used) EWiper Seal (2 used) I Spool End Screw MFilter
BCap Screw (2 used) F ORing (2 used) J Spring
CSpool GCap Screw (2 used) KSpool Cap
DSeal Plate (2 used) HSpring Seat Retainer (2 used) L Spool Housing
PN=522
Hydraulics
T7050AM UN25APR89
System Relief Valve
APiston GSpring MORing SCap
BRelief Valve Poppet HBackup Ring (2 used) NHousing T ORing
CBackup Ring I ORing ONut UBackup Ring
DORing J Poppet PShims (as required)
EORing KSpring QPiston
F AntiCavitation Valve Poppet L Housing RORing
TX,3160,QQ485 1930JUL901/1
PN=523
Hydraulics
T6683AC UN18OCT88
1. Scribe a line on adjusting cap (I) and pilot body (D).
Loosen lock nut and count the number of turns to
remove adjusting cap (I).
2. Disassemble system relief valve.
3. Check relief valve parts for wear, plugged ports or
damaged Orings. Replace complete relief valve
assembly if any part is worn or damaged.
IMPORTANT: Pilot poppet (E) must be free ABackup Ring (2 used) KSpring
of contaminates, nicks or damage for BORing L Poppet (Orificed)
CORing MSpool
valve to work properly. DPilot Body NORing
EPilot Poppet OBackup Ring
Orifice of poppet (L) must be free of obstructions. F Spring PPoppet Sleeve
GShim (as required) QBackup Ring
4. Assemble valve. Install adjusting screw the same HSpool RORing
number of turns as removed. Tighten lock nut. I Cap SRelief Valve Body
J ORing T ORing
Specification
System Relief Valve Lock
NutTorque.................................................. 61 6 Nm (45 4.5 lbin.)
T8068AA UN08SEP93
1. Scribe a line on adjusting cap (I) and pilot body (D).
Loosen lock nut and count the number of turns to
remove adjusting cap (I).
2. Disassemble bucket circuit relief valve.
3. Check relief valve parts for wear, plugged ports or
damaged Orings. Replace complete relief valve
assembly if any part is worn or damaged. ABackup Ring (2 used) KSpring
BORing L Spring
IMPORTANT: Pilot poppet (E) must be free CORing MPoppet
of contaminates, nicks or damage for DPilot Body NSpool
valve to work properly. EPilot Poppet OORing
F Spring PBackup Ring
Passage in poppet (M) must be free GShim (as required) QPoppet Sleeve
of obstructions. HSpool RRelief Valve Body
I Cap SORing
J ORing
4. Assembly valve. Install adjusting screw the same
number of turns as removed. Tighten lock nut.
Specification
Circuit Relief Valve Lock
5. Check valve pressure setting after installation. (See
NutTorque.................................................. 61 6 Nm (45 4.5 lbin.)
Group 902525 in TM1403.)
TX,3160,BD864 1908SEP931/1
PN=524
Hydraulics
T6683AE UN18OCT88
Bucket and boom circuit reliefs are similar.
Bucket circuit relief shown.
T6190AS UN19OCT88
making disassembly more difficult.
TX,31,RB290 1927JAN981/7
PN=525
Hydraulics
T6119AM UN12APR91
Remove snap ring. Do not damage rod guide threads
or seal.
TX,31,RB290 1927JAN983/7
T6119AN UN19OCT88
TX,31,RB290 1927JAN984/7
T6172BQ UN19OCT88
PN=526
Hydraulics
T6119AK UN19OCT88
CORing GSeal
DBackup Ring
TX,31,RB290 1927JAN986/7
T6119AO UN19OCT88
TX,31,RB290 1927JAN987/7
PN=527
Hydraulics
T6223AZ UN26MAY89
ANut F Rod KSnap Ring PSeal Expander
BPiston GWiper Seal L Backup Ring QWear Ring
CBarrel HWear Ring MORing
DNut I Rod Seal NBackup Ring (2 used)
ERod Guide J Buffer Seal OCap Seal
TX,3160,BR302 1924OCT941/1
PN=528
Hydraulics
T6126AN UN27OCT88
TX,3160,BD917 1914JUN112/11
T6122AB UN19OCT88
PN=529
Hydraulics
T6122AC UN06AUG90
possible to keep the amount of time that seal
is stretched to a minimum.
T6122AE UN19OCT88
TX,3160,BD917 1914JUN114/11
10. Install backup rings (A) with radius (B) toward seal
expander (D).
11. Check if cap seal (C) is loose seal must fit tight
against seal expander and not turn. If seal can be
turned, it has been stretched too much and can be
damaged during assembly into barrel.
PN=530
Hydraulics
T86565 UN09NOV88
TX,3160,BD917 1914JUN116/11
T6122AF UN19OCT88
PN=531
Hydraulics
14. Install nut, snap ring, rod guide and piston assembly
on rod.
15. Install nut. Tighten nut to initial torque specification.
Specification
455G Boom
CylinderSize..................................................................... 100 x 50 mm
Weight ................................................................................53 kg (116 lb)
Snug Torque .............................................................. 340 Nm (250 lbft)
555G Boom
CylinderSize......................................................................115 x 63 mm
Weight ............................................................................... 73 kg (162 lb)
Snug Torque .............................................................. 600 Nm (442 lbft)
455G Bucket
CylinderSize....................................................................... 90 x 50 mm
Weight ................................................................................. 40 kg (88 lb)
Snug Torque .............................................................. 130 Nm (100 lbft)
555G Bucket
CylinderSize..................................................................... 100 x 50 mm
T6684AC UN19OCT88
Weight ................................................................................50 kg (110 lb)
Snug Torque .............................................................. 340 Nm (250 lbft)
20. Carefully push piston and rod guide into barrel. Keep
piston and rod guide together.
PN=532
Hydraulics
21. Push rod guide into barrel just enough to install snap
ring. Install snap ring.
22. Pull rod guide against snap ring.
23. Apply a light film of oil to ID of barrel at void between
rod guide and spanner nut to help minimize rust.
T6133AE UN27OCT88
24. Place filler ring between rod guide and spanner nut.
TX,3160,BD917 1914JUN1110/11
25. Clean spanner nut and rod guide threads using clean
and cure primer.
Apply thread lock and sealer (medium strength) to
threads.
26. Install nut and tighten nut until rod guide and nut
T6119AR UN27OCT88
marks, made before disassembly, align. Be sure nut
is tight.
TX,3160,BD917 1914JUN1111/11
PN=533
Hydraulics
T6693AR UN19OCT88
ABushing (2 used) F Retainer KBackup Washer PSnap Ring
BGrease Fitting GVPacking L Snap Ring QWiper Seal
CBarrel HORing MVPacking RSpanner Nut
DLock Nut I Piston NWear Ring SRod
EWear Ring J ORing ORod Guide T Bushing
PN=534
Section 32
Bulldozer
Contents
Page
Group 3201Blades
Other Material............................................ 3232011
Specifications ............................................ 3232011
Remove and Install Dozer Blade
(S.N. 785733)..................................... 3232012
Remove and Install Dozer Blade
(S.N. 785734 ).................................... 3232014
Remove and Install Cutting Edges
and End Bits .......................................... 3232015
Group 3240Frames
Service Equipment and Tools .................... 3232401
Remove and Install Dozer
CFrame ................................................ 3232401
Disassemble and Assemble Blade
Pitch Strut .............................................. 3232405
PN=1
Contents
PN=2
Group 3201
Blades
Other Material
Number Name Use
PT569 (U.S.) NEVERSEEZ Lubricant Apply to blade pin (S.N. 785734).
T43513 (U.S.) Thread Lock and Sealer (High To be applied to threads of pitch
TY9474 (Canadian) Strength) pin retaining cap screw.
271 (LOCTITE)
Specifications
Item Measurement Specification
PN=537
Blades
T6675AP UN07OCT93
PN=538
Blades
PN=539
Blades
T8068AB UN09SEP93
PN=540
Blades
T6676AL UN07OCT93
PN=541
Blades
PN=542
Group 3215
Controls Linkage
Other Material
Number Name Use
T43513 (U.S.) Thread Lock and Sealer (High To be applied to all linkage hardware
TY9474 (Canadian) Strength) that do not have locking nuts.
271 (LOCTITE)
T43512 (U.S.) Thread Lock and Sealer (Medium To be applied to ball joint threads.
TY9473 (Canadian) Strength)
242 (LOCTITE)
T8061AA UN08SEP93
NOTE: Auxiliary lever (B) is used when an auxiliary 4. Apply high strength thread lock sealer to threads of
hydraulic function is required. ball joint (A).
1. Remove linkage assembly. 5. Assemble parts.
2. Disassemble parts.
3. Inspect linkage for worn or damaged parts. Replace
as necessary.
TX,3215,BA907 1911OCT931/1
PN=543
Controls Linkage
T7269BI UN12APR90
PN=544
Controls Linkage
NOTE: Auxiliary lever (D) is used when an auxiliary 3. Apply medium strength thread lock and sealer to
hydraulic function is required. threads of ball joints (A and B) and nut (C).
1. Remove linkage assembly. 4. Assemble parts.
2. Disassemble and inspect parts for wear or damage.
Replace as necessary.
TX,3215,QQ493 1909AUG902/2
T6679AA UN20OCT88
NOTE: Auxiliary lever (C) is used when an auxiliary IMPORTANT: Overtightening nut (A) will cause
hydraulic function is required. linkage to stay in one position and not
move freely to other functions.
1. Remove linkage assembly as shown.
2. Inspect linkage for worn or damaged parts. Replace 4. Tighten nut (A).
as necessary. 5. Assemble parts.
3. Apply thread lock and sealer (high strength) to threads
of ball joint (B).
TX,3215,QQ496 1911OCT931/1
PN=545
Controls Linkage
T112881 UN20JAN98
PN=546
Controls Linkage
NOTE: Auxiliary lever (D) is used when an auxiliary 3. Apply medium strength thread lock and sealer to
function is required. threads of ball joints (A and B) and nut (C) when used.
1. Remove linkage assembly. 4. Assemble parts.
2. Disassemble and inspect parts for wear or damage.
Replace as necessary.
TX,3215,QQ495 1909AUG902/2
PN=547
Controls Linkage
PN=548
Group 3240
Frames
Service Equipment and Tools Tool Catalog (MTC). Some tools may be
available from a local supplier.
NOTE: Order tools from the U.S. SERVICEGARD
Catalog or from the European Microfiche
Puller Set
Used to remove Cframe mounting pins.
3240,QQ2 1914JUN112/3
Disks
Used to remove and install bushings.
3240,QQ2 1914JUN113/3
X9811 UN23AUG88
all connections before applying pressure. Search
for leaks with a piece of cardboard. Protect hands
and body from high pressure fluids.
If an accident occurs, see a doctor immediately.
Any fluid injected into the skin must be surgically
removed within a few hours or gangrene
may result. Doctors unfamiliar with this type
of injury should reference a knowledgeable
medical source. Such information is available Machines (S.N. 790251834650) use two
from Deere & Company Medical Department hoses which are coupled together to aid
in Moline, Illinois, U.S.A. in Cframe removal.
Machines (S.N. 834651) have bulkhead
NOTE: Cframe can be removed with blade attached.
connectors on the front grille to aid in
Cframe removal.
1. Lower all equipment to ground.
2. Stop engine. Operate all control valves to release 4. Machines (S.N. 790250):
pressure in hydraulic system.
Remove shields.
3. If desired, remove dozer blade. (See Group 3201.) Tag and disconnect hoses on angle and tilt cylinders.
Use caps and plugs to close all openings.
NOTE: Machines (S.N. 790250) have one hose
from control valve or crossover tube to tilt
and angle cylinders.
Continued on next page TX,3240,BA908 1911OCT931/6
PN=549
Frames
AHoses CCover
BClamp DClamp
T112892 UN20JAN98
(S.N. 790251834650)
TX,3240,BA908 1911OCT932/6
T112883 UN20JAN98
Continued on next page TX,3240,BA908 1911OCT933/6
PN=550
Frames
T8073AB UN13SEP93
Legend for Dozer CFrame
APin (2 used) CBushing (4 used) ECap Screw (2 used)
BLifting Chain DPin (2 used)
7. Attach lifting chain (B) to Cframe. 12. Remove and install bushings (C) using disks from
NOTE: Early style Cframe shown. Later style is similar. driver set.
13. Install Cframe using pins and cap screws.
NOTE: Cframe can be removed with blade attached.
14. Install lift cylinders using pins and cap screws.
8. Remove cap screws and pins (A).
15. Install new Orings and connect hydraulic lines.
9. Remove cap screws (E) and pins (D)
16. Machines (S.N. 790250):
10. Use a hoist to remove Cframe from unit.
Install shields.
11. Inspect all parts and replace as necessary.
Continued on next page TX,3240,BA908 1911OCT934/6
PN=551
Frames
T112892 UN20JAN98
(S.N. 790251834650)
TX,3240,BA908 1911OCT935/6
T112883 UN20JAN98
operation.
ACable CHoses
BClamp DShield
(S.N. 834651 )
TX,3240,BA908 1911OCT936/6
PN=552
Frames
T6690AC UN07OCT93
3240,QQ7 1911OCT931/1
PN=553
Frames
PN=554
Group 3260
Hydraulic System
Specifications
Item Measurement Specification
PN=555
Hydraulic System
T8037BF 1923JUL93
(S.N. 834560)
AReservoir F Blade Lift Section KAngle Cylinders PStabilizer Valve
BReturn Filter GPower Beyond Port L Oil Cooler (if equipped) QBackhoe Control Valve
CAuxiliary Section HHydraulic Pump (Torque MTilt Cylinder RTo Return Filter Inlet
DAngle Section Converter) NBreather SBackhoe System (if equipped)
ETilt Section I Hydraulic Pump (Direct Drive) OFrom Power Beyond Port T Dozer Hydraulic System (S.N.
J Blade Lift Cylinders 834560)
TX,32,RB291 1927JAN981/1
PN=556
Hydraulic System
T112518 1909JAN98
(S.N. 834561 )
AReservoir F Blade Lift Section KAngle Cylinders PStabilizer Valve
BReturn Filter GPower Beyond Port L Oil Cooler (if equipped) QBackhoe Control Valve
CAuxiliary Section HHydraulic Pump (Torque MTilt Cylinder RTo Return Filter Inlet
DAngle Section Converter) NBreather SBackhoe System (if equipped)
ETilt Section I Hydraulic Pump (Direct Drive) OFrom Power Beyond Port T Dozer Hydraulic System (S.N.
J Blade Lift Cylinders 834561 )
TX,3260,BA910 1930AUG931/1
PN=557
Hydraulic System
T6685AG UN18OCT88
3. Remove valve mounting plate (E) with valve.
Specification
Mounting PlateWeight....................................................... 27 kg (60 lb)
T112884 UN20JAN98
Line Cylinder Head End Line
BTilt SectiontoCylinder HTilt SectiontoCylinder
Rod End Line Head End Line
CBlade Raise/Lower I Blade Raise/Lower
SectiontoCylinder Head SectiontoCylinder Rod
End Line End Line
DControl ValvetoPump J Control ValvetoReturn
Outlet Port Line Filter Line
EValve Mounting Plate (S.N. 834561 )
TX,3260,BA911 1930AUG932/2
T6685AH UN18OCT88
section together as a set.
1. Disassemble valve.
2. Inspect parts for wear or damage.
3. Replace Orings (E) in each section.
4. Assemble parts. Tighten nuts (C).
Specification AEnd Plate F System Relief Valve
BCap Screw (3 used) GInlet and Outlet Port Plate
Dozer Control Valve Tie CNut (3 used) HBlade Raise Section
Bolt NutsTorque.......................................................... 43 Nm (32 lbft) DLift Checks I Tilt Section
EORings J Angle Section
3260,SS3 1911OCT931/1
PN=558
Hydraulic System
T6033AE UN03NOV88
3. Install relief valve.
3260,SS4 1926JAN881/1
T6024AL UN03NOV88
ALift Check Poppet EORing
BSpring F Backup Ring
CORing GBackup Ring (2 used)
DORing
3260,SS5 1926JAN881/1
PN=559
Hydraulic System
T6685AM UN18OCT88
ACap Screw (2 used) EWasher (2 used) I Orifice (2 or 4 used) Angle MSpring Retainer (2 used)
BSeal Retainer Plate F Washer (2 used) and Tilt Sections Only NSpring
CWiper Seal Retainer GORing (2 used) J Cap Screw (2 used) OSpool
DWiper Seal HSpring (2 or 4 used) Angle Tilt KCap PValve Section
Sections Only L Spool End Screw
PN=560
Hydraulic System
T6685AL UN18OCT88
ACap Screw (2 used) GORing MSpring Retainer (2 used) SDetent Cone
BSeal Retainer Plate HValve Section NSpring T Spring
CWiper Seal Retainer I Cap Screw (2 used) ODetent Collar UBall (4 used)
DWiper Seal J Lock Washer (2 used) PORing VSpool
EWasher KEnd Cap QORing
F Washer L Snap Ring RSpacer
PN=561
Hydraulic System
T6023AP UN03NOV88
8. Put petroleum jelly on detent balls (J) and install in
holes in spool.
9. Carefully slide detent collar (D) over balls while holding
detent cone (K) and spring (I) in spool using a punch.
T6023AQ UN03NOV88
3260,SS7 1911OCT932/5
T6023AR UN03NOV88
PN=562
Hydraulic System
T6023AK UN03NOV88
3260,SS7 1911OCT934/5
T6685AI UN18OCT88
DWasher
3260,SS7 1911OCT935/5
PN=563
Hydraulic System
Repair Cylinders
1. Remove snap rings (A).
2. Use disks from driver set to remove and install bushing
(B or C).
T8068AE UN09SEP93
NOTE: Tilt and angle cylinders use selfaligning bushing
(B). Lift cylinders use bushing (C).
PN=564
Section 33
Backhoe
Contents
Page Page
PN=1
Contents
PN=2
Group 3300
Removal and Installation
Remove Backhoe Assembly
1. Park unit on level surface. Lower equipment as shown.
T6662AA UN08NOV88
T54,3300,J75 1917SEP871/4
T6662AB UN08NOV88
weight from upper mounting pins.
NOTE: Early style backhoe uses cotter pins (C) to secure
pins (B) later style uses quick lock pins.
PN=567
Removal and Installation
T6662AC UN08NOV88
T54,3300,J75 1917SEP873/4
T6662AD UN08NOV88
T54,3300,J75 1917SEP874/4
PN=568
Removal and Installation
T6662AC UN08NOV88
T54,3300,J79 1911OCT931/2
5. Install pin (B) and cotter pin (C) (or quick lock pin, if
equipped) on both sides. Remove lock pin (A).
T6662AB UN08NOV88
T54,3300,J79 1911OCT932/2
PN=569
Removal and Installation
PN=570
Group 3302
Buckets
Service Equipment and Tools Tool Catalog (MTC). Some tools may be
available from a local supplier.
NOTE: Order tools from the U.S. SERVICEGARD
Catalog or from the European Microfiche
31 mm 49 mm Disk 37 mm 55 mm Disk
Used to install ripper bushings. Used to install 457 mm, 610 mm, 762 mm, 914 mm
37 mm 55 mm Disk 18 in. and 24 in. bucket bushings.
31 mm 49 mm Disk
Used to install ripper bushings.
31 mm 43 mm Disk Used to install heavyduty bucket bushings.
37 mm 55 mm Disk
Used to install 406 mm (16 in.) Bucket Bushings.
37 mm 49 mm Disk Used to install heavyduty bucket bushings.
31 mm 43 mm Disk
Used to install 406 mm (16 in.) Bucket Bushings.
31 mm 49 mm Disk Used to install cemetery bucket bushings.
37 mm 49 mm Disk
Used to install 457 mm, 610 mm, 762 mm, 914 mm
18 in. and 24 in. bucket bushings. Used to install cemetery bucket bushings.
T54,3302,J62 1914JUN112/2
T93210 UN01NOV88
pins (A) later style uses snap rings.
PN=571
Buckets
T92506 UN25MAY89
TX,3302,BA972 1916SEP931/1
T92509 UN31OCT88
T92510 UN31OCT88
PN=572
Buckets
T92511 UN31OCT88
T54,3302,21 1920MAY832/5
T92512 UN25MAY89
T54,3302,21 1920MAY833/5
T92513 UN31OCT88
Leave 19 mm 3 mm (0.75 0.12 in.) on the front of
the cutting edge free of weld.
PN=573
Buckets
T92514 UN31OCT88
T54,3302,21 1920MAY835/5
T92515 UN31OCT88
T92516 UN31OCT88
PN=574
Buckets
T92517 UN31OCT88
T54,3302,26 1920MAY832/5
T92518 UN31OCT88
PN=575
Buckets
T92519 UN31OCT88
T54,3302,26 1920MAY834/5
T92520 UN31OCT88
T54,3302,26 1920MAY835/5
PN=576
Group 3315
Controls Linkage
Specifications
Item Measurement Specification
5. Install cover.
T6668AB UN31OCT88
T54,3315,K1 1901AUG901/1
T54,3315,K2 1928SEP871/1
PN=577
Controls Linkage
PN=578
Group 3340
Frames
Service Equipment and Tools Tool Catalog (MTC). Some tools may be
available from a local supplier.
NOTE: Order tools from the U.S. SERVICEGARD
Catalog or from the European Microfiche
64 mm and 74 mm Disks
Used to install boom bushings.
Used to install swing frame to main frame bushings. 38 mm and 50 mm Disks
38 mm and 54 mm Disks
Used to install dipperstick to bucket links bushings.
Used to install swing frame to boom bushings. 38 mm and 55 mm Disks
54 mm and 64 mm Disks
Used to install dipperstick to bucket bushings.
T54,3340,K1 1914JUN112/2
Other Material
Number Name Use
TY15969 (U.S.) Retaining Compound (Maximum Applied to new bushings.
TY9479 (Canadian) Strength)
680 (LOCTITE)
Specifications
Item Measurement Specification
PN=579
Frames
X9811 UN23AUG88
all connections before applying pressure. Search
for leaks with a piece of cardboard. Protect hands
and body from high pressure fluids.
If an accident occurs, see a doctor immediately.
Any fluid injected into the skin must be surgically
removed within a few hours or gangrene
may result. Doctors unfamiliar with this type
of injury should reference a knowledgeable
medical source. Such information is available NOTE: If bucket linkage is removed, put a chain around
from Deere & Company Medical Department cylinder rod. Use a rag to protect rod.
in Moline, Illinois, U.S.A.
3. Relieve pressure in the hydraulic system. Disconnect
1. Remove bucket. (See procedure in Group 3302.) both bucket cylinder hydraulic lines. Close all openings
using caps and plugs.
2. Install a floor stand under boom. Put a wooden block
under crowd cylinder.
T54,3340,K3 1911OCT931/5
T6124AQ1 UN31OCT88
Specification
Dipperstick (With Bucket
Cylinder)Weight............................................................ 204 kg (450 lb)
T54,3340,K3 1911OCT932/5
PN=580
Frames
T6124AT UN31OCT88
T54,3340,K3 1911OCT934/5
T6124AU UN31OCT88
T54,3340,K3 1911OCT935/5
PN=581
Frames
T6669BA UN31OCT88
Continued on next page T54,3340,K7 1928SEP871/3
PN=582
Frames
T6669BB UN31OCT88
Continued on next page T54,3340,K7 1928SEP872/3
PN=583
Frames
T6130AG UN25MAY89
T54,3340,K7 1928SEP873/3
PN=584
Frames
T6669BC UN31OCT88
7. Install swing frame, thrust washer (E), pins (A and D)
and cap screws (B and C).
8. Install boom and dipperstick. (See procedure in this
group.)
T54,3340,K10 1911OCT931/1
T93378 UN01NOV88
4. Remove stabilizer.
5. Install stabilizer and mounting pin using cap screw
and locknut.
T54,3340,K11 1920OCT871/1
PN=585
Frames
T6679AC UN31OCT88
T54,3340,K12 1911OCT931/1
PN=586
Group 3360
Hydraulic System
Other Material
Number Name Use
TY16285 (U.S.) Cure Primer Applied to clean threads of
TY9485 (Canadian) spanner nut.
7649 (LOCTITE)
T43512 (U.S.) Thread Lock and Sealer (Medium Applied to spanner nut threads.
TY9473 (Canadian) Strength)
242 (LOCTITE)
PN=587
Hydraulic System
Specifications
Item Measurement Specification
PN=588
Hydraulic System
T6190AS UN19OCT88
making disassembly more difficult.
T6119AL UN19OCT88
cylinder in a vise. Vise jaws must contact cylinder
barrel behind nut and over rod guide area. Tighten
vise just enough to hold rod guide.
TX,3360,BR412 1924OCT942/8
T6119AM UN12APR91
snap ring. Do not damage rod guide threads or seals.
PN=589
Hydraulic System
T6119AN UN19OCT88
Continued on next page TX,3360,BR412 1924OCT944/8
PN=590
Hydraulic System
T6172BQ UN19OCT88
necessary
Remove wear ring, cap seal assembly and brake
seal ring. Remove piston assembly from rod, if
necessary.
T8079AD UN23SEP93
Boom Cylinder9310G
T7535AB UN16MAY91
PN=591
Hydraulic System
T7976AW UN14APR93
ANut DCap Seal Assembly
BBrake Seal Ring (2 used) EPiston
CWear Ring
T8079AF UN23SEP93
ACap Screw DBrake Seal Ring
BWear Ring EPiston
CCap Seal Assembly
Crowd Cylinder9310G
Continued on next page TX,3360,BR412 1924OCT946/8
PN=592
Hydraulic System
T6119AK UN19OCT88
CORing GSeal
DBackup Ring
T7545BS UN19JUN91
Swing Cylinder Only
TX,3360,BR412 1924OCT947/8
T6119AO UN19OCT88
TX,3360,BR412 1924OCT948/8
PN=593
Hydraulic System
T6223AZ UN26MAY89
ANut F Rod KSnap Ring PSeal Expander
BPiston GWiper Seal L Backup Ring QWear Ring
CBarrel HWear Ring MORing
DSpanner Nut I Rod Seal NBackup Ring (2 used)
ERod Guide J Buffer Seal OCap Seal Assembly
TX,3360,BA944 1916SEP931/1
PN=594
Hydraulic System
T8079AK UN23SEP93
ASpecial Lock Nut F Rod KFiller Ring PBackup Ring (2 used)
BPiston GWiper Seal L Snap Ring QCap Seal
CBarrel HWear Ring MBackup Ring RSeal Expander
DSpanner Nut I Rod Seal NORing SWear Ring
ERod Guide J Buffer Seal OBrake Seal Ring (2 used)
TX,3360,BA960 1916SEP931/1
PN=595
Hydraulic System
T6223BA UN26MAY89
ANut F Rod Guide KBuffer Seal PCap Seal
BWasher GRod L Snap Ring QExpander Seal
CPiston HWiper Seal MBackup Ring RWear Ring
DBarrel I Wear Ring NORing
ENut J Rod Seal OBackup Ring (2 used)
TX,3360,BA956 1916SEP931/1
PN=596
Hydraulic System
T6717BJ UN19OCT88
ANut F Buffer Seal KBackup Ring PSeal Expander
BWasher GRod Seal L ORing QWear Ring
CBarrel HWear Ring MBrake Seal Ring
DNut I Wiper Seal NBackup Ring (2 used)
ERod Guide J Snap Ring OCap Seal Assembly
TX,3360,BA957 1916SEP931/1
PN=597
Hydraulic System
T6223BA UN26MAY89
ANut F Rod Guide KBuffer Seal PCap Seal
BWasher GRod L Snap Ring QExpander Seal
CPiston HWiper Seal MBackup Ring RWear Ring
DBarrel I Wear Ring NORing
ENut J Rod Seal OBackup Ring (2 used)
TX,3360,BA958 1916SEP931/1
PN=598
Hydraulic System
T6223BC UN26MAY89
ANut F Rod KSnap Ring PExpander Seal
BPiston GWiper Seal L Backup Ring QWear Ring
CBarrel HWear Ring MORing RBrake Seal Ring
DSpanner Nut I Rod Seal NBackup Ring (2 used)
ERod Guide J Buffer Seal OCap Seal
TX,3360,BA959 1916SEP931/1
PN=599
Hydraulic System
T6119AK UN19OCT88
3. Install wear ring (F).
4. Install backup ring (D) and Oring (C).
T7545BS UN19JUN91
Swing Cylinder Only
TX,3360,BA961 1911OCT931/12
T6122AB UN19OCT88
PN=600
Hydraulic System
T6122AC UN06AUG90
possible to keep the amount of time that seal
is stretched to a minimum.
T6122AE UN19OCT88
TX,3360,BA961 1911OCT933/12
10. Install backup rings (A) with radius (B) toward seal
expander (D).
T6126AO UN19OCT88
PN=601
Hydraulic System
11. Check if cap seal is loose seal must fit tight against
seal expander and not turn. If seal can be turned, it
has been stretched too much and can be damaged
during assembly into barrel.
12. If necessary, shrink cap seal to its original size using
a ring compressor or a plastic tie band (A) and hose
clamp (C).
When using a ring compressor, put a piece of shim
stock between cap seal and compressor at the joint so
it does not damage seal.
When using a plastic tie band and hose clamp, grind
a taper (B) on one end of tie band. Install tie band
with the taper against cap seal. Before tightening the
hose clamp, tie band must be under hose clamp all
around piston.
T86565 UN09NOV88
TX,3360,BA961 1911OCT935/12
T6213BP UN11APR90
on each end of piston. (See Cross Section of
Boom Cylinder9310G, this group.)
14. Install brake seal ring or rings (B) with "UP" mark
toward the head end of cylinder.
PN=602
Hydraulic System
15. Install spanner nut, snap ring, rod guide and piston
assembly on rod.
NOTE: Steps 1619 apply to swing, boom and
bucket cylinders, only. For crowd and stabilizer
cylinders, go to step 20.
T6172BP UN19OCT88
16. Install piston retaining nut. Tighten nut to snug torque
specification.
Specification
Bucket Cylin
der9300GSize................................................................ 80 x 45 mm
Weight ............................................................................... 57 kg (125 lb)
Snug Torque .................................................................. 95 Nm (70 lbft)
Bucket Cylin
Boom Cylin
der9310GSize................................................................ 90 x 50 mm
der9310GSize...............................................................115 x 56 mm
Weight ............................................................................. 101 kg (223 lb)
Weight ............................................................................... 87 kg (192 lb)
Snug Torque .................................................................. 95 Nm (70 lbft)
Snug Torque .............................................................. 340 Nm (250 lbft)
Swing CylinderSize.......................................................... 100 x 50 mm
Weight ................................................................................. 32 kg (70 lb)
Snug Torque .............................................................. 476 Nm (350 lbft)
Boom Cylin
der9300GSize.............................................................. 100 x 50 mm
Weight ............................................................................... 56 kg (124 lb)
Snug Torque .............................................................. 340 Nm (250 lbft)
TX,3360,BA961 1911OCT937/12
T6149AG UN19OCT88
Continued on next page TX,3360,BA961 1911OCT938/12
PN=603
Hydraulic System
18. Put a piece of wire on the rod, over the piston, to point
to one of the marks.
19. Tighten to final torque specification.
Specification
Swing CylinderTorque
T6172BR UN19OCT88
Turn.................................................................................. 1/12 Turn (30)
Boom Cylin
der9300GTorque
Turn.................................................................................. 1/12 Turn (30)
Boom Cylin
der9310GTorque
Turn.................................................................................. 1/12 Turn (30)
Bucket Cylin
der9300GTorque
Crowd Cylin
Turn.................................................................................. 1/12 Turn (30)
der9300GSize................................................................ 90 x 50 mm
Bucket Cylin
Weight ............................................................................... 47 kg (103 lb)
der9310GTorque
Cap Screw Torque ..................................... 913 46 Nm (673 34 lbft)
Turn.................................................................................. 1/12 Turn (30)
Crowd Cylin
20. Install piston retaining cap screw (crowd or stabilizer der9310GSize.............................................................. 100 x 56 mm
cylinder, only). Tighten cap screw to specification. Weight ............................................................................... 59 kg (130 lb)
Cap Screw Torque ..................................... 913 46 Nm (673 34 lbft)
Specification
Stabilizer
CylinderSize....................................................................... 90 x 45 mm
Weight ................................................................................. 29 kg (64 lb)
Cap Screw Torque ..................................... 913 46 Nm (673 34 lbft)
TX,3360,BA961 1911OCT939/12
22. Carefully push piston and rod guide into barrel. Keep
T6122AH UN19OCT88
piston and rod guide together.
PN=604
Hydraulic System
23. Push rod guide into barrel just enough to install snap
ring. Install snap ring.
24. Pull rod guide against snap ring.
25. Clean threads of spanner nut with clean and cure
primer. Put thread lock and sealer (medium strength)
T6133AE UN27OCT88
on spanner nut threads.
26. Place filler ring between rod guide and spanner nut.
TX,3360,BA961 1911OCT9311/12
27. Install and tighten nut until marks (on spanner nut and
rod guide) made before disassembly are even.
T6119AR UN27OCT88
TX,3360,BA961 1911OCT9312/12
X9811 UN23AUG88
all connections before applying pressure. Search
for leaks with a piece of cardboard. Protect hands
and body from high pressure fluids.
If an accident occurs, see a doctor immediately.
Any fluid injected into the skin must be surgically
removed within a few hours or gangrene
may result. Doctors unfamiliar with this type
of injury should reference a knowledgeable
medical source. Such information is available 2. Disconnect linkage from valve.
from Deere & Company Medical Department
in Moline, Illinois, U.S.A. 3. Operate all hydraulic control valves to release
pressure in hydraulic system.
1. Remove valve cover.
Continued on next page 09T,3360,K10 1911OCT931/4
PN=605
Hydraulic System
T6684BB UN18OCT88
End Line I Bucket Section Bottom
CBoom Section Top PorttoCylinder Rod End
PorttoCylinder Head Line
End Line J Boom Section Bottom
DLeft Swing Top Port PorttoCylinder Rod End
ERight Swing Bottom Port Line
09T,3360,K10 1911OCT932/4
T6685AE UN18OCT88
ValveWeight............................................................. 45.40 kg (100 lbs)
09T,3360,K10 1911OCT933/4
T6684BB UN18OCT88
BBucket Section Top PorttoCylinder Head End
PorttoCylinder Head Line
End Line I Bucket Section Bottom
CBoom Section Top PorttoCylinder Rod End
PorttoCylinder Head Line
End Line J Boom Section Bottom
DLeft Swing Section Top Port PorttoCylinder Rod End
ERight Swing Section Line
Bottom Port
09T,3360,K10 1911OCT934/4
PN=606
Hydraulic System
T6684BD UN18OCT88
1. Remove nuts and tie rods from control valve.
2. Disassemble parts as shown.
3. Inspect parts for wear or damage and replace as
necessary.
4. Lubricate all parts with clean hydraulic oil.
5. Install parts (A, H and I).
ALift Check (4 used) F Crowd Valve Section
6. Install tie rods and nuts. BInlet End Plate GOutlet End Plate
Specification CSwing Valve Section HSpring (4 used)
DBoom Valve Section I ORing (5 used)
Tie Bolt Nuts (1/2 EBucket Valve Section
inch)Torque............................................................... 102 Nm (75 lbft)
Tie Bolt Nuts (7/16
inch)Torque................................................................. 68 Nm (50 lbft)
TX,3360,BA932 1916SEP931/1
T6684BC UN18OCT88
1. Disassemble relief valve with anticavitation.
2. Inspect parts for wear or damage and replace as
necessary.
3. Lubricate all parts with clean hydraulic oil.
4. Assemble relief valve. Tighten cap (A).
Specification ACap DORing
Relief Valve BORing EORing
(Circuit with Anti CSpring F Valve
Cavitation)Torque........................................................ 95 Nm (70 lbft)
09T,3360,K15 1911OCT931/1
PN=607
Hydraulic System
T6687AB UN18OCT88
IMPORTANT: Relief valve MUST be installed in
same section as removed.
09T,3360,K16 1911OCT931/1
PN=608
Hydraulic System
T6497AM UN18OCT88
ACircuit Relief Valve (2 used) EScrews (2 used) I ORing (2 used) MPlate (2 used)
BORing Nut (2 used) F Cap J Spool NScrew (2 used)
CORing (2 used) GSpring KSpring
DHousing HBackup Ring (2 used) L Left Check
PN=609
Hydraulic System
T6497AK UN18OCT88
ACircuit Relief Valve F Valve Body with KScrew (2 used) PSpool
BORing AntiCavitation L Cap QSpring
CSpring Retainer GHousing MSpring RLift Check
DSpring HORing NBackup Ring (2 used) SPlate (2 used)
EORing I ORing Nut OORing (2 used) T Screw (2 used)
J Circuit Relief Valve
PN=610
Hydraulic System
T6497AL UN18OCT88
ACap (2 used) F Valve Body with KBackup Ring (2 used) PPlate (2 used)
BORing (2 used) AntiCavitation (2 used) L ORing (2 used) QScrew (2 used)
CSpring Retainer (2 used) GHousing MSpool
DSpring (2 used) HScrew (2 used) NSpring
EORing (2 used) I Cap OLift Check
J Spring
PN=611
Hydraulic System
T6688AP UN18OCT88
DPlug L Unloading Valve
EORing MPlug
F Spring NORing
GCheck valve OSpring
HORing PLow Pressure Regenerated
Relief Valve
TX,3360,BA936 1916SEP931/1
T7247BS UN18APR90
System Relief
ValvePressure............................................................... + 1400 kPa0
kPa (+140 bar) (+ 2000 psi)
Circuit Relief ValveSpecification
Crowd OutRod
EndPressure...................................... 19 000 kPa (129 bar) (2750 psi)
Bucket DumpPres
sure..............................................................24 100 kPa (241) (3500 psi)
Boom RaisePressure......................... 12 900 kPa (129 bar) (1875 psi)
Crowd InHead
Swing LeftPressure............................ 19 000 kPa (190 bar) (2750 psi)
EndPressure...................................... 24 100 kPa (241 bar) (3500 psi)
Swing RightPressure........................ 19 000 kPa (190 bar) ( 2750 psi)
Boom LowerPressure........................ 26 200 kPa (262 bar) (3800 psi) See TM1403, Group 902525 for testing relief valves.
Bucket CurlPressure.......................... 24 100 kPa (241 bar) (3500 psi)
TX,3360,BA937 1911OCT931/1
PN=612
Hydraulic System
X9811 UN23AUG88
all connections before applying pressure. Search
for leaks with a piece of cardboard. Protect hands
and body from high pressure fluids.
If an accident occurs, see a doctor immediately.
Any fluid injected into the skin must be surgically
removed within a few hours or gangrene
may result. Doctors unfamiliar with this type
of injury should reference a knowledgeable
medical source. Such information is available
from Deere & Company Medical Department
in Moline, Illinois, U.S.A.
09T,3360,K25 1911OCT931/2
T6684BA UN18OCT88
lockouts. Lines MUST be opened slowly
to release hydraulic pressure.
09T,3360,K25 1911OCT932/2
PN=613
Hydraulic System
T6172AY UN25MAY89
T58,3360,J163 1901AUG901/1
PN=614
Hydraulic System
T6017AF UN03NOV88
T58,3360,J164 1911SEP851/3
T6172AZ UN25MAY89
Continued on next page T58,3360,J164 1911SEP852/3
PN=615
Hydraulic System
T6017AG1 UN03NOV88
T58,3360,J164 1911SEP853/3
PN=616
Hydraulic System
T6017AG1 UN03NOV88
APlunger (2 used) ESpring (2 used)
BSeat (2 used) F Seat Retainer (2 used)
CORing (2 used) GORing (2 used)
DPoppet (2 used) HFitting (2 used)
PN=617
Hydraulic System
T90867 UN28OCT88
Seat Retainer (Stabilizer
Control Valve)Torque................................... 4754 Nm (3540 lbft)
Early Units
T7273AB UN04APR90
Later Units
T58,3360,J167 1911OCT932/4
T6172AZ UN25MAY89
PN=618
Hydraulic System
T6017AF UN03NOV88
LUBRIPLATE is a registered trademark of Fiske Brothers Refining Co.
T58,3360,J167 1911OCT934/4
PN=619
Hydraulic System
PN=620
Index
Page Page
C F
Cable Fan
Speed control................................................. 0505151 Remove and install ........................................ 0505104
Carrier roller Fanreversible
Disassemble and assemble ......................... 01013010 Adjust ............................................................. 0505105
Measure wear ................................................ 0101309 Fenders
Oil level ........................................................ 01013013 Disassemble and assemble .....1919271,
Remove and install ........................................ 0101309 1919272, 1919274
Carrier roller oil specification ............................. 0000043 Filter, oil ........................................................... 03036020
Charge Final drive
Transmission accumulator ........................... 03036019 Axle shaft preload ........................................ 02025020
Clutch packs Disassemble and assemble ......................... 02025010
Disassemble and assemble ......................... 03035016 Idler shaft preload, double reduction............ 02025018
Oil specification.............................................. 0000043
PN=1
Index
Page Page
PN=2
Index
Page Page
PN=3
Index
Page Page
PN=4
Index
PN=5
Index
PN=6